1993 Dodge W250 Truck Service Manual PDF

19 9 3
SERVICE
MANUAL
D& W150-350
RAMCHARGER
REAR WHEEL DRIVE

TRUCK
CHRYSLER
CORPORATION
SERVICE MANUAL
1993 DODGE TRUCKS
To order the special service tools used and

illustrated, please refer to the instructions on
inside back cover.
CHRYSLER
W CORPORATION
NO PART OF THIS PUBLICATION MAY BE

REPRODUCED, STORED IN A RETRIEVAL
SYSTEM, OR TRANSMITTED, IN ANY FORM
OR BY ANY MEANS, ELECTRONIC, ME
CHANICAL, PHOTOCOPYING, RECORDING,
OR OTHERWISE, WITHOUT THE PRIOR
WRITTEN PERMISSION OF CHRYSLER
CORPORATION.
Chrysler Corporation reserves the right to make changes in design or to make

additions to or improvements in its products without imposing any obliga
tions upon itself to install them on its products previously manufactured.
Litho in U.S.A. Copyright © 1992 Chrysler Corporation 1 5 M 0 9 9 2

FOREWORD
The information contained in this service manual has been prepared for the professional automotive tech
nician involved in daily repair operations. This manual does not cover theory of operation, which is addressed
in service training material. Information describing the operation and use of standard and optional equipment
is included in the Owner's Manual provided with the vehicle.
Information in this manual is divided into groups. These groups contain general information, diagnosis,
testing, adjustments, removal, installation, disassembly, and assembly procedures for the components.
The Component and System Index of this manual identifies the correct group for the component or system
to be serviced. In addition, a Service Manual Comment form is included at the rear of this manual. Use the
form to provide Chrysler Corporation with your comments and suggestions.
To assist in locating a group title page, use the Group Tab Locator on the following page. The solid bar
after the group title is aligned to a solid tab on the first page of each group. The first page of the group has
a contents section t h a t lists major topics within the group.
Tightening torques are provided as a specific value throughout this manual. This value represents the
midpoint of the acceptable engineering torque range for a given fastener application. These torque values are
intended for use in service assembly and installation procedures using the correct OEM fasteners. When re
placing fasteners, always use the same type (part number) fastener as removed.
Chrysler Corporation reserves the right to change testing procedures, specifications, diagnosis, repair
methods, or vehicle wiring at any time without prior notice or incurring obligation.
NOTE: The acronyms, terminology and nomenclature used to identify emissions related components in
this manual may have changed from prior publications. These new terms are in compliance with S.A.E.
recommended practice J1930. This terminology standard (J1930) is required to comply with the 1993
California Air Research Board (CARB) requirements.
Navigation Tools: Click on the "Group" below, or use
the Bookmarks to the left.
GROUP TAB LOCATOR
Introduction
0 Lubrication and Maintenance
2 Front S u s p e n s i o n and Axle
3 Rear S u s p e n s i o n and Axles
5 Brakes
6 Clutch
7 Cooling S y s t e m
8 Electrical
9 Engines
11 Exhaust S y s t e m and Intake Manifold
F r a m e
13 and Bumpers
F u e l
14 System
16 Propeller Shafts
19 Steering
21 Transmission and Transfer C a s e
22 Wheels and Tires
B o d
23 y Components
24 Heating and Air Conditioning
25 Emission Control S y s t e m s
Component and System Index
Service Manual Comment Forms (Rear of Manual)

INTRODUCTION
INTRODUCTION
CONTENTS
page page
DESIGNATIONS, LABELS/PLATES/DECALS, MEASUREMENT AND TORQUE
CODES AND DIMENSIONS/WEIGHTS . ... 1 SPECIFICATIONS . 11
DESIGNATIONS, LABELS/PLATES/DECALS, CODES A N D DIMENSIONS/WEIGHTS
INDEX
page page
Engine and Transmission/Transfer C a s e Trailer Towing Specifications 4
Identification 2 Vehicle Code Plate 2
Engine/Transmission/GVWR 4 Vehicle Designations 1
Equipment Identification Plate 3 Vehicle Dimension 4
International Vehicle Control and Display Vehicle Identification Number (VIN) Plate 1
Symbols 10 Vehicle Safety Certification Label ............. 1
Major Component Identification 3 Vehicle Weights 4
VEHICLE DESIGNATIONS VEHICLE CODE DESIGNATIONS

The Vehicle Code chart lists description and code
for Ram Truck and Sport Utility vehicles. The codes
are used to identify vehicle types in charts, captions VEHICLE C O D E = A D ( D O D G E R A M
and in service procedures. The vehicle codes are dif PICKUP & CHASSIS CAB)
ferent t h a n the Vehicle Identification Number (VIN)
or the wheelbase/model code. VEHICLE DESCRIPTION
FAMILY LINE
VEHICLE SAFETY CERTIFICATION LABEL
A certification label is attached to the left side AD1 D150 PICKUP
B-pillar. The label certifies t h a t the vehicle conforms AD2 D250 4x2
AD3 D350
to Federal Motor Vehicle Safety Standards (FMVSS).
The label also lists the:
AD5 W150 PICKUP
• Month and year of vehicle manufacture AD6 W250
• Gross Vehicle Weight Rating (GVWR). The gross AD7 W350 4x4
front and rear axle weight ratings (GAWR's) are
based on a minimum rim size and maximum cold tire AD2 D250 CHASSIS CAB
inflation pressure AD3 D350 4x2
Vehicle Identification Number (VIN)
Type of vehicle AD6 W250 CHASSIS CAB
Type of rear wheels (single or dual) AD7 W350 4x4
Bar code
Month, Day and Hour (MDH) of final assembly AD4 AD100 SPORT UTILITY
AD4 AD150 4x2
VEHICLE IDENTIFICATION NUMBER (VIN) PLATE
The Vehicle Identification Number (VIN) plate is AD8 AD100 SPORT UTILITY
attached to the top left side of the instrument panel. AD8 AD 150 4x4
The VIN contains 17 characters t h a t provide data
concerning the vehicle. Refer to the decoding chart to J90IN-32
determine the identification of a vehicle.
2 INTRODUCTION •
MFD BY
CHRYSLER DATE OF MFR GVWR Refer to the decoding chart to decode lines 1
CORPORATION
through 3.
Lines 4 through 7 on the plate are imprinted in se
GAWR FRONT WITH TIRES RIMS AT PSI COLD quence according to the following descriptions:
• 3-character sales code
RIMS AT PSI COLD
GAWR REAR WITH TIRES • 3-digit numerical code
• 6-digit SEC code
THIS VEHICLE CONFORMS TO ALL APPLICABLE FEDERAL MOTOR VEHICLE SAFETY
If there is not enough space left in the row for all
STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE SHOWN ABOVE. of the 6-digit SEC code:
• The unused space will remain blank
SINGLE DUAL • The code will be listed in the next row.
BAR CODE
The last nine positions of row 7 will contain a
2-digit code and a 6-digit serial number.
The last code on a vehicle code plate will be fol
MDH: VEHICLE MADE IN 4648503 J9HN-25
lowed by the imprinted word END. When two plates
Fig. 1 Vehicle Safety Certification Label are required, the last available spaces on the first
plate will be imprinted with the letters CTD (for con
The Vehicle Identification Number is also im tinued).
printed on the: When a second vehicle code plate is necessary, the
• Body Code Plate first four spaces on each row will not be used because
• Equipment Identification Plate of the plate overlap.
• Vehicle Safety Certification Label To retrieve information from a vehicle code plate:
• And on a frame rail. • Illuminate the plate with a shop light
• View the plate via the cowl grille slots
VEHICLE CODE PLATE • Record the needed coded information.
A metal vehicle code plate (Fig. 2) is attached to
top, right side of cowl below cowl grille. There can be ENGINE AND TRANSMISSION/TRANSFER CASE
a maximum of seven rows of vehicle information im IDENTIFICATION
printed on the plate. The information should be read Refer to Group 9—Engines for all engine identifi
from left to right, starting with line 1 at the bottom cation data.
of the plate up to line 7 (as applicable) at the top of Refer to Group 21—Transmissions for all transmis
the code plate. sion/transfer case identification data.
VEHICLE IDENTIFICATION NUMBER (VIN) DECODING
Country Vehicle Type Truck Line Engines Sequential

1 = United States 4 = Multipurpose E = Ramcharger 4x2 X = 3.9L (MPI) Serial Number
2 = Canada Passenger Chassis Cab 4x2 Y = 5.2L (MPI) Six Digit Numbers
3 = Mexico 5 = Bus Pickup 4x2 Z = 5.9L (EFI)
6 = Incomplete M = Ramcharger 4x4 5 = 5.9L HDC
7 = Truck Chassis Cab 4x2 8 = 5.9L Turbo Diesel
Pickup 4x4
G V W R and
Hydraulic Brakes
0001 3000
3001 4000
4001 5000 Series
5001 6000
6001 7000 0 = 150S Job Rated
1 = 150 Job Rated Body Plant Location
7001 8000
8001 9000 2 = 250 Job Rated 3 = Club Cab S = Dodge City
9001 10,000 3 = 350 Job Rated 6 = Conventional Cab M = Lago Alberto
10,001 14,000 9 = Sport Utility 2 DR
Bus or I nc. J931N-18
INTRODUCTION
PRIMARY SECONDARY VINYL R O O F EQUIPMENT IDENTIFICATION PLATE

PAINT PAINT CODE The Equipment Identification Plate is located at
the right, front corner of the inner hood panel. The
plate lists information concerning the vehicle as fol
VEHICLE lows:
VEHICLE MODEL The model
ORDER- •NUMBER
NUMBER The wheelbase
PI XXX ) XXXXX) X XXX xxxxxx
ENGINE The VIN (Vehicle Identification Number)
PAINT- -CODE The T.O.N, (order number)
PROCEDURE (2) X)0C xxxx xxxx xxxx xxx
-INTERIOR The optional and special equipment installed on
(1) XXX x xxxxxxxxxxxxxxxxx TRIM CODE the vehicle
Refer to the information listed on the plate when
TRANSMISSION I VEHICLE IDENTIFICATION ordering replacement parts.
CODE J NUMBER
MARKET U-C-B-M r
CODE 90IN-3
§ W l l EQUIPMENT IDENTIFICATION mmm
Fig. 2 Vehicle Code Plate MODELS V.I.N. T.O.N.

VEHICLE CODE DECODING CODE N O . DESCRIPTION CODE N O . DESCRIPTION
Line #1 Digit 1-3 T r a n s m i s s i o n Sales Code
Digit 4 O p e n Space
Digit 5 M a r k e t Code - U-C-B-M
Digit 7-23 V e h i c l e Identification N o .
Line #2 Digit 1-3 Paint Procedure . ^

Digit 5-8 Primary Paint
Digit 9 O p e n Space Fig. 3 Equipment Identification Plate
Digit 10-13 S e c o n d a r y Paint
Digit 15-18 T r i m Code
Digit 20-22 E n g i n e Sales C o d e
Line #3 Digit 1-12 V e h i c l e O r d e r Number

Digit 14-16 Vinyl Roof Code (Door Combo
Code - P i l l e t t e )
Digit 18-23 Model
J901N-20
MAJOR COMPONENT IDENTIFICATION
Refer to the applicable group for identification
data.
4 INTRODUCTION •
VEHICLE DIMENSIONS
S f A N D A I D SODIES AVAILABLE
(LOAD SPACE D MENSIONS (2)
VEHICLE WHEELBASE CAB TO BODY NOMINAL MAX.
FAMILY AVAILABLE AXLE TYPE LENGTH LENGTH WIDTH HEIGHT V O L U M E
3
AD-1 AD-5 2921 mm — Sweptline 1981 mm 1981 mm 1778 mm 485 mm 1.71 m 3
(115 in) (6.5 ft) (78 in) (70 in) 19.1 in) (60.35 ft )
3
AD-1 AD-2 3327 mm — Sweptline 2438 mm 2489 mm 1778 mm 485 mm 2.15 m 3
AD-3 AD-5 (131 in) (8 ft) (98 in) (70 in) (19.1 in) (75.8 ft )
AD-6 AD-7
AD-2 AD-3 3327 mm 1422 mm Chassis 2438 mm — — — —
AD-7 (131 in) (56 in) Cab (8 ft)
AD-3 AD-7 3249 mm 1524 mm Chassis 2896 mm — — — —
(135 in) (60 in) Cab (9.5 ft)
AD-3 4039 mm 2134 mm Chassis 3810 mm — — —
(159 in) (84 in) Cab (12.5 ft)
AD-4 2692 mm Sport — 1778 mm 1588 mm 1062 mm 2.99 m 3
3
(106 in) Utility (62.5 in) (41.8 in) (105.8 ft )
4x2
AD-8 2692 mm Sport — 1778 mm 1588 mm 1062 mm 2.99 m 3
3
(106 in) Utility (62.5 in) (41.8 in) (105.8 ft )
4x4
3
AD-1 3378 mm — Sweptline 1981 mm 1984 mm 1778 mm 485 mm 1.71 m 3
(133 in) (6.5 ft) (78.1 in) (70 in) (19.1 in) (60.4 ft )
3
AD-1 AD-2 3785 mm — Sweptline 2438 mm 2489 mm 1778 mm 485 mm 2.15 M
AD-5 AD-6 (149 in) Club Cab (8 ft) (98 in) (70 in) (19.1 in) (75.8 ft )3
® Driver seat to tailgate.

(2) Based on S.A.E. procedure Jl 100. J901N-34
VEHICLE DIMENSION VEHICLE WEIGHTS
The Vehicle Dimension chart provides t h e dimen The Vehicle Weights chart provides:
sions for each type of Ram Truck, Ram Chassis Cab • The Gross Vehicle Weight Rating (GVWR),
and Ramcharger vehicle. • The payload
• The curb weight for each vehicle type/wheelbase
ENGINE/TRANSMISSION/GVWR
The Engine/Transmission/GVWR chart provides TRAILER TOWING SPECIFICATIONS
the maximum load data for each vehicle combina The Trailer Towing Specifications chart provides:
• The maximum trailer tongue weight
tion.
• The maximum trailer weight
• The maximum combined weight of the trailer/load/
towing vehicle with a specific engine/transmission/
axle combination.
• INTRODUCTION 5
ENGINE/TRANSMISSION/QVWR
RAM PICKUP
ENGINE & SALES CODE TRANSMISSION
VEHICLE 3.9L 5.2L 5.9L 5.9L 5.9L 5-SP 4-SP 4-SP
LINE WHEELBASE GVWR EFI EFI EFI EFI DIESEL M A N . M A N . 4 - S P 3 - S P A U T O
EHB ELG E M G EMJ ETA O.D. O.D. M A N . AUTO O.D.
D150 2921 mm 2495 kg S S O o
4x2 (115 in) (5500 lbs)
3327 mm
O S o o o
(131 in) O s o
3327 mm 2722 kg S s o o
(131 in) (6000 lbs)
o s o o o
o s o
3378 mm
(±33 in)
2722 kg
(6000 lbs)
s s o
3785 mm
(149 in) o s o
D250 3327 mm 3357 kg s s© o
4x2 (131 in) (7400 lbs)
o s© o o
o s o
3785 mm 3357 kg s s o
(149 in) (7400 lbs)
o s o
3327 mm
(131 in)
3860 kg
(8510 lbs)
s s o
3785 mm
(149 in) O s o
D350 3327 mm 3946 kg s s o
4x2 (131 in) (8700 lbs)
O s o
4581 kg S s o
(10,100 lbs)
o s o
W150 2921 mm 2858 kg s® s o
4x4 (115 in) (6300 lbs)
3327 mm 2903 kg
o s© o
(131 in) (6400 lbs) o s o
3785 mm 2903 kg s s© o
(149 in) (6400 lbs)
o s o
W250
4x4
3327 mm
Q31 in)
3402 kg
(7500 lbs)
s s© o
3/85 mm
(149 in) o s o
3327 mm
(131 in)
3860 kg
(8510 lbs)
s s o
3785 mm
(149 in) o s o
W350 3327 mm 3946 kg s s o
4x4 (131 in) (8700 lbs)
o s o
4581 kg s s o
(10,100 lbs)
o s o
S = STANDARD O = OPTIONAL © = Not available in California J90IN-39
6 INTRODUCTION •
ENGINE/TRANSMISSION/GVWR (CONT'D)
R A M CHASSISCAB
E N G I N E & SALES CODE TRANSMISSION

VEHICLE 3.9L 5.2L 5.9L 5.9L 5.9L 5-SP 4-SP 4-SP
LINE WHEELBASE GVWR EFI EFI EFI EFI DIESEL M A N . M A N . 4 - S P 3 - S P A U T O
EHB ELG E M G E M J ETA O.D. O.D. M A N . AUTO O . D .
D250 3327 mm 3357 kg
4x2 (131 in) (7400 lbs) S s
3860 kg s© S o
(8510 lbs)
s© s o
O S o
D350 3327 mm 3946 kg s© s o
4x2 (131 in) (8700 lbs)
s© s o
3429 mm 4581 kg
(135 in) (10,100 lbs) s s o
4039 mm
(159 in) 4763 kg
(10,500 lbs) o s o
W250 3327 mm 3860 kg s© s o
4x4 (131 in) (8510 lbs)
s© s o
o s o
W350 3327 mm 3946 kg s© s o
4x4 (131 in) (8700 lbs)
s® s o
o s o
3429 mm 4581 kg s s o
(135 in) (10,100 lbs)
4989 kg
(11,000 lbs)
o s o
R A M C H A R G E R S P O R T UTILITY
D100 2692 mm 2540 kg

4x2 (106 in) (5600 lbs) S S
D150 2692 mm 2540 kg

4x2 (106 in) (5600 lbs) S S
W100 2692 mm 2722 kg

4x4 (106 in) (6000 lbs) S S O
W150 2692 mm 2722 kg
4x4 (106 in) (6000 lbs) S S o
2903 kg S S® o
(6400 lbs)
S S o
S = STANDARD ® = Not available in California.

O = OPTIONAL = California Only. J901N-35
• INTRODUCTION 7
VEHICLE WEIGHTS
R A M PICKUP
MODEL/ BODY (3) GVWR

PAYLOAD CURB
FAMILY STYLE A L L O W A N C E (1) W E I G H T (2)
D150 AD1 61 2495 kg 5500 lbs 853 kg 1880 lb 1642 kg 3620 lbs
4x2
62 2495 kg 5500 lbs 804 kg 1772 lbs 1691 kg 3728 lbs
2722 kg 6000 lbs 1021 kg 2252 lbs 1700 kg 3748 lbs
D250 AD2 62 3357 kg 7400 lbs 1527 kg 3366 lbs 1830 kg 4034 lbs
4x2 3860 kg 8510 lbs 1952 kg 4304 lbs 1908 kg 4206 lbs

D350 AD3 62(4) 3946 kg 8700 lbs 2001 kg 4411 lbs 1945 kg 4289 lbs
4x2 4581 kg 10,100 lbs 2485 kg 5478 lbs 2097 kg 4622 lbs
W150 AD5 61 2858 kg 6300 lbs 978 kg 2156 lbs 1880 kg 4144 lbs
4x4

4x4
(1) Payload includes maximum weight of driver, passengers, cargo and optional equipment not included in pavload or GVW package
- rayload allowance for Chassis Cabs is not supplied due to large variations or body equipment installed.
(2) Includes base engine
(3) Body Style Cab Bed Length
61 Std. 1981 mm (6.5 ft
62 Std. 2438 mm 8.0 ft
31 Club 1981 mm 6.5 ft
32 Club 2438 mm 8.0 ft
63 Std. N.A
64 Std. N.A.
71 Sport Utility N.A.
(4) Dual Rear Wheels
J90IN-36
8 INTRODUCTION •
VEHICLE WEIGHTS (CONT'D)
RAM CHASSIS CAB
MODEL/ BODY(3) PAYLOAD CURB

FAMILY STYLE GVWR W E I G H T (2)
A L L O W A N C E (1)
D250 AD2 62 3357 kg 7400 lbs 1721 kg 3794 lbs

4x2 3860 kg 8510 lbs 1740 kg 3835 lbs
D350 AD3 62 3946 kg 8700 lbs ID 1794 kg 3954 lbs

4x2
4581 kg
4763 kg
10,100 lbs
10,500 lbs
.., 1963 kg
1972 kg
4327 lbs
4347 lbs
4581 kg 2032 kg 4479 lbs

"111 4763 kg
10,100 lbs
10,500 lbs
1.1
2043 kg 4505 lbs
W250 AD6 62 3860 kg 8510 lbs 1.) 1886 kg 4158 lbs

4x4
W350 AD7 62 3946 kg 8700 lbs ID 2038 kg 4494 lbs

4x4
4581 kg 10,100 lbs ID 2136 kg 4709 lbs
4990 kg 11,000 lbs 2145 kg 4729 lbs
RAMCHARGER - SPORT UTILITY
MODEL/ BODY(3) PAYLOAD CURB

FAMILY STYLE GVWR WEIGHT(2)
ALLOWANCES)
4x2
4x2
4x4
(1) Payload includes maximum weight of driver, passengers, cargo and optional equipment not included in payload or GVW package
- Payload allowance for Chassis Cabs is not supplied due to large variations of body equipment installed.
2) Includes base engine
! 3) Body Style Cab Bed Length
6V Std. 1981 mm [6.5 ft)
62 Std. 2438 mm 8.0 ft
31 Club 1981 mm 6.5 ft
32 Club 2438 mm 8.0 ft
63 Std. N.A
64 Std. N.A.
71 Sport Utility N.A.
(4) Dual Rear Wheels
J90IN-38
TRAILER TOWING SPECIFICATIONS
ALLOWABLE TONGUE WEIGHTS
M a x . Tongue
Model GVWR Weight
D/W150/150S Ramcharger All 800

D/W250 All 900
D/W350
Single Rear Wheels All 1000
Dual Rear Wheels All 1200
GCWR - GROSS COMBINED WEIGHT RATING

(Total truck, trailer, c a r g o , p e o p l e & fluids)
AXLE RATIOS
ENGINE TRANSMISSION 3.54 3.90 4.10 4.56
D-150
3.9L Man. 5-spd. 8,000 8,000
Auto. 3-spd. 8,800 9,200
Auto. 4-spd. O / D 8,800 9,200
5.2L Auto. 3-spd. 11,500 12,500
Auto. 4-spd. O / D 10,500 10,500
Auto. 4-spd. H.D. 11,500 12,500
5.9L Auto. 4-spd H.D. 12,000 13,000 13,500 14,000
D-250
3.9L Auto. 3-spd. 8,800 9,200
5.2L Auto. 4-spd. O / D 10,500 10,500
Auto. 4-spd. H.D. 11,500 12,500
5.9L Auto. 4-spd. H.D. 12,000 13,000 13,500 14,000
D-350
5.9L Auto. 4-spd. H.D. 12,000 13,000 13,500 14,000
W-150
3.9L Auto. 4-spd. H.D. 8,800 9,200
5.2L Auto. 4-spd. H.D. 11,500 12,500
5.9L Auto. 4-spd. H.D. 12,000 13,000 13,500 14,000
W-250
5.9L Auto. 3-spd. 12,000 13,000 13,500 14,000
W-350
5.9L Auto. 3-spd. 12,000 13,000 13,500 14,000
Auto. 4-spd. H.D. 12,000 13,000 13,500 14,000
Ramcharger 4 x 2
5.2L Auto. 4-spd. H.D. 11,500 12,500
5.9L Auto. 4-spd. H.D. 12,000 13,000 13,500 14,000
Ramcharger 4 x 4
5.2L Auto. 4-spd. H.D. 11,500 12,500
5.9L Auto. 4-spd. H.D. 12,000 13,000 13,500 14,000
10 INTRODUCTION •
INTERNATIONAL CONTROL AND DISPLAY SYMBOLS
ID P -& A
HEADLIGHTS,
PARKING UGHTS, WINDSHIELD
HIGH BEAM FOG UGHTS PANEL UGHTS TURN SIGNAL HAZARD WARNING WASHER
WINDSHIELD
WIPER
WINDSHIELD WIPER
AND WASHER
<W
WINDSCREEN
DEMISTING
AND DEFROSTING
*
VENTILATING FAN
8 M f
REAR WINDOW
DEFOGGER
sp
REARWINLX)W
WIPER
CD l
m
REAR WINDOW ENGINE COOLANT BATTERY CHARGING
WASHER FUEL TEMPERATURE CONDITION ENGINE OIL SEAT BELT
(©) (®) k y
11 J
REAR HOOD
BRAKE FAILURE PARKING BRAKE FRONT HOOD (TRUNK) HORN LIGHTER
93IN-9
INTERNATIONAL VEHICLE CONTROL AND DISPLAY
SYMBOLS
The graphic symbols illustrated in the chart below
are used to identify various instrument controls. The
symbols correspond to the controls and displays t h a t
are located on t h e instrument panel.
• INTRODUCTION 11
MEASUREMENT AND TORQUE SPECIFICATIONS
INDEX
page page
Metric and English/SAE Conversion 11 Torque Specifications 11
Specification Notations 11
SPECIFICATION NOTATIONS threads. Reduce the torque value by 10 percent when

the bolt threads are lubricated and by 20 percent if
WARNING: THE U S E OF INCORRECT ATTACHING new.
H A R D W A R E C A N R E S U L T IN C O M P O N E N T D A M
A G E A N D / O R P E R S O N A L INJURY. BOLT THREAD AND GRADE/CLASS
IDENTIFICATION
It is important to retain the original attaching
hardware for assembly of the components. If the at THREAD IDENTIFICATION
taching hardware is not reusable, hardware with SAE and metric bolt/nut threads are not the same.
equivalent specifications must be used. The difference is described in the Thread Notation
chart.
METRIC AND ENGLISH/SAE CONVERSION
The following chart will assist in converting metric GRADE/CLASS IDENTIFICATION
units to equivalent English and SAE units, or vise The SAE bolt strength grades range from grade 2
versa. to grade 8. The higher t h e grade number, the greater
the bolt strength. Identification is determined by the
TORQUE SPECIFICATIONS line marks on the top of each bolt head (Fig. 1). The
actual bolt strength grade corresponds to the number
TORQUE CHARTS of line m a r k s plus 2.
A torque chart for fasteners is provided at the end • A grade 2 bolt has no line marks on top of the bolt
of each group (of service information). Refer to the head
Standard Torque Specifications chart to determine • A grade 5 bolt h a s 3 line marks on top of t h e bolt
torque values not listed in the group (Figs. 1 and 2). head
It is important to be aware t h a t the torque values • A grade 7 bolt has 5 line marks on top of the bolt
listed in the chart are based on clean and dry bolt head
CONVERSION FORMULAS AND EQUIVALENT VALUES
Multiply
in-lbs
By
x 0.11298
To Get Multiply iy
x 8.851
BGef
- in-fbs
= Newton-Meters (N*m)
ft-lbs x 1.3558 = Newton-Meters (N*m) N*m 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) M x 1.0936 = Yards
Miles x 1.6093 = Kilometers (Km) Km x 0.6214 « Miles
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.
Kilometers/Hr. x 0.27778 « Meters/Sec. (M/S) M/S x 3.600 = Kilometers/Hr.
mph x 0.4470 = Meters/Sec. (M/S) M/S x 2.237 » mph
C O M M O N MITRIC 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
J91IN-1
12 INTRODUCTION
STANDARD TORQUE SPECIFICATIONS

SAE CLASSIFICATION
BOLT TORQUE GRADE 5 GRADE 8
ORAM 5 GRADES
BOLT
SIZE M*fn ft-lbs Nfft
(in-lbs)
ft-abs
(In-lbs)
MARKINGS FOUND
ON TOP OF BOLT
1/4-20 11 (95) 14 (125) HEAD INDICATE
1/4-28 11 (95) 17 (150) GRADE
5/16-18 23 (200) 31 (270)
5/16-24 27 20 34 25 120° 60°
3/8-16 41 30 54 40
3/8-24 48 35 61 45
7/16-14 68 50 88 65
7/16-20 75 55 95 70
1/2-13 102 75 136 100
1/2-20 115 85 149 110
9/16-12 142 105 183 135
GRADE 2 GRADE 5 GRADE 8
9/16-18 156 115 203 150
5/8-11 203 150 264 195 (SAE) BOLTS—IDENTIFICATION MARKS CORRESPOND
5/8-18 217 160 285 210 TO BOLT STRENGTH—INCREASING NUMBERS
3/4-16 237 175 305 225 REPRESENT INCREASING STRENGTH.
J89IN-11
J89IN-9 Fig. 1 SAE Bolt Grade Identification

THREAD NOT A TION—SAE AND METRIC greater the bolt strength. Some metric nuts are im
printed with a single-digit strength class on the n u t
INCH METRIC face.
5/16-18 M8 X 1.25
THREAD NUMBER THREAD DISTANCE
MAJOR OF MAJOR BETWEEN
DIAMETER THREADS DIAMETER IN THREADS IN
IN INCHES PER INCH MILLIMETERS MILLIMETERS
METRIC BOLTS—IDENTIFICATION CLASS NUMBERS
CORRESPOND TO BOLT STRENGTH— INCREASING NUMBERS
PR606B REPRESENT INCREASING STRENGTH. J89IN-10
• A grade 8 bolt has 6 line marks on top of the bolt
Fig. 2 Metric Bolt Class Identification
head
The most commonly used metric bolt strength METRIC CONVERSION
classes are 9.8 and 12.9. The metric strength class Refer to the Metric Conversion chart to convert
identification number is imprinted on the head of the torque values listed in metric Newton-meters (N»m).
bolt (Fig. 2). The higher the class number, the Also, use the chart to convert between millimeters
(mm) and inches (in.)
• INTRODUCTION 13
METRIC CONVERSION
in-lbs to N « m N * m to in-lbs
in- lb N®m in-lb N®m in-lb N»m in-lb N@m in-lb N«m in-lb N®m in-lb N®m in-lb N»m in-lb
2 162 18.3032 .2 1.7702 4.2 37.1747 8.2 72.5792 12.2 107.9837 16.2
.2260 42 4.7453 82 9.2646 122 13.7839
4 164 18.5292 .4 3.5404 4.4 38.9449 8.4 74.3494 12.4 109.7539 16.4
.4519 44 4.9713 84 9.4906 124 14.0099
6 18.7552 .6 5.3107 4.6 40.7152 8.6 76.1197 12.6 111.5242 16.6
.6779 46 5.1972 86 9.7165 126 14.2359 166
8 .9039 48 5.4232 88 9.9425 128 14.4618 168 18.9811 .8 7.0809 4.8 42.4854 8.8 77.8m 12.8 113.2944 16.8
10 19.2071 1 8.8511 5 44.25% 9 79.6601 13 115.0646 17
1.1298 50 5.6492 90 10.1685 130 14.6878 170
12 1.2 10.6213 5.2 46.0258 9.2 81.4303 13.2 116.8348 17.2
1.3558 52 5.8751 92 10.3944 132 14.9138 172 19.4331
14 1.4 12.3916 5.4 47.7961 9.4 83.2006 13.4 118.6051 17.4
1.5818 54 6.1011 94 10.6204 134 15.1397 174 19.6590
1.6 14.1618 5.6 49.5663 9.6 84.9708 13.6 120.3753 17.6
16 1.8077 56 6.3270 96 10.8464 136 15.3657 176 19.8850
1.8 15.9320 5.8 51.3365 9.8 86.7410 13.8 122.1455 17.8
18 2.0337 58 6.5530 98 11.0723 138 15.5917 178 20.1110
2 17.7022 6 53.1067 10 88.5112 14 123.9157 18
20 2.2597 60 6.7790 100 11.2983 140 15.8176 180 20.3369
2.2 19.4725 6.2 54.8770 10.2 90.2815 14.2 125.6860 18.5
22 2.4856 62 7.0049 102 11.5243 142 16.0436 182 20.5629
2.4 21.2427 6.4 56.6472 10.4 92.0517 14.4 127.4562 19
24 2.7116 64 7.2309 104 11.7502 144 16.2696 184 20.7889
2.6 23.0129 6.6 58.4174 10.6 93.8219 14.6 129.2264 19.5
26 2.9376 66 7.4569 106 11.9762 146 16.4955 186 21.0148
2.8 24.7831 6.8 60.1876 10.8 95.5921 14.8 130.9966 20
28 3.1635 68 7.6828 108 12.2022 148 16.7215 188 21.2408
3 26.5534 7 61.9579 11 97.3624 15 132.7669 20.5
30 3.3895 70 7.9088 110 12.4281 150 16.9475 190 21.4668
3.2 28.3236 7.2 63.7281 11.2 99.1326 15.2 134.5371 21
32 3.6155 72 8.1348 112 12.6541 152 17.1734 192 21.6927
3.4 30.0938 7.4 65.4983 11.4 100.9028 15.4 136.3073 22
34 3.8414 74 8.3607 114 12.8801 154 17.3994 194 21.9187
3.6 31.8640 7.6 67.2685 11.6 102.6730 15.6 138.0775 23
36 4.0674 76 8.5867 116 13.1060 156 17.6253 196 22.1447
3.8 33.6342 7.8 69.0388 11.8 104.4433 15.8 139.8478 24
38 4.2934 78 8.8127 118 13.3320 158 17.8513 198 22.3706
4 35.4045 8 70.8090 12 106.2135 16 141.6180 25
40 4.5193 80 9.0386 120 13.5580 160 18.0773 200 22.5966
ft-lbs to N * m N » m to ft-lbs
ft-lb N«m ft-lb N»m ft-lb N©m ft-lb N»m ft-lb N®m N®m ft-lb N®m ft-ib N®m ft-lb N©m ft-lb N®m ft-lb
1 1.3558 21 28.4722 41 55.5885 61 82.7049 81 109.8212 1 .7376 21 15.9888 41 30.240) 61 44.9913 81 59.7425
2 2.7116 22 29.8280 42 56.9444 62 84.0607 82 111.1770 2 1.4751 22 16.2264 42 30.9776 62 45.7289 82 60.4801
3 4.0675 23 31.1838 43 58.3002 63 85.4165 83 112.5328 3 2.2127 23 16.9639 43 31.7152 63 46.4664 83 61.2177
4 5.4233 24 32.5396 44 59.6560 64 86.7723 84 113.8888 4 2.9502 24 17.7015 44 32.4527 64 47.2040 84 61.9552
5 6.7791 25 33,8954 45 61.0118 65 88.1281 85 115.2446 5 3.6878 25 18.4391 45 33.1903 65 47.9415 85 62.6928
6 8.1349 26 35.2513 46 62.3676 66 89.4840 86 116.6004 6 4.4254 26 19.1766 46 33.9279 66 48.6791 86 63.4303
7 9.4907 27 36.6071 47 63.7234 67 90.8398 87 117.9562 7 5.1629 27 19.9142 47 34.6654 67 49.4167 87 64.1679
8 10.8465 28 37.9629 48 65.0793 68 92.1956 88 119.3120 8 5.9005 28 20.6517 48 35.4030 68 50.1542 88 64.9545
9 12.2024 29 39.3187 49 66.4351 69 93.5514 89 120.6678 9 6.6381 29 21.3893 49 36.1405 69 50.8918 89 65.6430
10 13.5582 30 40.6745 50 67.7909 70 94.9073 90 122.0236 10 7.3756 30 22.1269 50 36.8781 70 51.6293 90 66.3806
11 14.9140 31 42.0304 51 69.1467 71 96.2631 91 123.3794 11 8.1132 31 22.8644 51 37.6157 71 52.3669 91 67.1181
12 16.2698 32 43.3862 52 70.5025 72 97.6189 92 124.7352 12 8.8507 32 23.6020 52 38.3532 72 53.1045 92 67.8557
13 17.6256 33 44.7420 53 71.8583 73 98.9747 93 126.0910 13 9.5883 33 24.3395 53 39.0908 73 53.8420 93 68.5933
14 18.9815 34 46.0978 54 73.2142 74 100.3316 94 127.4468 14 10.3259 34 25.0771 54 39.8284 74 54.5720 94 69.3308
15 20.3373 35 47.4536 55 74.5700 75 101.6862 95 128.8026 15 11.0634 35 25.8147 55 40.5659 75 55.3172 95 70.0684
16 21.6931 36 48.8094 56 75.9258 76 103.0422 9 6 130.1586 16 11.8010 36 26.5522 56 41.3035 76 56.0547 96 70.8060
17 23.0489 77 104.3980 97 37 57 42.0410 77 56.7923 97
24.4047
37 50.1653 57
58
77.2816 13].5144
132.8702
17 12.5386
38
27.2898
28.0274 58 78 57.5298 98
71.5435
72.2811
18
19
38 51.5211 78.6374 78 105.7538 98
134.2260
18
19
13.2761
39 28.7649 59
42.77m
43.5162 79 58.2674 99 73.0187
25.7605 39 52.8769 59 79.9933 79 107.1196 99 14.0137
20 27.1164 40 54.2327 60 81.3491 80 108.4654 100 135.5820 20 14.7512 40 29.5025 60 44.2537 80 59.0050 100 73.7562
in. to m m m m to in.
in. mm in. mm in. mm in. mm in. mm mm in. mm in. mm in. mm in. mm in.
.01 .254 .21 5.334 .41 10.414 .61 15.494 .81 20.574 .01 .00039 .21 .00827 .41 .01614 .61 .02402 .81 .03189
.02 .508 .22 5.588 .42 10.668 .62 15.748 .82 20.828 .02 .00079 .22 .00866 .42 .01654 .62 .02441 .82 .03228
.03 .762 .23 5.842 .43 10.922 .63 16.002 .83 21.082 .03 .00118 .23 .00906 .43 .01693 .63 .02480 .83 .03268
.04 1.016 .24 6.096 .44 11.176 .64 16.256 .84 21.336 .04 .00157 .24 .00945 .44 .01732 .64 .02520 .84 .03307
.05 1.270 .25 6.350 .45 11.430 .65 16.510 .85 21.590 .05 .00197 .25 .00984 .45 .01772 .65 .02559 .85 .03346
.00236 .26 .01024 .46 .01811 66 .02598 .86
.06 1.524 .26 6.604 .46 11.684 .66 16.764 .86 21.844 .06
.07 .27 .01063 .47 .01850 .02638 .87
.03m
.03425
.07 1.778 .27 6.858 .47 11.938 .67 17.018 .87 22.098 .00276
.28 .01102 .48 .01890
.67
.68 .02677 .88 .03465
.08 2.032 .28 7.112 .48 12.192 .68 17.272 .88 22.352 .08 .00315
.09 2.286 .29 7.366 .49 12.446 .69 17.526 .89 22.606 .09 .00354 .29 .01142 .49 .01929 .69 .02717 .89 .03504
.10 2.540 .30 7.620 .50 12.700 .70 17.780 .90 22.860 .10 .00394 .30 .01181 .50 .01969 .70 .02756 .90 .03543
.11 2.794 .31 7.874 .51 12.954 .71 18.034 .91 23.114 .11 .00433 .31 .01220 .51 .02008 .71 .02795 .91 .03583
.12 3.048 .32 8.128 .52 13.208 .72 18.288 .92 23.368 .12 .00472 .32 .01260 .52 .02047 .72 .02835 .92 .03622
.13 3.302 .33 8.382 .53 13.462 .73 18.542 .93 23.622 .13 .00512 .33 .01299 .53 .02087 .73 .02874 .93 .03661
.14 3.5% .34 8.636 .54 13.716 .74 18.796 .94 23.876 .14 .00551 .34 .01339 .54 .02126 .74 .02913 .94 .03701
.15 3.810 .35 8.890 .55 13.970 .75 19.050 .95 24.130 .15 .00591 .35 .01378 .55 .02165 .75 .02953 .95 .03740
.16 4.064 .36 9.144 .56 14.224 .76 19.304 .96 24.384 .16 .00630 .36 .01417 .56 .02205 .76 .02992 .96 .03780
.17 3.318 .37 9.398 .57 14.478 .77 19.558 .97 24.638 .17 .00669 .37 .01457 .57 .02244 .77 .03032 .97 .03819
.18 4.572 .38 9.652 .58 14.732 .78 19.812 .98 24.892 .18 .00709 .38 .01496 .58 .02283 .78 .03071 .98 .03858
.19 4.826 .39 9.906 .59 14.986 .79 20.0% .99 25.146 .19 .00748 .39 .01535 .59 .02323 .79 .03110 .99 .03898
.20 5.080 .40 10.160 .60 15.240 .80 20.320 1.00 25.400 .20 .00787 .40 .01575 .60 .02362 .80 .03150 1.00 .03937
J901N-10
• • — LUiRICATlON AND MAINTENANCE 0 - 1
LUBRICATION AND MAINTENANCE
CONTENTS
page page
CHASSIS AND BODY 28 ENGINE MAINTENANCE 14

DRIVETRAIN . , , , 22 GENERAL INFORMATION 1
GENERAL INFORMATION
INDEl
page page
Classification of Lubricants . 3 Routine Maintenance 2
Components Requiring No Lubrication 4 Starting Assistance (Jump Starting) 9
Fuel Requirements . 2 Vehicle Lifting Recommendations . . . . . . . . . . . . 10
Introduction 1 Vehicle Noise Control 2
Lubrication and Replacement Parts Vehicle Towing Recommendations 11
Recommendation 3
INTRODUCTION M m rv
M F D B Y
CHRYSLER DATE OF MFR GVWR
CORPORATION
Lubrication and maintenance is divided into re
quired and recommended service tasks. The required
WITH TIRES RIMS AT PSI COLD
service tasks must be completed to verify the emis GAWR FRONT
sion controls function correctly. The recommended

RIMS AT PSI COLD
service tasks should be completed to maintain safety GAWR REAR WITH TIRES
and durability.
This information will assist the service personnel THIS VEHICLE CONFORMS TO ALL APPLICABLE FEDERAL MOTOR VEHICLE SAFETY
in providing maximum protection for each owner's STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE SHOWN ABOVE.
vehicle.
Conditions can vary with individual driving habits. SINGLE DUAL
It is necessary to schedule maintenance as a time in

BAR CODE
terval as well as a distance interval.
It is the owner's responsibility to determine the ap
plicable driving condition. Also to have the vehicle
VEHICLE MADE IN 4648503 J9UN-25
serviced according to the maintenance schedule, and Fig. 1 Vehicle Safety Certification Label
to pay for the necessary parts and labor.
Vehicles with a Gross Vehicle Weight Rating SEVERE DRIVING CONDITIONS
(GVWR) of 3 855 kg (8,500 lbs.) or less must conform Vehicles subjected to severe driving conditions
to light duty emission standards. Vehicles with a should decrease the interval between component
Gross Vehicle Weight Rating (GVWR) of 3 856 kg maintenance. Severe driving conditions are defined
(8,501 lbs.) or more must conform to heavy duty as:
emission standards. • Frequent short trip driving less than 24 km (15
The GVWR for each vehicle is listed on the Safety miles)
Certification Label. This label is affixed to the driver • Frequent driving in dusty conditions
side door pillar (Fig. 1). • Trailer towing
Additional maintenance and lubrication informa • Extensive engine idling
tion is listed in the Owner's Manual. • Sustained high speed operation
• Desert operation
• Frequent starting and stopping
• Cold climate operation
0 - 2 LUBRICATION AND MAINTENANCE
• Commercial service
When a vehicle is continuously subjected to severe VEHICLE NOISE EMISSION CONTROL INFORMATION
driving conditions, lubricate: DATE OF VEHICLE MANUFACTURE
• Body components
THIS VEHICLE CONFORMS TO U.S. EPA REGULATIONS FOR NOISE EMISSION
• All the driveline coupling joints APPLICABLE TO MEDIUM AND HEAVY DUTY TRUCKS.
THE FOLLOWING ACTS OR THE CAUSING THEREOF BY ANY PERSON ARE
• Steering linkage PROHIBITED BY THE NOISE CONTROL ACT OF 1972. (A) THE REMOVAL OR
RENDERING INOPERATIVE, OTHER THAN FOR PURPOSES OF MAINTENANCE,
More often t h a n normal driving conditions REPAIR. OR REPLACEMENT, OF ANY NOISE CONTROL DEVICE OR ELEMENT OF
DESIGN (LISTED IN THE OWNERS MANUAL) INCORPORATED INTO THIS VEHICLE
IN COMPLIANCE WITH THE NOISE CONTROL ACT: (B) THE USE OF THIS VEHICLE
AFTER SUCH DEVICE OR ELEMENT OF DESIGN HAS BEEN REMOVED OR
DUSTY AREAS RENDERED INOPERATIVE.
With this type of severe driving condition, special
PU626D
care should be given to the:
• Engine air cleaner filter Fig. 2 Vehicle Noise Emission Control Information
• PCV filter Label
• Crankcase ventilation system
• Brake booster control valve air filter. UNAUTHORIZED DEFEAT OF NOISE
Verify t h a t the filters and the associated compo CONTROL COMPONENTS
nents are clean. Also verify t h a t they are functioning Federal law prohibits removal, altering or other
effectively. This will minimize the amount of abra wise defeating any noise control component. This in
sive particles t h a t enter the engine. cludes before or after the vehicle is in use. Federal
law also prohibits the use of a vehicle after a noise
OFF-ROAD (4WD) OPERATION control component is defeated.
After off-road (4WD) operation, inspect the under
REQUIRED MAINTENANCE/SERVICE FOR
side of the vehicle. Inspect the:
NOISE CONTROL
• Tires
The following maintenance is required after each
• Body structure
6-month or 9 600 km (6,000 miles) interval. This will
• Steering components
ensure t h a t the vehicle noise control components are
• Suspension components
operating properly.
• Exhaust system
• Threaded fasteners EXHAUST SYSTEM
HARSH SURFACE ENVIRONMENTS Inspect exhaust system for exhaust leaks and dam
aged components. The exhaust hangers, clamps and
After extended operation in harsh environments,
U-bolts should be attached and in good condition.
the brake drums, brake linings, and rear wheel bear
Burned or ruptured mufflers, damaged exhaust pipes
ings should be inspected and cleaned. This will pre
should be replaced. Refer to Group 11—Exhaust Sys
vent wear and erratic brake action.
tem/Intake Manifold for service information.
ROUTINE MAINTENANCE AIR FILTER HOUSING/CANISTER
The following routine maintenance is recommended
Inspect the air filter assembly for proper fit. Verify
on a monthly basis:
the cover is securely attached to the housing/canis
TIRES—Inspect the tires for unusual wear/damage.
ter. Inspect all the air filter housing hoses for con
Determine if the inflation pressure is adequate for
nections. The gasket between the air filter housing
the vehicle load.
and throttle body must be in good condition. The air
BATTERY—Inspect and clean the terminals.
filter element should be clean and serviced according
Tighten the terminals if necessary.
to the maintenance schedule.
FLUIDS—Determine if the component fluid levels
are acceptable. Add fluid, if necessary.
FUEL REQUIREMENTS
LIGHTS/ELECTRICAL—Test all the electrical sys
tems in the vehicle for proper operation. GASOLINE ENGINES
It is also recommended t h a t the engine oil and the All engines require the use of unleaded gasoline to
washer fluid level be determined at each fuel fill-up. reduce the effects of lead to the environment. Also
unleaded fuel is necessary to prevent damage to the
VEHICLE NOISE CONTROL catalytic converter/0 sensor. The fuel must have a
2
Vehicles with a GVWR of 4 535 kg (10,000 lbs), or minimum octane rating of 87 based on the (R + M)/2
more, are required to comply with Federal Exterior calculation method.
Noise Regulations (Fig. 2).
• LUBRICATION AND MAINTENANCE 0- 3
CAUTION: UNLEADED FUEL ONLY must be u s e d in OIL

vehicles equipped with a catalyst e m i s s i o n control QUALITY
s y s t e m . All vehicles have reminders printed o n the
instrument panel below the fuel g a u g e a n d o n the
fuel filler door. T h e vehicles a l s o have fuel filler
tubes that are specially d e s i g n e d to accept only the SAE
small-diameter nozzles. It is illegal to b y p a s s the VISCOSITY
d e s i g n of a n unleaded fuel filler tube. GRADE
DIESEL ENGINES
All Ram Truck and Ram Cab/Chassis Diesel en
gines normally can use number 2D Diesel fuel for FUEL
most year-round operations. A fuel conforming to ECONOMY
NOTATION J91004
ASTM Specification D-975 is recommended. For ex
treme cold-weather, number I D Diesel fuel is recom
Fig. 3 SAE Oil Viscosity Grade & API Service Grade
mended.
CHASSIS COMPONENT AND WHEEL BEARING
CLASSIFICATION OF LUBRICANTS LUBRICANTS
Lubricating fluids and chassis lubricants are clas The chassis and wheel bearing lubricants are iden
tified by the NLGI Certification Symbol. The symbol
sified according to standards recommended by the:
contains a coded designation. This identifies the us
• Society of Automotive Engineers (SAE)
age and quality of t h e lubricant.
• American Petroleum Institute (API) The letter G within the symbol designates wheel
• National Lubricating Grease Institute (NLGI) bearing lubricant. The letter L designates chassis lu
bricant. When the letters are combined, the lubricant
ENGINE OIL
can be used for dual applications. Use only lubricants
t h a t display the NLGI Certification Symbol.
SAE VISCOSITY GRADE
An SAE viscosity grade is used to specify the vis
NATIONAL LUBRICATING
cosity of engine oil. SAE 30 specifies a single viscos G R E A S E INSTITUTE
ity engine oil. -CERTIFICATION
SYMBOL
Engine oils also have multiple viscosities. These
are specified with a dual SAE viscosity grade which
indicates the cold-to-hot temperature viscosity range
NLGI
AUTOMOTIVE
WHEEL B E A R I N G & C H A S S I S
(Fig. 3). LUBRICANT
API SERVICE GRADE — USAGE AND

The API Service Grade specifies the type of perfor
GC-LB QUALITY DESIGNATION
mance the engine oil is intended to provide. The API
Service Grade specifications also apply to energy con
serving engine oils (Fig. 3). J920W7
For maximum gasoline engine protection, use API
Service Grade SG, SG/CD or SG/CE engine oil. Fig. 4 NLGI Lubricant Container Certification/
For maximum Diesel engine protection, u s e Identification Symbol
API Service CE or SG/CE e n g i n e oil. LUBRICATION AND REPLACEMENT PARTS
GEAR LUBRICANTS RECOMMENDATION
A dual grade is also used to specify the viscosity of Ram Trucks are engineered to provide many years
multi-purpose gear lubricants. of dependable operation. However, lubrication service
The API grade designation identifies gear lubri and maintenance are required for each vehicle. When
necessary, MOPAR®brand lubricants and genuine re
cants in terms of recommended usage.
placement parts are recommended.
COMPONENTS REQUIRING NO LUBRICATION • Drive shaft center bearings

There are many components t h a t should not be lu • Idler arms
bricated. The components t h a t should not be lubri • Rubber bushings
cated are: • Starter motor bearings
• Air pumps • Suspension strut bearings
• Generator bearings • Rear spring shackle bolts
• Brake booster cylinder • Rear wheel bearings (not equipped with a Dana
• Clutch release bearings or 70 axle)
• Distributors • Throttle control cables
• Drive belts • Throttle linkage ball joints
• Drive belt idler pulleys • Water pump bearings
GASOLINE ENGINE MAINTENANCE SCHEDULE
LIGHT DUTY CYCLE

SCHEDULED MAINTENANCE FOR EMISSIONS CONTROL - PROPER VEHICLE PERFORMANCE
Inspection and service is also necessary any rime a malfunction is observed or suspected.
X = Scheduled maintenance for all vehicles.

O = Scheduled maintenance for all vehicles, Recommended for proper vehicle performance.
Where both time and mileage Miles (Thousand) 7'A 15 22'A 30 37'A 45 52'A 60 67'A 75 82'A 90 97'/2 105 112'A 120
are shown, follow the interval
which occurs first. Kilometers (Thousand) 12 24 36 48 60 72 84 96 108 120 132 144 156 168 180 192
Coolant Condition, Coolant Hoses/Clomps X X X X X X O O O O O O O O o O
Exhaust System—Check X X X X X X O O O o O O O o o o
Oil—Change (6 months) X X X X X X O O O o o O O o o o
Oil Filter—Change (2nd Oil Change) X X X o o O o o
Spark Plug—Replace X 0 o o
Air Filter—Replace X o O o
Coolant—Flush/Replace (36 months) &

24 months/48 000 km (30,000 miles) thereafter O X X
PCV Valve—Replace if Necessary O' O' O'
Battery—Replace O
This maintenance is recommended by Chrysler Corporation to the owner, but is not required to maintain the warranty.
GASOLINE ENGINE MAINTENANCE SCHEDULE
HEAVY DUTY CYCLE

Inspection and service is also necessary anytime a malfunction is observed or suspected.
W h e n both time a n d mileage are Miles (Thousand) 6 12 18 24 30 36 42 48 54 60 66 72 78 82V2 84 90 96 102 108

shewn, follow the interval
which occurs first. Kilometers (Thousand) 9.6 19 29 38 48 58 67 77 85 96 106 116 125 132 135 145 154 164 174
Coolant Condition, Coolant Hoses/Clamps X X X X X X X X X X X X X X X X X X

Exhaust System — Check X X X X X X X X X X X X X X X X X X
Oil — Change (6 Months) X X X X X X X X X X X X X X X X X X
Oil Filter — Change (2nd Oil Change) X X X X X X X X X
Drive Belt Tension — Inspect & Adjust X' X X 1
X X' X
Drive Belts (V-Type) — Replace X
Air Filter/Air Pump Air Filter — Replace X X X X
Crankcase Inlet Air Filter (6 & 8 Cyl. Eng. Only) — Clean X X X X
Spark Plug — Replace X X X
Fuel Filter — Replace as necessary
Coolant — Flush/Replace (36 months) & 24 months/48 000 km
X
(30,000 miles) thereafter
2
EGR Valve & Tube — Replace X
2
EGR Tube — Clean Passengers X
2
PCV Valve — Replace X
Vacuum Emission Components — Replace X
Ignition Timing — Adjust to Specs, as necessary X
Ignition Cables, Distributor Cap & Rotor — Replace X
Manifold Heat Control Valve — Lubricate X
Battery — Replace X
2
Oxygen Sensor — Replace X
1
For California vehicles, this maintenance is recommended by Chrysler Motors to the owner but, is not required to maintain the warranty on the air pump drive belt.
2
Requires Emission Maintenance Reminder Light. If so equipped, these parts are to be replaced at the indicated mileage, or when the emissions maintenance
reminded light remains on continuously with the key in the "on" position, whichever occurs first.
J9100-20
DIESEL ENGINE MAINTENANCE SCHEDULE
HEAVY DUTY CYCLE Inspection and service is also necessary any time a malfunction is observed or suspected.
Iff both time and distance Miles (Thousand) 6 12 18 24 30 36 42 4S 54 60 66 72 78 84 90 96 102 108
are listed, use the interval
that ends first. Kilometers (Thousand) 9,6 19 29 38 48 58 67 77 85 96 106 116 125 135 145 154 164 174
Coolant Condition, Coolant Hoses/Clamps (12 months)
Coolant Flush/Replace (36 months) & 24 months/ O
48 000 km (30,000 miles) thereafter
Oil—Change (6 months) X X X X X X X X X X X X X X X X X X
Oil Filter—Replace (Every Oil Change) X X X X X X X X X X X X X X X X X X
Drive Belts—Replace As Necessary X X X X X X
Air Filter—Replace X X X X
Air Filter—Clean (California Only) e ® • •
Air Filter Canister—Clean o o o o
Fuel Filter—Service When Necessary
Injection Pump Timing & Engine Idle Speed— © • 9 • • •
Check & Adjust
Underhood Rubber/Plastic Components—Inspect/Replace • • • • •
X — All vehicles O — All vehicles except California. Recommended for California. • — California only. Recommended for all vehicles.
CHASSIS LUBRICATION
For light duty cycle v e h i c l e s G V W resting of 3 855 K g (8,500 lbs ) and below.
Component Truck Models Fittings Service Interval Lubricant
Center Link AD1 AD2 2 3 6 0 0 0 km ( 2 2 , 5 0 0 miles) or 2 years Multi-purpose grease - NGLI grade 2 EP
AD 4 (Multi-Mileage Lubricant)
Drag Link Bali joints AW1 AW 2 2 1 2 0 0 0 km ( 7 , 5 0 0 miles) or 6 months Multi-purpose grease - NGLI grade 2 EP
AW 8 (Multi-Mileage Lubricant)
Gearshift Mechanism AD1 1 3 6 0 0 0 km ( 2 2 , 5 0 0 miles) or 2 years Multi-purpose grease - NGLI grade 2 EP
Overdrive 4 (Multi-Purpose Lubricant)
Parking Brake Ratio AD1 AD 2 AD4 — 3 6 0 0 0 km ( 2 2 , 5 0 0 miles) or 2 years Multi-purpose grease - NGLI grade 2 EP
Lever Pivot AW1 AW 8 (Multi-Purpose Lubricant)
Propeller Shaft U-joint AW1 AW2 3 (1 Piece 1 2 0 0 0 km ( 7 , 5 0 0 miles) or 6 months Multi-purpose grease - NGLI grade 2 EP
rear (Multi-Purpose Lubricant)
AW 8
P/shaft)
Propeller Shaft Slip Spline AD1 AD 2 1 3 6 0 0 0 km ( 2 2 , 5 0 0 miles) or 2 years. For severe Multi-purpose grease - NGLI grade 2 EP
( 2 piece P/shaft) service, every 4 8 0 0 km ( 3 , 0 0 0 miles) or 3 months. (Multi-Purpose Lubricant)
Daily, if vehicle is operated in water
Suspension Ball Joints AD1 AD 2 4 3 6 0 0 0 km ( 2 2 , 5 0 0 miles) or 2 years — every engine Multi-purpose grease - NGLI grade 2 EP
oil change for off-highway operation (Multi-Mileage Lubricant)
Tie Rod Ball Joints AD1 AD2 4 3 6 0 0 0 km ( 2 2 , 5 0 0 miles) or 2 years Multi-purpose grease - NGLI grade 2 EP
AD4 (Multi-Mileage Lubricant)
AW1 AW 2 2 1 2 0 0 0 km ( 7 , 5 0 0 miles) or 6 months. Daily, if
AW8 vehicle is operated in water
NP-241 Transfer Case Shift AW1 AW2 — As Required Multi-purpose grease - NGLI grade 2 EP
Lever Pivot AW8 (Multi-Purpose Lubricant)
Wheel Stop AD1 AD 2 AD4 — 3 6 0 0 0 km ( 2 2 , 5 0 0 miles) or as required Wax Type Lubricant
Constant Velocity Joint AW1 AW2 1 1 2 0 0 0 km ( 7 , 5 0 0 miles) Multi-purpose grease - NGLI grade 2 EP
(Front P/shaft) AW8 (Multi-Purpose Lubricant)
>
J9000-59
>
CHASSIS LUBRICATION (CONT'D)
For heavy duty cycle vehicles GVW rating of 3 856 Kg (8,501 Sbs.) and above.
Component Truck Models Fittings Service Interval Lubricant
Center Link AD2-3 2 39 000 km (24,000 miles) or 2 years Multi-purpose grease - NGLI grade 2 EP
(Multi-Mileage Lubricant)
Drag Link Ball Joints AW3 2 9 600 km (6,000 miles) or 6 months Multi-purpose grease - NGLI grade 2 EP
Constant Velocity Joint AW3 1 9 600 km (6,000 miles) Multi-purpose grease - NGLI grade 2 EP
(Front P/shaft) (Multi-Purpose Lubricant)
P/shaft U-Joints AW3 3 9 600 km (6,000 miles) or 6 months. For severe Multi-purpose grease - NGLI grade 2 EP
service, every 1 600 km (1,000 miles). Daily, if (Multi-Purpose Lubricant)
vehicle is operated in water.
P/shaft Slip Spline AW3 (135" WB) 1 39 000 km (24,000 miles) or 2 years. For severe Multi-purpose grease - NGLI grade 2 EP
service every 4 800 km (3,000 miles) or 3 months. (Multi-Purpose Lubricant)
Daily, if vehicle is operated in water.
Suspension Ball Joints AD2-3 4 39 000 km (24,000 miles) Multi-purpose grease - NGLI grade 2 EP
Tie Rod Ball Joints AD2-3 4 39 000 km (24,000 miles) or 2 years Multi-purpose grease - NGLI grade 2 EP
AW2-3 2 9 600 km (6,000 miles) or 6 months (Multi-Mileage Lubricant)
NP-205 Transfer Case AW2-3 — As required Light Engine Oil

Shift Linkage
NP-241 Transfer Case Shift AW2 — As required Multi-purpose grease - NGLI grade 2 EP
Lever Pivot (Multi-Purpose Lubricant)
J9000-60
• LUBRICATION AND MAINTENANCE 0-9
FLUID CAPACITIES
C O O L I N G SYSTEM QUARTS LITERS POWER STEERING PINTS LITERS

3.9L ENGINE 15.1 14.3 ALL 2.7 1.28
5.2L ENGINE ( WD) 2 17.0 16.1 REAR AXLE PINTS LITERS
5.2L ENGINE ( WD) 4 16.5 15.6 CHRYSLER BVa Inch (210 mm) 4.4 2.08
5.9L ENGINE ( 2 WD) 15.5 14.7 CHRYSLER 9Va Inch (235 mm) 4.5 2.13
5.9L ENGINE ( WD) 4 15.0 14.2 D A N A 60 6.0 2.84
5.9L DIESEL ENGINE (MAN.TRANS.) 15.5 14.7 D A N A 70 7.0 3.31
5.9L DIESEL ENGINE (AUTO, T R A N S ) 16.5 15.6 FRONT A X L E PINTS LITERS
ENGINE CRANKCASE QUARTS LITERS D A N A 44 FBJ 5.6 2.65
3.9L, 5.2L & 5.9 ENGINES 4.0* 3.8* D A N A 60 F 6.5 3.07
5.9L DIESEL ENGINES 12.0* 11.4** TRANSMISSION-AUTOMATIC QUARTS LITERS
FUEL T A N K GALLON LITERS A 727 (5.9L ENGINE) 8.4 7.9
STANDARD 3.9L & 5.2L ENGINES 22.0 83.0 A 998 (3.9L ENGINE) 8.6 8.1
OPTIONAL 3.9L & 5.2L ENGINES 30.0 113.0 A 999 (5.2L ENGINE) 8.6 8.1
5.9L ENGINE {G OR D) 30.0 113.0 A 518 (5.2L & 5.9L ENGINES) 10.2 9.6
AD 100 & A W 100 34.0 128.0 TRANSMISSION-MANUAL QUARTS LITERS
TRANSFER CASE PINTS LITERS NV 4500 4.0 3.8
NP-205 4.5 2.13 GETRAG 360 (5 Speed) 3.5 3.3
NP-241 6.0 2.84
* Add 0.5 qt. or 0.45 liter when the oil filter is changed
* * Add 1 qt. or 0.9 liter with oil filter change J9200-86
STARTING ASSISTANCE (JUMP STARTING) (1) Engage the parking brake. Shift the automatic
transmission to PARK (if a m a n u a l transmission,
W A R N I N G : D O NOT ATTEMPT TO PUSH O R TOW A shift to NEUTRAL).
VEHICLE TO START THE ENGINE. U N B U R N E D (2) Turn off all lights, and all other electrical
FUEL COULD ENTER CATALYTIC CONVERTER loads.
A N D IGNITE A F T E R T H E E N G I N E I S S T A R T E D . (3) Observe the battery condition indicator (Fig. 5).
THIS C O U L D C A U S E THE C O N V E R T E R T O OVER If the battery condition indicator is light/bright col
HEAT A N D RUPTURE. ored (or yellow), replace the battery. D o not attempt
to j u m p start a n e n g i n e w h e n the condition indi
cator is light/bright colored (or yellow). If the
BOOSTER BATTERY
condition indicator is dark in the center (but without
a green dot), proceed with connecting the jumper ca
W A R N I N G : TO PREVENT P E R S O N A L INJURY O R ,
bles.
DO NOT ALLOW BATTERY ACID TO CONTACT
E Y E S , S K I N O R CLOTHING. D O NOT LEAN OVER A W A R N I N G : T H E E L E C T R O L Y T E (ACID) IN A D I S
BATTERY WHEN CONNECTING JUMPER CABLES. C H A R G E D B A T T E R Y C A N F R E E Z E . D O N O T AT
DO NOT A L L O W THE POSITIVE A N D NEGATIVE T E M P T TO J U M P S T A R T A N E N G I N E B E F O R E
C A B L E C L A M P S TO CONTACT EACH OTHER. DETERMINING THE CONDITION OF THE BATTERY
KEEP OPEN FLAMES A N D S P A R K S AWAY FROM ELECTROLYTE. THE BATTERY COULD EXPLODE
T H E B A T T E R Y E L E C T R O L Y T E VENT H O L E S . A L A N D C A U S E S E V E R E P E R S O N A L INJURY.
W A Y S W E A R E Y E PROTECTION WHEN INVOLVED
WITH V E H I C L E B A T T E R I E S .
C A U T I O N : D o not permit the metal surfaces o n the
If it becomes necessary to use a booster battery and vehicles to contact. This could establish ground
jumper cables to start a n engine, use the following (negative) continuity between the vehicle bodies.
procedure. This could cause the on-board computers to be
damaged. In addition it could reduce the amount of
current flow through the starter motor.
0-10 LUBRICATION AND MAINTENANCE •
• Black (negative) cable connector clamp from the
negative terminal (-) on the booster battery
D A R K E N E D I N D I C A T O R W I T H G R E E N DOT
• Red (positive) cable connector clamps from the pos
• LETTERS U k- itive ( + ) terminals on both batteries
O.K.TO FLUID Lt- E:L .
JUMP
START
D A R K E N E D INDICATOR NO G R E E N DOT POSITIVE
• BATTERY C H A R G E 10'//
BATTERY NEGATIVE JUMPER
• Ft UID L E V E l OK
CABLE TERMINAL CABLE
BATTERY
CONDITION
INDICATOR
DO NOT L I G H T O R B R I G H T INDICATOR
JUMP • R A T - c c i , C H A P C; F R ^ ' ^ O w h
START
t
A M . w - G E FlAf S I l l BE
BATTERY
r - • ! F- r tjr r
? STA F • r O U n C AI :
J9100-26
Fig. 5 Battery Condition indicator

(4) Attach a red jumper cable connector clamp to
the positive (4-) terminal on the booster battery. At J9000-37
tach the other red cable connector clamp to the pos
itive ( + ) terminal on the discharged battery (Fig. 6). Fig. 6 Positive Jumper Cable Connection
C A U T I O N : D o not allow the positive ( + ) and nega ENGINE BATTERY

•GROUND NEGATIVE
tive (-) cable clamps to contact each other. D o not NEGATIVE CABLE
lean over the battery when connecting the cable -JUMPER
clamps. CABLE
WARNING: D O NOT CONNECT A JUMPER CABLE

CONNECTOR CLAMP TO THE NEGATIVE POST OF
THE DISCHARGED BATTERY.
(5) Connect a black jumper cable connector clamp
to the negative (-) terminal on the booster battery.
Connect the other black jumper cable connector
clamp to a good ground source on the engine t h a t is
to be started (Fig. 7). J9000-38
BATTERY
Verify the engine ground (negative) contact
surface area is free of grease. Make sure there is Fig. 7 Both Jumper Cables Connected On Disabled
a g o o d connection to bare metal. The engine Vehicle
ground (negative) connection must provide g o o d
PORTABLE STARTING UNIT
electrical continuity.
(6) Start the engine. There are many types of portable starting units
available for starting engines. Follow the manufac
WARNING: THE USE OF ANY JUMPER CABLE DIS turer's instructions.
CONNECTION PROCEDURE OTHER THAN THAT
DESCRIBED BELOW COULD RESULT IN: VEHICLE LIFTING RECOMMENDATIONS
Refer to the Owner's Manual for emergency vehicle
• PERSONAL INJURY CAUSED BY BATTERY lifting procedures.
ACID SQUIRTING FROM THE BATTERY VENTS
• PERSONAL INJURY AND/OR PROPERTY DAM FLOOR JACK
AGE CAUSED BY BATTERY EXPLOSION When properly positioned, a floor jack can be used
• DAMAGE TO THE BOOSTER VEHICLE OR THE to lift a vehicle (Fig. 8). Support the vehicle in the
DISABLED VEHICLE CHARGING SYSTEM. raised position with jack stands at the front and rear
(7) After the engine is started, the jumper cables ends of the frame rails.
must be disconnected in the following order:
• Black (negative) cable connector clamp from the CAUTION: D o not attempt to lift a vehicle with a
engine ground contact floor jack positioned under:
LUBRICATION AND MAINTENANCE 0-11
The lift arms, pads or ramps should be adjusted to

ensure t h a t there is adequate clearance (Fig. 9).
ADJUSTMENT PAD
ii 7
M A I N T A I N CLEARANCE
HOIST ARM
RK44
J DRIVE-ON HOIST TWIN POST CHASSIS HOIST Fig. 9 Lifting 4WD Vehicle With Single-Post
I FRAME CONTACT HOIST Hoist— Typical
FLOOR JACK RROOD30
When a twin-post hoist is used, a 4 x 4 x 12-inch
Fig. 8 Correct Vehicle Lifting Locations wood spacer also could be required. Place the wood
An axle tube spacer under the front axle (opposite the differential
A body side sill housing). This will maintain balance and level lift
A steering linkage component ing.
A drive shaft C A U T I O N : The block that is used must be secured
The engine or transmission oil pan in a safe manner. This will ensure that it will not un
The fuel tank balance the vehicle.
• A front suspension arm
Use the correct frame rail lifting l o c a t i o n s only
(Fig. 8). VEHICLE TOWING RECOMMENDATIONS
When it is necessary to tow a Ram Truck, the rec
HOIST ommended method is either:
A vehicle can be lifted with: • the sling-type, rear-end raised towing method; or
• A single-post, frame-contact hoist • the wheel-lift towing method with a tow dolly lo
• A twin-post, chassis hoist cated under the front wheels.
• A ramp-type, drive-on hoist A vehicle with flat-bed hauling equipment can also
When a frame-contact type hoist is used, verify be used to transport a disabled vehicle.
that the lifting p a d s are positioned properly
(Fig. 8).
WARNING: WHEN A SERVICE PROCEDURE R E

Q U I R E S T H E R E M O V A L O F T H E R E A R AXLE, F U E L SLING-TYPE
TANK, O R S P A R E T I R E , E I T H E R :
• PLACE ADDITIONAL WEIGHT ON THE REAR

END OF THE VEHICLE
« ATTACH THE VEHICLE TO THE HOIST
« PLACE JACK STANDS UNDER THE VEHICLE
FOR SUPPORT TO PREVENT TIPPING WHEN
THE CENTER OF BALANCE CHANGES
4WD VEHICLES FLAT BED RR0OD29

A standard hoist can be used to lift a 4WD vehicle.
The hoist should be inspected for adequate clearance. Fig. 10 Tow Vehicles With Approved Equipment
0 - 12 LUBRICATION AND MAINTENANCE •
A vehicle equipped with SAE approved sling-type (1) Attach the J-hooks around the axle shaft tubes
towing equipment can be used (Fig. 10). However, outboard of the rear springs.
many vehicles are equipped with air dams, spoilers, (2) Position and center the sling under and for
and/or ground effect panels. In this case a wheel-lift ward of the rear bumper.
towing vehicle or a flat-bed hauling vehicle is recom (3) Attach safety chains (with pads) at each end of
mended (Fig. 10). If a flat bed device is used, the ap the rear bumper.
proach angle should not exceed 15 degrees. (4) Turn the ignition switch to the OFF position to
unlock the steering wheel.
GROUND CLEARANCE (5) Clamp the steering wheel with the front wheels
The lifted wheels of the disabled vehicle should be in the straight ahead position.
a minimum of 10 cm (4 in.) off the ground. Make
sure there is enough clearance at the opposite end. C A U T I O N : D o not use the steering column lock to
This is critical when towing over rough terrain. If secure front wheel in the straight-ahead position.
necessary, the rear ground clearance can be in
creased by removing the wheels from the lifted end (6) Shift the transmission to NEUTRAL.
and then towing with the lifted end closer to the
ground. If the rear wheels are removed, secure the
brake drums. A 20 cm (8 in.) ground clearance must
be maintained between brake drums or rotors and
the ground.
SAFETY PRECAUTIONS
The following safety precautions must be consid
ered when preparing for and during a vehicle towing
operation:
• Remove exhaust pipe tips t h a t interfere with the
tow sling and crossbar
• Padding should be placed between the tow sling/
crossbar and any painted surfaces
• If the vehicle is damaged, secure the loose and pro
truding parts
• Always use a safety chain system t h a t is indepen
dent of the lifting and towing equipment POSITION CENTER BAR FORWARD OF BUMPER -
• When placing tow hooks on the rear axle, position / J - H O O K S OUTBOARD OF SPRINGS RN967A
them so they do not damage the brake tubing or
hoses Fig. 11 Rear-End Raised Towing
• Do not allow any of the towing equipment to con FRONT'END RAISED TOWING
tact the fuel tank If a vehicle cannot be towed from the rear, the
• Do not tow the vehicle by connecting to the front front-end raised towing method normally can be
or rear shock absorbers used (Fig. 12).
• The operator should not go under a vehicle while (1) Center the sling with the bumper and position
it is lifted by the towing equipment. The vehicle it at the frame front crossmember.
should first be supported by safety stands
• Do not allow passengers in a vehicle being towed C A U T I O N : Use tow chains with J-hooks for con
• Observe all state and local laws involving warning necting to the disabled vehicle's lower s u s p e n s i o n
signals, night illumination, speed, etc. arms. Never use T-hooks.
• Do not exceed a towing speed of 48 km/h (30 mph)
• Avoid towing distances of more t h a n 24 km (15 (2) Route the J-hooks and tow chains over the
miles) whenever possible steering linkage outboard of the coil spring.
• Do not attach tow chains or a tow sling to a (3) Attach the J-hooks to the outer end of the
bumper, the steering linkage, the universal joints, or lower suspension arms.
a drive shaft (4) Raise the vehicle.
REAR-END RAISED TOWING (5.) Attach the safety chains to the disabled vehicle
It is recommended t h a t the rear-end raised towing at the frame rails.
method be used. Vehicles can be towed with the front Vehicles equipped with a MANUAL TRANSMIS
wheels on the ground for extended distances at SION can be towed with the rear wheels on the
speeds not exceeding 48 km/h (30 mph) (Fig. 11).
• LUBRICATION AND MAINTENANCE 0 - 13
ground. Do not exceed speeds of 48 km/h (30 mph) or

a distance of 24 k m (15 miles). The transmission
must be in neutral.
Front-end raised towing for a vehicle equipped
with an AUTOMATIC TRANSMISSION is not rec
ommended.
CAUTION:lt is not recommended to flat tow a vehi

cle.
LOCKED VEHICLE TOWING

When a locked vehicle must be towed, use a tow
dolly or flat bed hauler.
POSITION CENTER BAR AND WOOD BEAM BEHIND

BUMPER AND AHEAD OF STRUTS TO SUPPORT
CHAINS CLEAR OF SWAY BAR RN966
Fig. 12 Front-End Raised Towing—Typical

ENGINE MAINTENANCE
INDEX
page page
Air Injection Systems/Air Pump . 17 Exhaust Manifold Heat Control Valve . 17
Air-Conditioner Compressor 21 Exhaust System , 21
Battery 19 Fuel System 18
Cooling System 15 Hoses and Fittings 16
Crankcase Ventilation System 17 Ignition Cables, Distributor C a p and Rotor . . . . . . 19
Diesel Engine Air Filter Canister 17 Ignition Timing . 19
Drive Belts 20 Oxygen ( 0 ) Sensor
2 19
Engine Air Cleaner Filter Element 16 Rubber/Plastic Components 20
Engine Break-In 14 Spark Plugs . 19
Engine Oil 14 Throttle Control Linkage 18
Engine Oil Change and Filter Replacement 15 Vacuum Operated, Emission Control
Exhaust G a s Recirculation ( E G R ) System . . . . . . 19 Components 19
ENGINE BREAK-IN
After first starting a new engine, allow it to idle
10W-30
for 15 seconds before shifting into a drive gear. Also:
• Drive the vehicle at varying speeds less t h a n 88
km/h (55 mph) for the first 480 km (300 miles). < 1
5W-30
1 1
• Avoid fast acceleration and sudden stops. F -20 0 10 20 32 60 80 100
• Do not drive at full-throttle for extended periods of C -29 -18 -12 -7 0 16 27 38
time ANTICIPATED TEMPERATURE RANGE
• Do not drive at constant speeds BEFORE NEXT OIL CHANGE J9000-39
• Do not idle the engine excessively
A special break-in engine oil is not required. The Fig. 1 Temperature/Engine Oil Viscosity—Gasoline
original engine oil installed is a high quality lubri Engines
cant.
New engines tend to consume more fuel and oil un 15W-40
til after the break-in period has ended. -12°C 10°F
ENGINE OIL -18°C 0°F-

WITH
BLOCK
I 10W-30
WITHOUT BLOCK HEATER

SYNTHETIC OIL
SPECIFICATIONS e HEATER 10W-30 5W-30
-23°c(^-10 F
API SERWICE GRADE
Use an engine oil t h a t conforms to API Service
J9100-29
Grade S SG/CD or SG/CE. MOPAR®provides engine
5
oils t h a t conform to all of these service grades. Fig. 2 Temperature/Engine Oil Viscosity—Diesel
Engines
SULFATED ASH—DIESEL ENGINES
ENERGY G0NSERWING OIL
Oils t h a t contain an excessive amount of sulfated
An Energy Conserving type oil is recommended for
ash can cause deposits to develop on Diesel engine
gasoline engines. They are designated as either EN
valves. These deposits can result in valve wear. ERGY CONSERVING or ENERGY CONSERVING
II.
SAE WISC0SITY
An SAE viscosity grade is used to specify the vis OIL LEVEL INDICATOR (DIPSTICK)
cosity of engine oil. SAE 30 specifies a single viscos
ity engine oil. GASOLINE ENGINES
Engine oils also have multiple viscosities. The engine oil indicator is located at the right
front of the engine.
DIESEL ENGINES ENGINE OIL FILTER

The Diesel engine oil level indicator is located at All engines are equipped with a throw-away type
the left center of the engine, above the fuel injection oil filter. The same type of filter is recommended
pump (Fig. 3). when the filter is changed.
OIL CHANGE AND FILTER REPLACEMENT

Bring engine up to normal operating temperature.
A more complete drainage of oil will result.
(1) Remove the drain hole plug and drain the en
gine oil from the crankcase.
(2) Install the drain hole plug with a replacement
gasket.
For gasoline engines, the oil filter should be
replaced during every s e c o n d engine oil change.
For Diesel engines, the oil filter should b e re
placed during every engine oil change.
(3) Rotate t h e oil filter counterclockwise to remove
it.
(4) Clean the engine cylinder block oil filter boss.
(5) Apply a light coat of new engine oil to t h e rub
Fig. 3 Diesel Engine Oil Dipstick ber seal on the oil filter.
(6) Install and hand tighten the oil filter 1/2 to 3/4
ACCEPTABLE OIL LEVEL
of a turn clockwise.
To maintain proper lubrication of an engine, the (7) Add new engine oil at the fill hole location on
engine oil must be maintained at an acceptable level. top of the engine cylinder head cover. Wipe off any
For gasoline engines, the acceptable levels are indi spilled oil.
cated between the ADD and F U L L marks on oil dip (8) Observe the oil level on the dipstick.
stick. For Diesel engines, the acceptable levels are
indicated between the L (low) and H (high) marks on C A U T I O N : Do not overfill the engine crankcase with
oil dipstick. oil.
The oil level should be checked periodically. The
vehicle should be on a level surface. Wait for five (9) Start the engine. Observe the oil pressure
minutes after stopping the engine. For gasoline en gauge or warning lamp (as applicable). If the oil
gines, add oil only when the level indicated on the pressure does not increase, stop the engine immedi
dipstick is at or below the ADD mark. For Diesel en ately. Check oil level.
gines, add oil only when the level indicated on the
dipstick is between the L and H marks. N e v e r oper COOLING SYSTEM
a t e a Diesel engine w h e n the oil level i s b e l o w
WARNING: U S E EXTREME CAUTION WHEN THE
t h e L m a r k . The distance between the L and H
E N G I N E I S O P E R A T I N G . D O NOT P U T Y O U R
m a r k s represents 1.9L (2 Qts) engine oil. H A N D S N E A R T H E D R I V E BELT(S), P U L L E Y S O R
F A N B L A D E . D O NOT S T A N D IN A D I R E C T LINE
C A U T I O N : Do not overfill an engine crankcase with
WITH T H E F A N B L A D E .
oil. This will cause oil aeration and result in a de
crease in the engine oil pressure.
INSPECTION SCHEDULE
Determine the coolant level. Inspect the cooling
ENGINE OIL CHANGE AND FILTER REPLACEMENT system hoses/clamps after each service interval has
elapsed.
W A R N I N G : P R O T E C T I V E CLOTHING A N D G L O V E S
SHOULD B E WORN. EXPOSED SKIN SHOULD B E COOLANT LEVEL
W A S H E D WITH S O A P A N D W A T E R TO R E M O V E It is recommended that the engine coolant level be
U S E D E N G I N E OIL. D O NOT U S E G A S O L I N E , THIN inspected at least once a month during periods of hot
N E R , O R S O L V E N T S TO R E M O V E E N G I N E O I L weather.
F R O M S K I N . D O NOT POLLUTE. D I S P O S E O F U S E D With the engine at normal operating temperature,
E N G I N E OIL P R O P E R L Y . check the coolant level in the coolant reserve tank.
The coolant level must be at least above the ADD
mark. Add coolant to the coolant reserve t a n k only.
COOLANT FREEZE PROTECTION ENGINE AIR CLEANER FILTER ELEMENT
Cooling systems contain a 50/50 mixture of anti
freeze (ethylene glycol) and distilled water. This is MAINTENANCE SCHEDULE
the recommended coolant mixture. With normal driving conditions, the engine air
It is recommended t h a t the degree of coolant pro cleaner filter element should be replaced:
tection be tested every 12 months. If the coolant is • Light-Duty C y c l e - a f t e r each 48 000 km (30,000
contaminated or rusty, the cooling system should be miles) interval has elapsed
drained, flushed. Refill with a 50/50 mixture of fresh • Heavy-Duty C y c l e - a f t e r each 38 000 km (24,000
coolant. Refer to Group 7—Cooling Systems for addi miles) interval has elapsed
tional information. When the vehicle is operated in dusty areas, the
filter element should be replaced more often.
SYSTEM INSPECTION For Diesel engines, the air filter canister should be
cleaned at the same time the filter is replaced.
W A R N I N G : IF T H E E N G I N E H A S B E E N R E C E N T L Y
OPERATED, DO NOT R E M O V E THE RADIATOR SERVICE/REPLACEMENT
C A P . THIS WILL A V O I D Y O U B E I N G S C A L D E D (1) Remove the air cleaner cover.
WITH HOT, P R E S S U R I Z E D C O O L A N T . (2) Remove the air cleaner filter (Fig. 4).
(1) Test the radiator cap for proper sealing and op C A U T I O N : Do not tap the filter or immerse the filter
eration. Use caution when removing the radiator cap medium in liquid to remove trapped debris.
to avoid contact with hot coolant. Place a heavy rag
or towel over the cap and t u r n to the first stop. Do (3) Clean filter by blowing the trapped debris from
not press down. Pause to allow the pressure to re the filter with compressed air (Fig. 5). Direct the air
lease through the overflow tube. Then press down in the opposite direction of normal intake air flow.
and t u r n counterclockwise to remove the cap. Keep the air nozzle at least two inches away from
(2) Inspect the coolant overflow tubing and the the filter.
connections at the coolant reserve t a n k and at the (4) If the filter has become partially saturated with
radiator. oil, replace the filter. Inspect the crankcase ventilat
(3) Inspect the entire cooling system for leaks. A ing system for proper operation.
black-light detector can be used as an aid in detect (5) Wash the air cleaner cover and body with
ing the source of coolant leaks. cleaning solvent. Wipe it dry.
(4) Inspect the radiator and air conditioner con (6) Install the air cleaner filter element. Attach
denser fins for debris, etc. the cover to the body (Fig. 4).
(5) If necessary, refer to Group 7—Cooling Systems
for additional information and service procedures.
RADIATOR CAP
The radiator cap must be completely tightened to
provide proper pressure. Inspect and test radiator cap
when cooling system service is performed.
MAIN, FLUSH AND FILL
WARNING: ANTI-FREEZE (ETHYLENE GLYCOL) IS

P O I S O N O U S . K E E P O U T O F T H E R E A C H O F CHIL
DREN.
Drain, flush, and fill the cooling system at the in

terval specified in maintenance schedule. For proper
service instructions see Group 7, Cooling System.
HOSES AND FITTINGS

It is recommended t h a t rubber hoses be periodi
cally inspected. Inspect all hose fittings for looseness
and corrosion.
Fig, 4 Engine Air Oeaner— Typical
WARNING: USE EXTREME CAUTION WHEN THE

ENGINE IS OPERATING. DO NOT PUT YOUR
HANDS NEAR THE DRIVE BELT(S), PULLEYS OR
FAN BLADE. DO NOT STAND IN A DIRECT LINE
WITH THE FAN BLADE.
(1) With the engine idling, accelerate momen
tarily. The valve shaft counterweight should move
CLOCKWISE.
(2) If no movement is observed, either the shaft is
binding or the thermostat spring is weak or broken.
(3) If the thermostat spring is weak or broken, re
place the spring.
(4) Verify the manifold is COOL. Apply
MOPAR®Rust Penetrant (or an equivalent product)
to each end of the valve shaft at the bearings (Fig.
6).
Fig. 5 Cleaning Filter Element—Typical (5) Allow the solvent to penetrate for a few min
utes. Then, rotate the valve shaft back and forth un
DIESEL ENGINE AIR FILTER CANISTER til it turns without restriction.
MAINTENANCE SCHEDULE
The Diesel engine air filter should be cleaned after
AIR INJECTION SYSTEMS/AIR PUMP
Air injection system/air pump valves and switches
each interval specified in the Diesel engine mainte
should be periodically tested for proper operation. In
nance schedule.
spect the check valve tubing for corrosion. Replace it
When the vehicle is operated in dusty areas, the
if excessive corrosion exists.
canister should be cleaned more frequently.
CRANKCASE VENTILATION SYSTEM
EXHAUST MANIFOLD HEAT CONTROL VALVE
All gasoline engines are equipped with a positive
MAINTENANCE SCHEDULE crankcase ventilation (PCV) system. The PCV sys
The exhaust manifold heat valve should be ser tem prevents emission of residual engine oil vapor
viced after the interval specified in the maintenance from the crankcase (Fig. 7).
schedule has elapsed.
SERVICE
The exhaust manifold heat valve is located at the
left manifold (Fig. 6). Test the valve for non-re
stricted movement.
Fig. 7 Positive Crankcase Ventilation

System—Typical
SYSTEM OPERATION
Each PCV system is comprised of an air inlet filter,
a flow-control (PCV) valve, and the associated hoses.
The air inlet filter is located at the cylinder head
Fig. 6 Manifold Heat Control Valve cover (Fig. 7).
MAINTENANCE SCHEDULE THROTTLE CONTROL LINKAGE
A crankcase ventilation system must be clean to Transmission linkage pivot pin areas (Fig. 9),
provide good operation and durability. Periodic main should be serviced. The areas lubricated every second
tenance is necessary. Replace the PCV valve. Re oil change with a multi-purpose lubricant (NLGI GC-
move residual combustion deposits from the hoses LB).
and throttle body/intake manifold passages.
PIVOT AREAS
The PCV valve should be replaced and the system
should be serviced at the interval specified in main
tenance schedule. If a vehicle is routinely used for
short trips, the crankcase ventilation system could
possibly require more maintenance.
CRANKCASE AIR INLET FILTER
Replace or clean, the air inlet filter at the interval
specified in maintenance schedule.
More frequent PCV system maintenance could be
required for:
• Vehicles routinely used for short trips
Fig. 9 Transmission Linkage Pivot Areas
• Vehicles routinely involved in stop and go traffic
operation FUEL SYSTEM
• Vehicles routinely involved in extended periods of
INSPECTION
engine idle
The fuel system filler cap, nozzle, tubes, hoses, and
MAINTENANCE connections should be inspected periodically.
Clean and lubricate the crankcase air inlet filter
FUEL FILTER
according to the following procedure.
The fuel filter requires service only when a fuel
(1) Disconnect the fresh air hose from the port on
contamination problem is suspected. For proper diag
the crankcase air inlet filter housing (Fig. 8).
nosis and service procedures refer to Group 14, Fuel
(2) Remove the air filter housing from the cylinder
System.
head cover (Fig. 8). Clean the filter in kerosene or a
similar solvent. GASOLINE ENGINE FUEL REQUIREMENTS
(3) Lubricate the filter by inverting the housing All gasoline engines require fuel t h a t has a mini
and filling it with SAE 30 viscosity engine oil. mum octane rating of 87 determined by the (R +
(4) Insert the air filter housing nipple in the cylin M)/2 calculation method.
der head cover grommet. Connect the fresh air hose The use of a brand of unleaded gasoline t h a t con
to the upper port (Fig. 8). tains additives is recommended. Gasoline with addi
tives will improve fuel economy and reduce
emissions.
ALCOHOL/GASOLINE BLENDS
Many brands of blended unleaded gasoline a m now
available.
Unleaded gasoline is blended with oxygenated-type
fuels to produce a clean air gasoline in many areas.
The use of this type of blended fuel is recommended.
ETH ANOL—Unleaded gasoline and ethanol
blended fuels are a mixture of 10 percent ethanol
and 90 percent unleaded gasoline. This is an accept
able blend of fuel.
MTBE— MTBE blended fuels are a mixture of un
J9000-52 leaded gasoline and up to 15 percent MTBE (Methyl
Tertiary Butyl Ether). Unleaded gasoline blended
Fig. 8 Crankcase Air Inlet Filter with MTBE is acceptable.
ETBE— This fuel is a mixture of unleaded gasoline OXYGEN (0 ) SENSOR

2
and up to 17 percent ETBE (Ethyl Tertiary Butyl

Ether). Unleaded gasoline blended with ETBE is ac MAINTENANCE SCHEDULE
ceptable. Replace t h e 0 sensor at the interval specified in
2
METHANOL—Do not use unleaded gasoline maintenance schedule.

blended with methanol. The use of this type of alco
hol can result in engine performance and damage to IGNITION CABLES, DISTRIBUTOR CAP AND
critical components. Engine problems that result ROTOR
from the use of methanol possibly will not b e
covered b y the n e w vehicle warranty.
Replace the ignition cables, distributor cap, and ro
Certain brands of unleaded gasoline contain a per
tor at the interval specified in maintenance schedule.
centage of unidentified alcohol. These types of un
Inspect the distributor for excessive wear and re
leaded gasoline are not recommended.
place, as necessary. Refer to Group 8D—Ignition Sys
ADDITIVES MIXED WITH GASOLINE
tems for additional information.
Use of fuel system cleaning additives should be
IGNITION TIMING
avoided. Many of these solutions could contain highly
active solvents. This type of solvent can be harmful MAINTENANCE SCHEDULE
to the gasket and diaphragm material within the Test and adjust, if necessary, the ignition timing at
fuel system. the interval specified in maintenance schedule. Refer
to the specifications listed on the engine Emission
DIESEL ENGINE FUEL REQUIREMENTS Control Information label. Refer to Group 8D—Igni
All Diesel engines normally can use number 2D tion Systems and to Group 25—Emission Control
Diesel fuel for most year-round operations. A fuel Systems for additional service information.
conforming to ASTM Specification D-975 is recom
mended. For extreme cold-weather operation (below SPARK PLUGS
-18°C/0°F), or for prolonged cold-climate operation ei
ther: MAINTENANCE SCHEDULE
• Use No. ID fuel, or Replace the spark plugs at the interval specified in
• Add an equal quantity of kerosene to No. 2D fuel maintenance schedule. Refer to the Spark Plugs
(a 50/50 mixture). chart below and to Group 8D—Ignition Systems for
Both methods provide protection against fuel gel additional service information.
ling and waxing. SPARK PLUGS
Diesel fuel seldom is without water contamination.
To help prevent fuel system malfunctions, drain all
accumulated water from the separators periodically. ENGINE SPARK SPARK TORQUE
PLUG PLUG G A P
VACUUM OPERATED, EMISSION CONTROL

COMPONENTS 3.9L RN12YC 0.9 mm (0.035 in.) 41 N*m (30 ft. lb.)
MAINTENANCE SCHEDULE 5.2L RN12YC 0.9 mm (0.035 in.) 41 NVn (30 ft. lb.)
The following emission controls should be replaced
5.9L RN12YC 0.9 mm (0.035 in.) 41 N*m (30 ft. lb.)
at the interval specified in the maintenance sched
ule:
• Bi-level purge check valves
• Delay valves
• Heated air temperature sensor (HATS)
• Air cleaner vacuum motors
J9100-17
EXHAUST GAS RECIRCULATION (EGR) SYSTEM
BATTERY
Replace the EGR valve and tube, and clean the MAINTENANCE SCHEDULE
passages at the interval specified in maintenance Replace battery at interval specified in mainte
schedule. If necessary, refer to Group 25—Emission nance schedule.
Control Systems for additional information.
SERVICE INFORMATION INCREASED SEALED TEST
All vehicles are equipped with a maintenance-free ELECTROUTE VENT CAPS INDICATOR
(MF) battery when shipped from the factory (Fig. 10). CAPACITY
A maintenance-free battery does not have removable
cell caps and does not require additional water.
Each MF battery has a visual battery condition in
dicator (Fig. 11). When an adequate battery charge
exists, the indicator will have a GREEN dot. When
battery charging is necessary, the indicator will be
dark. When the indicator is light brown colored or
yellow, the battery should be replaced.
INSPECTION
WARNING; WEAR SAFETY GLASSES, RUBBER

G L O V E S A N D PROTECTIVE CLOTHING WHEN S E R
VICING A B A T T E R Y . T H E B A T T E R Y E L E C T R O L Y T E
C O N T A I N S S U L F U R I C A C I D A N D WILL C A U S E BATTERY
H A R M IF IT C O N T A C T S S K I N , E Y E S O R C L O T H I N G . ENVELOPE HOLD DOWN
SEPARATORS RK92
IF S U L F U R I C A C I D C O N T A C T S S K I N O R E Y E S , G E T
I M M E D I A T E M E D I C A L ATTENTION. D O NOT S M O K E Fig. 10 Maintenance-Free (MF) Battery
IN T H E VICINITY O F A B A T T E R Y . K E E P O P E N
FLAMES A N D S P A R K S AWAY FROM BATTERY
FILLER C A P S B E C A U S E E X P L O S I V E G A S I S A L
WAYS PRESENT. D A R K E N E D INDICATOR W I T H G R E E N DOT
• BATTERY C H A R G E OK '
• FLUID L E V E L OK
O.K. TO
Battery maintenance should be completed before JUMP
D A R K E N E D INDICATOR N O G R E E N DOT
START
the beginning of every winter season. • BATTERY C H A R G E LOW
FLUID L E V E L O K
Use the following battery maintenance and inspec
BATTERY
tion procedure. CONDITION
(1) Disconnect the battery negative cable and then INDICATOR
the positive cable. LIGHT O R B R I G H T INDICATOR

• BATTERY C H A R G E U N K N O W N
(2) Clean the battery cables and terminal posts • FLUID uEv'EL LOW
with a wire brush and a battery terminal cleaner. ( C H A R G E MAY STILL B E
S U F F I C I E N T TO START YOUR C A R )
(3) Remove the battery holddown strap. Clean the
battery tray with a solution of baking soda and wa
ter. Rinse and dry the battery tray. J9100-26
(4) Position the battery in the tray and install the
holddown strap. Do not over-tighten the nuts. Fig. 11 Battery Condition Indicator
(5) Connect the battery positive cable and then the Inspect all the hose connections. Verify they are se
negative cable to the battery. cure and there is no fluid leakage.
(6) Apply a small amount of chassis lubricant (or
an equivalent protective coating) to the cable termi ENGINE MOUNTS
nals. Inspect the rubber in the engine mounts for exces
sive wear. Slight wear at the ends will not affect the
RUBBER/PLASTIC COMPONENTS functioning of an engine mount. If excessive engine
INSPECTION movement is detected, the engine mount(s) should be
Components should be inspected at the same time replaced.
as scheduled underhood maintenance is conducted.
Rubber/plastic components should be replaced imme DRIVE BELTS
diately if there is any evidence of wear.
Inspect the exterior surface of rubber hoses and ny
Replace the drive belt(s) and adjust the drive ten
lon tubing for evidence of heat damage. The rubber
hose and nylon tubing located close to an exhaust sion at the interval specified in maintenance sched
manifold should be given special attention. Verify ule. If necessary, refer to Group 7—Cooling Systems.
the nylon tubing located at these areas has not col
lapsed.
ROUTINE INSPECTION • Contact with body panels or the frame

It is recommended that the drive belt(s) be rou • Catalytic converter bulging or excessive heat dam
tinely inspected for cracks, fraying and excessive age
wear. Replace as necessary.
C A U T I O N : A catalytic converter will become con
EXHAUST SYSTEM taminated if leaded gasoline is burned in the en
An exhaust system must be properly aligned to gine. If this occurs, the complete converter must be
prevent stress, leakage, and vehicle body contact. replaced.
Inspect the exhaust system at the interval specified AIR-CONDITIONER COMPRESSOR
in maintenance schedule. LUBRICANT AND REFRIGERANT
The lubricant level in the compressor should be
INSPECTION checked if there are indications t h a t oil was lost.
Inspect for cracked or loose joints, corrosion dam Loss of lubricating oil usually accompanies a loss of
age, and worn or broken hangers. Replace all compo refrigerant. The presence of bubbles in sight glass in
nents t h a t are damaged. Do not attempt repair. Also, dicates t h a t loss of refrigerant has occurred.
inspect for the following conditions and correct as For additional information involving the A/C sys
necessary: tem, refer to Group 24—Heater And Air Condition
• Exhaust system leaks, misalignment ing.
DRIVETRAIN
INDEX
page page
Axles 25 Front Axle U-Joint and Pivot Bearings . . . . . . . . . 26
Clutch and Brake Pedal Bushings . . . . . . . . . . . . 22 Transfer C a s e (4WD Vehicles) .. . . . . . . . . 24
Clutch Master Cylinder 22 Transmissions . 22
Drive Shafts 26
CLUTCH AND BRAKE PEDAL product is identified as SAE J-1703 or DOT 3 flu
If the clutch and brake pedal mechanism squeaks, id.Do not use any other type of fluid.
the pivot bushings should be lubricated (Fig. 1). Use
MOPAR®Multi-Purpose Lubricant, or an equivalent. C A U T I O N : Never use reclaimed brake fluid or fluid
from an unsealed container. D o not use fluid that
CLUTCH MASTER CYLINDER has been opened and allowed to stand for an ex
tended length of time.
HYDRAULIC FLUID LEVEL
The clutch master cylinder fluid level should be in
spected at the same time as underhood maintenance
TRANSMISSIONS
is conducted. The fluid level should be at indicating
line (Fig. 1). If the fluid level is low, locate and cor SPECIAL ADDITIVES
rect any possible leaks. Fill the reservoir with clean, Chrysler Motors does not recommend the addition
moisture-free brake fluid. of any special additives to a transmission. Black
FLUID SPECIFICATION light detection dye can be used as an aid in detecting
The only fluid recommended for use is fluid leaks.
MOPAR®Brake Fluid, or an equivalent product. The
RESERVOIR
SLAVE
CYLINDER
CLUTCH
23 N«m (200 IN. LBS.)
HOUSING
5 N«m
STUD (40 IN. LBS
VIEW IN DIRECTION
GtAKBQWZ
#
23 N m
LUBRICATE (200 IN. LBS.)
CLUTCH
PEDAL
MASTER
CYLINDER
COTTER PIN
NUT 23 N*m (200 IN. LBS.)
WAVE WASHER
RETAINING RING
BRAKE PEDAL VIEW IN DIRECTION FLAT WASHER

OF ARROW Y RR06F1
Fig. 1 Clutch & Brake Pedal Mechanism

GEAR SHIFTER BOOTS

Inspect the shifter boots periodically for stone and
heat damage. Replace, if necessary.
SEVERE DRIVING CONDITIONS

The interval between the transmission drain and
refill maintenance should be decreased to:
• NV4500 manual transmission—every 29 000 km
(18,000 miles)
• Automatic transmission—every 19 000 k m (12,000
miles)
A severe driving condition includes:
• Extended operation with heavy cargo loads
• Driving in deep mud or snow
• Off-road operation (4WD)
• Trailer towing
• Operation as a commercial vehicle
• Snow plowing
MANUAL TRANSMISSIONS
INSPECTION/LUBE OIL LEVEL

The transmission should be checked for leaks when Fig. 3 Getrag 360 Manual Transmission
other service is necessary under the vehicle. To check MANUAL TRANSMISSION-DRAIN & REFILL
the lube oil level, remove the fill hole plug (Fig. 2 ). INTERVALS
If the level is below the bottom of the fill hole, raise
the level to the bottom of the fill hole with: Light Duty Cycle
• Castrol Syntorq for NV4500 transmissions Normal 60 000 km 37,500 miles
• SAE 5W-30 engine oil (API Service SG, SG/CD or Service Heavy Duty Cycle
SG/CE) for Getrag 360 transmissions. 58 000 km 36,000 miles
Severe
29 000 km 18,000 miles
Service
J9000-43
The condition of the ATF also should be deter

mined. If the ATF is dark in color and has a strong
odor, the fluid should be changed. Also the filter
should be replaced and the bands adjusted.
The following procedure must be used to check the
automatic transmission fluid (ATF) level.
(1) Position the vehicle on level ground.
(2) Operate the engine at idle speed.
Fig. 2 NV4500 Manual Transmission (3) Apply the parking brake.
(4) Place the gear selector in N (neutral).
DRAIN AND FILL (5) Remove the dipstick from the tube. Wipe it
The NV4500 transmission fluid should be changed clean and determine if the ATF is hot or warm.
according to the intervals listed in the Manual Hot ATF h a s a temperature of approximately
Transmission—Drain & Refill Intervals chart below. 82°C (180°F). Warm ATF is w h e n its temperature
Also, refer to the Fluid Capacities chart. is b e t w e e n 29-52°C (85-125°F).
AUTOMATIC TRANSMISSIONS (6) Wipe the dipstick clean and completely insert it
into the tube. Remove the dipstick from the tube and
FLUID LEWEL observe the ATF level.
It is recommended that the fluid (ATF) level in au (7) If the ATF is hot, the level should be in the
tomatic transmissions be checked while involved crosshatched area t h a t is marked OK.
with other underhood maintenance. (8) If the ATF is warm, the level should be be
Vehicle operation with an incorrect ATF level tween the two dimples.
will greatly reduce the life of the transmission.
C A U T I O N : D o not overfill the t r a n s m i s s i o n . • MOPAR®ATF PLUS or an equivalent Dexron II®
ATF for NP241 transfer case
(9) Adjust the level of the ATF accordingly. • Multi-purpose gear oil (API GL-5) or engine oil
It is i m p o r t a n t to u s e t h e c o r r e c t fluid in a n (API SG, SG/CD O R SG/CE) for NP205 transfer
automatic t r a n s m i s s i o n . MOPAR®ATF P L U S cases.
(ATF T y p e 7176) should b e u s e d . Dexron® II Add fluid in small amounts to raise the level.
ATF c a n be u s e d if the r e c o m m e n d e d fluid is not (4) Install the fill hole plug (Figs. 4 and 5).
available, Tighten the fill hole plug to 27 N-m (20 ft-lbs)
(10) Insert the dipstick into the tube. torque.
(5) Remove the support and lower the vehicle.
DRAIN, FILTER CHANGE, BAND ADJUSTMENT AND REFILL
The chart below lists the intervals at which the
transmission should be serviced. Also, refer to the
Fluid Capacities chart for fill capacity.
AUTOMATIC TRANSMISSION SERVICE IN-
TERVALS
Light Duty Cycle

Normal 60 000 km 37,500 miles
Usage Heavy Duty Cycle
38 000 km 24,000 miles
Severe 19 000 km 12,000 miles
Usage
J9100-19
It is very important to u s e the correct fluid in

an automatic transmission. MOPAR®ATF PLUS
(ATF Type 7176) should b e used. A n equivalent Fig. 4 HP241 Transfer Case
Dexron® II ATF could b e u s e d only if the recom
m e n d e d fluid is not available.
The torque converter does not have a drain plug.
No attempt should be made to drain the converter.
Refer to Group 21 —Transmissions for transmission
drain and refill procedures.
TRANSFER CASE (4WD VEHICLES)

INSPECTION
The NP205 and NP241 transfer cases fluid level
should be checked whenever maintenance is neces
sary under the vehicle.
FLUID LEVEL
The vehicle must b e level w h e n the fluid level
is c h e c k e d . Fig. 5 NP205 Transfer Case
The transfer case drain fill hole plugs are located FLUID DRAIN AND REFILL
at the rear of the housing (Figs. 4 and 5).
The transfer case fluid should be changed every 60
Determine t h e transfer case fluid level according to 000 km (37,500 miles). For vehicles subject to the
the following procedure. HEAVY DUTY CYCLE Maintenance Schedule, a 58
(1) Raise and support the vehicle. 000 km (36,000 miles) interval is recommended.
(2) Remove the fill hole plug (Figs. 4 and 5) from (1) Raise and support the vehicle.
the transfer case. The fluid level should be at the (2) Remove the fill hole plug (Figs. 4 and 5) from
bottom edge of the fill hole. The level can be slightly the transfer case.
below the bottom edge of the fill hole if the fluid is (3) Place an appropriate container under the trans
cold. fer case drain hole plug (Figs. 4 and 5).
(3) If the level is not acceptable, raise the fluid (4) Remove the drain hole plug. Drain the fluid
level to the bottom edge of the fill hole with: from the transfer case into the container.
C A U T I O N : D o not over-tighten the drain a n d fill hole TRANSMISSION GEARSHIFT TRANSFER CASE
plugs. Over-tightening c a n strip the hole threads ASSEMBLY MECHANISM
and/or crack the aluminum h o u s i n g .
(5) Install the drain hole plug (Figs. 4 and 5) in

the transfer case. Tighten the drain hole plug to 27
N*m (20 ft-lbs) torque.
(6) Fill the transfer case to the bottom edge of the SHIFT ROD
fill hole (Figs. 4 and 5) with:
• MOPAR®ATF PLUS or an equivalent Dexron II®
ATF for NP241 transfer cases
• Multi-purpose gear oil (API GL-5) or engine oil SCREW
(API SG, SG/CD or SG/CE) for NP205 transfer cases. SCREWS (2) 80 IN. LBS.
50 FT. LBS. (9 N*m)
(7) Install the fill hole plug (Figs. 4 and 5) in the (68 N*m) CLAMP
RP1091
transfer case. Tighten the plug to 27 N«m (20 ft-lbs)
torque. Fig. 6 Shift Mechanism Lubrication—NP241 Transfer
Case
(8) Remove the support and lower the vehicle.
FLUID SPECIFICATION
• MOPAR®ATF PLUS or an equivalent Dexron II®
ATF for NP241 transfer cases
• Multi-purpose gear oil (API GL-5) or engine oil
(API SG, SG/CD or SG/CE) for NP205 transfer cases
NP20I MULTI-PURPOSE GEAR OIL/ENGINE OIL SELECTION
MULTI-PURPOSE GEAR O I L - i f the anticipated
minimum temperature will:
• Be above 32°C (90°F)-use SAE 140, API GL-5;
• Decrease to as low as -23°C (-10°F)-use SAE 90,
API GL-5; and
• Be below -23°C (-10°F)-use SAE 80, API GL-5.
ENGINE OIL—if the anticipated minimum tem
perature will be:
® Above 0°C (32°F)-use SAE 50, API SG, SG/CD or
SG/CE;
• Below 0°C (32°F)-use SAE 30, API SG, SG/CD or RY682
SG/CE.
Fig. 7 Shift Mechanism Lubrication—NP205 Transfer
SHIFT MECHANISM-NP241 AND NP205 Case
The transfer case shift mechanism should be
plug from the differential housing. The front axle
cleaned and lubricated as necessary.
(4WD vehicles)*differential housings have a thread
Lubricate the pivot, the sliding contact areas and
ed-type fill plug (Fig. 9). Un-thread the fill plug from
the shift linkage pivot ends with light-weight engine
oil (Figs. 6 and 7). the differential housing.
(3) The lubricant level should be within 12 mm
AXLES (1/2 in) of the fill hole for the 8.25 and 9.25 rear ax
les. The lubricant level should be between 12mm (1/2
INSPECTION/LUBRICANT LEVEL in) and 24mm (1 in.) of the fill hole for the Dana ax
For normal vehicle operation, periodic axle lubri les.
cant level checks are not necessary. The exterior of (4) If necessary, add lubricant to raise the level to
the axle housing should be inspected for leakage. the acceptable position.
Check the lubricant level to confirm the leakage. (5) Install the fill hole plug in the differential
housing (Figs. 8 and 9).
LUBRICANT LEVEL
(1) Raise the vehicle with an axle or wheel type DRAIN AND REFILL
hoist. Support the vehicle. Periodic axle lubricant change for normal vehicle
(2) The rear axle differential housings have a rub operation is not necessary. Refer to the chart below-
ber, PRESS-IN type fill plug (Fig. 8). Pry the fill
"PRESS-IN" TYPE LUBRICANT VISCOSITIES FOR ANTICIPATED
FILLER PLUG TEMPERATURE RANGES
Anticipated Temp. Range Recommended SAE Grade

Above 32°C SAi 140
(90°F) SAE SOW-140
S \ E 85W-140
- 23°C to 32°C SAE 90
(-10°F to 90°F) SAE 80W-90
SAE 80W-140
oAE 85W-140
(ielow -23°C SAE 75W
(-10°F) SAE 75W-90
SAE 80W
SAE 80W-I40
J9000-56
LUBRICANT SPECIFICA TION

A multi-purpose lubricant should be used in all ax
les with either a standard or a limited-slip differen
tial. A friction additive must also be used in 8.25 and
9.25 limited-slip differentials. The use of a friction
RK43 t
modifier is helpful in preventing axle chatter. Dana
Fig. 8 Rear Axle Fill Plug Location—Typical axles do not require any friction additive.
FRONT AXLE U-JOINT AND PIVOT BEARINGS

MODEL W350 (WITH DANA 60 AXLE)
For vehicles subject to the LIGHT DUTY CYCLE
Maintenance Schedule, lubricate the pivot bearings
at each 12 000 k m (7,500 miles) interval. For vehi
cles subject to t h e HEAVY DUTY CYCLE Mainte
nance Schedule, lubricate the pivot bearings at each
9 600 k m (6,000 miles) interval.
LUBRICATION SPECIFICATION
Lubricate the pivot bearings with a multi-purpose
lubricant, grade 2 EP.
Do not u s e h i g h pressure to lubricate the front
a x l e universal drive joints.
Fig. 9 Front Axle (4 WD) Fill Plug Location MODELS WiOO, W150, W250 (WITH DANA 44
.All axles contain S A E 80W-90 multi-purpose AXLE)
type h y p o i d gear lubricant w h e n delivered from The front axle universal joint and pivot bearings
the factory. are permanently lubricated and normally do not re
U s e the s a m e maintenance procedures for rear quire service.
axles e q u i p p e d with a limited-slip differential.
DRIVE SHAFTS
C A U T I O N : Water contaminated gear lubricant will
result in possible failure of the axle differential SLIP-YOKE LUBRICATION
components. Operation of the vehicle in water, will When equipped with lube fittings, it is recom
require that: mended t h a t the slip-yoke splines be lubricated every
9 600 km (6,000 miles). For severe usage, lubricate
• The lubricant be drained the splines every 1 600 km (1,000 miles).
• The differential housing flushed (except limited- The method described below will ensure complete
slip differentials) lubrication of the slip-yoke splines.
• The differential refilled with fresh lubricant (1) Clean the Zerk type lubrication fittings.
(2) Use a lubricant dispenser to force lubricant
into the slip yoke fittings.
(3) Continue lubricating until it appears at the

pressure relief hole in the expansion plug located at
the slip-yoke end.
(4) Cover t h e pressure relief hole with a finger.
Continue to force lubricant into the fitting until it
appears at the slip-yoke seal.
U-JOINT INSPECTION
U-joint seals should be inspected for damage when
ever the vehicle is serviced for other reasons (Fig.
10). If external leaks or damage exists, the U-joint
coupler should be replaced.
GREASE FITTINGS RK40
Fig. 11 Rear Drive Shaft U-Joint
Fig. 10 U-Joint Seal Inspection

U-JOINT/CV-JOINT LUBRICATION
Lubrication of u-joint couplers t h a t are not
equipped with lube (Zerk) fittings is not necessary.
Replacement U-joints are equipped with lube fittings.
If installed, lubricate them according to the informa
tion provided below.
Lubricate t h e U-joint and CV-joints every 12 000
km (7,500 miles) for LIGHT DUTY CYCLE vehicles. Fig. 12 Front Drive Shaft CV-Joint (4WD)
For HEAVY DUTY CYCLE vehicles, the couplers • Off-road driving
should be lubricated every 9 600 km (6,000 miles). • Driving in deep mud or snow
Refer to Figures 11 and 12. If the vehicle is operated • When 1/3 or more of the vehicle operation involves
in water, the U-joint/CV-joint couplers should be lu driving with a full-load.
bricated daily.
If a vehicle, is u s e d i n a severe driving condi LUBRICANT SPECIFICATION
tion, lubricate t h e U-joint/CV-joints every 4 800 Drive shaft slip yokes and U-joint/CV-joint couplers
k m (3,000 miles). Lubricate R a m Truck Model should be lubricated with a NLGI GC-LB lubricant.
W350 U-joint/CV-joint couplers every 1 600 k m The U-joints/CV-joint couplers should be lubricated
(1,000 miles). with MOPAR®Multipurpose Lubricant, NLGI GC-
A severe driving condition includes: LB).
CHASSIS AND BODY
page page
Body Component Mechanisms 32 Power Brake System 30
Front Suspension Ball Joints 28 Power Steering System .. 29
Front Wheel Bearings 29 Rear Wheel Bearings 30
Headlamps 32 Speedometer Cable 33
Lower and Upper Suspension Arm Bushings . . . . 30 Steering Linkage 28
Manual Steering Gear 28 Tires 32
STEERING LINKAGE FRONT SUSPENSION BALL JOINTS

INSPECTION INSPECTION
When a vehicle is raised for maintenance under When a vehicle is raised for lubrication/general
the vehicle, all steering components should be maintenance, the ball joints should be inspected.
checked.
LUBRICATION SCHEDULE
LUBRICATION SCHEDULE The front suspension ball joints are lubricated dur
The steering linkage is lubricated with a chassis ing manufacture with a long-life chassis lubricant.
lubricant. However, it is recommended t h a t t h e link However, it is recommended t h a t the ball joints be
age be inspected and lubricated after each: inspected and the studs lubricated:
• 24 000 k m (15,000 miles) interval or every 6 • At each 36 000 k m (22,500 miles) interval or every
months, for 2WD vehicles subject to t h e LIGHT 2 years, for vehicles subject to the LIGHT DUTY CY
DUTY CYCLE Maintenance Schedule CLE Maintenance Schedule
• 9 600 k m (6,000 miles) interval or every 6 months, • At each 9 600 k m (6,000 miles) interval or every 2
for 2WD vehicles subject to the HEAVY DUTY CY years, for vehicles subject to t h e HEAVY DUTY CY
CLE Maintenance Schedule CLE Maintenance Schedule.
• 12 000 k m (7,500 miles) interval or every 6 4WD vehicles that are frequently driven off-
months, for 4WD vehicles subject to t h e LIGHT road should b e lubricated at every engine oil
DUTY CYCLE Maintenance Schedule change.
• 9 600 k m (6,000 miles) interval or every 6 months,
for 4WD vehicles subject to t h e HEAVY DUTY CY LUBRICATION
CLE Maintenance Schedule. (1) Inspect the front suspension. Examine t h e ball
studs for looseness and excessive wear.
LUBRICATION (2) Replace all torn ball-stud seals and damaged
(1) Inspect t h e steering linkage for looseness and ball joints. Damaged seals should be replaced to pre
excessive wear. vent leakage and contamination.
(2) Replace, all ruptured seals and damaged steer
ing linkage components. Damaged seals should be re C A U T I O N : U s e care to prevent lubricant from con
placed to prevent leakage and contamination of t h e tacting the brake rotors.
lubricant.
(3) Lubricate t h e ball studs:
C A U T I O N : U s e care to prevent lubricant from con • Clean the Zerk type lubrication fittings on the
tacting the brake rotors. ball-stud ends
• Lubricate the ball studs with MOPAR®Multi-Mile-
(3) Lubricate t h e steering linkage: age Lubricant
• Clean t h e Zerk type lubrication fittings on t h e tie- • Wipe the excess lubricant from t h e exterior sur
rod and center link ball-stud ends faces of the ball joints
• Lubricate t h e ball studs with MOPAR®Multi-Mile-
age Lubricant MANUAL STEERING GEAR
• Wipe t h e excess lubricant from the exterior sur
LUBRICATION
faces of t h e ball joints
Manual steering gears are permanently lubricated
during manufacture. Periodic lubrication is not nec
essary.
POWER STEERING SYSTEM 4WD VEHICLES

It is recommended t h a t 4WD front wheel bearings
SERVICE SCHEDULE be inspected for proper lubrication whenever the
brake rotors are removed or at least:
FLUID LEWEL
• At each 24 000 km (15,000 miles) interval for ve
hicles subject to the LIGHT DUTY CYCLE Mainte
W A R N I N G . T H E P O W E R S T E E R I N G FLUID L E V E L
nance Schedule
S H O U L D A L W A Y S B E C H E C K E D WITH T H E E N
• At each 19 000 km (12,000 miles) interval for ve
G I N E O F F TO P R E V E N T P E R S O N A L INJURY.
hicles subject to the HEAVY DUTY CYCLE Mainte
The power steering fluid should be checked when nance Schedule
ever the engine is being serviced for other reasons. For vehicles used for extensive off-road, 4WD
Clean the outside of the cap before removing. The operation, the front w h e e l bearings should be in
fluid should be at the proper level indicated on cap spected every 1 600 km (1,000 miles).
dipstick (Fig. 1). The bearings should be c l e a n e d and re-packed
with a high temperature, multi-purpose E P lu
bricant w h e n e v e r the disc brake rotors are re
surfaced.
INSPECTION
If the lubricant:
• Is not sufficient
• Contaminated with foreign particles
• Appears dry or has been contaminated with water
to produce a milky appearance, the bearings should
be cleaned and re-packed with lubricant.
C A U T I O N : D o not add lubricant to the wheel bear

ings. Re-pack completely. Mixing of different types
Fig. 1 Power Steering Reservoir & Cap—Typical
of lubricants in wheel bearings should be avoided.
The reservoir fluid level can be determined with This could possibly result in excessive thinning and
the fluid either hot or cold. If the fluid level is below leakage of the lubricant.
the FULL HOT or FULL COLD marks on the dip
stick, add power steering fluid. The dipstick is at
tached to the reservoir cap (Fig. 1). LUBRICATION
(1) Discard the original seal.
FLUID SPECIFICATION (2) Clean the original lubricant from the bearings
03)
MOPAR Power Steering Fluid is highly recom and from the hub cavity (Figs. 2 and 3).
mended. (3) Inspect the bearing rollers for indications of
pitting. Light bearing roller discoloration is consid
FRONT WHEEL BEARINGS ered normal. A wheel bearing must be replaced if
any serious damage exists.
INSPECTION/LUBRICATION SCHEDULE
(4) Re-pack the bearings with a high temperature,
multi-purpose NLGI GC-LB lubricant. The use of a
2WD VEHICLES
bearing packer is recommended. A small amount of
It is recommended that 2WD front wheel bearings
fresh lubricant also should be added to the hub cav
be inspected for proper lubrication whenever the
ity.
brake rotors are removed or at least:
• At each 39 000 k m (24,000 miles) interval for ve BEARING INSTALLA TION/ADJUSTMENT
hicles subject to the LIGHT DUTY CYCLE Mainte (1) Install the hub/rotor (with inner bearing and
nance Schedule seal) on steering knuckle spindle.
• At each 36 000 km (22,500 miles) interval for ve (2) Install the outer bearing, t h e thrust washer
hicles subject to the HEAVY DUTY CYCLE Mainte and the nut.
nance Schedule (3) Tighten wheel bearing nut to 27-34 N^m (240-
The bearings should be cleaned and re-packed 300 in. lbs.) torque while rotating hub/rotor. This
with a high temperature, multi-purpose E P lu will seat the bearings.
bricant. (4) Loosen the nut 1/4 of-a-turn (90°), then tighten
it finger-tight.
0 - 30 LUBRICATION AND MAINTENANCE — - •
REAR WHEEL BEARINGS

LUBRICATION
DANA 60 AND 70 AXLES

The rear wheel bearings for vehicles equipped with
a Dana 60 or 70 axle should be cleaned and re
packed whenever the rear brakes are serviced. Refer
to Group 3—Rear Axles for the service procedure.
CHRYSLER AXLES ,
Vehicles equipped with 8 3/8-inch and 9 1/4-inch
axles have axle shaft bearings instead of wheel bear
ings. These bearings are lubricated by the axle hous
ing sump.
LOWER AND UPPER SUSPENSION ARM

BUSHINGS
INSPECTION SCHEDULE
The lower and upper suspension arm bushings
Fig. 2 Front Wheel Bearing—2WD Vehicles should be inspected each time the underside of the
vehicle is serviced.
INSPECTION
The lower suspension arm bushings can be visually
inspected by raising the vehicle on a hoist and in
specting from underneath. The upper suspension arm
bushings can be inspected after removing the front
wheels. If failure exists, replace the bushing (refer to
Group 2—Front Suspension for the proper proce
dures).
The suspension arm b u s h i n g s never should be
lubricated.
GUIDELINES
(1) Faulty bushings are detected by the bushing
being off-center in relation to the outer sleeve.
(2) Total failure is evident by excessive movement
within the bushing.
(3) Small cracks in the outer, non-confined rubber
Fig. 3 Front Wheel & Spindle Bearings—4WD does not indicate failure of the rubber. '
Vehicles
(5) Position n u t lock on the nut with one pair of POWER BRAKE SYSTEM
slots aligned with the cotter pin hole. Install the cot Vehicles are equipped with power disc brakes at
ter pin. the front wheels and drum brakes at the rear wheels.
(6) Install the dust cap and wheel/tire. Tighten the
MASTER CYLINDER
wheel lug nuts to 115 N*m (85 ft. lbs.) torque. Install
the wheel cover. FLUID LEVEL INSPECTION
LUBRICANT SPECIFICATION The brake fluid level should be inspected at the

Use a high temperature, multi-purpose NLGI same time as other underhood service is done (Fig.
GC-LB lubricant (MOPAR®Wheel Bearing Lubricant, 4). If necessary, add fluid to raise the level to the
or an equivalent lubricant). bottom of the split rings. With disc-brakes, the fluid
level can be expected to lower as the brake pads
wear. However, a low fluid level can also be caused
by a leak, and repair will then be necessary.
(5) Inspect the self-adjuster components for frayed

cables, loose or overheated springs, and a binding
condition.
(6) Inspect the caliper dust boots for damage/tears
and indications of brake fluid leakage. Inspect the
bushings and pins for corrosion, tears and a binding
condition.
(7) Inspect the rear wheel cylinder dust boots for
fluid leaks. Inspect the pistons and cylinder bores for
proper appearance.
(8) Inspect the brake differential warning valve
and housing for indications of leakage, kinked hoses
and loose fittings.
BRAKE FLUID HOSES/TUBING

The rubber brake fluid hoses should be inspected
for:
• Correct length
• Severe surface cracking
• Swelling
• Pulling
• Scuffing
Fig. 4 Master Cylinder Fluid Level • Excessively worn areas
FLUID SPECIFICATION If the hose fabric c a s i n g is e x p o s e d either by
cracks or abrasions in the rubber cover, the
Power brake systems require MOP AR®Heavy-D uty
h o s e should b e replaced.
Brake Fluid, or an equivalent product identified with
Faulty brake fluid hose installation can cause
FMVSS No. 116, DOT-3 and SAE J-1703 Standard twisting, and wheel/tire or chassis interference.
designations. (1) Inspect all the hoses for kinks, a distorted con
Use fresh brake fluid only when adding fluid to the dition and fluid leakage.
reservoir. Never use reclaimed fluid, fluid t h a t does (2) Inspect the hose and tubing routing under the
not conform to the DOT/SAE Standards, or fluid from vehicle. Verify that no hose/tubing is rubbing against
a container t h a t has been left open. any exhaust system or other underbody components.
C A U T I O N : U s e of a brake fluid that h a s a lower ini PARKING BRAKE LUBRICATION
tial boiling point then specified by F M V S S N o . 116 The pivot and sliding contact areas of the parking
or D O T 3 could result in sudden brake failure dur brake ratio lever should be lubricated to maintain
ing hard, prolonged braking. ease of operation (Fig. 5).
(1) Apply MOPAR®Spray White Lube or equiva
lent to the sliding contact areas.
C A U T I O N : D o not allow petroleum base fluids to
(2) Lubricate the control lever pivot areas with en
contaminate the brake fluid. Seal damage will re
gine oil.
sult.
PARKING BRAKE FUNCTIONAL TEST AND INSPECTION
BRAKE SYSTEM INSPECTION (1) Engage the parking brake pedal and then re
(1) Inspect the brake pads and linings for excessive lease it.
(2) Test it for smooth operation and vehicle-hold
wear, cracks and broken rivets.
ing capability.
(2) Inspect brake pads and linings for contamina
(3) Inspect the parking brake cables for kinks,
tion with brake fluid, axle lubricant and/or other flu
fraying and a binding condition.
ids.
(4) With the parking brake released, the rear
(3) Replace the front brake pads and the rear wheels should rotate without restriction. Adjust the
brake linings if they are worn to within 0.78 mm parking brake cable tension, if necessary.
(1/32 in) of a rivet head. (5) Repair any parking brake malfunctions.
(4) Operate the rear brake self-adjuster lever and
pivot. Test the operation of the self-adjuster screw for BRAKE OPERATIONAL TEST
ease of movement. (1) Drive the vehicle and test for proper brake ac
tion.
(3) Before applying lubricant, the component
should be wiped clean. After lubrication, any excess
lubricant should be removed.
(4) The hood latch, latch release mechanism, latch
striker and safety latch should be lubricated periodi
cally.
(5) The door lock cylinders should be lubricated 2
times each year (preferably autumn and spring):
• Spray a small amount of lock cylinder lubricant di
rectly into the lock cylinder
• Apply a small amount to the key and insert it into
the lock cylinder
• Rotate it to the locked position and then back to
the unlocked position several times
• Remove the key. Wipe the lubricant from it with a
clean cloth to avoid soiling of clothing.
Fig. 5 Parking Brake Ratio Lever Lubrication
TIRES
(2) Note any indication of brake overheating,
wheel dragging or the vehicle pulling to one side. RECOMMENDED MAINTENANCE
(3) Evaluate any performance complaints received The condition of the tires should be inspected. The
from the owner/operator. inflation pressures tested/corrected at the same time
(4) Repair the brake system as necessary (refer to as the engine oil is changed and the oil filter is re
Group 5—Brakes for additional information and ser placed.
vice procedures). The tires/wheels should be rotated periodically to
ensure even tread wear. The tires/wheels should be
BODY COMPONENT MECHANISMS rotated at the first 12 000 km (7,500-miles) interval.
Thereafter, at each 24 000 km (15,000-miles) inter
LUBRICATION REQUIREMENTS val.
All operating mechanisms and linkages should be
lubricated when necessary. This will maintain ease INSPECTION
of operation and provide protection against rust and Inspect the tires for excessive wear, damage. Test
excessive wear. The door weatherstrip seals should the tires for the recommended inflation pressure and
be lubricated to prolong their life as well as to im adjust the pressure accordingly. Refer to the tire in
prove door sealing. flation pressure decal located on the left door face.
Also to Group 22—Tires And Wheels for tire pres
LUBRICANT SPECIFICATIONS sure charts, tire replacement, and treadwear indica
All applicable exterior and interior vehicle operat tors.
ing mechanisms should be:
ROTATION
• Inspected
Tires/wheels should be rotated according to the rec
• Cleaned
ommended interval. The first tire/wheel rotation is
• All the pivoting/sliding contact areas on the mech the most important for establishing the prevention of
anisms should then be lubricated. uneven tread wear. After rotation, adjust the tire in
MOPAR®Multi-Mileage Lubricant or an equiva flation pressure to the air pressure recommended on
lent, should be used to lubricate the mechanisms. the decal located on the left door face.
The door weatherstrip seals should be lubricated Refer to Group 22—Tires And Wheels for the rec
with silicone lubricant spray. Refer to the Body Lu ommended method of tire/wheel rotation.
bricant Specifications chart below for additional lu
bricant applications. HEADLAMPS
LUBRICATION MAINTENANCE SCHEDULE
(1) When necessary, lubricate the cab and cargo Every six months check the headlamp beams to en
box operating mechanisms with the specified lubri sure t h a t the headlamp beams are correctly posi
cants. tioned.
(2) Apply silicone lubricant to a cloth and wipe it
AIM ADJUSTMENT
on door seals to avoid over-spray t h a t can soil pas
Refer to Group 8L—Lamps for headlamp aim ad
senger clothing.
justment procedures.
BODY LUBRICANT SPECIFICATIONS
COMPONENT SERVICE INTERVAL LUBRICANT

Door Hinges As Required Engine Oil
Door Latches As Required Multi-Purpose Grease NLGI GC-LB
(Water Resistant) (1)
Hood Latch Release Mechanism & Safety Latch As Required Multi-Purpose Grease NLGI GC-LB 2 EP (2)
(When Performing
Other Underhood
Services)
Hood Hinges As Required Engine Oil
Seat Regulator & Track Release Mechanism As Required Multi-Purpose Grease NLGI GC-LB 2 EP (2)
Tailgate Hinge As Required Multi-Purpose Grease NLGI GC-LB 2 EP (2)
Tailgate Support Arms As Required Engine Oil
Tailgate Latches As Required White Spray Lubricant (3)
Tailgate Release Handle (Pivot & Slide Contact Surfaces) As Required Multi-Purpose Grease NLGI GC-LB 2 EP (2)
Window System Components (Regulators, Tracks, Rods As Required White Spray Lubricant (3)
& Channel Areas — Except Glass Run Weatherstrips
and Felt Lubricator, if Equipped)
Lock Cylinders Twice/Year Lock Cylinder Lubricant (4)
Parking Brake Mechanism As Required Multi-Purpose Grease NLGI GC-LB (1)
1. Mopar Wheel Bearing Grease (High Temperature)
2. Mopar Multi-Mileage Lubricant
3. Mopar Spray White Lube
4. Mopar Lock Cylinder Lubricant
J9200-58
SPEEDOMETER CABLE
SERVICE INFORMATION
Speedometer cable lubrication is not necessary. For
service information involving noisy or erratic cables,
refer to Group 8E—Instrument Panel and Gauges.
/
• FRONT SUSPENSION AND AXLE 2-1
FRONT SUSPENSION A N D AXLE
CONTENTS
page page
FRONT SUSPENSION—2WD VEHICLES . . . . . . 7 MODEL 44 FRONT AXLE 17

FRONT SUSPENSION—4WD VEHICLES 14 MODEL 80 FRONT AXLE 49
FRONT WHEEL ALIGNMENT . . . . . . . . . . . . . . . 3 TORQUE SPECIFICATIONS 75
GENERAL INFORMATION 1
GENERAL INFORMATION
FRONT SUSPENSION—2WD VEHICLES • Stabilizer b a r (optional)
All two-wheel drive (2WD) R a m Truck and Ram • Jounce bumpers (used to limit t h e travel of t h e
charger vehicles a r e equipped with (Fig 1); suspension)
• Steering knuckles Air-adjustable shock absorbers a r e installed on ve
• Stabilizer b a r (optional) hicles equipped with t h e H e a v y D u t y S n o w P l o w
• Suspension arms P a c k a g e w i t h t h e Diesel e n g i n e . Refer to the Own
• Strut rod ers Manual for additional information.
• Coil springs
• Dual-action shock absorbers FRONT DRIVE AXLE
• Jounce bumpers (used to limit t h e travel of t h e The front axle on 4WD Ram Truck and Ram
charger vehicles h a s a hypoid gear differential.
suspension)
Model 44 and 60 axles consists of an iron center cast
The upper and lower suspension arms (Fig. 1) have
ing with axle shaft tubes extending from either side.
replaceable bushings located a t t h e inboard end. Re
Ram Truck and Ramcharger vehicles equipped for
placeable ball studs a r e located a t t h e outboard end.
standard duty 4WD operation use t h e Model 44 front
The lower suspension arms a r e equipped with ten axle.
sion-type ball studs. The upper suspension arms also Vehicles equipped for heavy duty 4WD operation use
provide for caster a n d camber adjustments. a Model 60 front axle. The Model 60 front axle has lock
ing hubs that must be engaged for 4WD operation.
The steel cover provides a means for service with
out removing t h e complete axle.
A metal axle gear ratio identification t a g is at
tached to t h e housing cover via one of t h e cover
bolts. This t a g also identifies the number of ring and
pinion gear teeth.
IDENTIFICATION
Model 44 and 60 axles have t h e assembly part
number a n d gear ratio listed on a tag. The t a g is at
tached to t h e left side of the housing cover (Fig. 3, 4).
Build date identification codes on axles a r e stamped
on t h e axle shaft tube cover side.
STABILIZER BAR J9102-67
LUBRICANTS
Multi-purpose API GL 5 quality hypoid gear lubri
Fig. 1 Front Suspension—2WD Vehicles
cant should be used for front axles. MOPAR Hypoid
FRONT SUSPENSION—4WD VEHICLES Gear Lubricant conforms to these specifications.
All four-wheel drive (4WD) Ram Truck a n d Ram The axle h a s a fitting for a vent hose used to re
charger vehicles a r e equipped with (Fig 2); lieve internal pressure.
• Leaf-springs (fixed-rate type) If t h e front a x l e is s u b m e r g e d i n w a t e r , t h e lu
• Dual-action shock absorbers bricant must b e replaced immediately.
2 - 2 FRONT SUSPENSION AND AXLE •
FRONT SUSPENSION AND AXLE 2-3
FRONT WHEEL ALIGNMENT

GENERAL INFORMATION wheel off-center. The wheel toe position is t h e final
Front wheel alignment involves the correct posi front wheel alignment adjustment.
tioning of the tire contact patch in relation to t h e • STEERING AXIS INCLINATION ANGLE is mea
pavement. The positioning is accomplished through sured in degrees and is t h e angle t h a t the steering
the suspension and steering linkage adjustments. An knuckles are tilted (Fig. 1). The inclination angle h a s
alignment is essential for efficient steering and direc a fixed relationship with the camber angle. This will
tional stability. The most important factors of front not change except when a spindle or ball stud is
end alignment are camber, caster and toe position. damaged or bent. The angle is not adjustable and t h e
R o u t i n e i n s p e c t i o n o f the f r o n t s u s p e n s i o n a n d damaged component(s) must be replaced to correct
steering components is a g o o d preventative mis-alignment.
m a i n t e n a n c e p r a c t i c e . I n s p e c t i o n also h e l p s t o
e n s u r e safe o p e r a t i o n o f the vehicle. C A U T I O N : Do not attempt to modify any s u s p e n s i o n
or steering component by heating and bending.
• CAMBER is the number of degrees the top of the
wheel is tilted either inward or outward. An excessive
negative camber angle will cause tread wear at the in PRE-ALIGNMENT INSPECTION
side of the tire. An excessive positive camber angle will Before starting a front wheel alignment, t h e follow
cause tread wear at the outside of the tire (Fig. 1), ing inspection and necessary corrections must be
• CASTER is the number of degrees of forward or completed.
rearward tilt of t h e steering knuckles. Forward tilt (1) Tires with the same recommended air pressure,
provides a negative caster angle. Rearward tilt pro size, and tread wear. Refer to Group 22, Wheels and
vides a positive caster angle (Fig. 1). Tires for diagnosis information.
• WHEEL TOE POSITION is the difference between (2) Front wheel bearings for wear or adjustment.
the leading and trailing inside edges of the front (3) Ball studs and linkage pivot points, steering
tires (Fig. 1). Incorrect wheel toe position is the most gear for looseness, roughness, binding or a sticking
common cause of unstable steering and steering condition. Refer to Group 19, Steering for additional
information.
CASTER CAMBER TOE
POSITIVE CASTER
NEGATIVE TOE (TOE OUT) B>A FRONT Of VEHICLE

POSITIVE TOE (TOE IN) 6<A
STEERING WHEEL CENTER

THRUST ANGLE
NEGATIVE CAMBER (SHOWN)
TOP OF WHEEL INBOARD
POSITIVE CAMBER (NOT SHOWN)

TOP OF WHEEL OUTBOARD
i 0.5 CCW
ft
NOMINAL-PREFERRED
THE NOMINAL VALUE IS
THE PREFERRED VALUE
LEFT/RIGHT DIFFERENCE
ANGLE OF REAR AXLE RELATIVE TO VEHICLE CENTERUNE
THE VALUE O f THE LEFT SIDE
0 5 CW MINUS THE VALUE OF THE (+) AXLE POINTS LEFT (-) AXLE POINTS RIGHT
RIGHT SIDE
EX.
If FT CASTER - +6 5 PRODUCTION TOLERANCE
RIGHT CASTER » +8.0
THE RANGE O f ACCEPTABLE
PRODUCTION +6.5A7.5
VALUES AROUND THE NOMINAL
CCW = COUNTER CLOCKWISE LEFT/RIGHT DIFFERENCE PREFERRED: +7.0
- PREFERRED
CW - CLOCKWISE 65 8.0 = 1 5 TOLERANCE: 0.5
J9302-61
Fig. 1 Wheel Alignment Measurements

SUSPENSION AND STEERING SYSTEM DIAGNOSIS
I FRONT END |
EXCiSSIVE PLAY
STEERING
LINKAGE
E
|*?£ ;
DIFFICULT
STEERING
1 v s n c i E i
I
I
1
|
PULLS TO
O N E SIDE
I
j
LOOSE OR WORN LOOSE OR WORN LOOSE OR WORN LOW OR UNEVEN LOW OR UNEVEN LOW OR UNEVEN
FRONT WHEEL FRONT WHEEL WHEEL BEARINGS TIRE AIR PRESSURE TIRE AIR PRESSURE TIRE PRESSURE
BEARINGS BEARINGS
LOOSE C)RWORN
SHOCKS JSORBER LOOSE C)RWORN LOOSE, WORN OR WHILE BR AKING—
STEERINC7 COLUMN TIRE/V VHEEL LO(DSE GLAZED P/S REFE R TO
MOUNTir nIG HARD- WHEEL B EARINGS
WAR E OR SHAFT C OUPLING OUT OF fJA LANCE PUMP BELT BRAKES SERVICE
SHOCK A BSORBER
LOOSE STEERING UNEVEN TIRE TREAD LOW

LOOSE STEERING WEAR, OR EX BROKEN OR WEAK BROKEN OR WEAK
GEAR-TO-FRAME GEAR-TO-FRAME POWER STEERING
RAIL BOLTS CESSIVELY WORN REAR SPRING REAR SPRING
RAIL BOLTS FLUID LEVEL
TIRE TREAD
WORN WORN TIE- WORN TIE- SHOCK ABSORBER LACK OF ASSIST LOOSE OR WORN
UPPER SUSPENSION ROD END ROD END NOT FUNCTIONING FROM POWER SUSPENSION
ARM BUSHINGS BALL STUDS BALL STUDS CORRECTLY STEERING PUMP BUSHINGS
INCORRECT FRONT
WORN LOWER INCORRECT LOOSE OR WORN INCORRECT BALL STUDS WHEEL ALIGNMENT
SUSPENSION ARM STEERING GEAR SUSPENSION ARM STEERING GEAR REQUIRE (EITHER CASTER
PIVOT BUSHINGS ADJUSTMENT BUSHINGS ADJUSTMENT LUBRICATION OR CAMBER)
LOOSE LOWER LOOSE OR WORN LOOSE OR WORN STEERING GEAR

SUSPENSION ARM UPPER SUSPENSION SUSPENSION ARM LUBRICANT LEVEL
ARM BALL STUDS BUSHINGS LOW
WORN ISOLATOR INCORRECT FRONT- INCORRECT

PAD BETWEEN COIL WHEEL ALIGNMENT INCORRECT FRONT
WHEEL ALIGNMENT STEERING GEAR
SPRING AND (PARTICULARLY ADJUSTMENT
FRAME BRACKET CASTER)
STEERING
GEAR
MALFUNCTION
INCORRECT FRONT
WHEEL ALIGNMENT
(PARTICULARLY
CASTER)
J9002-97
• FRONT SUSPENSION AND AXLE 2 -5
(4) Front wheels for excessive radial, lateral turn toward the center position unassisted, an incor
runout and unbalance. Refer to Group 22, Wheels rect caster angle is probable.
and Tires for diagnosis information. (1) The caster angle is factory preset at positive
(5) Suspension components for wear and noise. Check two degrees ( + 2°). The acceptable range is +1/2° to
components for correct torque. Refer to Groups 2 and 3, + 3 1/2°.
Suspension and Axle for additional information. (2) The caster angle should be measured with ac
curate wheel alignment equipment.
WHEEL ALIGNMENT MEASUREMENTS/ADJUSTMENTS (3) Caster angle can be adjusted by installing ta
The front wheel alignment positions must be set to pered shims between the front axle pads and the
the specified limits. This will prevent abnormal tire spring brackets. The caster angle should be adjusted
tread wear. as near as possible to the preferred angle.
The equipment manufacturer's recommenda (4) Record the caster measurement before remov
t i o n s for u s e o f their e q u i p m e n t s h o u l d a l w a y s ing the original shims from the spring pads.
b e followed. A l l d a m a g e d f r o n t s u s p e n s i o n sys (5) The caster should be the same at both sides of
t e m c o m p o n e n t s s h o u l d b e r e p l a c e d . D o n o t at the vehicle. Refer to the Specifications chart.
t e m p t to s t r a i g h t e n a n y b e n t c o m p o n e n t .
CAMBER AND CASTER-2WD VEHICLES

Camber and caster angle adjustments involve repo
sitioning the upper suspension arm cam adjustment
bolts (Fig. 2). Alignment adjustments are accom
plished by loosening the nuts and changing the posi
tion of the cam bolt.
(1) Remove all foreign material from the adjust
ment bolt threads.
(2) Record the camber and caster measurements
before loosening the adjustment bolt nuts.
(3) The camber angle should be adjusted as near as
possible to the preferred angle. The caster should be
the same at both sides of the vehicle. Refer to the
Specifications chart.
RN1030
CAMBER AND CASTER—4WD VEHICLES
For 4WD vehicles, the correct wheel camber (verti Fig. 2 Caster & Camber Adjustment Location—2WD
cal tilt) angle is factory preset at zero degree (0°). Vehicles
Camber cannot be altered by adjustment. WHEEL TOE POSITION
The wheel toe position adjustment should be the fi
CAUTION: D o not attempt to adjust the camber a n nal front wheel alignment adjustment. In all in
gle by heating or bending the axle or a n y s u s p e n stances, follow the equipment manufacturer's
s i o n c o m p o n e n t . If camber angle is incorrect, the recommended procedure.
component(s) c a u s i n g a n incorrect angle m u s t be (1) Secure the steering wheel with the front wheels
replaced. in the straight-ahead position. For vehicles equipped
with power steering, start the engine before straight
(1) It is important t h a t the camber (vertical tilt)
ening the wheels.
angle be the same for both front wheels.
With p o w e r steering, the engine should be op
(2) The camber angle should be measured with ac
erating during the wheel toe position adjust
curate wheel alignment equipment. The acceptable
ment.
range is -1° to +1°. Refer to the Specifications chart.
(2) Loosen the tie rod adjustment sleeve clamp
Road test the vehicle and observe the steering
bolts (Fig. 3).
wheel return-to-center position.
Before r o a d testing, c h e c k a n d c o r r e c t t h e t i r e (3) Adjust the wheel toe position by rotating the
inflation p r e s s u r e s . Inflate b o t h o f the f r o n t t i r e s tie rod adjustment sleeve (Fig. 3).
with exactly the same pressure. Rotate e a c h tie-rod e n d in the direction of
During the road test, make vehicle t u r n s to both sleeve rotation during the adjustment (Fig. 3).
the left and right. If the steering wheel returns to This will ensure that both tie-rod e n d s are at the
ward the center position unassisted, the caster angle center of their travel.
is correct. However, if the steering wheel does not re (4) If applicable, t u r n the ignition switch off.
TIE RODS
(5) Position the adjustment sleeve clamps so the
ends a r e n o t l o c a t e d at the sleeve slot. Tighten the
clamp bolt nuts to 26 N*m (225 in. lbs.) torque.
Tighten Model D350 and all 4WD vehicle (heavy
duty tie rods) nuts to 34 N*m (25 ft. lbs.) torque. En
sure clamp bolts are located at the underside of the
sleeve.
CLAMP RN1036
Fig. 3 Toe Position Adjustment (Typical)
ALIGNMENT SPECIFICATIONS
ALIGNMENT (4WD) ASGSPTABLE R A N G E PREFERRED

Camber -rto+r 0°
"Caster + 1/2° to 37*° +2°
King Pin Inclination 8.5° 8.5°
Toe-In (at Hub Height) -0.05° to +0.45° 0.20°
ALIGNMENT (2WD) ACCEPTABLE R A N G E PREFERRED
Camber 0°to 1° +1/2°
'Caster -1° to +2° +1/2°
Toe-in (at Hub Height) 0° to 0.50° 0.25°
Turning Angle (Base Tire) Left and Right 33° 3 3
° J9102-64
*lf vehicle w a n d e r s , caster should be increased. If steering effort is very high (especially when cornering), caster should be decreased.
• FRONT SUSPENSION AND AXLE 2 • 7
F R O N T S U S P E N S I O N —2WD VEHICLES
INDEX
page page
Coil Springs 9 Stabilizer Bar 8
Lower Ball Stud . 10 Steering Knuckle 13
Lower Suspension Arm 10 Upper Ball Stud 11
Lower Suspension Arm Bushing 11 Upper Suspension Arm 11
Lower Suspension Arm Strut 8 Upper Suspension Arm Bushing Replacement . . . 12
Service Information 7 Wheel Hub and Bearings 7
Shock Absorber 9
SERVICE INFORMATION BRAKE INNER

Periodic lubrication of the front suspension (steer
ing) system components is required. Refer to Group
0, Lubrication And Maintenance for the service in
terval.
Rubber bushings must n e v e r be lubricated.
All front suspension c o m p o n e n t s that are
cushioned b y rubber should be tightened with
the suspension system at the normal height.
WHEEL HUB AND BEARINGS

REMOVAL
(1) Block the brake pedal in the up (non-depressed)
position.
(2) Raise and support the vehicle.
(3) Remove the wheel.
(4) Remove bolts from the disc brake caliper.
(5) Separate the disc brake caliper from the rotor.
Position and support the caliper away from the im
mediate work area. Do not allow the caliper to
Fig. 1 Front Wheel Bearings & Hub/Rotor
h a n g from the brake fluid hose.
(6) Remove the dust cap, cotter pin, and remaining • Strike the flat of each bearing against a hardwood
block several times
hub components from the spindle (Fig. 1).
• Flush bearing between strikes
C A U T I O N : Use care to prevent the inner wheel bear • Repeat the procedure above until each bearing is
ing and bearing seal from contacting the steering clean
knuckle spindle threads during removal (Fig. 1). • Dry the bearings with compressed air but do not
Otherwise, the threads, bearing, and seal could all spin them
be damaged. (3) After cleaning, apply engine oil to each bear
ing.
(7) Carefully slide the wheel hub/rotor from steer (4) Rotate each bearing slowly while applying
ing knuckle spindle (Fig. 1). downward force. Examine the rollers for pitting and
(8) For bearing cleaning or replacement, remove roughness. Replace worn or otherwise defective bear
the seal and inner wheel bearing from the wheel ings. If a bearing has pitted and/or rough surfaced
hub/rotor bore (Fig. 1). rollers, replace both the bearing and bearing cup
(Fig. 1).
CLEANING AND INSPECTION (5) If reusable, remove the engine oil from each
(1) Thoroughly clean both wheel bearings and in bearing. Pack each bearing with multi-purpose
terior of the hub/rotor (Fig. 1). R e m o v e all of the NLGI, grade 2, EP-type lubricant. Place the bearings
residual lubricant. in a clean, safe place.
(2) To clean the bearings: Ensure that lubricant is forced into all the cav
• Soak them in an appropriate cleaning solvent ities b e t w e e n the bearing cage and rollers.
INSTALLATION NUT
(1) If a bearing and cup must be replaced, remove
the cup from the wheel hub/rotor bore (Fig. 1). Use a
brass drift or an appropriate removal tool to tap out
the cup.
(2) Install the replacement bearing cup(s) with an
appropriate installation tool.
(3) Apply lubricant to surface area of the wheel
hub/rotor bore. Install the inner wheel bearing in the
hub/rotor. Install a replacement bearing seal with an
appropriate seal installation tool.
(4) Inspect the bearing and seal contact surfaces on
the steering knuckle spindle for burrs and/or rough
ness (Fig. 1).
FRONT RETAINER STRUT J9002-120
(5) Remove all the rough contact surfaces from the
spindle. Apply a coating of multi-purpose NLGI, Fig. 2 Lower Suspension Arm Strut Removal/
grade 2, EP-type lubricant to the spindle surface. Installation
CAUTION: Us© care to prevent the inner wheel bear INSTALLATION

ing and bearing seal from contacting the steering (1) Position the rear retainer and rear bushing on
knuckle spindle threads during removal (Fig. 1). the front end of the strut (Fig. 2).
Otherwise, the threads, bearing, and seal could be (2) Carefully slide the strut into position. Install
damaged. the rear bolts. Tighten the bolts to 182 Nnn (135 ft.
lbs.) torque.
(6) Carefully slide the wheel hub/rotor onto the (3) Install the front bushing, front retainer and
spindle. n u t at the front end of the strut. Tighten the n u t
Install the outer wheel bearing, the washer and with 70 Nnn (52 ft. lbs.) torque.
nut. (4) Install the spring pin.
(7) Tighten the n u t to 41 to 54 Nnn (30 to 40 ft.
lbs.) torque while rotating the wheel hub/rotor. Stop STABILIZER BAR
the hub/rotor and loosen the nut to completely re
REMOVAL
lease the bearing preload torque. Next, tighten the
(1) Remove the link rod nut at each end of the sta
nut finger-tight, install the n u t lock. Install a re
bilizer bar (Fig. 3).
placement cotter pin.
(8) The wheel bearing adjustment (above) should
have 0.001 to 0.003 inch (0.254 to 0.0762 mm) end
play.
(9) Clean the dust cap. Apply a coating of multi
purpose NLGI, grade 2, EP-type lubricant to internal
surface. Install the cap.
D o not fill the dust c a p with lubricant.
(10) Install the brake caliper, refer to Group 5,
Brakes.
(11) Install the wheel and tire, refer to Wheel and
Tire Installation in this section. Lower the vehicle.
LOWER SUSPENSION ARM STRUT

REMOVAL
(2) Use a small drift and a hammer to drive the
spring pin from the front of the strut. Remove the
spring pin, nut, retainer and bushing from the end of
the strut (Fig. 2).
(3) Remove the strut rear bolts and jounce bumper
from the bracket. Remove the strut from the vehicle
(Fig. 2). Fig. 3 Stabilizer Bar
4 FRONT SUSPENSION AND AXLE 2 - i
(2) Remove the outer retainers and rubber bush (4) Remove support stands and lower vehicle to
ings from the link rods (Fig. 3). ground.
(3) Remove the bolts or nuts from the U-shaped
stabilizer bar support brackets. Remove the stabilizer COIL SPRINGS
bar from the vehicle (Fig. 3).
REMOVAL
INSTALLATION (1) Raise vehicle on hoist. Position support stands
(1) Position the stabilizer bar ends over the link on frame and lower front hoist. Remove front tire.
rods. Install the U-shaped support brackets and bolts/ (2) Remove brake caliper assembly, refer to Group
nuts (Fig. 3). Tighten the bolts/nuts to 23 Nnn (200 5, Brakes.
in. lbs.) torque. (3) Remove shock absorber.
(2) Install the outer retainers and rubber bushings (4) Remove lower control arm strut.
on the link rods (Fig. 3). (5) Install Spring Compressor DD-1278 in the
(3) Install the link rod nuts (Fig. 3). Tighten the spring (Fig. 5). Tighten the nut finger-tight, and
nuts to 11 Nnn (100 in. lbs.). then loosen the nut 1/2 of-a-turn.
(6) Remove cotter pins and ball joint nuts.
SHOCK ABSORBER (7) Install Ball Stud Remover C-3564-A on the
lower ball stud (Fig. 4). Turn the threaded portion of
REMOVAL the tool and lock the tool securely against the lower
(1) Raise vehicle on hoist. Position support stands stud (Fig. 5). Expand the tool enough to place force
on frame and lower front hoist. on the lower ball stud. Strike the steering knuckle
(2) Remove upper nut and retainer. sharply with a hammer to loosen the stud. D o not
(3) Remove two lower mounting bolts, lower shock attempt to force the stud out of the steering
from suspension arm (Fig. 4). k n u c k l e with the loosening tool.
FRONT SHOCK ABSORBER J9017-29
Fig. 4 Coil Spring Suspension

INSTALLATION
(1) Extend shock fully, install retainer on shock
absorber. Install bushing and sleeve, make sure they Fig. 5 Spring Compressor & Ball Stud Loosening
are not worn or broken. Tools Installed
(2) Guide shock up through coil spring. Install top (8) Remove the loosening tool. Slowly loosen the
retainer and nut. Tighten nut to 34 Nnn (25 ft. lbs.) coil spring compressor tool until all tension is re
torque. lieved from the spring. Remove the spring compres
(3) Align lower end of shock and install mounting sor and spring with the rubber isolation pad.
bolts. Tighten bolts to 23 Nnn (200 in. lbs.) torque.
INSTALLATION REMOVAL
(1) Position the spring and isolation pad on the (1) Follow procedure under Coil Spring Removal.
suspension arm. Install the spring compressor tool. (2) Remove ball joint seal. Use assembled Remov
Compress the spring until the lower suspension arm er/Installer C-4212 to force the ball stud out of the
can be properly positioned in the steering knuckle. lower suspension arm bore (Fig. 6).
(2) Install the nuts on the ball studs. Tighten the
upper nut to 142 Nnn (105 ft. lbs.) torque. Tighten
the lower nut.
* 11/16-16 bolt, to 183 Nnn (135 ft. lbs.) torque
• 3/4-16 bolt, to 237 Nnn (175 ft. lbs.) torque
Install replacement cotter pins.
(3) Install the strut.
(4) Connect the stabilizer bar.
(5) Install the shock absorber.
(6) Install the brake splash shield on the steering
knuckle. Tighten the screws to 23 Nnn (200 in. lbs.)
torque.
(7) Carefully install the hub/rotor and bearings.
(8) Install the brake caliper, refer to Group 5, Brakes.
(9) Install the wheel and tire, refer to Wheel and Tire
Installation within this section. Lower the vehicle.
(10) Test the vehicle brakes and the suspension for
proper operation.
LOWER SUSPENSION ARM

REMOVAL
(1) Follow procedure under Coil Spring Removal. Fig. 6 Lower Bail Stud Removal
(2) Remove hex-head mounting bolt from the cross-
INSTALLATION
member.
(1) Force the replacement ball stud into the lower
(3) Remove the lower suspension arm from vehicle.
suspension arm bore with assembled Remover/In
INSTALLATION staller C-4212 (Fig. 7).
(1) Position lower suspension arm on vehicle.
(2) Install mounting bolt, tighten finger-tight.
(3) Follow procedure under Coil Spring Installa
tion.
(4) Lower the vehicle to the surface with the
wheels/tires supporting the vehicle weight. Tighten
the lower suspension arm mounting bolt to 305 Nnn
(225 ft. lbs.) torque.
LOWER BALL STUD

INSPECTION
(1) Raise the front of the vehicle. Install safety
floor stands under both lower suspension arms as far
outboard as possible. The upper suspension arms
must not contact the rebound bumpers.
(2) Install a dial indicator and clamp assembly to
the lower suspension arm.
(3) Position indicator plunger against knuckle arm
and zero indicator.
(4) Raise and lower the wheel with a pry bar under
the center of the tire. Measure the axial movement of
the knuckle with respect to the suspension arm. Fig. 7 Lower Ball Stud Installation
(5) If the travel of the suspension arm is 0.020
inch (0.51 mm) or more, replace the ball joint.
• FRONT SUSPENSION AND AXLE 2 - 11
(2) Position the seal over the ball stud (if neces
sary, use a replacement seal). Force portion of the
seal downward on the ball stud housing with a n ap
propriate size socket wrench until it is securely
locked in place.
(3) Install lower suspension a r m using procedure
under Lower Suspension Arm Installation.
LOWER SUSPENSION ARM BUSHING

REMOVAL
(1) Follow procedure under Coil Spring and Lower
Suspension Arm Removal.
(2) Use an arbor press and an appropriate size
sleeve to force the original bushing from the lower
suspension arm bore.
INSTALLATION
(1) Use an arbor press and an appropriate size
sleeve to force t h e replacement bushing into the
lower suspension a r m bore. Ensure t h a t it is com
pletely seated in t h e bore.
(2) Install the lower suspension arm according to in Fig. 8 Ball Stud Loosening Tool Installed
structions provided within the installation procedure. (4) Install the shock absorber. Tighten n u t to 34
N*m (25 ft. lbs.) torque and lower bolts to 23 N*m
UPPER SUSPENSION ARM (200 in. lbs.) torque.
(5) Install the wheel/tire. Raise the vehicle, remove
REMOVAL
the support stands and lower the vehicle to the surface.
(1) Raise the vehicle. Position support stands un
(6) Adjust the caster and camber angles. Tighten
der the frame rail and lower the front of the hoist.
the eccentric (cam) nuts to 95 N*m (70 ft. lbs.)
Remove the wheel/tire.
torque.
(2) Remove shock absorber, refer to above proce
dures. UPPER BALL STUD
(3) Install Spring Compressor DD-1278 (Fig. 5).
Tighten the n u t finger-tight and then loosen it 1/2 of- INSPECTION
a-turn. (1) Position a floor jack under the lower suspension
(4) Remove the cotter pins and t h e ball stud nuts. arm. Raise the wheel and allow the tire to lightly
(5) Install Ball Stud Remover C^3564-A (Fig. 8). contact the floor (vehicle weight relieved from the
Turn the threaded portion of the tool to lock it se tire).
curely against the upper ball stud (Fig. 8). Spread (2) Grasp the top of the tire and apply force in and
the tool enough to apply force against the upper ball out. Look for any movement a t t h e b a l l j o i n t s be
stud. Strike the steering knuckle sharply with a tween the upper suspension arm and steering
hammer to loosen the upper ball stud. Do not at knuckle.
tempt to force the ball stud out of the steering (3) If any lateral movement is evident, replace the
knuckle bore with t h e loosening tool. ball joint.
(6) Remove the loosening tool. Remove the nuts,
eccentric (cam) bolts and suspension arm from the REMOVAL
vehicle (Fig. 9). (1) Position a support under the outer end of the
lower suspension arm. Lower the vehicle so t h a t the
INSTALLATION support compresses the coil spring.
(1) Position the suspension arm and install the ec (2) Remove the wheel/tire.
centric (cam) bolts (Fig. 9). and n u t s finger-tight. (3) Remove the ball stud nuts. Use Ball Stud Re
(2) Install upper ball stud into steering knuckle. mover C-3564-A to loosen the upper ball stud (Fig.
Install nuts on the ball studs. Tighten to 142 N« (105 8).
ft. lbs.) torque. Install replacement cotter pins. (4) Use Wrench C-3561 to un-thread the upper ball
(3) Remove the spring compressor tool (Fig. 5). stud from the upper suspension arm.
1—Nut 4—Bushing 7—Upper Suspension Arm 10—Sleeve

2—Lockwasher 5—Ball Joint 8—Upper Ball Joint Seal 11—Cam and Bolt
3—Cam 6—Locknut 9—Bumper
J9202-98
Fig. 9 Upper Suspension Arm Removal/Installation
INSTALLATION SP-3952A
(1) Thread the replacement ball stud into the up
per suspension arm bore as far as possible by hand. BUSHING
Use Wrench C-3561 to tighten the ball stud to 169
N«m (125 ft. lbs.) torque. Ensure that the ball stud
SP-3953
is completely s e a t e d a g a i n s t the arm.
(2) Install and seat the replacement ball stud seal.
(3) Insert the upper ball stud into steering
knuckle. Install ball stud nuts. Tighten the nuts to
#
142 N m (105 ft. lbs.) torque. Install replacement cot
ter pins.
(4) Install the wheel/tire. Remove the support and
lower the vehicle to the surface. RH393
UPPER SUSPENSION ARM BUSHING Fig. 10 Upper Suspension Arm Bushing Removal
REPLACEMENT forced in the bore. Do not u s e oil or any other
REMOVAL lubricant to aid the installation.
(1) Follow procedure under Upper Suspension Arm (1) Position flange end of the replacement bushing
Removal. in Remover/Installer C-3962. Support suspension arm
(2) Place the upper suspension arm in a vise. As firmly and force the bushing in the suspension arm
semble Remover/Installer C-3962 and Adaptor bore (from outside). Tighten until the flanged end is
SP-3953 (Fig. 10) over the bushing. Tighten the nuts seated on the arm (Fig. 11).
and force the bushing out of the arm bore. (2) Follow procedure under Upper Suspension Arm
Installation.
INSTALLATION
B e sure the s u s p e n s i o n arm is supported
firmly at the area w h e r e the b u s h i n g is b e i n g
(6) Remove the shock absorber from the vehicle,

refer to the removal procedures.
(7) Install Spring Compressor Tool DD-1278 in t h e
spring (Fig. 5). Tighten the n u t finger-tight, and
then loosen the n u t 1/2 of-a-turn.
(8) Remove the cotter pins and t h e lower and up
per ball stud nuts at the steering knuckle.
(9) Install Ball Stud Loosening Tool C-3564-A on
the lower ball stud (Fig. 4). Turn t h e threaded por
tion of the tool and lock the tool securely against the
lower stud (Fig. 5). Expand t h e tool enough to place
force on the lower ball stud. Strike the steering
knuckle sharply with a hammer to loosen the stud.
D o not attempt to force the stud o u t of the steer
Fig. 11 Upper Suspension Arm Bushing installation ing k n u c k l e with the loosening tool.
(10) Remove the loosening tool and remove the
STEERING KNUCKLE
lower ball stud from the steering knuckle bore with
REMOVAL an appropriate tool.
(1) Block the brake pedal in the up position. Raise (11) Reverse the position of Ball Stud Loosening
the vehicle and remove the wheel cover and wheel/ Tool C-3564-A, and remove t h e upper ball stud.
tire. Remove the brake caliper, refer to Group 5, (12) Remove the loosening tool.
Brakes. (13) Remove the upper ball stud from the steering
(2) Remove the brake rotor from the spindle. Refer knuckle bore with an appropriate tool.
to Wheel Hub and Bearings service procedures (14) Slowly loosen the coil spring compressor tool
within this Group. (Fig. 5) until all tension is relieved from the spring.
(3) Remove the brake splash shield. Remove and (15) Separate the steering knuckle and the steer
discard the dust seal. ing knuckle arm from the ball studs (Fig. 13).
(4) Remove the cotter pin and the nut from the tie-
rod end ball stud.
(5) Install Puller Tool C-3894A (Fig. 12) and apply
sufficient force with the tool to loosen the tie-rod end
ball stud from the steering knuckle arm bore.
Fig. 13 Steering Knuckle

(16) Remove the brake adapter and steering
knuckle bolts from the steering knuckle. Separate
the components.
INSTALLATION
(1) Install the brake adaptor on the steering
knuckle. Tighten the bolts to 136 Nnn (100 ft-lbs)
torque.
(2) Align the steering knuckle a r m bolt holes with
Fig. 12 Tie-Rod End Ball Stud Removal the steering knuckle bolt holes. Install the bolts and
tighten to 291 Nnn (215 ft-lbs) torque.
(3) Mount the knuckle to the suspension arms and (6) Install the shock absorber, refer to the installa
install the nuts. Tighten the upper nut to 142 Nnn tion procedures.
(105 ft-lbs) torque and the lower nut. (7) Install the hub/rotor, refer to the procedures
• 11/16-16 bolt, to 183 Nnn (135 ft-lbs) torque above.
• 3/4-16 bolt, to 237 Nnn (175 ft-lbs) torque (8) Install the brake caliper, refer to Group 5,
Install replacement cotter pins. Brakes for additional installation information.
(4) Connect the tie-rod end. Install and tighten the
n u t to 61 Nnn (45 ft-lbs) torque. Install a replace
Tire Installation in this section. Lower the vehicle.
ment cotter pin.
(5) Position a replacement dust seal on the steer (10) Test the vehicle brakes and the front suspen
ing knuckle. Install the splash shield and tighten the sion for proper operation.
bolts to 24 Nnn (18 ft. lbs.) torque.
FRONT SUSPENSION—4WD VEHICLES
STABILIZER BAR SHOCK ABSORBER
REMOVAL SERVICE INFORM A TION
(1) Remove the link rod n u t at each end of the sta Air-adjustable shock absorbers are installed on ve
bilizer bar (Fig. 1). hicles equipped with the H e a v y D u t y S n o w P l o w
STABILIZER BAR P a c k a g e a n d Diesel e n g i n e .
REMOVAL
FRONT (1) Remove the shock absorber upper n u t and re
tainer from the frame bracket (Fig. 2).
PLATE
BRACKET
NUT
STABILIZER BAR
BUSHING
RETAINER
LINK ROD
J9017-37
Fig. 1 Stabilizer Bar

AXLE NUT
(2) Remove the outer retainers and rubber bush AXLE
ings from the link rods (Fig. 1). J9202-99
(3) Remove the bolts or nuts from the U-shaped
stabilizer bar support brackets. Remove the stabilizer Fig. 2 Shock Absorber (4 WD)
bar from the vehicle (Fig. 1).
(2) Remove the shock absorber lower n u t and re
INSTALLATION tainer from the axle. Pull the shock outward at top
(1) Position the stabilizer bar ends over the link and swing down to remove.
rods. Install the U-shaped support brackets and bolts/ (3) Remove the inner retainers from the mounting
nuts (Fig. 1). Tighten the bolts/nuts to 23 Nnn (200 studs.
in. lbs.) torque.
(2) Install the outer retainers and rubber bushings INSTALLATION
on the link rods (Fig. 1). (1) Before installing the shock absorber, ensure
(3) Install the link rod nuts (Fig. 1). Tighten the t h a t the bushing is inserted in the shock absorber
nuts to 11 Nnn (100 in. lbs.). eye.
Ensure the shock absorber is positioned on the INSTALLATION

stud with retainers correctly located (Fig. 2). (1) Align the spring front eye with the bolt hole in
(2) Position the inner retainers on the mounting the frame bracket and install the pivot bolt and n u t
studs. (Fig. 3).
(3) Install the shock on the upper and lower stud (2) Position t h e shackle plates at the spring rear
and install the outer retainers. eye and frame rail bracket. Install the nuts (Fig. 3).
(4) Install the nuts on the frame bracket and axle (3) Tighten t h e shackle plate nuts and front pivot
(Fig. 2). bolt nut until all slack is t a k e n up.
(5) Tighten the shock absorber upper and lower (4) Position t h e spring on the axle tube with the
nuts; spring center bolt seated in locating hole in axle tube
• Standard shock upper and lower n u t to 75 Nnn (55 pad (Fig. 3).
ft. lbs.) torque
(5) Install the U-bolts, new lockwashers a n d nuts.
• Air-adjustable shock upper nut to 75 N»m (55 ft.
(6) Tighten the nuts snug against t h e spring
lbs.) torque, lower n u t to 271 Nnn (200 ft. lbs.)
bracket.
torque
(7) Remove the supports and lower the vehicle
C A U T I O N : Vehicles with air s h o c k s M U S T maintain with the weight being supported by the tires.
a minimum pressure of 10 to 15 psi (70 to 105 kPa). (8) Tighten t h e spring nuts according to t h e follow
Operation below the specified minimum pressures ing specifications:
may cause damage. • Model 44 Axle:
U-bolt/Stud n u t s - 115 Nnn (85 ft. lbs.) torque
(6) Remove the supports and lower the vehicle. Front pivot bolt/nut — 135 Nnn (100 ft. lbs.) torque
Rear shackle bolt/nut — 81 Nnn (60 ft. lbs.) torque
LEAF SPRINGS • Model 60 Axle:
U-bolt n u t s - 129 Nnn (95 ft. lbs.) torque
REMOVAL
(1) Raise and support the frame until all weight is Front pivot bolt/nut - 135 Nnn (100 ft. lbs.) torque
removed from the front springs. Rear shackle bolt/nut - 108 Nnn (80 ft. lbs.)
(2) With the front tires in contact with the surface, torque
position support stands under the frame side rails.
(3) Remove the nuts, lockwashers, U-bolts t h a t at SPRING LEAF-REPLACEMENT
tach the spring to the axle shaft tubes (Fig. 3). If a spring h a s acquired a set (lost significant
height), it should be replaced.
SPRING
BRACKET (1) Remove the spring from the vehicle. If neces
SPRING
sary, refer to t h e removal procedure.
BRACKET SPRING (2) Remove the spring leaf alignment clips.
SHACKLE (3) Clamp t h e spring in a vise. Remove the n u t
PLATE and center bolt (Fig. 4).
SPRING CENTER RATCHET
AND
SOCKET
WRENCH
FRONT
SPRING LEFT SIDE
AXLE TUBE U-BOLT J9017-33
Fig. 3 Front Suspension Fig. 4 Leaf Spring Disassembly
(4) Remove the spring front eye pivot n u t and bolt, (4) Insert a long drift or punch into the center bolt
rear spring shackle nuts, shackle plates. Remove the hole and slowly release the vise jaws.
spring from the vehicle (Fig. 3).
2-16 FRONT SUSPENSION AND AXLE •
(5) Remove the spring from the vise. Replace the NUT PIPE
broken/defective leaf. Insert a long drift or punch (RECEIVER)
into the spring center bolt hole.
(6) Position the spring between vise jaws and
SPRING
slowly tighten the vise jaws. Keep the spring leaves EYE
aligned with the long drift or punch.
(7) Remove the drift/punch from the spring center
bolt hole. Install a replacement center bolt and nut
(Fig. 4).
(8) Tighten the n u t to 27 N*m (20 ft. lbs.) torque.
An alternate is to tighten until the center of the NUT
spring has no gaps. Use a maximum of 54 N*m (40 ft.
lbs.) torque for this method.
(9) Install the alignment clips.
(10) Install the spring in the vehicle. If necessary
refer to the installation procedure.
SOCKET
WRENCH
LEAF SPRING EYE BUSHING REPLACEMENT (DRIVER)
(1) Assemble tools shown (Fig. 5). Tighten the n u t
located at the socket wrench end of the threaded rod
FLAT THREADED
until the bushing is forced out. WASHER ROD J8917-20
(2) Assemble and align the bushing installation
tools. Fig. 5 Spring Eye Bushing Removal
(3) Align the bushing with the spring eye and
eye. The e n d s of the bushing must b e flush or
tighten the nut located at the socket wrench end of
slightly r e c e s s e d within the e n d surfaces of the
the threaded rod. Tighten until the bushing is forced
into the spring eye. spring eye.
The bushing must b e centered in the spring
M O D E L 4 4 F R O N T AXLE
INDEX
page page
Axle Shaft and U-Joint Service 23 Pinion Gear Depth Measurement and Adjustment
Complete Axle Removal/Installation 31 with Tool Set C-3715-B 40
Differential Assembly 35 Pinion Gear Depth Measurement and Adjustment
Differential Disassembly . 32 with Tool Set D-115-44 . . . 38
Drain and Refill 19 Pinion Shaft Seal 19
General Information 17 Specifications 48
Hub, Spindle and Axle Shaft 20 Steering Knuckle Arm 31
Intermediate Axle Shaft 30 Steering Knuckle, Upper and Lower Ball Studs . . 2 4
Lubricant 17 Vacuum Shift Motor 26
GENERAL INFORMATION A small, stamped metal axle gear ratio identifica

Model 44 front axles (Fig. 1) consists of an iron tion t a g is attached to the housing cover via one of
center casting with axle shaft tubes extending from the cover bolts. This t a g also identifies the number of
either side. ring gear and pinion gear teeth.
The integral type housing, hypoid gear design h a s The differential case is a one-piece design. The dif
the centerline of the pinion set below the centerline ferential pinion mate shaft is retained with a roll
of the ring gear. pin. Differential bearing preload and ring gear back
The axle shaft disconnect housing is welded to the
lash are adjusted by the use of shims located between
left axle shaft tube. A splined, two-piece axle shaft is
the differential bearing cones and case.
located on the left side and it is engaged or disen
gaged by a shift collar. The collar is moved by a shift
fork controlled by a vacuum shift motor. The shift LUBRICANT
motor is operated by engine vacuum controlled by a Multi-purpose API GL 5 quality hypoid gear lubri
switch located a t the transfer case. cant should be used for Model 44 axles. MOPAR Hy
The axles are equipped with full-floating axle poid Gear Lubricant conforms with these
shafts, meaning t h a t loads are supported by the spin specifications and is recommended.
dles attached to the steering knuckles.
The removable, stamped steel cover provides a C A U T I O N : If a front axle is submerged in water, the
means for inspection and service without removing axle lubricant must be replaced immediately.
the complete axle from the vehicle.
J9202-105
Fig. 1 Model 44 Front Axle

FRONT SUSPENSION AND AXLE 2 - 19
DRAIN AND REFILL PINION SHAFT SEAL

(1) Drive the vehicle until the gear lubricant
reaches normal operating temperature. REMOVAL
(2) Raise and support the vehicle. (1) Raise and support the vehicle.
(3) Remove the lubricant fill hole plug from the (2) Mark the U-joint, pinion yoke, and pinion shaft
differential housing cover. for reference.
(4) Remove the differential housing cover. Allow (3) Disconnect the drive shaft from the pinion
the original lubricant to completely drain from the yoke. Secure the drive shaft in a n upright position to
housing and axle shaft tubes. prevent damage to the rear U-joint.
(5) With standard differential, clean the differen (4) Remove the pinion yoke n u t and washer. Use
tial and the housing cavity with a flushing oil (or Remover C-452 and Wrench C-3281 to remove the
light engine oil). This will remove the residual lubri pinion yoke (Fig. 3).
cant and foreign matter. Do not u s e water, steam, (5) Mark the positions of the yoke and pinion gear
kerosene or gasoline for flushing. for installation alignment reference.
(6) Scrape the residual gasket from the housing SPECIAL TOOL
and cover mating surfaces. Clean the mating sur C-3281
faces with mineral spirits. Install a new cover gas
ket. Apply a bead of MOPAR® Silicone Rubber
Sealant on the housing cover (Fig. 2). A l l o w the
sealant to cure for a few minutes.
SEALING CONTOUR OF BEAD
SURFACE
SPECIAL TOOL
C-452 J9102-31
Fig. 3 Pinion Yoke Removal

(6) Use Remover C-748 to remove the pinion gear
seal (Fig. 4).
PINION SEAL
BEAD
THICKNESS
6.35mm (1/4") J9302-30
Fig. 2 Sealant On Housing Cover
Install the housing cover within 5 minutes af
ter applying the sealant. If not installed the seal
ant must be removed and another bead applied.
(7) Install the cover on the differential with the
bolts. Install the identification tag. Tighten the cover
bolts to 47 Nnn (35 ft. lbs.) torque.
C A U T I O N : Overfilling the differential can result in

the lubricant foaming and overheating.
SPECIAL TOOL
(8) Refill the differential housing with the speci C-748
fied quantity of MOPAR® Hypoid Gear Lubricant.
# J9203-55
(9) Install the fill hole plug and tighten to 34 N m
(25 ft. lbs.) torque. Fig. 4 Pinion Seal Removal
(10) Road test the vehicle.
INSTALLATION (4) Align the installation reference marks and at
(1) Apply a light coating of gear lubricant on the tach the drive shaft to the yoke.
lip of pinion seal. Install the new seal (Fig. 5) use In (5) Add API grade GL 5 hypoid gear lubricant to
staller W-147-E and Handle C-4171. the differential housing, if necessary.
(6) Lower the vehicle.
HUB, SPINDLE AND AXLE SHAFT

REMOVAL/DISASSEMBLY
(1) Raise and support the front of vehicle.
(2) Remove the wheel/tire.
(3) Remove the brake caliper and adapter, refer to
Group 5, Brakes. Support the caliper to the frame
structure with wire.
(4) Remove the dust cap and drive hub snap ring
(Fig. 7).
Fig. 5 Pinion Seal Installation

(2) Align the installation reference marks and po
sition the yoke on the pinion gear.
(3) Install the pinion yoke, washer, and n u t on
shaft. Tighten the nut to 271-298 N»m (200-220 ft.
lbs.) torque (Fig. 6).
DIFFERENTIAL
Fig. 7 Drive Hub Snap Ring

(5) Remove the drive hub and spacer (Fig. 8).
(6) Remove the wheel bearing outer lock n u t with
Wrench C-4170-A (Fig. 9).
(7) Remove the lock washer and inner lock n u t
(Fig. 10).
(8) Remove the hub and rotor assembly from the
spindle.
(9) Remove the nuts t h a t attach the spindle to the
steering knuckle. Remove the spindle from the
knuckle, use a soft faced mallet if necessary to tap
loose (Fig. 11).
(10) Pull the axle shaft (with spacer, seal and
slinger) from the steering knuckle (Fig. 12).
(11) Clamp the spindle in a soft-jawed vise. Do not
clamp at the bearing contact surfaces. Remove the
bearing seal.
Fig. 6 Tightening Pinion Shaft Nut
(12) Use Puller D-131 to remove needle bearings
from the spindle (Fig. 13).
LOCK WASHER INNER LOCK NUT
Fig. 8 Spacer Removal/Installation Fig. 10 Lock Washer Removal/Installation
Fig. 11 Spindle Removal

(4) Right side only: carefully install the axle shaft
through the knuckle into the axle housing. Ensure
the axle shaft splines are engaged with the differen
tial side gears. Avoid damaging the differential
seals.
Fig. 9 Wheel Bearing Lock Nut Removal (5) Left side only: remove the shift motor housing
ASSEMBL Y/INSTALLA TION from axle. Position the shift collar on the intermedi
(1) Add Wheel Bearing Grease lubricant (NLGI ate axle shaft. Install the axle shaft, ensure the axle
Grade 2, E P or an equivalent lubricant) to the bear shaft splines are engaged with the shift collar. In
ings. Install a new needle bearing in the spindle with stall the shift motor (ensure the fork is engaged with
Installer D-122 and Handle C-4171 (Fig. 14). the shift collar) and tighten the bolts to 14 Nnn (10
(2) Lubricate and install a new spindle seal with ft. lbs.) torque.
Installer D-155 and Handle C-4171 (Fig. 15). (6) Install the spacer on the axle shaft end.
(3) Install the seal with lip facing the axle shaft (7) Install the brake splash shield and spindle on
splines (Fig. 16). Lubricate the seal (Fig. 17) with the steering knuckle. Install new nuts and tighten to
Wheel Bearing Grease lubricant (NLGI Grade 2, E P 34-41 Nnn (25-35 ft. lbs.) torque (Fig. 18).
or an equivalent lubricant).
2 - 22 FRONT SUSPENSION AND AXLE — — •
STEERING AXLE SHAFT
J9202-79
Fig. 12 Axle Shaft Removal

Fig. 14 Spindle Needle Bearing Installation
Fig. 13 Spindle Needle Bearing Removal

(8) Install the hub and rotor assembly onto the
spindle. Add Wheel Bearing Grease lubricant (NLGI
Grade 2, E P or an equivalent lubricant) to the bear
ings.
(9) Install the wheel bearing inner lock n u t on the
spindle with Wrench C-4170 (Fig. 19). Tighten the Fig. 15 Seal Installation
lock n u t to 68 N*m (50 ft. lbs.) torque to seat the
bearings. bearing adjustment should be within 0.001 inch to
0.010 inch (0.03 to 0.25 mm).
(10) Loosen the inner lock nut. Tighten to 41-54
N*m (31-39 ft. lbs.) torque while rotating the hub and (13) Install the spacer, driving hub and ring (Fig.
rotor assembly. 7, 8). Ensure the ring is seated.
(11) Back off the inner lock nut 135-150 degrees to (14) Apply MOPAR® Silicone Rubber Sealant to
the edge of the dust cap and install cap onto hub.
set the free play.
(15) Install the brake caliper and adapter, refer to
(12) Install the tabbed lock washer in the nearest
Group 5, Brakes.
hole in the washer (Fig. 8). Install and tighten the
outer n u t lock with Wrench C-4170 (Fig. 19 ) to 68
Tire—Installation within this section. Lower the ve
N«m (50 ft. lbs.) torque. The end play after the final
hicle.
•
Fig. 19 Wheel Bearing Lock Nut Installation

(2) Position t h e U-joint on the top of the vise jaws
(Fig. 20). Do not tighten the vise.
RN328
Fig. 17 Lubricating Axle Shaft Seal
Fig. 20 Bearing Cap Removal

(3) Use a mallet to drive the vertical yoke down
ward to remove the upper needle bearing and cap out
(Fig. 20).
(4) Reverse t h e position of the yoke and remove op
posite needle bearing and cap (Fig. 20).
(5) Remove t h e yoke from the spider.
(6) Position the open ends of the spider in a soft-
jawed vise. Repeat steps 3 and 4 (above) to remove
remaining bearings and caps.
Fig. 18 Spindle Installation (7) Remove the spider from the yoke.
AXLE SHAFT AND U-JOINT SERVICE (8) Clean and inspect all the components. Clean
any rust from the axle shaft splines. Retain each
DISASSEMBLY bearing and cap separate. If any component is exces
(1) Remove the snap rings from the yokes. sively worn or damaged, replace the U-joint.
2 - 24 FRONT SUSPENSION AND AXLE
ASSEMBLY STEERING KNUCKLE, UPPER AID LOWER BALL STUDS

(1) Insert the needle bearing and cap in one yoke
arm bore. REMOVAL/DISASSEMBLY
(2) Place the yoke in a vise (Fig. 21) and press the (1) Remove axle shaft, refer to Hub, Spindle and
needle bearing and cap into position. Install the snap Axle Shaft Removal.
ring. (2) Disconnect the tie-rod end from the steering
knuckle arm.
(3) Remove the cotter pin from the upper ball stud
nut. Remove the upper and lower ball stud nuts (Fig.
23). Discard the lower nut.
WRENCH
STEERING
KNUCKLE
Fig. 21 Bearing Cap installation

(3) Remove the yoke from the vise and insert one
end of the spider into the bearing. Insert opposite
bearing and cap in the yoke arm bore by hand and
align it with the spider.
(4) Place the yoke in a vise and press the cap into
J9202-83
the yoke arm bore and onto the spider (Fig. 22).
Fig. 23 Upper Ball Stud Nut Removal
YOKE
(4) Separate the steering knuckle from the tube
with a soft hammer (Fig. 24).
RAWHIDE
HAMMER
UPPER
BALL STUD
STEERING
KNUCKLE
RH403
Fig. 22 Bearing Cap & Spider Installation

(5) Use a short plug or a socket wrench to force the
bearing cap into the correct position and install the
snap ring.
(6) Repeat the instructions in steps 1 through 5 for
installing remaining bearings, caps and yoke. J9202-84
Fig. 24 Steering Knuckle Removal
(5) Remove the sleeve from the upper yoke with

Wrench C-4169 (Fig. 25). Discard t h e sleeve.
Fig. 25 Sleeve Removal/Installation

(6) Remove the snap ring retaining the lower ball
stud with Snap Ring Pliers (Fig. 26).
Fig. 28 Upper Ball Stud Removal

burrs, chips, excessive wear and cracks. Replace com
ponents as necessary.
ASSEMBL Y/INSTALLA TION

(1) Install lower ball stud with Remover/Installer
Fig. 26 Snap Ring Removal/Installation C-4212-L and Adaptor Set C-4288 (Fig. 29). Install
(7) Remove the lower ball stud from steering the snap ring retaining the lower ball stud. Ensure
knuckle with Remover/Installer C-4212-L and Adap the ring is seated.
tor Set C-4288 (Fig. 27). (2) Install the upper ball stud with Remover/In
(8) Re-position the tools and remove the upper ball staller C-4212-L and Adaptor Set C-4288 (Fig. 30).
stud (Fig. 28). Install new rubber boots over both ball studs. Re
(9) Clean all components with solvent and dry move the steering knuckle from the vise.
with compressed air. Inspect all the components for
C-4212-L
C-4288-1
J9202-90
Fig. 30 Upper Ball Stud Installation

Fig. 29 Lower Ball Stud Installation the cotter pin can be installed. Do not loosen the nut
to align the hole and the slot. Install a new cotter
(3) Thread new sleeve into the upper yoke with
pin.
Wrench C-4169 (Fig. 25). Allow two threads to re
main exposed at the top. VACUUM SHIFT MOTOR
(4) Position steering knuckle on the yoke arms. In
stall a new lower ball stud nut and tighten to 108 VACUUM CONTROL SYSTEM (FIG. 31)
Nnn (80 ft. lbs.) torque. The disconnect axle control system consists of;
(5) Tighten the sleeve in upper yoke arm to 54 N* • Vacuum control switch on the transfer case
• Air vent filter
(40 ft. lbs.) torque with Wrench C-4169.
• Shift motor
(6) Install the upper ball stud nut and tighten to
• Indicator switch
136 Nnn (100 ft. lbs.) torque. Tighten the n u t until • Vacuum switch
• Two check valves
• And a harness
Refer to Group 21, Transmissions for addi
tional information.
TORQUE
LET. NEWTON
POUNDS
LEFT ENGINE METRES
MOUNT FULLY SEATED
HAND TIGHTENED
55 IN. 6
LEFT ENGINE MOUNT
15 FT. 20
CLIP
NUT ANDyv
WASHER <C>
ALIGN WHITE TAPE

TO END OF CLIP
VIEW IN DIRECTION SHIFT MOTOR VIEW IN DIRECTION

OF ARROW W OF ARROW Z
ROUTE HOSE TO
VIEW IN DIRECTION CLIP. REAR OF DISTRIBUTOR
OF ARROW Z
WITH V-6
NUT
VIEW IN DIRECTION
OF ARROW X
J9102-61
Fig. 31 Disconnect Axle Vacuum Hose Routing

DISCONNECT AXLE/SHIFT MOTOR DIAGNOSIS
TWO-WHEEL DRIVE OPERATION DIAGNOSIS

F O U R - W H E E L DRIVE
I N D I C A T O R LIGHT WILL
NOT G O OUT W H E N
T R A N S F E R C A S E SELECTOR
IS M O V E D F R O M 4H TO
2H P O S I T I O N .
YES i
START E N G I N E D E P R E S S BRAKE TEST COMPLETE

INSPECT I N D I C A T O R PEDAL. PLACE T R A N S F E R
R A I S E VEHICLE S O ALL SWITCH A N D W I R I N G O N C A S E SELECTOR I N 2H P O S I T I O N
FOUR W H E E L S A R E SHIFT M O T O R H O U S I N G A N D T R A N S M I S S I O N IN
FREE TO ROTATE. FOR D A M A G E A N D DRIVE (AUTOMATIC) O R FIRST
SHORT-CIRCUIT. G E A R ( M A N U A L ) . E A S E OFF F R O M
REPAIR A S N E C E S S A R Y . BRAKE A N D LET W H E E L S ROTATE
SLOWLY.
FRONT DRIVE FRONT DRIVE

SHAFT D O E S SHAFT ROTATES.
N O T ROTATE.
INSPECT T R A N S F E R
F O U R - W H E E L DRIVE CASE LINKAGE.
I N D I C A T O R LIGHT
REMAINS O N .
CHECK TRANSFER
C A S E . REPAIR
PLACE T R A N S M I S S I O N AS NECESSARY.
IN NEUTRAL. TEST FOR V A C U U M
IN VACUUM H O S E
THAT C O N N E C T S TO
I N B O A R D SHIFT
M O T O R PORT.
(VACUUM S H O U L D BE
B E T W E E N 10-20 I N . HG.)
VACUUM OK
N O VACUUM
O R LOW VACUUM.
STOP E N G I N E
I N S P E C T INTAKE M A N I F O L D — r ~
V A C U U M SUPPLY H O S E C O N N E C T I O N ,
TRANSFER CASE VACUUM SWITCH
C O N N E C T I O N , VACUUM RESERVOIR,
A N D SHIFT SYSTEM V A C U U M H O S E S
FOR PROPER C O N N E C T I O N , R E S T R I C T I O N ,
A I R L E A K S , A N D D A M A G E . REPAIR O R REPLACE
A S NECESSARY.
F R O N T AXLE F R O N T AXLE
DISCONNECTS. DOES NOT
DISCONNECT.
INSPECT VACUUM
H O S E S FOR A I R L E A K S , K I N K S , ETC.
REPAIR A S N E C E S S A R Y . R E M O V E SHIFT M O T O R
H O U S I N G COVER. CONNECT
V A C U U M P U M P TO
SHIFT M O T O R PORT. FRONT AXLE
REPLACE SHIFT M O T O R WILL N O T D I S C O N N E C T .
IF A R M A T U R E D O E S
NOT MOVE IN A N D OUT
FREELY.
R E M O V E SHIFT M O T O R H O U S I N G
C O V E R . I N S P E C T SHIFT F O R K ,
C O L L A R , A N D AXLE SHAFTS.
REPAIR O R REPLACE A S
J9002-95 NECESSARY
DISCONNECT AXLE/SHIFT MOTOR DIAGNOSIS (CONT'D)
FOUR-WHEEL DRIVE OPERATION DIAGNOSIS
FOUR-WHEEL DRIVE INDICATOR

LIGHT D O E S NOT LIGHT W H E N
TRANSFER C A S E SELECTOR IN
4H O R 4L P O S I T I O N .
RAISE VEHICLE S O ALL FOUR

W H E E L S ARE FREE TO ROTATE.
START E N G I N E , DEPRESS BRAKE PEDAL.

PLACE TRANSFER C A S E SELECTOR IN 4H
P O S I T I O N A N D T R A N S M I S S I O N LEVER IN
DRIVE (AUTOMATIC) O R IN FIRST G E A R
(MANUAL) TO C O N F I R M TRANSFER C A S E
E N G A G E M E N T IN 4H. LET W H E E L S
ROTATE SLOWLY.
FRONT DRIVE FRONT DRIVE

SHAFT D O E S SHAFT T U R N S .
NOT ROTATE.
INSPECT TRANSFER FRONT AXLE RECOMMENDATION:

CHECK VACUUM PLACE T R A N S M I S S I O N FRONT AXLE
CASE L I N K A G E . CONNECTS. LEVER I N NEUTRAL D O E S NOT
SHIFT SYSTEM
FOR PROPER POSITION. CONNECT.
OPERATION.
CHECK TRANSFER FOUR-WHEEL DRIVE
C A S E . REPAIR A S INDICATOR LIGHT
NECESSARY. D O E S NOT LIGHT. R E M O V E VACUUM H O S E S
FROM AXLE SHIFT
MOTOR PORTS.
INSPECT F W D INDICATOR
SWITCH, W I R I N G , A N D START E N G I N E . TEST FOR V A C U U M
LAMP FOR D A M A G E . AT H O S E R E M O V E D FROM OUT
REPAIR A S NECESSARY. B O A R D PORT O N SHIFT M O T O R ,
S H O U L D BE BETWEEN 10-20 I N HG.
N O VACUUM
O R LOW VACUUM.
STOP E N G I N E
H VACUUM O K
C O N N E C T A VACUUM PUMP
INSPECT INTAKE M A N I F O L D TO THE O U T B O A R D
VACUUM SUPPLY H O S E C O N N E C T I O N , SHIFT MOTOR PORT.
TRANSFER C A S E VACUUM SWITCH APPLY 15 I N C H E S H G . VACUUM
C O N N E C T I O N , VACUUM RESERVOIR, A N D SHIFT A N D ROTATE LEFT WHEEL.
SYSTEM VACUUM H O S E S FOR PROPER C O N N E C T I O N ,
RESTRICTION, LEAKS, A N D D A M A G E .
REPAIR O R REPLACE A S NECESSARY.
FRONT AXLE FRONT AXLE

N O VACUUM CONNECTED. DOES NOT
CONNECT.
CHECK TRANSFER C A S E
VACUUM S W I T C H . REPLACE INSPECT VACUUM H O S E S
O R REPAIR IF SWITCH FOR LEAKS, K I N K S , ETC. REMOVE SHIFT MOTOR
PLUNGER IS DIFFICULT TO REPAIR A S NECESSARY. H O U S I N G COVER. C O N N E C T
MOVE OR BINDS. VACUUM PUMP TO
SHIFT MOTOR PORT.
REPLACE SHIFT MOTOR
IF ARMATURE D O E S
NOT M O V E I N A N D OUT
FREELY.
R E M O V E SHIFT M O T O R H O U S I N G *
COVER. INSPECT SHIFT FORK,
FRONT AXLE
COLLAR, A N D AXLE SHAFTS.
WILL NOT C O N N E C T .
REPAIR O R REPLACE A S
NECESSARY.
J9002-96
REMOVAUDISASSEMBL Y center of the vehicle. Remove the C-lock from the
(1) Raise and support the vehicle. shaft and side gear in the differential.
(2) Disconnect the vacuum and wiring connector (6) Remove the intermediate axle shaft with Re
from the shift housing. mover/Installer D-354-4 and Adaptor D-354-3 (Fig.
(3) Remove the shift motor housing cover, gasket 33).
and shield from the housing.
(4) Remove the E-clips from the shift motor hous
ing and shaft. Remove shift motor and shift fork
from the housing (Fig. 32).
Fig. 32 Vacuum Shift Motor Components

(5) Remove the O-ring seal from the shift motor J9202-104
shaft.
(6) Clean and inspect all the components. If any Fig. 33 intermediate Axle Shaft Removal/Installation
component is excessively worn or damaged, it should (7) Remove the intermediate axle shaft bearing
be replaced. with Tool D-354-4, Tool D-354-1, and Slide Hammer
C-637 (Fig. 34, 35).
ASSEMBL Y/IHSTALLA TION (8) Remove the needle bearing from intermediate
(1) Install a replacement O-ring seal on the shift axle shaft with Remover/Installer D-330 (Fig. 34, 35).
motor shaft (Fig. 32).
(2) Insert the shift motor shaft through the hole in
the housing and shift fork. The shift fork offset
should be toward the differential.
(3) Install the E-clips on the shift motor shaft and
housing.
(4) Install the shift motor housing gasket and
cover. Ensure the shift fork is correctly guided
into the shift collar groove.
(5) Install the shift motor housing shield and bolts.
Tighten the bolts to 14 N*m (10 ft. lbs.) torque.
INTERMEDIATE AXLE SHAFT

REMOVAL/DISASSEMBLY
(1) Remove the vacuum motor housing from the RK724
axle, refer to Vacuum Shift Motor Removal.
(2) Remove the hub, spindle and axle shaft, refer Fig. 34 Intermediate Shaft Bearing Removal
to the removal procedures above.
(9) Remove the inner axle shaft seal from the shift
(3) Remove the shift collar from the shift motor
motor housing. Certain vehicles could also have a
housing.
(4) Remove the differential housing cover and seal guard; discard both components. The guard is
drain the lubricant. not used with a replacement seal.
(5) Push the intermediate axle shaft toward the
STEERING KNUCKLE ARM

REMOVAL
(1) Install Puller C-4150 on each drag-link ball
stud. Apply sufficient force with the tool to loosen
the drag-link ball stud from the steering arm.
(2) Remove the lock nuts that attach the steering
arm to the knuckle (Fig. 37). Tap the steering arm to
loosen it from the knuckle. Pry upward to remove.
Fig. 35 Disconnect Axle Service Tools

ASSEMBLY/INSTALLATION
(1) Install the needle bearing in the end of the in
termediate shaft with Installer D-328 and Driver
Handle C-4171 (Fig. 36).
RK 727
Fig. 36 Intermediate Shaft Bearing installation Fig. 37 Steering Knuckle Arm Removal
(2) Install the intermediate axle shaft bearing with INSTALLATION

Tool D-354-4, Tool 354-2 and Slide Hammer C-637 (1) Position the steering arm on the knuckle. In
(Fig. 34, 35). stall the nuts. Tighten the nuts to 122 N«m (90 ft.
(3) Install the intermediate axle shaft with Tool lbs.).
D-354-4 and Adaptor Tool D-354-3. (2) Position the drag link at steering knuckle arm.
(4) Install the C-lock in the axle shaft and side (3) Install and tighten the ball stud n u t to 81 N*m
gear. (60 ft. lbs.) torque. Install new cotter pins.
(5) Clean the tube bore and remove any rust from
the seal area.
COMPLETE AXLE REMOVAL/INSTALLATION
(6) Place the axle shaft seal on Tool 5041-1 and po SERVICE INFORMATION
sition in housing. Thread Tool 5041-2 through the It is not necessary to remove the complete front
seal into Tool 5041-1. Install Tool 5041-3 and n u t on axle from the vehicle for routine service. If the hous
the end of the threaded bar tool. Tighten the nut un ing or axle shaft tubes are damaged, the complete
til the tool contacts the threaded bar shoulder. axle can be removed and installed via the following
(7) Install the shift collar on the splined end of the procedures.
intermediate axle shaft.
(8) Lubricate the splined end of the intermediate REMOVAL
axle shaft with multi-purpose lubricant. (1) Remove the front wheels/tires.
(9) Install the axle shaft, spindle and hub, refer to (2) Mark the front drive shaft and the pinion yoke
the installation procedures above. for installation alignment reference.
(10) Install the shift motor housing, refer to Vac (3) Disconnect the front drive shaft from the axle
uum Shift Motor Installation. yoke. Attach the drive shaft to the frame rail with
wire.
(4) Remove the cotter pin, nut, and disconnect the
drag link from the steering knuckle arm (left side
only). Discard the cotter pin.
(5) Disconnect flexible brake fluid hose fittings at INSTALLATION
the frame crossmember. Plug the hoses at the fit EFERENCE LETTERS
tings.
(6) Remove the shock absorber lower n u t and stud
from the axle shaft tube bracket. Remove the nuts
and disconnect the stabilizer bar links from the
spring brackets.
(7) Disconnect the vacuum hoses and wiring con
nections from the shift motor housing.
(8) Remove nuts and the washers from the spring
U-bolts. Remove the complete front axle from the ve
hicle.
INSTALLATION
(1) Position the front axle under the front of the J9003-92
vehicle with the axle spring pads under the springs.
Place the spring brackets over the springs. Make Fig. 38 Bearing Cap Identification
sure the stabilizer bar link bolt holes face toward the
SPECIAL TOOL DIAL
rear of the vehicle. MODEL 44-W-129-A INDICATOR
(2) Install the spring U-bolts, washers and nuts. MODEL 60-D-167
Refer to Front Suspension — 4WD Vehicles within
this group.
(3) Install the shock absorber. Refer to Front Sus
pension — 4WD Vehicles within this group.
(4) Connect the stabilizer bar links to the spring
brackets. Refer to Front Suspension-4WD Vehicles
within this group.
(5) Remove plugs and connect the brake hose fit
tings. Refer to Group 5, Brakes.
(6) Connect the drag-link ball stud to the steering
knuckle arm. Refer to Group 19, Steering.
(7) Connect the drive shaft to the pinion yoke with «ar"P—
the installation reference m a r k s aligned. Install the J9202-113

washers and the nuts and tighten to 19 N*m (14 ft.
Fig. 39 Differential Housing Separation
lbs.) torque.
(8) Connect the vacuum hoses and wiring connec (4) Install a pilot stud at the left side of the differ
tions to the shift motor housing. ential housing. Attach Dial Indicator to housing pilot
(9) Remove the supports, lower the vehicle and re stud. Load the indicator plunger against the opposite
move the block from the brake pedal. side of the housing (Fig. 39) and zero the indicator.
(10) Raise the vehicle.
• Bleed and adjust the brakes C A U T I O N : D o not spread over the specified dis
• Lubricate all the ball stud fittings tance. If the housing is over-separated, it could be
• Inspect the differential housing lubricant level. Re distorted or damaged.
fer to Group 0, Lubrication and Maintenance.
(11) Lower the vehicle and test the axle and sus (5) Separate the housing enough to remove the
pension operation. case from the housing. Separate h o u s i n g a maxi
m u m distance of 0.38 m m (0.015 in) with the
DIFFERENTIAL DISASSEMBLY spreader tool. Measure the distance with the dial
indicator (Fig. 39).
REMOVAL/DISASSEMBLY (6) Remove the dial indicator.
(1) Note the installation reference letters (7) Pry the differential case loose from the hous
stamped on the bearing caps and h o u s i n g ma ing. To prevent damage, pivot on housing with the
chined sealing surface (Fig. 38). end of the pry bar against case.
(2) Remove the differential bearing caps.
(8) Remove the case from housing. If they are re
(3) Position Spreader W-129-A with the tool dowel
usable, retain the differential bearing cups and bear
pins seated in the locating holes (Fig. 39). Install the
ings together as matched sets.
holddown clamps and tighten the tool turnbuckle fin
ger-tight.
(9) Clamp the differential case in a vise equipped SPECIAL TOOL

with soft jaws. Remove and discard the ring gear C-3281
bolts. Tap the ring gear with a rawhide mallet and
remove (Fig. 40).
RING GEAR
SPECIAL TOOL
C-452 J9102-31
RAWHIDE
HAMMER save time if they should become misplaced.
J9202-76 (13) Remove the front pinion bearing cup with Re
mover D-158 and Handle C-4171 (Fig. 43).
Fig. 40 Ring Gear Removal (14) Remove the rear bearing cup from housing
(10) Remove the pinion yoke nut and washer. Use (Fig. 44). Use Remover D-162 and Handle C-4171.
Remover C-452 and Wrench C-3281 to remove the (15) Remove the depth shims from the housing
pinion yoke (Fig. 41). bore. Record the thickness of the depth shims.
(11) Use Remover C-748 to remove the pinion gear (16) Remove the inner bearing from the pinion
seal. with Puller C-293-PA and Plate C-293-39 (Fig. 45).
(12) Remove oil slinger, front bearing and shims
(Fig. 42). Record the thickness of the shims. This will
PINION WASHER
YOKE
PINION
NUT
SLINGER
FRONT
BEARING
CUP
PINION
PRELOAD
SHIMS PINION
OIL SEAL
PINION PRELOAD
SPACER FRONT
BEARING
CONE
SHOULDER FOR J9203-63

• PINION PRELOAD SPACER
Fig. 42 Pinion Front Bearing and Preload Shims

SPECIAL TOOL SPECIAL TOOL SPECIAL
D-158 C-4171 TOOL
C-293-PA
Fig. 46 Mate Shaft Lock Pin Removal

(22) Remove the bearings from the differential
case with Press C-293-PA, Plug C-293-3, Plate
C-293-18 and a vise (Fig. 49).
U s e care that adapter rings are placed so they
do not damage the bearing cage.
Fig. 44 Rear Bearing Cup Removal (23) Remove bearing shims from case hubs and
(17) Clamp the differential case in a vise equipped mark them (with hub identity) for assembly refer
with soft jaws. Use a pin punch to remove the pinion ence. Record the thickness of the shims.
gear mate shaft lock pin (Fig, 46).
(18) Remove the mate shaft with a drift and ham CLEANING/INSPECTION
mer (Fig. 47). (1) Wash and clean all the differential components
(19) Rotate the differential side gears and remove with cleaning solvent. Dry with compressed air.
the pinion mate gears and thrust washers (Fig. 48). D o not steam clean the differential compo
(20) Remove the differential side gears and t h r u s t nents.
washers. (2) Clean the axle shaft tubes. Insert a stiff wire
(21) Remove the case from the vise. into each tube, attach a clean cloth to the wire at the
PINION MATE SHAFT ADAPTERS
SPECIAL
TOOL
C-293-PA
DRIFT J9203-60
Fig. 47 Mate Shaft Removal

THRUST
WASHER
PLUG
J9202-42
Fig. 49 Differential Bearing Removal

(4) Examine the differential pinion mate shaft,
pinion gears, side gears and thrust washers for wear
and damage. Replace all defective components.
If either of the differential pinion gears is not
reusable, both gears must b e replaced as a
matched set only. Do not replace only one gear.
(5) Examine the ring gear and the pinion gear for
PINION
worn and chipped teeth. Examine the ring gear for
MATE GEAR SIDE GEAR J9203-61 damaged bolt threads.
If replacement of either gear is necessary, both
Fig. 48 Pinion Mate Gear Removal must be replaced as a matched set only.
housing opening. Draw the wire (and cloth) from the (6) Inspect the pinion yoke for cracks, worn
housing outward through the tube. splines, pitted areas, and a rough/corroded seal con
(3) Inspect the differential and pinion gear bearings. tact surface. Repair or replace the yoke as necessary.
Inspect the differential case and housing. (7) Inspect the pinion bearing preload shims for
• Bearings and cups should have a smooth appear cracks, damage and distortion. Install replacement
ance. shims (if necessary) for the preload torque adjust
• Bearing races must not be distorted or cracked ment.
Cup and bearing must b e replaced a s a
matched set only. DIFFERENTIAL ASSEMBLY
• All machined surfaces in the housing and on bearing ASSEMBLY
caps should be smooth and without any raised edges. (1) Install the following components in the differ
• Pinion gear front and rear bearing cup bores ential case.
should be smooth • Differential side gears and t h r u s t washers
• Raised metal on shoulders of cup bores should be • Pinion gears and thrust washers
removed with a hand stone
• Pinion gear mate shaft (align holes in shaft and TORQUE
case)
(2) Install and seat the lock pin in the differential
case and mate shaft with a punch and hammer (Fig.
50). Peen metal part of case over pin in two places.
If replacement gears a n d thrust w a s h e r s w e r e
installed, it is not n e c e s s a r y to measure the gear
backlash. Correct fit is due to close machining
tolerances during manufacture.
Fig. 51 Ring Gear Bolt Hole Installation

SPECIAL TOOL
D-345
Fig. 50 Mate Shaft Pin installation

(3) Invert the differential case and start two ring
gear bolts. This will provide case-to-ring gear bolt
hole alignment (Fig. 51).
(4) Install new ring gear bolts and alternately
tighten to 61-81 N*m (45-60 ft. lbs.) torque.
(5) Lubricate all differential components with hy
poid gear lubricant.
(6) Place Master Differential Bearing D-345
(D-135) on the case hubs (Fig. 52).
(7) Install a pilot stud at the right side of housing.
J9203-20
Attach Dial Indicator C-3339 to the pilot stud. Load
indicator plunger against the back of the ring gear Fig. 52 Master Bearing Tools On Hubs
(Fig. 53).
PINION GEAR DEPTH INFORMATION
(8) Insert a small pry bar between the bearing cap
Gears are supplied as matched sets only. The iden
and left side of differential case. Pry the case as far
tifying numbers for the ring and pinion gear are
as possible to right side (Fig. 53). Zero the dial indi
etched into the face of each gear (Fig. 54). A plus ( + )
cator pointer.
number, minus (-) number or zero (0) is etched into
(9) Pry the case to left side and record the travel
the face of the pinion gear. This number is the
distance.
amount (in thousandths of an inch) the depth varies
The measurement a b o v e is the shim thickness
from the standard depth setting. The standard depth
n e c e s s a r y for c a s e zero end-play. The total
provides the best tooth contact pattern.
thickness will b e determined during the ring
gear b a c k l a s h adjustment.
(10) Remove indicator and pilot stud.
AXLE DEPTH
MODEL SETTING
Fig. 55 Pinion Gear Standard Depth/Distance

DRIVE
Fig, 53 Differential Case End Play Measurement

DRIVE PINION
Fig. 54 Pinion Gear ID Numbers

Fig. 56 Shim Locations
The standard depth is the distance (Fig. 55) from
• If marked zero will use the nominal setting as de
the centerline of the axle shaft/ring gear to the
termined in this procedure.
shoulder of the rear pinion bearing.
Shims are available in 0.003-inch, 0.005-inch,
Compensation for depth variance is achieved by
0.010-inch, and 0.030-inch thicknesses.
shims placed adjacent to the pinion gear r e a r bearing
If original gear set is installed but the depth shims
cup (Fig. 56).
replaced, measure the thickness of the original depth
If a new gear set is being installed, note the depth
shims. Build a replacement pack of depth shims with
variance etched into the original and new pinion
the same thickness.
gear. Add or subtract the thickness of the original
If equipped, the oil slinger must be m e a s u r e d
depth shims to compensate for the difference in the
a n d the thickness included with the total shim
depth variances. Refer to the Depth Variance charts.
p a c k thickness.
For Example:
The shim thickness for the new pinion gear must
• If a positive marking, this means the shim pack
be determined before installing the differential case.
must decrease by the same number of thousandths.
• If a negative marking, this means the shim pack
must increase by the same number of thousandths.
PINION GEAR DEPTH VARIANCE
Or§@iftî Linton IsptocMnwtt HnS®n O i o r Itoplli fflttanct
-4 -2 -1 0 +1 -ft +3 +4
+4 + 0.008 + 0.007 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0
+3 + 0.007 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001
+2 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001 -0.002
+1 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001 -0.002 -0.003
0 + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001 -0.002 -0.003 -0.004
-1 + 0.003 + 0.002 + 0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005
-2 + 0.002 + 0.001 . 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006
-3 + 0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007
-.4 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007 -0.008

J8902-46
PINION GEAR DEPTH MEASUREMENT AND DIFFERENTIAL
PINION BLOCK TOOL
ADJUSTMENT WITH TOOL SET D-11144 HOUSING
The following gear depth measurement and adjust
ment procedure involves using Tool Set D-115-44.
(1) Insert Master Pinion Block D-139 into the dif
ferential housing (Fig. 57).
PINION BLOCK TOOL
ARBOR
TOOL
ARBOR DISC TOOL J9003-103
Fig. 58 Disc & Arbor In Housing

(5) Move the gauge block toward the arbor until
the indicator plunger contacts the arbor tool (Fig.
DIFFERENTIAL 60). Slide the gauge block across the arbor while ob
HOUSING J9003-101 serving indicator. Record the longest travel distance,
whether inward (-) or outward (+•), indicated by the
Fig. 57 Pinion Block In Shaft Bore pointer.
(2) Place Disc D-115-4 on Arbor D-115-3 and posi The distance indicated, plus or minus the
tion in the bearing cradles (Fig. 58). This is the cen amount etched in the gear is the required thick
terline of the ring gear/axle shaft. ness.
(3) Place Pinion Height Block D-115-1 on top of (6) Measure the thickness of each depth shim with
master pinion block tool and against arbor tool (Fig. a micrometer and combine the shims necessary for
59). total required pack thickness. Include oil s l i n g e r
(4) Place Gauge Block D-115-2 and Dial Indicator thickness with the total shim pack thickness if
D-106-5 on lowest step of block tool (Fig. 60). Zero required.
the dial indicator pointer. (7) Remove the measurement tools from the differ
ential housing.
SPECIAL TOOL
Fig. 59 Pinion Height Block Against Arbor
C-4171 J9202-95
Fig. 61 Pinion Rear Bearing Cup Installation

SPECIAL TOOL
D-144 SPECIAL
Fig. 60 Pinion Gear Depth Measurement

(8) Place the depth shims in the pinion gear rear
bearing bore. Install the bearing cup (Fig. 61) with
Installer D-145 and Handle C-4171.
Ensure the cup is correctly seated.
(9) Install the pinion front bearing cup with In Fig. 62 Pinion Front Bearing Cup Installation
staller D-144 and Handle C-4171 (Fig. 62). If the preload torque is not within the specified tol
(10) Install the rear bearing (and slinger if used) erance, correct the shim thickness accordingly (Fig.
on the pinion gear with Installer W-262 until com 66);
pletely seated (Fig. 63). • Increase the preload torque, decrease the shim
(11) Assemble preload shims onto pinion and in thickness
stall the pinion gear in housing. • Decrease the preload torque, increase the shim
(12) Install pinion front bearing, oil slinger, yoke, thickness
washer and nut. Install the yoke with Installer (15) Remove the pinion yoke nut and washer. Use
C-3718 and Wrench C-3281 (Fig. 64). Remover C-452 and Wrench C-3281 to remove the
(13) Tighten the yoke nut to 271-298 N-m (200-220 pinion yoke (Fig. 67).
ft. lbs.) torque. (16) Apply a light coating of gear lubricant on the
(14) Check bearing preload torque with an inch lip of pinion seal. Install the new seal (Fig. 68) with
pound torque wrench (Fig. 65). The torque necessary Installer W-147-E and Handle C-4171
to rotate the pinion gear should be; (17) Install the yoke with Installer C-3718 and
• Original Bearings — 1 to 3 N*m (10 to 20 in. lbs.) Wrench C-3281 (Fig. 64).
• New Bearings — 2 to 5 N*m (20 to 40 in. lbs.) (18) Install a new yoke n u t and tighten to 271 to
298 N-m (200 to 220 ft. lbs.) torque.
SHIM PACKS RY660
J9103-21 • Position Spacer (SP-5586) over Shaft (SP-5385)

• Position pinion rear bearing on shaft
Fig. 64 Pinion Yoke Installation • Position tools (with bearing) in the housing
• Install Sleeve (SP-5585)
PINION GEAR DEPTH MEASUREMENT AND
• Install pinion front bearing
ADJUSTMENT WITH TOOL SET C-3715-B
The alternate measurement and adjustment proce m Install Sleeve (SP-3194-B), Washer (SP-534) and
dure involves using Axle Measurement Gauge Set N u t (SP-3193)
C-3715-B. (3) Prevent compression sleeve tool from turning
(1) Install the pinion rear bearing cup (Fig. 69) with Wrench C-3281. Tighten the nut to seat the pin
with Installer D-145 and Handle C-4171 ion bearings in the housing (Fig. 71). Allow the
(2) Install the pinion front bearing cup with In sleeve to t u r n several times during the tightening to
staller D-144 and Handle C-4171 (Fig. 70). prevent brinelling the bearing cups or the bearings.
Ensure the cup is correctly seated. D e p t h shim(s) a r e p o s i t i o n e d b e t w e e n t h e pin
A s s e m b l e C - 3 7 1 5 - B Tool S e t a s d e s c r i b e d ; ion gear r e a r bearing a n d pinion gear to provide
SPECIAL TOOL
D-145
SPECIAL
HANDLE TOOL
C-4171 C-4171 J9202-95

SPECIAL TOOL
D-144 SPECIAL
TOOL
C-4171
SPECIAL
TOOL
W-147-E
(J25104)
J9202-19 J9202-35
Fig. 68 Pinion Seal Installation Fig. 70 Pinion Front Bearing Cup Installation
the separation distance. The required thickness Center the arbor in cradles so equal space exists at
of the depth shim(s) is determined according to both ends. Position the bearing caps on the arbor
the following information. tool. Install the bolts. Tighten the cap bolts to 14
(4) Loosen the compression nut tool. Lubricate the N*m (10 ft. lbs.) torque.
pinion gear front and rear bearings with gear lubri (7) Trial fit depth shim(s) or feeler gauge between
cant. Re-tighten t h e compression nut tool to 1 to 3 the crossbore arbor and gauge block (Fig. 72). The fit
N«m (15 to 25 in. lbs.) torque. Rotate the pinion gear must b e snug but not tight (drag friction of a
several complete revolutions to align the bearing feeler g a u g e blade).
rollers. D e p t h shims are available in 0.001-inch incre
(5) Install Gauge Block SP-5260 at the end of SP- m e n t s from 0.020 i n c h to 0.038 inch.
526. Install Cap Screw (SP-536) and tighten with (8) Note the etched number on the face of the drive
Wrench SP-531. pinion gear (e.g., -0, - 1 , -2, + 1 , + 2 , etc.). The num
(6) Position Crossbore Arbor (SP-5183) in the dif bers represent thousands-of-an-inch deviation from
ferential housing. the standard. If the number is - (negative), add t h a t
value to the required thickness of the depth shim(s).
If the number is + (positive), subtract t h a t value
DIFFERENTIAL HAMMER DRIVER

HOUSING HANDLE
YOKE
HOLDING
TOOL
C-3281 J9002-91
Fig. 71 Seating Pinion Bearings

SPACER
REAR PINION
BEARING J9203-58
DEPTH SHIMS
HERE SHAFT Fig. 73 Rear Bearing Cup Removal
PRESS •
INSTALLATION
TOOL
BEARING CAP ARBOR J9203-53
Fig. 72 Depth Shim(s) Selection DRIVE

PINION GEAR
from the thickness of the depth shim(s). If the num SHAFT
ber is 0, no change is necessary. REAR BEARING ^
(9) Remove the tools from the differential housing.
(10) Remove the rear bearing cup from housing
(Fig. 73). Use Remover D-162 and Handle C-4171. OIL
(11) Position depth shims in housing rear bearing SUNGER
cup bore.
(12) Install the pinion rear bearing cup (Fig. 70) DRIVE
with Installer D-145 and Handle C-4171. PINION GEAR J9302-68
(13) If the depth of mesh has been followed accord Fig. 74 Pinion Rear Bearing Installation
ing to the instructions above, good gear teeth contact (18) Tighten the yoke nut to 271-298 N-m (200-220
should exist. ft. lbs.) torque.
(14) Install the rear bearing (and slinger if used) (19) Check bearing preload torque with an inch
on the pinion gear with Installer W-262 until com pound torque wrench (Fig. 76). The torque necessary
pletely seated (Fig. 74). to rotate the pinion gear should be;
(15) Install pinion in housing bore. • Original Bearings — 1 to 3 N-m (10 to 20 in. lbs.)
(16) Assemble preload shims onto pinion and in • New Bearings — 2 to 5 N-m (20 to 40 in. lbs.)
stall the pinion gear in housing. If the preload torque is not within the specified tol
(17) Install pinion front bearing, oil slinger, yoke, erance, correct the shim thickness accordingly (Fig.
washer and nut. Install the yoke with Installer 77);
C-3718 and Wrench C-3281 (Fig. 75).
FRONT SUSPENSION AND AXLE 2 43
SPECIAL DIFFERENTIAL
TOOL HOUSING
REMOVE SHIMS
J9103-21
Fig. 75 Pinion Yoke Installation

SHIM PACKS RY660
Fig. 76 Rotating Pinion Gear

C-452 J9102-31
• Increase the preload torque, decrease the shim
thickness Fig. 78 Pinion Yoke Removal
• Decrease the preload torque, increase the shim RING GEAR BACKLASH ADJUSTMENT
thickness (1) Place Master Differential Bearing D-135
(20) Remove the pinion yoke n u t and washer. Use (D-345) on the case hubs.
Remover C-452 and Wrench C-3281 to remove the (2) Install a pilot stud at the right side of housing.
pinion yoke (Fig. 78). Attach Dial Indicator C-3339 to the pilot stud. Load
(21) Apply a light coating of gear lubricant on the indicator plunger against the back of the ring gear
lip of pinion seal. Install the new seal (Fig. 79) with (Fig. 81). Ensure ring and pinion gear teeth are
Installer W-147-E and Handle C-4171. tightly meshed. Zero the indicator.
(22) Install the yoke with Installer C-3718 and (3) Insert a small pry bar between the bearing cap
Wrench C-3281 (Fig. 80). and left side of differential case. Pry the case as far
(23) Install a new yoke nut and tighten to 271-298 as possible to right side (Fig. 81). Zero the dial indi
N*m (200-220 ft. lbs.) torque. cator pointer.
(4) Repeat the measurement several times to check
consistency. Record the travel distance.

Fig. 81 Ring Gear Backlash Measurement
TOOL HOUSING (8) Position the backlash shims (with determined
thickness) on case hub (ring gear side). Install bear
ing on the hub with Installer D-156 and Handle
C-4171 (Fig. 82).
J9103-21

The measurement s h o w s shim thickness neces
sary to eliminate ring gear backlash. Subtract
this thickness from c a s e zero end-play shim
thickness. The shims must b e placed at the ring
gear side b e t w e e n the c a s e a n d bearing. Fig. 82 Differential Bearing Installation
(6) Remove the differential case from housing. (9) Position the remaining zero end-play shims on
(7) Remove the master bearing tools from the dif hub at opposite side of case. Include an additional
ferential case hubs. 0.015-in (0.38-mm) thick shim on this hub. This will
provide the required differential bearing preload
torque.
4 _ _ _ _ _ _ _ _ _ _ _ _ FRONT SUSPENSION AND AXLE 2 - 45
(10) Install bearing on h u b with Installer D-156

and Handle C-4171 (Fig. 82).
(11) Install new axle shaft oil seal in differential
housing with Installer D-112-44. Apply lubricant to
lip of seal.
(12) Match each bearing cup with bearing (origi
nal). Install the cups on the bearings.
(13) Position Spreader W-129-A with the tool
dowel pins seated in the locating holes (Fig. 83). In
stall the holddown clamps and tighten the tool turn-
buckle finger-tight.
Fig. 84 Differential Bearing Cap Reference Letters

(14) Install a pilot stud at the left side of the dif
ferential housing. Attach Dial Indicator to housing
pilot stud. Load the indicator plunger against the op
posite side of the housing (Fig. 83) and zero the indi
cator.
Fig. 85 Ring Gear Backlash Measurement
C A U T I O N : Do not spread over the specified dis The ring gear b a c k l a s h must be within 0.004 -
tance. If the housing is over-separated, it could be 0.009 inch (0.10 - 0.23 mm). It cannot vary more
distorted or damaged. than 0.002 inch (0.05 mm) b e t w e e n the points
checked.
(15) Separate the housing enough to install the (20) Excessive backlash is corrected by moving the
case in the housing. Separate h o u s i n g a maximum ring gear teeth closer to the pinion gear teeth. Insuf
distance of 0.38 m m (0.015 in) with the spreader ficient backlash is corrected by moving the ring gear
tool. Measure the distance with the dial indicator away from the pinion gear. Backlash correction is ac
(Fig. 83). complished by transferring shims from one side to
(16) Remove the dial indicator. the other.
(17) Install case in the housing. Ensure the differ If the mesh and backlash steps have been followed
ential bearings are fully seated. Remove the in the procedures above, good gear teeth contact pat
spreader. terns should exist.
(18) Observe the assembly reference marks and po
sition the bearing caps at their original locations RING mMR TEETH CONTACT PATTERN
(Fig. 84). Tighten the bearing cap bolts to 95-122 ANALYSIS
N-m (70-90 ft. lbs.) torque. The ring gear teeth contact patterns will show if
(19) Rotate assembly several revolutions to seat the pinion gear depth shim(s) have the correct thick
bearings. Measure backlash at three equally spaced ness. It will also show if the ring gear backlash has
locations with a dial indicator (Fig. 85). been adjusted correctly. The backlash must be main
tained within the specified limits until the correct
teeth contact patterns are obtained.
(1) Apply a thin coat of hydrated ferric oxide, to (3) Note patterns in compound. Refer to (Fig. 86)
the ring gear teeth. for interpretation of contact patterns and adjust ac
(2) Rotate the ring gear one complete revolution in cordingly.
both directions while a load is being applied. Insert a (4) Install the axle shafts. Refer to Axle Shaft In
pry bar between the differential housing and the case stallation within this group.
flange. This action will produce distinct contact pat (5) Install the housing cover. Refill the differential
terns on both the drive side and coast side of the ring
with lubricant. Refer to Axle Shaft Installation.
gear teeth.
DRIVE SIDE COAST SIDE

OF RING OF RING
GEAR TEETH GEAR TEETH
DESIRABLE CONTACT PATTERN.

PATTERN SHOULD BE CENTERED
O N THE DRIVE SIDE OF TOOTH.
HEEL TOE TOE HEEL PATTERN SHOULD BE CENTERED O N
THE COAST SIDE OF TOOTH,
BUT MAY BE SLIGHTLY TOWARD
THE TOE. THERE SHOULD ALWAYS
BE S O M E CLEARANCE BETWEEN
CONTACT PATTERN A N D TOP OF
THE TOOTH.
RING GEAR BACKLASH CORRECT

THINNER PINION GEAR DEPTH
SHIM REQUIRED.
RING GEAR BACKLASH CORRECT.

THICKER PINION GEAR DEPTH
SHIM REQUIRED.
PINION GEAR DEPTH SHIM

CORRECT DECREASE RING
GEAR BACKLASH.

CORRECT INCREASE RING
GEAR BACKLASH.
J9003-24
Fig. 86 Gear Teeth Contact Patterns

SPECIFICATIONS
MODEL 44 FRONT AXLE
Axle Type Semi-floating, hypoid Differential Bearing

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

J9202-106
M O D E L 6 0 FRONT A X L E
INDEX
page page
Axle Shaft and U-Joint Service 55 Pinion Gear Depth Measurement and Adjustment
Complete Axle Removal/Installation 59 with Tool Set C-758-D6 68
Differential Assembly 63 Pinion Gear Depth Measurement and Adjustment
Differential Disassembly 59 with Tool Set D-116 66
Locking Hubs, Spindle and Axle Shaft 52
Lubricant 51 Steering Knuckle, Upper and Lower Kingpins .. . 56
GENERAL INFORMATION The removable, stamped steel cover provides a

Model 60 front axles (Fig. 1) consist of an iron cen means for inspection and service without removing
ter casting with axle shaft tubes extending from ei the complete axle from t h e vehicle.
ther side. The tubes are pressed into and welded to A small, stamped metal axle gear ratio identifica
the differential housing. tion t a g is attached to t h e housing cover via one of
The integral type housing, hypoid gear design h a s the cover bolts. This tag also identifies the number of
the centerline of t h e pinion set below t h e centerline ring gear and pinion gear teeth.
of the ring gear.
The differential case is a one-piece design. The dif
The axles are equipped with full-floating axle
ferential pinion mate shaft is retained with a roll
shafts, meaning t h a t loads are supported by t h e spin
dles attached to t h e steering knuckles. Two tapered pin. Differential bearing preload and ring gear back
opposed roller bearings allow the hub and rotor as lash are adjusted by the use of shims located between
sembly to rotate on t h e spindle. the differential bearing cones and case.
oi
BEARING SEAL BUSHING SLINGER U-JOINT AXLE SHAFT NUT WASHER
30
O
STEERING e
SPINDLE
ARM AND CAP m
22
o
STUDS
LEFT
STEERING
>•
KNUCKLE x
GASKET
OR
SEALER
COVER
PLUG
BEARING CAP
MATE
f SHAFT SCREW
BOLT J9202-67
Fig. 1 Model 60 Front Axle
w
LUBRICANT (7) Install the cover on the differential with the

Multi-purpose API GL 5 quality hypoid gear lubri bolts. Install the identification tag. Tighten the cover
cant should be used for Model 60 axles. MOPAR Hy bolts to 47 Nnn (35 ft. lbs.) torque.
poid Gear Lubricant conforms to these specifications
and is recommended.
the lubricant foaming and overheating.
C A U T I O N : If a front axle is submerged in water, the
(8) Refill the differential housing with the speci
axle lubricant must be replaced immediately.
(9) Install the fill hole plug and tighten to 34 N«m
DRAIN AND REFILL (25 ft. lbs.) torque.
(1) Drive the vehicle until the gear lubricant (10) Road test t h e vehicle.
reaches normal operating temperature.
(2) Raise and support the vehicle. PINION SHAFT SEAL
(3) Remove the lubricant fill hole plug from the REMOVAL
differential housing cover. (1) Raise and support the vehicle.
(4) Remove the differential housing cover. Allow (2) Mark the drive shaft yoke and pinion yoke for
the original lubricant to completely drain from the installation alignment reference.
housing and axle shaft tubes. (3) Remove the drive shaft from the yoke.
(5) With standard differential, clean the differen (4) Rotate the pinion gear three or four times.
tial and the housing cavity with a flushing oil (or (5) Remove the pinion yoke nut and washer. Use
light engine oil). This will remove the residual lubri Remover C-452 and Wrench C-3281 to remove the
cant and foreign matter. Do not use water, steam, pinion yoke (Fig. 3).
kerosene or gasoline for flushing. (6) Mark the positions of the yoke and pinion gear
(6) Scrape the residual gasket from the housing for installation alignment reference.
and cover mating surfaces. Clean the m a t i n g sur SPECIAL TOOL
faces with mineral spirits. Install a new cover gas C-3281
ket. Apply a bead of MOPAR® Silicone Rubber
Sealant on the housing cover (Fig. 2). A l l o w the
sealant to cure for a few minutes.
SURFACE
SPECIAL TOOL
C-452 J9102-31

seal (Fig. 4).
INSTALLATION
(1) Apply a light coating of gear lubricant on the
lip of pinion seal. Install the new seal (Fig. 5) use In
BEAD
staller C-3719-A and Handle C-4735
THICKNESS (2) Align the installation reference marks and po
6.35mm (1/4 sition the yoke on the pinion gear.
J9302-30
(3) Install the pinion yoke, washer, and n u t on
Fig. 2 Sealant On Housing Cover shaft. Tighten the nut to 339-366 N-m (250-270 ft.
lbs.) torque (Fig. 6).
Install the h o u s i n g cover within 5 minutes af
(4) Align the installation reference marks and at
ter applying the sealant. If not installed the seal
tach the drive shaft to the yoke.
ant must be r e m o v e d a n d another bead applied. (5) Add API grade GL 5 hypoid gear lubricant to
P I N I O N SEAL DIFFERENTIAL
J9203-55
Fig. 4 Seal Removal

SPECIAL TOOL
G4735 (4) Remove the allen-head screws t h a t retain the
cap to the hub (Fig. 7).
J9203-56

the differential housing, if necessary.
Fig. 7 Allen-Head Screw Removal
LOCKING HUBS, SPINDLE AND AXLE SHAFT (5) Remove the snap ring retaining the axle shaft
in the hub (Fig. 8).
REM0VAL/D1SASSEMBL Y (6) Remove the lock ring from the groove in the
(1) Raise and support the front of vehicle. hub (Fig. 9).
(2) Remove the wheel/tire. (7) Install two allen-head screws in hub locking
(3) Remove the brake caliper, refer to Group 5, body (to assist in removal). Remove the hub locking
Brakes. Support the caliper to the frame structure body assembly from the hub (Fig. 10).
with wire.
• _ _ _ — . ^ FRONT SUSPENSION AND AXLE 2 - 53
SNAP HUB LOCKING PRESSURE CLUTCH SNAP
RING SEAL CAP J9202-71
Fig. 10 Locking Hub Components
SCREWDRIVER J9202-70
Fig. 11 Lock Nut Ring Removal
Fig. 9 Lock Ring Removal
(8) Remove the wheel bearing outer lock n u t from (12) Pull the axle shaft (with spacer, seal and
the spindle with Wrench 7158 (Fig. 11). Remove the slinger) from the steering knuckle (Fig. 13).
tabbed lock washer from the spindle. (13) Clamp the spindle in a soft-jawed vise. Do not
(9) Remove the wheel bearing inner lock n u t ring clamp at the bearing contact surfaces. Remove the
from the spindle with Wrench 7158 (Fig. 11). bearing seal.
(10) Remove the hub and rotor assembly from the (14) Use Puller D-131 to remove needle bearings
spindle. from the spindle (Fig. 14).
(11) Remove the nuts t h a t attach the spindle to ASSEMBL Y/INSTALLA TION
the steering knuckle. Remove the spindle from the
(1) Install needle bearing in the spindle with In
knuckle, use a soft faced mallet if necessary to tap
staller C-4370 and Handle C-4171 (Fig. 15).
loose (Fig. 12).
Fig. 12 Spindle Removal
Fig. 15 Spindle Needle Bearing Installation
SEAL J9202-73
Fig. 13 Axle Shaft Removal
Fig. 16 Spindle Seal Installation

(4) Carefully install the axle shaft through the
knuckle into the axle housing. Ensure the axle shaft
Fig. 14 Spindle Needle Bearing Removal splines are engaged with the differential side gears.
(2) Install a new spindle seal with Installer C-4373 (5) Install the spacer on the axle shaft end.
and Handle C-4171 (Fig. 16). (6) Install the brake splash shield and brake cali
(3) Install the seal with lip facing the axle shaft per support bracket.
splines (Fig. 17). Lubricate the seal (Fig. 18) with (7) Install the splash shield and spindle on the
Wheel Bearing Grease lubricant (NLGI Grade 2, E P steering knuckle. Install the nuts and tighten to 81-
or an equivalent lubricant). 108 N-m (60-80 ft. lbs.) torque (Fig. 19).
(9) Install the wheel bearing inner lock nut on the

spindle with Wrench 7158 (Fig. 11). Tighten the lock
nut to 68 N*m (50 ft. lbs.) to seat t h e bearings.
(10) Loosen the inner lock nut. Tighten to 41-54
N*m (31-39 ft. lbs.) torque while rotating the hub and
rotor assembly.
(11) Back off the inner lock n u t 135-150 degrees to
set the free play.
(12) Install the tabbed lock washer in the nearest
hole in the washer. Install and tighten the outer lock
nut with Wrench 7158 (Fig. 11) to 217-278 N-m (160-
205 ft. lbs.) torque. The end play after the final bear
ing adjustment should be within 0.001 inch to 0.010
inch (0.03 to 0.25 mm).
(13) Install the locking body assembly in the hub.
(14) Install the lock ring in the groove in the hub.
Fig. 17 Axle Shaft Seal Installation
Ensure the ring is seated.
(15) Install the snap ring on the end of the axle
shaft. Ensure the snap ring is seated.
(16) Install the cap onto the hub. Ensure the seal
is in place and not distorted.
(17) Install and tighten the allen-head screws to
4-5 N-m (35-45 in. lbs.) torque.
(18) Install the brake caliper, refer to Group 5,
Brakes.
Tire Installation within this section. Lower the vehicle.
AXLE SHAFT AND U-JOINT SERVICE

DISASSEMBLY
(1) Remove the snap rings from the yokes.
(2) Position the U-joint on the top of the vise jaws
(Fig. 20). Do not tighten the vise.
Fig. 19 Spindle Installation

Fig. 20 Bearing Cap Removal
(8) Install the h u b and rotor assembly on the spin
(3) Use a mallet to drive the vertical yoke down
dle. Add Wheel Bearing Grease lubricant (NLGI
ward to remove the upper needle bearing and cap
Grade 2, E P or an equivalent lubricant) to the bear
(Fig. 20).
ings.
(4) Reverse the position of the yoke and remove op
posite needle bearing and cap (Fig. 20).
(5) Remove the yoke from the spider.
(6) Position the open ends of the spider in a soft-
jawed vise. Repeat steps 3 and 4 (above) to remove
remaining bearings and caps.
(7) Remove the spider from the yoke.
(8) Clean and inspect all the components. Clean
any rust from the axle shaft splines. Retain each
bearing and cap separate. If any component is exces
sively worn or damaged, replace the U-joint.
ASSEMBLY
(1) Insert the needle bearing and cap in one yoke
arm bore.
(2) Place the yoke in a vise (Fig. 21) and press the
needle bearing and cap into position. Install the snap
ring.
Fig. 22 Bearing Cap & Spider Installation
Fig. 21 Bearing Cap installation

(3) Remove the yoke from the vise and insert one
end of the spider into t h e bearing. Insert opposite
bearing and cap in the yoke a r m bore by hand and
align it with the spider.
(4) Place the yoke in a vise and press the cap into Fig. 23 Upper Cap Removal
the yoke arm bore and onto the spider (Fig. 22).
(5) Use a short plug or a socket wrench to force the (4) Remove the steering knuckle lower cap (Fig.
bearing cap into the correct position and install the 25).
snap ring. (5) Dislodge the cap from the steering knuckle and
(6) Repeat the instructions in steps 1 through 5 for yoke.
installing remaining bearings, caps and yoke. (6) Remove the tapered bushing from the top of the
kingpin in the knuckle (Fig. 26). Remove the
STEERING KNUCKLE, UPPER AND LOWER knuckle.
KINGPINS (7) Use Remover/Installer D-192 to remove the up
per kingpin (Fig, 27). Discard the seal.
REMOVAL (8) Use Tool C-4212-1, C-4366-1 and C-4366-2 to
(1) Remove axle shaft, refer to Axle Shaft And remove lower ball socket from lower arm bore (Fig.
U-Joint Service. 28). Discard the grease seal, retainer and lower bear
(2) Remove the steering knuckle upper cap (Fig. ing cup.
23).
(3) Remove the spring and retainer (Fig. 24). Dis
card the gasket.
TAPERED
BUSHING
J9202-53
Fig. 26 Tapered Bushing Removal
Fig. 24 Spring and Retainer Removal
LOWER KINGPIN
A N D RETAINER
CAP
J9202-66
Fig. 27 Upper Kingpin Removal

C-4366-3 and C-4366-5 (Fig. 30) and press the lower
bearing cup and seal into yoke lower arm bore.
^ J9202-51 (5) Use Remover/Installer D-192 to install the up
Fig. 25 Lower Cap Removal per kingpin (Fig. 31). Tighten the kingpin to 668-813
N-m (500-600 ft. lbs.) torque. Install the seal over the
INSTALLATION kingpin.
(1) Apply sealant to the mating surface of the (6) Install the knuckle on the axle yoke.
grease retainer. Lubricate the lower ball socket with (7) Insert the tapered bushing over the upper king
MOPAR Multi-Mileage Lubricant (or equivalent). pin (Fig. 32).
(2) Install the grease retainer in the yoke bore (8) Fill the socket lower cavity with MOPAR
with the concave side facing the upper kingpin. Multi-Mileage Lubricant (or equivalent). Install the
(3) Use Remover/Installer C-4212-L, C-4366-3, and lower king pin and retainer cap on the steering
C-4366-4 (Fig. 29) to install a new grease seal and knuckle (Fig. 33). Install the capscrews and tighten
lower bearing cup. to 95-122 N-m (70-90 ft. lbs.) torque.
(4) Fill the area in grease retainer with specified (9) Install the retainer and compression spring on
grease, grease bearing cone and install. Install new the tapered bushing.
king pin bearing oil seal. Reposition Tools C-4212-L,
C-4212-L
C-4212-L
C-4366-3
C-4366-2
C-4366-1
RH432A
Fig. 28 Lower Ball Socket Removal RH434A
Fig. 30 Lower Bearing & Seal Installation

TORQUE
C-4212-L WRENCH
C-4366-3
C-4366-4
SEAL
J9202-66
Fig. 31 Upper Kingpin Installation

RH433A
on the left side). Install the bolts/nuts and tighten to
96-122 N*m (70-90 ft. lbs.) torque.
Fig. 29 Lower Bearing Cup Installation
(11) Lubricate the upper and lower king pin
(10) Install a new gasket over the steering knuckle through the fittings with MOPAR Multi-Mileage Lu
upper studs. Install the upper cap (and steering arm bricant (or equivalent).
TAPERED (3) Mark the front drive shaft and the pinion yoke
BUSHING for installation alignment reference.
(4) Disconnect the front drive shaft from the axle
yoke. Attach the drive shaft to the frame rail with
wire.
(5) Remove the cotter pin, the nut, and disconnect
the drag link from the steering knuckle arm (left
side only). Discard the cotter pin.
(6) Disconnect flexible brake fluid hose fittings at
the frame crossmember. P l u g the hoses at the fit
tings.
(7) Remove the shock absorber lower n u t and stud
from the axle shaft tube bracket. Remove the nuts
and disconnect the stabilizer bar links from the
J9202-53 spring brackets.
(8) Remove nuts and the washers from the spring
Fig. 32 Tapered Bushing Installation U-bolts. Remove the complete front axle from the ve
hicle.
INSTALLATION
(1) Position the front axle under the front of the
vehicle with the axle spring pads under the springs.
Place the spring brackets over the springs. Make
sure the stabilizer bar link bolt holes face toward the
rear of the vehicle.
(2) Install the spring U-bolts, washers and nuts.
Refer to Front Suspension — 4WD Vehicles within
this group.
(3) Install the shock absorber. Refer to Front Sus
pension—4 WD Vehicles within this group.
(4) Connect the stabilizer bar links to the spring
brackets. Refer to Front Suspension—4WD Vehicles
within this group.
(5) Remove plugs and connect the brake hose fit
tings. Refer to Group 5, Brakes.
(6) Connect the drag-link ball stud to the steering
knuckle arm. Refer to Group 19, Steering.
J9202-52 (7) Connect the drive shaft to the pinion yoke with
the installation reference m a r k s aligned. Install the
Fig. 33 Lower King Pin and Retainer Installation washers and the nuts and tighten to 19 N-m (14 ft.
lbs.) torque.
(12) Install the axle shaft, refer to Axle Shaft and
(8) Remove the supports, lower the vehicle and re
U-Joint Installation.
move the block from the brake pedal.
(9) Raise the vehicle.
COMPLETE AXLE REMOVAL/INSTALLATION
• Bleed and adjust the brakes
SERVICE INFORMATION • Lubricate all the ball stud fittings
It is not necessary to remove the complete front • Inspect the differential housing lubricant level. Re
axle from the vehicle for routine service. If the hous fer to Group 0, Lubrication and Maintenance.
ing or axle shaft tubes are damaged, the complete (10) Lower the vehicle and test the axle and sus
pension operation.
axle can be removed and installed via the following
procedures.
DIFFERENTIAL DISASSEMBLY
REMOVAL REMOVAL/DISASSEMBLY
(1) Block the brake pedal in the up position. Raise (1) Note the installation reference letters
and support the vehicle at a comfortable working stamped o n the bearing c a p s a n d h o u s i n g ma
height. chined sealing surface (Fig. 34).
(2) Remove the front wheels/tires. (2) Remove the differential bearing caps.
(9) Clamp the differential case in a vise equipped
with soft jaws. Remove and discard the ring gear
remove (Fig. 36).
Fig. 34 Bearing Cap identification

(3) Position Spreader D-167 with the tool dowel
ger-tight.
SPECIAL TOOL DIAL
MODEL 44 - W-129-A INDICATOR
Fig. 36 Ring Gear Removal
(10) Remove the pinion yoke nut and washer. Use
Remover C-452 and Wrench C-3281 to remove the
pinion yoke (Fig. 37).

(4) Install a pilot stud at the left side of the differ
ential housing. Attach Dial Indicator to housing pilot
stud. Load the indicator plunger against the opposite
side of the housing (Fig. 35) and zero the indicator. C-452 J9102-31
C A U T I O N : D o not spread over the specified dis Fig. 37 Pinion Yoke Removal
tance. If the housing is over-separated, it could be (11) Use Remover C-748 to remove the pinion gear
distorted or damaged. seal (Fig. 4).
(5) Separate the housing enough to remove the
case from the housing. S e p a r a t e h o u s i n g a maxi
save time if they should become misplaced.
m u m distance of 0.38 m m (0.015 in) w i t h t h e
(13) Remove the front pinion bearing cup with Re
spreader tool. Measure the distance with the dial
mover D-158 and Handle C-4171 (Fig. 39).
indicator (Fig. 35).
(14) Remove the rear bearing cup from housing
(6) Remove the dial indicator.
(Fig. 40). Use Remover D-162 and Handle C-4171.
(7) Pry the differential case loose from the hous
(15) Remove the depth shims from the housing
ing. To prevent damage, pivot on housing with the
bore. Record the thickness of the depth shims.
end of the pry bar against case.
PINION WASHER
YOKE
PINION
NUT
SLINGER
FRONT
BEARING
CUP
PINION
PRELOAD,
SHIMS PINION
OIL SEAL
PINION PRELOAD
SPACER
FRONT
BEARING
CONE
SHOULDER FOR
• PINION PRELOAD SPACER J9203-63

SPECIAL TOOL SPECIAL TOOL HAMMER DRIVER
D-158 C-4171 HANDLE
FRONT
BEARING CUP
J9203-57 J9203-58
Fig. 39 Front Bearing Cup Removal Fig. 40 Rear Bearing Cup Removal
(16) Remove the pinion r e a r bearing (Fig. 41). Use (18) Remove the case from the vise.
Puller DD-914-P, Adapter Ring DD-914-9 and Plate (19) Remove the bearings (Fig. 42) with:
C-293-37. Remover DD-914-P
(17) Remove the differential side gears and thrust Adapter Ring DD-914-8
washers. Plate DD-914-62
SPECIAL TOOL
DD-914-P
J9203-59
Fig. 41 Pinion Rear Bearing Removal Fig. 43 Mate Shaft Lock Pin Removal
• Screw Extension DD-914-7
• Button DD-914-42
Use e a r e t h a t a d a p t e r r i n g s a r e p l a c e d so t h e y
do not damage the bearing cage.
Fig. 44 Mate Shaft Removal

the pinion mate gears and thrust washers (Fig. 45).
(24) Remove axle shaft oil seals from differential
housing with a pry bar.
CLEANING/INSPECTION
(1) Wash and clean all the differential components
with cleaning solvent. Dry with compressed air.
Fig. 42 Differential Bearing Removal Do not steam clean the differential compo
(20) Remove bearing shims from case hubs and nents.
mark them (with hub identity) for assembly refer (2) Clean the axle shaft tubes. Insert a stiff wire
ence. Record the thickness of the shims. into each tube, attach a clean cloth to the wire at the
(21) Clamp the differential case in a vise equipped housing opening. Draw the wire (and cloth) from the
with soft jaws. Use a pin punch to remove the pinion housing outward through the tube.
gear mate shaft lock pin (Fig. 43). (3) Inspect the differential and pinion gear bear
(22) Remove the mate shaft with a drift and ham ings. Inspect the differential case and housing.
mer (Fig. 44). • Bearings and cups should have a smooth appear
(23) Rotate the differential side gears and remove ance.
THRUST • Differential side gears and t h r u s t washers

WASHER • Pinion gears and thrust washers
• Pinion gear mate shaft (align holes in shaft and
case)
case and mate shaft with a punch and hammer (Fig.
46). Peen metal part of case over pin in two places.
If replacement gears a n d thrust w a s h e r s w e r e
installed, it is not n e c e s s a r y to measure the gear
backlash. Correct fit is due to close machining
Fig. 45 Pinion Mate Gear Removal

• Bearing races must not be distorted or cracked
C u p a n d b e a r i n g must be r e p l a c e d as a
m a t c h e d set only.
• All machined surfaces in t h e housing and on bear
ing caps should be smooth and without any raised
edges.
• Pinion gear front and rear bearing cup bores
should be smooth
• Raised metal on shoulders of cup bores should be
removed with a hand stone.
(4) Examine the differential pinion gear mate Fig. 46 Mate Shaft Pin Installation
shaft, pinion gears, side gears and thrust washers for (3) Invert the differential case and start two ring
wear and damage. Replace all defective components. gear bolts. This will provide case-to-ring gear bolt
If either of the differential pinion gears is not hole alignment (Fig. 47).
reusable, both gears must be replaced as a (4) Install new ring gear bolts and alternately
m a t c h e d set only. Do not r e p l a c e only one g e a r . tighten to;
(5) Examine t h e ring gear and the pinion gear for • Grade 8 bolts to 136-163 N*m (100-120 ft. lbs.)
worn and chipped teeth. Examine the ring gear for torque
damaged bolt threads. • Grade 9 bolts (7 radial lines) to 169-183 N*m (125-
If replacement of either gear is necessary, both 135 ft. lbs.) torque.
must be replaced as a matched set only. (5) Lubricate all differential components with hy
(6) Inspect the pinion yoke for cracks, worn poid gear lubricant.
splines, pitted areas, and a rough/corroded seal con (6) Place Master Differential Bearing D-343
tact surface. Repair or replace the yoke as necessary. (D-117) on the case hubs (Fig. 48).
(7) Inspect the pinion bearing preload shims for
cracks, damage and distortion. Install replacement
indicator plunger against the back of the ring gear
shims (if necessary) for the preload torque adjust
(Fig. 49).
ment.
(8) Insert a small pry bar between the bearing cap
DIFFERENTIAL ASSEMBLY and right side of differential case. Pry the case as far
as possible to left side (Fig. 49). Zero the dial indica
ASSEMBLY tor pointer.
(1) Install the following components in the differ (9) Pry the case to right side and record the
ential case (Fig. 47). travel distance.
2 - 64 FRONT SUSPENSION AND AXLE — •
TORQUE
Fig. 47 Ring Gear Bolt Hole installation Fig. 49 Differential Case End Play Measurement
the face of the pinion gear. This number is the
MASTER BEARING
amount (in thousandths of an inch) the depth varies
from the standard depth setting. The standard depth
provides the best teeth contact pattern.
DRIVE PINION
RY652 Fig. 50 Pinion Gear ID Numbers

Fig. 48 Master Bearing Tools On Hubs
The m e a s u r e m e n t a b o v e is the shim thickness shoulder of the rear pinion bearing.
n e c e s s a r y for c a s e zero end-play. The total • Model 60 axle, the standard depth/distance is
thickness will b e determined during the ring 5.000 inches (127.0 mm).
gear b a c k l a s h adjustment. Compensation for depth variance is achieved by
(10) Remove indicator and pilot stud. shims placed adjacent to the pinion gear rear bearing
cup (Fig. 52).
PINION GEAR DEPTH INFORMATION If a new gear set is being installed, note the depth
Gears are supplied as matched sets only. The iden variance etched into the original and new pinion
tifying numbers for the ring and pinion gear are gear. Add or subtract the thickness of the original
etched into the face of each gear (Fig. 50). A plus ( + ) depth shims to compensate for the difference in the
number, minus (-) number or zero (0) is etched into depth variances. Refer to the Depth Variance charts.
AXLE DEPTH DRIVE

MODEL SETTING

For Example:
• If a positive marking, this means t h e shim pack
must decrease by the same number of thousandths.
• If a negative marking, this means the shim pack
must increase by the same number of thousandths.
• If marked zero will use the nominal setting as de
termined in this procedure. If e q u i p p e d , t h e oil s l i n g e r m u s t b e m e a s u r e d
Shims are available in 0.003-inch, 0.005-inch, a n d the thickness included with the total shim
0.010-inch, and 0.030-inch thicknesses. pack thickness.
If original gear set is installed but the depth shims The shim thickness for the new pinion gear must
replaced, measure the thickness of the original depth be determined before installing the differential case.
the same thickness.
Original Pinion Replacement Pinion Gear Depth Variance

Gear Depth
Variance -4 -3 -2 -1 0 +1 -ft +3
+4 + 0.008 + 0.007 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0
+S +0.007 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001
4-1 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001 -0.002
4-1 + 0.005 + 0.004 + 0.003 +0.002 + 0.001 0 -0.001 -0.002 -0.003
0 + 0.004 +0.003 + 0.002 + 0.001 0 -0.001 -0.002 -0.003 -0.004
-I + 0.003 + 0.002 + 0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005
-2 + 0.002 + 0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006
-3 + 0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007
-4 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007 -0.008

J8902-46
ADJUSTMENT WITH TOOL SET D-116
ment procedure involves using Tool Set D-116.
(1) Insert Master Pinion Block D-120 into the dif
ferential housing (Fig. 53).
Fig. 53 Pinion Block In Shaft Bore

(2) Place Disc D-116-2 on Arbor D-115-3 and posi
tion in the bearing cradles (Fig. 54). This is the cen
terline of the ring gear/axle shaft.

Plunger travel distance indicated, plus or mi
n u s the amount etched in gear is required thick
ness.
(6) Measure the thickness of each depth shim with
a micrometer and combine the shims necessary for
total required pack thickness. Include oil slinger
thickness with the total shim p a c k thickness.
(7) Remove the measurement tools from the differ
Fig. 54 Disc & Arbor In Housing ential housing.
(8) Place the depth shims in the pinion gear rear
(3) Place Pinion Height Block D-116-1 on top of bearing bore. Install the bearing cup (Fig. 57) with
master pinion block tool and against arbor tool (Fig. Installer D - l l l and Handle C-4171.
55). Ensure the cup is correctly seated.
(4) Place Gauge Block D-115-2 and Dial Indicator (9) Install the pinion front bearing cup with In
D-106-5 on lowest step (Fig. 56). Zero the dial indi staller C-4203 and Handle C-4171 (Fig. 58).
cator pointer. (10) Install the rear bearing (and slinger if used)
(5) Move the gauge block toward the arbor until on the pinion gear with Installer C-3095-A until
the indicator plunger contacts the arbor tool (Fig. completely seated (Fig. 59).
56). Slide the gauge block across the arbor while ob (11) Assemble preload shims onto pinion and in
serving indicator. Record the longest travel distance, stall the pinion gear in housing.
whether inward (-) or outward ( + ), indicated by the
pointer.
SPECIAL TOOL
D-111 PRESS
INSTALLATION
TOOL
DRIVE
PINION GEAR
SHAFT
REAR BEARING'
OIL
SUNGER
SPECIAL
TOOL DRIVE
C-4171 J9203-65 PINION GEAR J9302-68
Fig. 57 Pinion Rear Bearing Cup Installation Fig. 59 Pinion Rear Bearing Installation
BEARING CUP DRIVER SPECIAL DIFFERENTIAL
INSTALLATION TOOL C-4203 HANDLE TOOL HOUSING
TOOL C-3718
C-4171
SPECIAL
TOOL
C-3281
Fig. 58 Pinion Front Bearing Cup Installation
(12) Install pinion front bearing, oil slinger, yoke,
washer and nut. Install the yoke with Installer
J9103-21
(13) Tighten the yoke n u t to 339-366 N-m (250-270
ft. lbs.) torque. Fig. 60 Pinion Yoke Installation
(14) Check bearing preload torque with an inch
• Decrease the preload torque, increase the shim
pound torque wrench (Fig. 61). The torque necessary
thickness
to rotate the pinion gear should be;
• Original Bearings — 1 to 3 N*m (10 to 20 in. lbs.)
• New Bearings — 2 to 5 N-m (20 to 40 in. lbs.)
If the preload torque is not within the specified tol
erance, correct the shim thickness accordingly (Fig.
lip of pinion seal. Install the new seal (Fig. 64) with
62);
Installer C-3719-A and Handle C-4735
(17) Install the yoke with Installer C-3718 and
thickness
Wrench C-3281 (Fig. 60).
TORQUE WRENCH SPECIAL TOOL
C-3281
SPECIAL TOOL
RH418A C-452 J9102-31
Fig. 61 Rotating Pinion Gear Fig. 63 Pinion Yoke Removal
Ml
SPECIAL TOOL
C4735
REMOVE SHIMS
BEARING
PRELOAD
SHIM PACK
PINION
LOCATING
SHIM PACK
DIFFERENTIAL
C-3719-A HOUSING
J9203-56
DIFFERENTIAL BEARING Fig. 64 Pinion Seal Installation

S H I M PACKS RY660
SPECIAL TOOL SET
Fig. 62 Shim Locations C-758-D6
SP-5184
(18) Install a new yoke n u t and tighten to 339-366
N-m (250-270 ft. lbs.) torque.

ADJUSTMENT WITH TOOL SET C-758-D6
The alternate measurement and adjustment proce
dure involves using Pinion Depth Measurement
Gauge Set C-758-D6 (Fig. 65).
(1) Install the pinion rear bearing cup (Fig. 66)
with Installer D - l l l and Handle C-4171.
(2) Install the pinion front bearing cup with In
staller C-4203 and Handle C-4171 (Fig. 67). J9203-67
Assemble C-758-D6 Tool Set a s described (Fig.
68); Fig. 65 Pinion Adjustment Tools
• . FRONT SUSPENSION AND AXLE 2 - 69
SPECIAL TOOL

of t h e depth shim(s) is determined according t o
the following information.
(4) Loosen the compression n u t tool. Lubricate the
C-4171 J9203-65
pinion gear front and rear bearings with gear lubri
cant. Re-tighten the compression n u t tool to 1 to 3
Nnn (15 to 25 in. lbs.) torque. Rotate the pinion gear
BEARING CUP DRIVER several complete revolutions to align the bearing
INSTALLATION TOOL C-4203 HANDLE rollers.
(5) Install Gauge Block SP-5260 at the end of SP-
526. Install Cap Screw (SP-536) and tighten with
Wrench SP-531.
(6) Position Crossbore Arbor (SP-5183) in the dif
ferential housing.
Center the arbor in cradles so equal space exists at
both ends. Position the bearing caps on the arbor
tool. Install the bolts. Tighten the cap bolts to 14
Nnn (10 ft. lbs.) torque.
(7) Trial fit depth shim(s) between the crossbore
arbor and gauge block (Fig. 69). The depth shim(s)
fit m u s t b e s n u g but not tight (drag friction of a
feeler gauge blade).
Fig. 67 Pinion Front Bearing Cup Installation SPACER
• Position Spacer (SP-5814 for Model 60) over Shaft
(SP-526)
• Position tools (with bearing) in the housing
• Install Sleeve (SP-535-A), Washer (SP-534) and
Nut (SP-533).
(3) Prevent compression sleeve tool from turning
with Wrench C-3281. Tighten the nut to seat the pin
ion bearings in the housing (Fig. 68). Allow the
sleeve to t u r n several times during the tightening to
prevent brinelling the bearing cups or the bearings.
D e p t h shim(s) are positioned b e t w e e n the pin
ion gear rear bearing and pinion gear to provide
the separation distance. The required thickness Fig. 69 Depth Shim(s) Selection
Depth shims are available in O.OOl-ineh incre
ments from 0.020 inch to 0.038 inch. PRESS
(8) Note the etched number on the face of the drive
pinion gear (e.g., -0, - 1 , -2, + 1 , + 2 , etc.). The num
bers represent thousands-of-an-inch deviation from
the standard. If the number is - (negative), add t h a t
value to the required thickness of the depth shim(s). INSTALLATION
If the number is + (positive), subtract t h a t value TOOL
from the thickness of the depth shim(s). If the num
ber is 0, no change is necessary.
(9) Remove the tools from the differential housing. DRIVE
PINION GEAR
(10) Remove the rear bearing cup from housing SHAFT
(Fig. 70) with Remover D-162 and Handle C-4171. REAR BEARING'
HAMMER DRIVER
HANDLE
OIL
SUNGER
DRIVE
PINION GEAR J9302-68
Fig. 71 Pinion Rear Bearing Installation

TOOL HOUSING
C-3718
J9203-58
Fig. 70 Rear Bearing Cup Removal

(11) Position depth shims in housing rear bearing SPECIAL
TOOL
cup bore. C-3281
(12) Install the pinion rear bearing cup (Fig. 66)
with Installer D - l l l and Handle C-4171.
(13) If the depth of mesh has been followed accord
ing to the instructions above, good gear teeth contact J9103-21
should exist.
(14) Install the rear bearing (and slinger if used) Fig. 72 Pinion Yoke Installation
on the pinion gear with Installer C-3095-A until (19) Check bearing preload torque with an inch
completely seated (Fig. 71). pound torque wrench (Fig. 73). The torque necessary
(15) Install pinion in housing bore. to rotate the pinion gear should be;
(16) Assemble preload shims onto pinion and in • Original Bearings — 1 to 3 N*m (10 to 20 in. lbs.)
stall the pinion gear in housing. • New Bearings — 2 to 5 N»m (20 to 40 in. lbs.)
(17) Install pinion front bearing, oil slinger, yoke, If the preload torque is not within the specified tol
washer and nut. Install the yoke with Installer erance, correct the shim thickness accordingly (Fig.
C-3718 and Wrench C-3281 (Fig. 72). 74);
(18) Tighten the yoke n u t to 339-366 N-m (250-270 • Increase the preload torque, decrease the shim
ft. lbs.) torque. thickness
TORQUE WRENCH SPECIAL T O O L

G3281
SPECIAL TOOL
RH418A C-452 J9102-31

• Decrease the preload torque, increase the shim SPECIAL TOOL
thickness C-4735
BEARING
PRELOAD
SHIM PACK
PINION
LOCATING
SHIM PACK
SPECIAL TOOL DIFFERENTIAL

C-3719-A HOUSING
J9203-56

RING GEAR BACKLASH ADJUSTMENT
DIFFERENTIAL BEARING (1) Place Master Differential Bearing D-343
SHIM PACKS RY660 (D-117) on the case hubs (Fig. 78).
Fig. 74 Shim Locations (2) Install a pilot stud at t h e right side of housing.
(20) Remove the pinion yoke nut and washer. Use indicator plunger against the back of the ring gear
Remover C-452 and Wrench C-3281 to remove the (Fig. 78). Ensure ring and pinion gear teeth are
pinion yoke (Fig. 75). tightly meshed. Zero the indicator.
(21) Apply a light coating of gear lubricant on the (3) Insert a small pry bar between the bearing cap
lip of pinion seal. Install the new seal (Fig. 76) with and right side of differential case. Pry the case as far
Installer C-3719-A and Handle C-4735 as possible to left side (Fig. 78). Zero the dial indica
(22) Install the yoke with Installer C-3718 and tor pointer.
Wrench C-3281 (Fig. 77). (4) Repeat the measurement several times to check
(23) Install a new yoke n u t and tighten to 339-366 consistency. Record the travel distance.
N*m (250-270 ft. lbs.) torque. The measurement above s h o w s shim thickness
necessary to eliminate ring gear backlash. Sub-
SPECIAL DIFFERENTIAL (8) Position the backlash shims (with determined
TOOL HOUSING thickness) on case hub (ring gear side). Install bear
ing on the h u b with Installer C-4025-A and Handle
C-4171 (Fig. 79).
J9103-21
Fig. 79 Differential Bearing Installation

(9) Position the remaining zero end-play shims on
hub at opposite side of case. Include an additional
0.015-in (0.38-mm) thick shim on this hub. This will
provide the required differential bearing preload
torque.
(10) Install bearing on h u b with Installer
C-4025-A and Handle C-4171 (Fig. 79).
(11) Install new axle shaft oil seals in differential
housing with Installer D-195. Apply lubricant to lip
of seals.
(12) Match each bearing cup with bearing (origi
nal). Install the cups on the bearings.
(13) Position Spreader D-167 with the tool dowel
ger-tight.
(14) Install a pilot stud a t the left side of the dif
Fig. 78 Ring Gear Backlash Measurement ferential housing. Attach Dial Indicator to housing
tract this thickness from c a s e zero end-play pilot stud. Load the indicator plunger against the op
shim thickness. The shims must b e placed at the posite side of the housing (Fig. 80) and zero the indi
ring gear side b e t w e e n the c a s e a n d bearing. cator.
C A U T I O N : D o not spread over the specified dis
(6) Remove t h e differential case from housing.
tance. If the housing is over-separated, it could he
(7) Remove the master bearing tools from the dif
distorted or damaged.
ferential case hubs.
(15) Separate the housing enough to install the
case in the housing. S e p a r a t e h o u s i n g a m a x i m u m
SPECIAL TOOL
.MODEL 4 4 - W - 1 2 9 - A
MODEL 60 - D-167 DIAL
INDICATOR
J9202-114 TOOL
C-3339
Fig. 80 Differential Housing Separation Fig. 82 Ring Gear Backlash Measurement

distance of 0.38 m m (0.015 in) w i t h the spreader away from the pinion gear. Backlash correction is ac
tool. Measure the distance with t h e dial indicator complished by transferring shims from one side to
(Fig. 80). the other.
(16) Remove the dial indicator. If the mesh and backlash steps have been followed
(17) Install case in the housing. Ensure the differ in the procedures above, good gear teeth contact pat
ential bearings are fully seated. Remove the terns should exist.
spreader.
(18) Observe the assembly reference marks and po RING GEAR TEETH CONTACT PATTERN
sition the bearing caps at their original locations ANALYSIS
(Fig. 81). Tighten the bearing cap bolts to 95-122 The ring gear teeth contact patterns will show if
Nnn (70-90 ft. lbs.) torque. the pinion gear depth shim(s) have the correct thick
ness. It will also show if the ring gear backlash h a s
been adjusted correctly. The backlash must be main
(1) Apply a thin coat of hydrated ferric oxide, to
the ring gear teeth.
(2) Rotate the ring gear one complete revolution in
both directions while a load is being applied. Insert a
pry bar between the differential housing and the case
flange. This action will produce distinct contact pat
gear teeth.
(3) Note patterns in compound. Refer to (Fig. 83)
for interpretation of contact patterns and adjust ac
cordingly.
(4) Install the axle shafts. Refer to Axle Shaft In
stallation within this group.
Fig. 81 Differential Bearing Cap Reference Letters (5) Install the housing cover. Refill the differential
(19) Rotate the assembly several revolutions to
seat the bearings. Measure backlash a t three equally
spaced locations with a dial indicator (Fig. 82).
The ring gear backlash must be within 0.004 -
0.009 inch (0.10 - 0.23 mm). It cannot vary more
than 0.002 inch (0.05 mm) b e t w e e n the points
checked.
(20) Excessive backlash is corrected by moving the
ring gear teeth closer to the pinion gear teeth. Insuf
ficient backlash is corrected by moving the ring gear
DRIVE SIDE COAST SIDE

OF RING OF RING
DESIRABLE CONTACT PATTERN.

PATTERN SHOULD BE CENTERED
O N THE DRIVE SIDE OF TOOTH.
HEEL TOE TOE HEEL PATTERN SHOULD BE CENTERED O N
THE COAST SIDE OF TOOTH,
BUT MAY BE SLIGHTLY TOWARD
THE TOE. THERE SHOULD ALWAYS
BE SOME CLEARANCE BETWEEN
CONTACT PATTERN A N D TOP OF
THE TOOTH.

THINNER PINION GEAR DEPTH
SHIM REQUIRED.

THICKER PINION GEAR DEPTH
SHIM REQUIRED.

CORRECT DECREASE RING
GEAR BACKLASH.

CORRECT INCREASE RING
GEAR BACKLASH.
J9003-24

SPECIFICATIONS
MODEL 60 FRONT AXLE
Axle Type........ Semi-floating, hypoid Differential Bearing

Preload Shim 0.015 in. 0.38 mm
Application D-TRK
Differential Side
Ring Gear Diameter 9.75 in. (24.76 cm) Gear-to-Case Clearance.. 0.000-0.007 in. 0.00-0.18 mm
Lubricants MOPAR Gear Lubricant or Ring Gear Backlash 0.005-0,008 in. 0.12-0.20 mm
equivalent SAE 75W-90,
API Grade GL-5, MIL-L-2105C Drive Pinion Gearshaft Bearing
Break-Away Preload Torque
Locking Hubs Manual type
Original Bearings.... 10-20 in. lbs. l-2N®m
Lubricant Capacity 6.5 pts. (3.1L)
Replacement Bearings. 20-40 in. lbs. 2-5 N®m
Axle Model Dana M60F
Drive Pinion Gear Depth Select shims
Axle Ratio......... 3.54
Tol 4.10 Standard Setting.... 3.125 in. 79.37 mm
4.56
Track... 65.7 in. Side Gear Clearance (max.) 0.006 in. 0.15 mm
GAWR.................... 4500 lbs. Case Runout (max.) 0.006 in. 0.15 mm

J9202-107
TORQUE SPECIFICATIONS
FRONT SUSPENSION COMPONENTS- 2WD FRONT SUSPENSION COMPONENTS- 4WD
FRONT S U S P E N S I O N C O M P O N E N T S FRONT S U S P E N S I O N C O M P O N E N T S
% WHEEL DRIVE 4 WHEEL DRIVE
DESCRIPTION TOROUE DESCRIPTION TORQUE
Brake Rotor Dust Shield . 20 N-m (180 in. lbs. Jounce Bumper to Bracket .... ... 41 N-m (30ft.lbs.)
Jounce Bumper to Bracket.... .... 41 N-m (30 ft. lbs. Stabilizer Bar Retainer Bolts.. 23 N-m (200 in. lbs.)
Stabilizer Bar Link Nut 11 N-m (100 in. lbs.)
Lower Suspension Arm Pivot. 305 N-m (225 ft. lbs.
Shock Absorber/Jounce
Lower Ball Stud Nut Bracket to Frame .. 101 N-m (75ft.lbs.)
(11/16-18 Bolt)............... 183 N-m (135 ft. lbs.
Shock Absorber (Standard)
Lower Ball Stud Nut Upper and Lower Nut .... 75 N-m (55ft.lbs.)
237 N-m (175 ft. lbs. Shock Absorber (Air Adjust)
(3/4-16 Bolt).....
.... 34 N-m (25 ft. lbs. Upper Nut .... 75 N-m (55ft.lbs.)
Shock Absorber Upper Nut..
Shock Absorber (Air Adjust)
. 23 N-m (200 in. lbs.
Shock Absorber Lower Bolt .. Lower Nut 271 N-m (200ft.lbs.)
. 23 N-m (200 in. lbs. Spring U-bolt/Stud Nuts
Stabilizer Bar Retainer Bolts .
. 11 N-m (100 in. lbs. (Model 44) ... .. 115 N-m (85ft.lbs.)
Stabilizer Bar Link Nut
Spring Front Pivot Nut
Steering Arm to Knuckle (Model 44) 135 N-m (100ft.lbs.)
290 N-m (215 ft. lbs.
5/8-18 Bolt/Nut ............. Spring Rear Shackle Nut
Steering Arm to Knuckle (Model 44) .... 81 N-m (60ft.lbs.)
3/4-16 Bolt/Nut 330 N-m (225ft.lbs. Spring U-bolt/Stud Nuts
Strut/Jounce Bumper to (Model 60) .. 129 N-m (95ft.lbs.)
Suspension Arm Bolt/Nut. .. 129 N-m (95ft.lbs. Spring Front Pivot Nut
.... 68 N-m (50ft.lbs. (Model 60) 135 N-m (100ft.lbs.)
Strut Front Nut
Spring Rear Shackle Nut
Upper Ball Stud Nut 142 N-m (105ft.lbs. (Model 60) ,. 108 N-m (80ft.lbs.)
J9202-108 J9202-109
MODEL 44 AXLE MODEL 60 AXLE
FRONT AXLE M O D E L 4 4 FRONT AXLE M O D E L # 0

DESCRIPTION TORQUE DESCRIPTION TORQUE
Bearing Cap Bolts 95 to 122 N-m Bearing Cap Bolts 95 to 122 N-m
(70 to 90 ft. lbs.) (70 to 90 ft. lbs.)
Brake/Spindle Splash Shield 34 to 41 N-m Brake Splash Shield/Spindle. 68 to 81 N-m
(25 to 35 ft. lbs.)
(50 to 60 ft. lbs.)
Differential Cover Bolts 47 N-m (35 ft. lbs.) Differential Cover Bolts 47 N-m (35 ft. lbs.)
Fill Hole Plug 34 N-m (25 ft. lbs.)
Fill Hole Plug 34 N-m (25 ft. lbs.)
Lower Ball Stud Nut 108 N-m (80 ft. lbs.)
Lower King Pin Cap Screws... 95 to 122 N-m
Pinion Yoke Nut 271 to 298 N-m
(200 to 220 ft. lbs.) (70 to 90 ft. lbs.)
Shift Motor Housing Bolts 14 N-m (10 ft. lbs.) Pinion Yoke Nut. 339 to 366 N-m
Spindle Wheel Bearing (250 to 270 ft. lbs.)
Outer Lock Nut...... 68 N-m (50 ft. lbs.)
Spindle Wheel Bearing
Steering Knuckle Arm Nuts 122 N-m (90 ft. lbs.) Outer Lock Nut .... 217 to 278 N-m
Ring Gear Bolts 61 to 81 N-m (160 to 205 ft. lbs.)
(45 to 60 ft. lbs.) Ring Gear Bolts (Grade 8) 136tol63N-m
Upper Ball Stud Nut 136 N-m (100 ft. lbs.) (100 to 120 ft. lbs.)
Upper Yoke Sleeve 54 N-m (40 ft. lbs.) Ring Gear Bolts (Grade 9) ..... 169 to 183 N-m
J9202-110 (125 to 135 ft. lbs.)
Upper King Pin Cap 96 to 122 N-m
(70 to 90 ft. lbs.)
Upper King Pin 668 to 813 N-m
(500 to 600 ft. lbs.)
J9202-111
• REAR SUSPENSION AND AXLE 3- 1
REAR SUSPENSION AND AXLE
CONTENTS
page page
8 3/8 and 9 1/4 AXLE 11 SERVICE DIAGNOSIS 6

GENERAL INFORMATION 1 SPECIFICATIONS 27
MODEL 60 and 70 AXLES 29 SURE-GRIP DIFFERENTIAL SERVICE 28
POWER-LOK DIFFERENTIAL 55 TORQUE SPECIFICATIONS 59
REAR SUSPENSION—2WD and TRAC-LOK DIFFERENTIAL 51
4WD VEHICLES 3
GENERAL INFORMATION
SUSPENSION A rear axle equipped with a Sure-Grip differential
Ram Truck rear suspensions are comprised of; is optionally available for both Ram Truck and Ram
• Drive axle charger vehicles. The Sure-Grip has a two-piece case
• Leaf springs t h a t is interchangeable with a standard differential.
• Dual-action shock absorbers A limited-slip differential is optional on Model 60,
• Jounce bumpers (used to limit t h e travel of t h e and 70 rear axles. The Model 60 uses t h e Trac-Lok
suspension) differential and the Model 70 uses the Power-Lok dif
All Ram Truck and Ramcharger vehicles are ferential. The Trac-Lok differential uses a one-piece
equipped with leaf-type rear springs. The springs case while the Power-Lok differential uses a two-
have a one-piece, rubber bushing pressed into their piece case. Both use t h e same internal components as
main leaf front eye. Model 150 and Ramcharger ve a standard differential, plus two clutch disc packs.
hicles are equipped with a fixed-rate type leaf spring.
Progressive-rate type rear leaf springs are standard IDENTIFICATION
equipment for all Model 250 and 350 vehicles. The axle differential covers can be used for identi
fication (Fig. 1, 2, 3).
AXLES Model 60 axle has the assembly part number and
The 8 3/8, 9 1/4-Inch , Model 60 and 70 axle hous
gear ratio listed on a tag. The t a g is attached to the
ings consist of a cast iron center section. They also
left side of the housing cover (Fig. 3). Build date
have two steel axle shaft tubes t h a t are pressed into
identification codes on axles are stamped on the axle
and welded to t h e differential housing.
The removable, stamped steel cover provides a shaft tube cover side.
means for inspection and service without removing
the complete axle from the vehicle. LUBRICANTS
Both axle types are equipped with a remote vent Multi-purpose, hypoid gear lubricant should be
fitting. used for rear axles with either a standard or a Sure-
A small, stamped metal axle gear ratio identifica Grip differential. The lubricant should have MIL-L-
tion tag is attached to the housing cover. 2105-B and by API GL 5 quality specifications.
The rear wheel anti-lock (RWAL) brake speed sen MOPAR Hypoid Gear Lubricant conforms to both of
sor is attached to t h e top, forward exterior of the dif these specifications. In addition, 4 ounces of Hypoid
ferential housing. A seal is located between t h e Additive must be included with a re-fill for Sure-Grip
sensor and the wire harness connector. The seal differentials.
must b e in-plaee w h e n the wire connector is If the rear axle is submerged in water, the lu
connected to the sensor. The RWAL brake exciter bricant must b e replaced immediately. Avoid
ring is press-fitted onto the differential case against axle failure resulting from water contamination
the flange. of the lubricant.
3 - 2 REAR SUSPENSION AND AXLE •
DIFFERENTIAL IDENTIFICATION DIFFERENTIAL
FILL PLUG J9202-40

Fig. 3 Model 60 and 70 Differential Cover
Fig. 1 Differential Cover — 8 3/8 Inch Axle
IDENTIFICATION
TAG
J9203-32
Fig. 2 Differential Cover — 9 1/4 Inch Axle

• REAR SUSPENSION AND AXLE 3 - 3
REAR SUSPENSION—2WD and 4 W D VEHICLES

SPRING AND SHOCK DIAGNOSIS If the vehicle is used for severe, off-road operation,
A squeak noise from the shock absorber or spring the springs should be examined periodically. Check
bushings can be produced if movement between the for broken and shifted leafs, loose and missing clips,
rubber bushings and the metal occurs. This noise can and broken center bolts.
usually be stopped by tightening the attaching nuts.
If the squeak noise persists, inspect for damaged and VEHICLE LOADING AND WEIGHT DISTRIBUTION
worn bushings, and attaching components. Repair as A vehicle should always be loaded so the vehicle
necessary if any of these conditions exist. weight center-line is located immediately forward of
the rear axle. Correct vehicle loading provides proper
The shock absorber bushings do not require any
front tire-to-road contact. This results in maximum
type of lubrication. Do not lubricate the bushings to
vehicle handling stability and safety. Refer to Spring
reduce bushing noise. Grease or mineral oil-base lu
and Shock Absorber Diagnosis chart for further in
bricants will deteriorate the bushing rubber.
formation.
The shock absorbers are not reflllable or adjust Incorrect w e i g h t distribution s h o u l d be consid
able. If a malfunction occurs, the shock absorber ered as a possible c a u s e for erratic steering,
must be replaced. To test a shock absorber, hold it in spring failure or tire wear.
an upright position and force the piston into and out
of the cylinder four or five times. The action through
out each stroke should be smooth and even.
The spring eye and shock absorber bushings do not
require any type of lubrication. Do not attempt to
stop spring bushing noise by lubricating them.
Grease and mineral oil-base lubricants will deterio
rate the bushing rubber.
SPRING AND SHOCK ABSORBER DIAGNOSIS
FATIGUE FROM
SHOCK LOOSE EYE BOLT
OPERATION LOOSE WORN
ABSORBERS O R NUT
O N SEVERE U-BOLT SEAL
NOT OR
TERRAIN O R NUTS
FUNCTIONING W O R N BUSHINGS
OVERLOADING
UNDERCOATING DAMAGED
BROKEN WORN O N SHOCK FLUID
LEAVES BUSHINGS ABSORBER RESERVOIR
CYLINDER
INTERNAL
VEHICLE SHOCK
LEAF-TIP OVERLOADING
VEHICLE AIR TRAPPED ABSORBER
OVERLOADED LINERS W O R N O R SEVERE INTERNALLY DEFECT
OR M I S S I N G CORROSION
J9017-17
SHOCK ABSORBER The vehicle must b e raised under the frame
side rail at the crossmember behind the axle.
REMOVAL U s e care to avoid b e n d i n g the side rail flange.
(1) Raise and support the vehicle. (2) Position support stands under the frame side
(2) Remove the retaining locknut and bolt from the rails.
frame crossmember at the upper end of the shock ab (3) Remove the nuts, lockwashers, and U-bolts t h a t
sorber (Fig. 1). attach the spring to the axle (Fig. 2, 3 and 4).
BOLT SPRING
U-BOLT
LOCKNUT
SPRING
SHACKLE
SPRING
BRACKET BUMPER
A N D STUD
LOCKNUT
LOCKNUT
OUTER
INNER RETAINER
RETAINER J90T7-31 LOCKNUT
Fig. 1 Rear Shock Absorber

FRAME
(3) Remove the locknut and the outer retainer A X L E TUBE
RAIL
from the spring bracket stud (Fig. 1). BRACKET A N D STUD
LOCKNUT
(4) Remove the rear shock absorber and the inner
NUT J9017-3Q
retainer from the vehicle (Fig. 1).
Fig. 2 Spring— W-150 Vehicles
INSTALLATION
(1) Before installing the shock absorber, ensure U-BOLT^ U-BOLT
~ ' PLATE
t h a t the bushing is inserted in the shock absorber
eye. IB*
Ensure the s h o c k absorber is positioned o n the
AUXILIARY SPRING SPRING
stud w i t h the retainers correctly located o n ei
ther side of the bushing (Fig. 1).
(2) Position the inner retainer and shock absorber
eye on the spring bracket stud. Install the outer re
tainer and the locknut (Fig. 1). Tighten the locknut
FRAME PIVOT
finger-tight. BRACKET
RAIL
(3) Rotate the shock absorber upward and position
the upper end at the frame crossmember.
(4) Align and insert the bolt through the upper
shock absorber eye and the crossmember (Fig. 1).
(5) Install the locknut on the upper bolt and
tighten it finger-tight.
(6) Remove the supports and lower the vehicle to ^ . , _ BOLT
the surface. 'PIVOT' WA^HFP ^ in^gJ \ BRACKET

BRACKET WASHER ^
(7) Tighten the shock absorber nuts to 82 N*m (60 1
FRONT C3> >>JL ^ T^ A X L E TUBE
ft. lbs.) torque.
LOCKNUT ——Hr SPRING BRACKET J9017-34
SPRINGS Fig. 3 Spring & Auxiliary Spring—D-250, 350
Vehicles
REMOVAL
(1) Raise and support the frame until all weight is
removed from the rear springs.
• — REAR SUSPENSION AND AXLE 3 • 5
• Spring front and rear eye pivot bolt n u t (1/2-20) —

88 N«m (65 ft. lbs.) torque
© Spring front and rear eye pivot bolt n u t (5/8-18) —
135 N»m (100 ft. lbs.) torque
• Spring front and rear eye pivot bolt n u t (3/4-16) —
183 N-m (135 ft. lbs.) torque
SPRING LEAF—REPLACEMENT
If a spring has acquired a set (lost significant
height), it should be replaced.
(1) Remove the spring from the vehicle. If neces
sary, refer to the removal procedure.
(2) Remove the spring leaf alignment clips.
(3) Clamp the spring in a vise. Remove t h e nut
and center bolt (Fig. 5).
Fig. 4 Spring & Auxiliary Spring—W-250, 350

Vehicles
(4) Remove the nuts and bolts from the spring
front and rear eyes. Remove the spring from the ve
hicle (Figs. 2, 3 and 4).
INSTALLATION
(1) Position the spring on the axle shaft tube so
that the spring center bolt is inserted into the locat
ing hole in the axle tube spring pad (Figs. 2, 3 and
Fig. 5 Leaf Spring Disassembly
4).
(2) Align the spring front eye with the bolt hole in (4) Insert a long drift or punch into the center bolt
the front bracket and install the eye pivot bolt and hole and slowly release the vise jaws.
nut (Figs. 2, 3 and 4). (5) Remove the spring from the vise. Replace the
(3) Align the spring rear eye with t h e bolt hole in broken/defective leaf. Insert a long drift or punch
into the spring center bolt hole.
the spring shackle or the rear bracket (as applicable)
(6) Position the spring between vise jaws and
and install the spring eye pivot bolt and nut (Figs. 2,
slowly tighten the vise jaws. Keep the spring leaves
3 and 4).
aligned with the long drift or punch.
(4) Tighten the spring front and rear eye pivot bolt
(7) Remove the drift/punch from the spring center
nuts until all separation between t h e metal is re
bolt hole. Install a replacement center bolt and nut
moved. (Fig. 5).
(5) Install the U-bolts, replacement lockwashers (8) Tighten the nut to 20 N-m (15 ft. lbs.) torque.
and the retaining nuts (Figs. 2, 3 and 4). An alternate is to tighten until the center of the
(6) Tighten the nuts until they force the lockwash spring has no gaps. Use a maximum of 54 N*m (40 ft.
ers flush against the spring bracket. lbs.) torque for this method.
(7) Align the auxiliary spring with the primary (9) Install the alignment clips.
spring (Figs. 2, 3 and 4). (10) Install the spring in the vehicle. If necessary
(8) Remove the supports and lower the vehicle so refer to the installation procedure.
that the weight is being supported by the tires.
(9) Tighten the spring retaining n u t s according to LEAF SPRING EYE BUSHING REPLACEMENT
the following specifications: (1) Assemble tools shown (Fig. 6). Tighten the nut
• U-bolt nuts (1/2-20) - 88 N*m (65 ft. lbs.) torque located at the socket wrench end of the threaded rod
# U-bolt nuts (9/16-18) - 149 N-m (110 ft. lbs.) until the bushing is forced out.
torque (2) Assemble and align the bushing installation
tools.
NUT PIPE (3) Align t h e bushing with t h e spring eye and
tighten t h e n u t located a t t h e socket wrench end of
the threaded rod. Tighten until t h e bushing is forced
into t h e spring eye.
The b u s h i n g must b e centered in the spring
eye. The e n d s of the bushing must be flush or
slightly r e c e s s e d within the e n d surfaces of the
spring e y e .
SOCKET
WRENCH
(DRIVER)
FLAT THREADED
WASHER ROD J8917-20
Fig. 6 Spring Eye Bushing Removal
8ERW1GE DIAGNOSIS
INDEX
page page
Driveline S n a p 8 Low Speed Knock . . . . . . . . . . . . . . . . . . . . . . . . . 8
Gear and Bearing Noise 7 Rear Axle Alignment . . . . . . . . . . . . . . . . . . . . . . . 7
General Information 6 Tire Noise 7
Limited Slip Differential 8 Vibration 8
GENERAL INFORMATION shaft or pinion gear seals. Check for cracks or porous
Axle bearing problem conditions are usually caused areas in t h e housing or tubes.
by: Using t h e wrong lubricant will cause overheating
• Insufficient or incorrect lubricant and gear failure. Gear tooth cracking and bearing
• Foreign matter/water contamination spalling are indicators of this.
• Incorrect bearing preload torque adjustment Axle component breakage is most often t h e result
When serviced, t h e bearings must be cleaned thor of:
oughly. They should be dried with lint-free shop tow • Severe overloading
els. Never dry bearings w i t h c o m p r e s s e d air. • Insufficient lubricant
This will overheat them a n d brinell the bearing • Incorrect lubricant
surfaces. This will result in noisy operation after • Improperly tightened components
repair. Common causes of overloading is from full-throttle
Axle gear problem conditions are usually t h e result acceleration. Overloading occurs when towing
of: heavier t h a n normal loads. Component breakage can
• Insufficient lubrication occur when t h e wheels are spun excessively. Insuffi
• Incorrect or contaminated lubricant cient or incorrect lubricants contribute to breakage
• Overloading (excessive engine torque) through overheating. Loose differential components
• Incorrect clearance or backlash adjustment can also cause breakage.
Insufficient lubrication is usually t h e result of a Incorrect bearing preload or gear backlash will not
housing cover leak. It can also be from worn axle result in component breakage. Mis-adjustment will
produce enough noise to cause service repair before a
• RfAR SUSPENSION AND AXLE 3 - 7
failure occurs. If a mis-adjustment condition is not Tire noise will usually vary with different road
corrected, component failure can result. conditions. Tire noise is sensitive to inflation pres
sure. The pitch of tire noise changes when the vehi
REAR AXLE ALIGNMENT cle speed is varied.
Drive t h e vehicle over different road surfaces. Note
MEASUREMENT the changes in the noise. If the noise changes, the
The following procedure can be used to determine tires are the source of the noise.
if abnormal rear tire tread wear is the result of a Refer to Group 22, Wheels and Tires for additional
bent or deformed rear axle shaft. information.
(1) Raise both rear wheels off the surface with a
frame contact hoist. GEAR AND BEARING NOISE
(2) Attach a one-inch long piece of masking tape at
the center of each tire tread for use as reference GEAR NOISE
marks. Axle gear noise can be caused by insufficient lubri
(3) Rotate the rear wheels until both reference cant. Incorrect backlash, tooth contact, or worn/dam
marks face the front of the vehicle. Measure the dis aged gears can cause noise.
tance between the outside edges of the two pieces of Gear noise usually happens at a specific speed
tape. Record this measurement as the front of tire range. The range is 30 to 40 mph, or above 50 mph.
(FTR) measurement. The noise can also occur during a specific type of
(4) Rotate the rear wheels until both reference driving condition. These conditions are, acceleration,
marks face the rear of the vehicle. Measure the dis deceleration, coast, or constant load.
tance between the outside edges of the two pieces of When road testing, accelerate the vehicle to the
tape. Record this measurement as the rear of tire speed range where the noise is the greatest. Shift
(RTR) measurement. out-of-gear and coast through the peak-noise range.
(5) Subtract the (RTR) measurement from the If the noise stops or changes greatly, check for insuf
(FTR) measurement to obtain the amount of wheel ficient lubricant. Incorrect ring gear backlash, or
toe. The acceptable rear wheel toe-in position is 1/16 gear damage can cause noise changes.
inch (1.6 mm) to 3/16 inch (4.8 mm) toe-out. Differential side and pinion gears can be checked
(6) Rotate the rear wheels until the reference by turning the vehicle. They usually do not cause
marks are facing downward. Measure the distance noise in straight-ahead driving. These gears are
between the outside edges of the two pieces of tape. loaded during vehicle turns. If noise does occur dur
Record this measurement as the bottom of tire (BTR) ing vehicle turns, the side or pinion gears could be
measurement. worn or damaged. A worn pinion gear mate shaft can
(7) Average the (FTR) and the (RTR) distance also cause a snapping or a knocking noise.
measurements. Subtract the (BTR) measurement
from this average distance to obtain the camber. The BEARING NOISE
acceptable amount of camber is 1/16 inch to 3/32 inch The axle shaft, differential and pinion gear bear
(1.6 to 2.4 mm). ings can all produce noise when worn or damaged.
(FTR + RTR) D I V I D E D BY 2 (TWO) M I N U S Bearing noise can be either a whining, or a growling
BTR E Q U A L S C A M B E R sound.
If the (BTR) distance m e a s u r e m e n t is less than Pinion gear bearings have a constant-pitch noise.
This noise changes only with vehicle speed. Pinion
the average FTR and RTR distance measure
bearing noise will be higher because it rotates at a
ment, the camber will be positive ( + ). If the
faster rate. Drive the vehicle and load the differen
(BTR) distance m e a s u r e m e n t is greater than the
tial. If bearing noise occurs the pinion rear bearing is
average FTR and RTR distance, the camber will
the source of the noise. If the bearing noise is heard
be negative ( - ). during a coast, front bearing is the source.
If the toe position or camber is not acceptable, a Worn, damaged differential bearings usually pro
bent or deformed rear axle shaft is most likely the duce a low pitch noise. Differential bearing noise is
cause. similar to pinion bearing. The pitch of differential
bearing noise is also constant and varies only with
TIRE NOISE vehicle speed.
Check tires t h a t are damaged, unbalanced, incor Axle shaft bearings produce noise and vibration
rectly inflated. Tires t h a t have deep treads can emit when worn or damaged. The noise generally changes
sounds like axle noise. Differentiate between tire and when the bearings are loaded. Road test the vehicle.
axle noise during a road test. Turn the vehicle sharply to the left and to the right.
This will load the bearings and change the noise
level. Where axle bearing damage is slight, the noise • High engine idle speed
is usually not noticeable at speeds above 30 mph. • Loose engine/transmission/transfer case mounts
9 Worn U-joints
LOW SPEED KNOCK • Loose spring shackles or U-bolts
Low speed knock is generally caused by a worn • Loose pinion gear nut and yoke
U-joint or by worn side-gear thrust washers. A worn
• Excessive ring gear backlash
pinion gear shaft bore will also cause low speed
• Excessive differential side gear-to-case clearance
knock.
A w o r n bushing in the transmission extension
VIBRATION h o u s i n g c a n also c a u s e noise.
Vibration at the rear of the vehicle is usually The source of a snap or a clunk noise can be deter
caused by a: mined with the assistance of a helper. Raise the ve
• Damaged drive shaft hicle on a hoist with the wheels free to rotate.
• Missing drive shaft balance weight Instruct the helper to shift the transmission into
• Worn, out-of-balance wheel and tires gear. Listen for the noise, a mechanics stethoscope is
• Loose wheel lug nuts helpful in isolating the source of a noise.
• Worn U-joint
• Loose spring U-bolts LIMITED SLIP DIFFERENTIAL
• Loose/broken rear springs or shackles Under normal traction conditions, engine torque is
• Damaged axle shaft bearings divided evenly. With low-traction surfaces, engine
• Loose pinion gear n u t torque is transferred to the wheel with the most tire
• Excessive pinion yoke run out traction. When diagnosing a limited-slip differential
• Bent axle shaft problem condition, the wheel with the least traction
Check for loose or damaged front-end components can continue spinning.
or engine/transmission mounts. These components The most common problem is a chatter noise when
can contribute to what appears to be a rear-end vi turning corners. Check for incorrect or contaminated
bration. Do not overlook engine accessories, brackets
lubricant. Replace the gear lubricant if necessary.
and drive belts.
• With Sure-Grip differentials add a container of
All driveline components should be examined be
MOPAR® Hypoid Gear Additive
fore starting any repair.
This will correct the condition in most instances. If
Refer to Group 22, Wheels and Tires for additional
information. the chatter persists, clutch damage could have oc
curred.
DRIVELINE SNAP After changing the lubricant, drive the vehicle and
A snap or clunk noise when the vehicle is shifted make 10 to 12 slow, figure-eight turns. This maneu
into gear (or the clutch engaged), can be caused by: ver will pump lubricant through the clutches.
REAR SUSPENSION AND AXLE 3 - 9
SERVICE DIAGNOSIS
Condition Possible C a u s e Correction

WHEEL NOISE (a) Wheel loose. (a) Tighten loose nuts.
(b) Faulty, brinelled wheel bearing. (b) Faulty or brinelled bearings must be
replaced.
AXLE SHAFT NOISE (a) Misaligned axle shaft tube. (a) Inspect axle shaft tube alignment.
Correct as necessary.
(b) Bent or sprung axle shaft. (b) Replace bent or sprung axle shaft.
(c) End play in drive pinion bearings. (c) Refer to Drive Pinion Bearing Pre-Load
Adjustment.
(d) Excessive gear backlash between ring (d) Check adjustment of ring gear
gear and pinion gear. backlash and pinion gear. Correct a s
necessary.
(e) Improper adjustment of drive pinion (e) Adjust drive pinion shaft bearings.
gear shaft bearings. (f) Tighten drive pinion gearshaft yoke nut
(f) Loose drive pinion gearshaft yoke nut. with specified torque.
(g) Improper wheel bearing adjustment. (g) Readjust as necessary.
(h) Scuffed gear tooth contact surfaces. (h) If necessary, replace scuffed gears.
AXLE SHAFT BROKE (a) Misaligned axle shaft tube. (a) Replace broken axle shaft after
correcting axle shaft tube alignment.
(b) Vehicle overloaded. (b) Replace broken axle shaft. Avoid
excessive weight on vehicle.
(c) Erratic clutch operation (c) Replace broken axle shaft after
inspecting for other possible causes.
Avoid erratic use of clutch.
(d) Grabbing clutch. (d) Replace broken axle shaft. Inspect
clutch and make necessary repairs or
adjustments.
DIFFERENTIAL C A S E (a) Improper adjustment of differential (a) Replace cracked case; examine gears
CRACKED bearings. and bearings for possible damage. At
reassembly, adjust
differential bearings properly.
(b) Excessive ring gear backlash. (b) Replace cracked case; examine gears
and bearings for possible damage. At
reassembly, adjust ring gear backlash
properly.
(c) Vehicle overloaded. (c) Replace cracked case; examine gears
and bearings for possible damage.
Avoid excessive weight on vehicle.
(d) Erratic clutch operation. (d) Replace cracked case. After inspecting
for other possible causes, examine
gears and bearings for possible
damage. Avoid erratic use of clutch.
DIFFERENTIAL G E A R S (a) Insufficient lubrication. (a) Replace scored gears. Scoring marks
SCORED on the drive face of gear teeth or in
the bore are caused by instantaneous
fusing of the mating surfaces. Scored
gears should be replaced. Fill rear
differential housing to required capacity
with proper lubricant. Refer to
Specifications.
(b) Improper grade of lubricant. (b) Replace scored gears. Inspect all
gears and bearings for possible
damage. Clean and refill differential
housing to required capacity with
proper lubricant.
(c) Excessive spinning of one wheel/tire. (c) Replace scored gears. Inspect all
gears, pinion bores and shaft for
damage. Service as necessary.
L O S S OF LUBRICANT (a) Lubricant level too high. (a) Drain excess lubricant by removing fill
plug and allow lubricant to level at
lower edge of fill plug hole.
J9003-49
3-10 REAR SUSPENSION AND AXLE
SERVICE DIAGNOSIS (CONT'D)
Condition Possible Cause Correction

(b) Worn axle shaft seals. (b) Replace worn seals.
(c) Repair or replace housing as
(c) Cracked differential housing. necessary.
(d) Replace worn drive pinion gear shaft
(d) Worn drive pinion gear shaft seal. seal.
(e) Replace worn or scored yoke and seal.
(e) Scored and worn yoke. (f) Remove cover and clean flange and
(f) Axle cover not properly sealed. reseal.
A X L E OVERHEATING (a) Lubricant level too low. (a) Refill differential housing.
(b) Incorrect grade of lubricant. (b) Drain, flush and refill with correct
amount of the correct lubricant.
(c) Bearings adjusted too tight. (c) Readjust bearings.
(d) Excessive gear wear. (d) Inspect gears for excessive wear or
scoring. Replace as necessary.
(e) Insufficient ring gear backlash, (e) Readjust ring gear backlash and
inspect gears for possible scoring.
GEAR TEETH BROKE (a) Overloading. (a) Replace gears. Examine other gears
(RING G E A R A N D and bearings for possible damage.
PINION) Replace parts as needed. Avoid
overloading of vehicle.
(b) Erratic clutch operation. (b) Replace gears and examine the
remaining parts for possible damage.
Avoid erratic clutch operation.
(c) Ice-spotted pavements. (c) Replace gears. Examine the remaining
parts for possible damage. Replace
parts as required.
(d) Improper adjustments. (d) Replace gears. Examine other parts for
possible damage. Ensure ring gear
backlash is correct.
AXLE NOISE (a) Insufficient lubricant. (a) Refill axle with correct amount of the
proper lubricant. Also inspect for leaks
and correct as necessary.
(b) Improper ring gear and drive pinion (b) Check ring gear and pinion gear teeth
gear adjustment. contact pattern.
(c) Unmatched ring gear and drive
pinion gear. (c) Remove unmatched ring gear and
drive pinion gear. Replace with
matched gear and drive pinion gear
set.
(d) Worn teeth on ring gear or drive (d) Check teeth on ring gear and drive pi
pinion gear. nion gear for correct contact.
If necessary, replace with new
matched set.
(e) Loose drive pinion gear shaft bearings. (e) Adjust drive pinion gearshaft bearing
preload torque.
(f) Loose differential bearings. (f) Adjust differential bearing preload
torque.
(g) Misaligned or sprung ring gear. (g) Measure ring gear runout.
(h) Loose differential bearing cap bolts. (h) Tighten with specified torque.
J9003-50
8 3/8 and 9 1/4 AXLE
INDEX
page page
Axle Shaft, Seal and Bearing Service . . . . . . . . . 11 Lubricant 11
Complete Axle Removal/Installation 16 Pinion Depth Measurement and Adjustment with
Differential Service 16 Gauge Set 20
Information 11 Pinion Seal Replacement 14
INFORMATION Install the housing c o v e r within 5 minutes af

The 8 3/8 and 9 1/4 axle (Fig. 1) housing consist of t e r applying the sealant. If not installed, the
a cast iron center section. They also have two steel sealant m u s t be r e m o v e d a n d another b e a d ap
axle shaft tubes t h a t are pressed into and welded to plied.
the differential housing. (7) Install the cover on t h e differential. Install the
#
The removable, stamped steel cover provides a identification tag. Tighten the cover bolts to 47 N m
means for inspection and service without removing (35 ft. lbs.) torque.
the complete axle from the vehicle.
LUBRICANT the lubricant foaming and overheating.
Multi-purpose, hypoid gear lubricant should be
(8) Refill the differential with the specified quan
used for 8 3/8 and 9 1/4 axles. The lubricant should tity of MOPAR® Hypoid Gear Lubricant. With Sure-
have MIL-L-2105C and API GL 5 quality specifica Grip differentials, add a container of MOPAR®
tions. MOPAR® Hypoid Gear Lubricant conforms to Hypoid Gear Lubricant Additive.
both of these specifications. (9) Install the fill hole plug.
Refer to Group 0, Lubrication and Maintenance for (10) Road test the vehicle.
additional information.
AXLE SHAFT, SEAL AND BEARING SERVICE
C A U T I O N : If a rear axle is submerged in water, the
axle lubricant must be replaced immediately. C A U T I O N : When rear axle service is necessary,
both rear wheels must be raised off the surface s o
that they are free to rotate. B e cautious when the
DRAIN AND REFILL tires are being rotated by the engine or by other
(1) Drive the vehicle until the gear lubricant means.
reaches normal operating temperature.
(3) Remove the lubricant fill hole plug from the C A U T I O N : If equipped with a Sure-Grip differential,
differential housing cover. do not rotate either axle shaft unless both are prop
(4) Remove the differential housing cover. Allow erly in-place. Rotation of one axle shaft without the
the original lubricant to completely drain from the other being installed can result in misalignment of
housing and axle shaft tubes. the side gears/splines. This will necessitate side
(5) With standard differential, clean the differen gear re-alignment before the axle shaft can be in
stalled.
tial and t h e housing cavity with a flushing oil (or
light engine oil). This will remove the residual lubri
cant and foreign matter.Do not use water, steam, AXLE SHAFT REMOVAL
kerosene or gasoline for flushing. (1) Raise and support the vehicle.
(2) Remove the wheel.
C A U T I O N : D O N O T F L U S H Sure-Grip differentials. (3) Remove the brake drum.
Sure-Grip differentials may be cleaned only by wip (4) Clean all the foreign material from housing
ing with clean, lint-free cloths. cover area.
(5) Loosen the housing cover bolts. Drain the lubri
(6) Scrape the residual sealant from the housing cant from the housing. Remove the housing cover.
and cover mating surfaces. Clean the mating sur (6) Rotate the differential case so the pinion mate
faces with mineral spirits. Apply a bead of MOPAR® gear shaft lock screw is accessible. Remove the lock
Silicone Rubber Sealant on the housing cover (Fig. screw and the pinion mate gear shaft from the case
2). Allow the sealant to c u r e for a few m i n u t e s . (Fig. 3).
HUB AXLE DIFFERENTIAL
SHAFT HOUSING
FRONT
BEARING
VENT
FITTING
NUT
SEAL
AXLE AXLE
SHAFT SHAFT
BEARING TUBE
BEARING
CAP
STUD
WASHER
LOCK
BOLT
DIFFERENTIAL
BEARING BEARING
CUP
SIDE
GEAR
CLIP ADJUSTER
LOCK
COVER
BOLT
HOUSING
BOLT J9003-109
PLUG COVER
Fig. 1 8 3/8-Inch Or 9 1/4-Inch Axle

SEALANT ADJUSTER , SIDE AXLE

1/16-TO LOCK ^ GEAR SHAFT •!
3/32-INCH
(1.59-TO
38-AAM)
THICK BEAD
DIFFERENTIAL
HOUSING
COVER C-CLIP
(TYPICAL) J9003-85 LOCK J9003-111
Fig, 2 Sealant On Homing Cower Fig. 4 Axle Shaft C-Clip Lock

PINION (10) If any of these conditions exist, the axle shaft
GEAR and bearing must be replaced.
MATE
SHAFT The normal a p p e a r a n c e will be a dull gray
surface that could appear slightly dented.
AXLE SHAFT SEAL AND BEARING REMOVAL

(1) Remove the axle shaft seal with a small pry
bar.
(2) Remove the bearing if it appears damaged or
the axle shaft shows any of the conditions described
above.
(3) Remove the axle shaft bearing.
• 8 3/8-inch diameter (Fig. 5), use Remover C-4167
and Slide H a m m e r C-637
• 9 1/4-inch diameter (Fig. 6), use Remover C-4828
SPECIAL TOOL SPECIAL TOOL
C-637 C-4167
O LOCK
DIFFERENTIAL SCREW
CASE J9003-110
Fig. 3 Pinion Mate Shaft Lock Screw

(7) Push the axle shaft in toward the center of the
vehicle. Remove the axle shaft C-clip lock from the
axle shaft (Fig. 4). AXLE
(8) Remove the axle shaft. Use care to prevent SHAFT
damage to the axle shaft bearing. TU1E
(9) Inspect the axle shaft bearing contact surface
area for indications of wear. J9103-11
i f w e a r exists, the a x l e s h a f t a n d b e a r i n g
should b e r e p l a c e d . N o r m a l b e a r i n g c o n t a c t o n Fig. 5 Bearing Removal (8 3/8-Axle)
t h e shaft w i l l b e a d u l l g r a y a n d it c o u l d a p p e a r
to b e lightly d e n t e d .
3 - 18 REAR SUSPENSION
3 - 14 REAR SUSPENSION AND AXLE
(5) When the tool cont (13) Install the brake drums.
(14) Install the wheels. Lower
(face), the seal will be a
(15) Adjust hoist so vehicle k
depth.
Check the differential housing h
AXLE SHAFT INSTALL* essary, add sufficient amount.
(1) Lubricate the bearin
the axle shaft and engage COMPLETE AXLE REMOVAL/IN!
gear. Use care to prevei It is not necessary to remov
damaging the axle shaft from the vehicle for routine or d
(2) Insert the C-clip loi the differential housing or axle
(Fig. 4). Push the axle s aged, the complete axle can 1
C-clip lock. stalled.
(3) Insert the pinion ge REMOVAL
Install through the thrust (1) Raise the vehicle to a <
Align the hole in the shaf height t h a t will permit support t
Install the lock screw wit at the front of the rear springs.
s
Fig. 6 Bearing Removal (9 1/4-Axle) Tighten the screw to 11 I (2) Block the brake pedal in tl
3). position with a wooden block.
(4) Inspect the axle shaft tube bore for roughness
(4) Clean the cover anc (3) Remove the rear wheels. '.
and burrs. Remove as necessary.
Refer to the Drain and Re brake drum retaining clips oi
C A U T I O N : Inspect the housing bore for burrs. Re (5) Install the brake drv (4) Disconnect the brake flui
move a s necessary. (6) Install the wheel an the wheel cylinders. Cap the fit
Tire Installation within th of brake fluid.
cle. (5) Remove the vent hose froi
BEARING AND SEAL INSTALLATION (7) Raise or lower the pie.
A l w a y s install a n e w seal. level. (6) Remove the brake tee be
(1) Wipe the bore in the axle shaft tube clean. (8) Remove the fill hole the brake fluid tubes from the c
(2) If the original bearing is not reusable, install a housing with lubricant. I (7) Disconnect the parking bn
new bearing. chart for the type and t h U-joint, pinion yoke, and pinion
• 8 3/8-Axle use Installer C-4198 with Handle hole plug. Mark the U-joint, pinion y o l
C-4171 for reference.
(9) Lower the vehicle. T
• 9 1/4-Axle use Installer C-4826 with Handle (8) Disconnect the drive she
correct operation.
C-4171 yoke. Secure the drive shaft in a
prevent damage to the rear U-jc
PINION SEAL REPLACE!!
C A U T I O N : D O N O T use the new axle shaft seal to (9) Remove the shock absorl
position or seat the bearing in the axle shaft bore. C A U T I O N : The following nuts and bolts. Remove the reai
s o the correct pinion bea the U-bolts and the spring brad
(3) Insert the bearing into the tube. Ensure t h a t tained. If not completely f (10) Remove the complete axL
the bearing is not cocked and is seated firmly against failure of the rear axle.
(11) Wash and clean the outei
the tube shoulder. ing and tubes. Use an appropri;
(4) Install the new axle shaft seal (Fig. 7). and dry the surface with comprc
• 8 3/8-Axle use Installer C-4203 and Handle C-4171 REMOVAL
(1) Raise and support tr INSTALLATION
• 9 1/4-Axle use Installer C-4826 and Handle C-4171
(2) Mark the U-joint, pi] (1) Position the rear axle sj
for reference. spring center bolts.
(3) Disconnect the drh (2) Install the spring U-bolts
absorber lower bolts. Tighten tl
yoke. Secure the drive sha
fled torque.
prevent damage to the re*
(3) Connect the parking brake
(4) Remove the rear w
(4) Connect the brake fluid
drums to prevent any dr
wheel cylinders. Bleed and adjui
false bearing preload torq (5) Align the installation refer
(5) Use a Newton-mete the drive shaft yoke to the pinii
wrench to measure the p U-joint clamp bolts to 19-23 N
t a t e the pinion shaft sev( torque.
wrench. Note the indicate (6) Install the rear wheels. Ti|
Fig. 7 Axle Shaft Seal Installation
moved through several re' correct tightening sequence.
REAR SUSPENSION A N i AXLE 3 - 17
(3) Eliminate any side play in the differential case.

Attach Dial Indicator to Pilot stud C-3288-B. Place
the indicator plunger at a right angle (90°) to the
ring gear (Fig. 11). The plunger should exert a slight
force against the gear face.
DIAL
INDICATOR
Fig. 12 Housing & Caps Marked For Installation

Reference
Fig. 11 Ring Gear Runout Measurement

(4) Measure the runout by turning the ring gear
several complete revolutions. Observe the dial indica
tor pointer. Mark the ring gear and the differential
case at the areas of maximum runout. The ring gear
runout should not exceed 0.005 inch (0.13 mm). If the
runout exceeds 0.005 inch (0.13 mm), a damaged dif
Fig. 13 Threaded Adjuster Tool
ferential case could be t h e cause.
The marking on the differential c a s e will b e
very useful later during the differential c a s e
runout. R e m o v e the rear w h e e l anti-lock
(RWAL) sensor.
(5) Mark the differential housing and the differen
tial bearing caps for installation reference (Fig. 12).
(6) Remove the bearing threaded adjuster lock
from each bearing cap. Loosen the bolts, but do not
remove the bearing caps.
(7) Loosen the threaded adjusters with Wrench
C-4164 (Fig. 13).
(8) Hold the differential case in place. Remove the
bearing caps (Fig. 14), adjusters and the differential
case.
E a c h differential b e a r i n g c u p and threaded
adjuster must b e kept w i t h their respective bear
ing.
PINION GEAR SHAFT REMOVAL Fig. 14 Differential Bearing Cap Removed

(1) Remove the pinion gear n u t and washer. Use (2) Use Puller C-748 to remove the pinion seal.
Puller C-452 and Wrench C-3281 to remove the pin Discard the seal.
ion gear yoke. (3) Force the pinion gear out the front bearing to
3-18 REAR SUSPENSION AND AXLE •
remove the shaft and front bearing. T h i s will d a m
a g e t h e front b e a r i n g r o l l e r s a n d b e a r i n g c u p .
T h e front b e a r i n g a n d c u p m u s t b e r e p l a c e d .
Discard the bearing collapsible spacer.
(4) Remove the front and rear bearing cups with
Remover C-4306 and Handle C-4171.
(5) Remove the rear bearing from the pinion shaft
with Puller C-293-PA and Adapter (Fig. 15). Remove
and record the pinion gear depth shims.
• 8 3/8 use Adapter C-293-42
• 9 1/4 use Adapter C-293-37
SPECIAL
TOOL
C-293-PA
Fig. 16 Case Flange Runout Measurement

(4) Rotate the differential case several times. Ob
serve the dial indicator pointer. Mark the area of
maximum flange runout. The differential case flange
runout must not exceed 0.003 inch (0.08 mm). If the
runout exceeds the amount replace the differential
case.
You c a n r e d u c e e x c e s s i v e r i n g g e a r r u n o u t b y
p o s i t i o n i n g t h e r i n g g e a r r u n o u t m a r k 180 de
g r e e s o p p o s i t e t h e flange r u n o u t m a r k .
(5) Remove the differential bearing cap bolts. Re
move the differential case from the differential hous
ing.
DIFFERENTIAL CASE DISASSEMBLY

(1) Rotate the side gears until the pinion gears are
located at the differential case opening and remove
Fig. 15 Inner Bearing Removal them.
RING GEAR (2) Remove the side gears and the thrust washers.
D o n o t r e m o v e t h e r i n g g e a r from c a s e u n l e s s (3) Remove the differential bearings from the case
the runout must be measured. hubs with Puller C-293-PA, Adapter (Fig. 17).
(1) Clamp the case (with the ring gear bolts facing • 8 3/8 use Adapter C-293-48 and Plug SP-3289
upward). Use a vise equipped with soft jaws (brass). • 8 1/4 use Adapter C-293-48 and Plug C-293-3
(2) Remove and discard the ring gear bolts. T h e CLEANING AND INSPECTION
b o l t s h a v e left-hand t h r e a d s . Use a h a m m e r and a (1) Clean all of the differential components in
brass drift to force the ring gear loose from the case cleaning solvent. Allow the bearings to either air dry
pilots. Remove the ring gear. or dry them with a lint-free cloth. Dry the other com
ponents with compressed air.
CASE FLANGE RUNOUT MEASUREMENT (2) Examine each component for wear or damage.
(1) If the ring gear runout exceeded 0.005 inch (3) Replace shims, bearings and cups as a set only.
(0.13 mm), case flange runout should also be mea Replace bearings and cups if either is galled, worn,
sured. Install the case with the bearing cups and the cracked, or damaged.
threaded adjusters close to their original position. (4) Inspect the differential side and pinion gears.
(2) Install the bearing caps and bolts. Tighten the Replace any gear t h a t is worn, cracked or chipped.
bolts lightly. Use Wrench C-4164 (Fig. 12) to thread (5) Inspect the differential case. Replace the case if
both adjusters inward. Remove all side play. cracked or damaged.
(3) Attach Dial Indicator to measure the flange P o l i s h e a c h a x l e shaft w i t h No. 600 c r o c u s
runout. The plunger should contact the ring squarely cloth. T h i s c a n r e m o v e slight s u r f a c e d a m a g e .
between the outer edge and the gear attaching bolt Do n o t r e d u c e t h e d i a m e t e r of t h e axle shaft seal
holes (Fig. 16). contact surface. When polishing, the crocus
ADAPTERS (2) Place the thrust washers on the differential

side gears. Position the gears in the differential case
counterbores.
If r e p l a c e m e n t side g e a r s o r t h r u s t w a s h e r s
a r e u s e d , r e f e r to Differential Side G e a r Clear
ance Measurement And Adjustment.
(3) Position the thrust washers on the differential
pinion gears. Mesh the pinion gears with the side
gears. E n s u r e t h a t t h e p i n i o n g e a r s a r e e x a c t l y
180 d e g r e e s o p p o s i t e e a c h o t h e r .
(4) Rotate t h e side gears to align the pinion gears
and thrust washers. Align these components with the
mate shaft bores in the case.
(5) If the ring gear was removed, clean all contact
surfaces. Use an Arkansas stone or fine file to re
move any sharp areas from t h e chamfered inside di
ameter.
(6) If removed, heat ring gear with a heat lamp or
by immersing in a hot fluid. The temperature should
not exceed 149°C (300°F). D o n o t u s e a t o r c h t o
heat the ring.
(7) Position heated gear on case. Use two equally
spaced Pilot Studs C-3288-B to align the gear with
t h e flange holes (Fig. 18).
Fig. 17 Differential Bearing Removal

cloth s h o u l d b e m o v e d a r o u n d t h e circumfer
e n c e of t h e shaft (not in-line w i t h t h e shaft).
When replacing a drive pinion gear bearing,
always replace the bearing and cup as a
m a t c h e d set only.
(6) Inspect the axle shaft C-clip locks for cracks
and excessive wear. Replace them if necessary.
(7) Test each threaded adjuster to determine if it
rotates freely.
(8) If an adjuster binds, repair the damaged
J9203-24
threads or replace the adjuster.
EXCITER RING REPLACEMENT Fig. 18 Case-To-Ring Gear Alignment

The ring gear must be removed before the RWAL (8) Install replacement ring gear bolts (with left
brake exciter ring can be replaced. hand threads). Alternately and evenly tighten each
(1) Remove exciter ring with a hammer and drift. bolt to 95 N-m (70 ft. lbs.) torque.
(2) Heat the replacement exciter ring with a heat
lamp or by immersing in a hot fluid. The tempera C A U T I O N : When installing a differential bearing,
ture should not exceed 149°C (300°F). Do n o t u s e a never apply force to the bearing c a g e because bear
torch to h e a t the ring. ing damage will result.
(3) After heating, quickly position the exciter ring
on the differential case adjacent to the flange. (9) Place a differential bearing on each hub (Fig.
19).
DIFFERENTIAL CASE ASSEMBLY • 8 3/8, use Installer C-4340 and Handle C-4171
(1) Lubricate all the differential case components • 9 1/4, use Installer C-4213 and Handle C-4171
with gear lubricant.
• Install Spacer (SP-6022)
• Install Sleeve (SP-3194-B), Washer (SP-534) and
Nut (SP-3193)
9 1/4 a x l e s a s s e m b l e C-758-D6 Tool Set a s d e
s c r i b e d (Fig. 21);
SPECIAL TOOL
C-4171 SPECIAL TOOL
C-758-D6 SP-6018
SPECIAL TOOL
8-3/8- C-4340
9.1/4- C-4213
J9203-33

PINION DEPTH MEASUREMENT AND ADJUSTMENT SP-536-*-<S^
WITH GAUGE SET
(1) Use pinion gear adjustment gauge set and con Fig. 21 9 1/4 Axle Pinion Adjustment Tools
tinue the assembly:
• Position Spacer (SP-6017) over Shaft (SP-526)
• 8 3/8, use C-3715-B (Fig. 20)
• 9 1/4, use C-758-D6 (Fig. 21)
(2) Install front (outer) bearing cup use Installer
D-130 and Handle C-4171.
(3) Install rear (inner) bearing cup.
• Install Spacer (SP-6022)
• 8 3/8 axles, use Installer C-4308 and Handle
• Install Sleeve (SP-535-A), Washer (SP-534) and
C-4171
Nut (SP-533)
• 9 1/4 axles, use Installer C-4310 and Handle
C-4171
with Wrench C-3281.
8 3/8 axles a s s e m b l e C-3715-B Tool Set as d e
scribed (Fig. 20); Tighten the n u t to seat the pinion bearings in the
housing (Fig. 22). Allow the sleeve to t u r n several
SPECIAL TOOL SET times during the tightening to prevent brinelling the
G3715-B
bearing cups or the bearings.
SP-6030
Depth shim(s) are positioned b e t w e e n the pin
ion gear rear bearing and pinion gear to provide
the separation distance. The required thickness
of the depth shim(s) is determined according to
the following information.
(5) Loosen the compression n u t tool. Lubricate the
pinion gear front and rear bearings with gear lubri
cant. Re-tighten the compression n u t tool to 1-3 N*m
(15-25 in. lbs.) torque. Rotate the pinion gear several
complete revolutions to align the bearing rollers.
(6) Install Gauge Block.
• 8 3/8 axles (Fig. 20)
SP-536— SP-531 J9203-51
• Install Gauge Block SP-5383 at the end of SP-5385
Fig. 20 8 3/8 Axle Pinion Adjustment Tools • Install Cap Screw (SP-536) and tighten with
Wrench SP-531
• Position Spacer (SP-6030) over Shaft (SP-5385) • 9 1/4 axles (Fig. 21)
SPACER

Fig. 22 Seating Pinion Bearings Fig. 23 Depth Shim(s) Selection
• Install Gauge Block SP-6020 at the end of SP-526 D e p t h shims are available in 0.001-inch incre
• Install Cap Screw (SP-536) and tighten with ments from 0.020 inch to 0.038 inch.
Wrench SP-531 (10) Note the etched number on the face of the
(7) Position Crossbore Arbor in the differential drive pinion gear (e.g., -0, - 1 , -2, + 1 , + 2 , etc.). The
housing. numbers represent thousands-of-an-inch deviation
• 8 3/8 (Fig. 20); (SP-6029) from the standard. If the number is - (negative), add
• 9 1/4 (Fig. 21); (SP-6018) t h a t value to the required thickness of the depth
(8) Center the tool. Place a piece of 0.002 inch shim(s). If the number is + (positive), subtract t h a t
shim stock at each end of the arbor. Position the value from the thickness of the depth shim(s). If the
bearing caps on the arbor tool. Install the attaching number is 0, no change is necessary.
bolts. Tighten the cap bolts to 14 N*m (10 ft. lbs.) (11) Remove the tools from the differential hous
torque. ing.
(9) Trial fit depth shim(s) between the crossbore (12) Position the depth shim(s) on the pinion gear.
arbor and gauge block (Fig. 23). The depth shim(s) Install the rear bearing (Fig. 24). Be sure the contact
fit must be s n u g but not tight (drag friction of a surfaces are clean and without foreign particles.
feeler g a u g e blade). • 8 3/8 axles use Installer C-4040
Replacement Pinion Gear Depth Variance

Original Pinion
Gear Depth -4 -3 -2 -1 0 +1 +2 +3 +4
Variance
+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 -0001 -0.002 -0.003 -0.004 -0.005
-2 + 0.002 + 0,001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006
- 3 + 0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007
-4 0 - 0.001 -0.002 -0.003 -0.004 -0.005 -0,006 -0.007 -0.008

J8902-46
3 - 22 REAR SUSPENSION AND AXLE 4
• 9 1/4 axles use Installer C-3095 SPECIAL DIFFERENTIAL

TOOL HOUSING
J9103-21

Fig. 24 Shaft Rear Bearing Installation
(13) Lubricate the pinion gear front and rear bear
ings with gear lubricant.
(14) Install the pinion gear in the housing. Install
the new collapsible spacer at the end of the pinion
gear. Install the pinion gear front bearing.
(15) Install the pinion yoke with Remover/Installer
It is n e c e s s a r y to u s e the tools (above) to cor
rectly seat the front bearing o n the drive pinion
gear shaft (Fig. 25).
C A U T I O N : U s e care to prevent collapsing preload

collapsible spacer during installation of the yoke
and seating the front bearing.
Fig. 26 Pinion Gear Seal Installation
(16) Remove yoke and tools from the pinion gear.
(17) Install the new pinion gear shaft seal (Fig. (20) Retain pinion yoke with Wrench C-3281. Ini
26). tially tighten the drive pinion gear shaft n u t enough
• 8 3/8-inch diameter use Seal Installer C-4076-A to remove the bearing end play. While tightening, ro
and Handle C-4735-1 tate the pinion shaft to ensure the bearing rollers are
• 9 1/4-inch diameter use Seal Installer C-3980-A or correctly seated.
C-4109-A and Handle C-4735 (21) Tighten the pinion nut to (Fig. 27) 285 N*m
The seal is correctly installed w h e n the seal (210 ft. lbs.) torque (minimum).
flange contacts the face of the differential hous (22) Remove the tools from the shaft. Rotate the
ing flange. pinion several complete revolutions (both directions)
The outer perimeter of the seal is pre-coated to additionally seat the bearing rollers.
with a special sealant. A n additional application
of sealant is not required. C A U T I O N : Never loosen the pinion gear nut to de
(18) Install the pinion yoke with Remover/Installer crease the pinion gear bearing preload torque. If the
C-3718 and Wrench C-3281. specified preload torque is exceeded, a replacement
(19) Remove the tools. Install the Belleville collapsible spacer must be installed. The torque s e
washer. The convex side of the washer must face out quence will have to be repeated.
ward. Install the pinion nut.
rotation of the shaft, there is an internal binding

that must b e corrected before final assembly.
(24) If t h e specified torque is not obtained, tighten
the nut in small increments until the preload torque
is obtained.
The differential will be unacceptable for use if
the final nut torque is less than 285 N-m (210 ft.
lbs.) torque. If the preload torque is not within
the specified range this is also unacceptable.
DIFFERENTIAL CASE INSTALLATION

(1) Apply a coating of hypoid gear lubricant to the
differential bearings, bearing cups and threaded ad
justers. A dab of grease can be used to keep the ad
justers in position. Carefully position the assembled
differential case in the housing.
(2) Observe the reference marks and install the
differential bearing caps at their original locations
(Fig. 29).
Fig. 27 Tightening Pinion Gear Nut

(23) Measure the pinion bearing preload torque by
rotating pinion shaft with a Newton-meter or an
inch-pound torque wrench. The correct bearing pre
load torque is 2-4 N-m (20-30 in. lbs.). This torque
value is with replacement bearings and pinion nut
tightened to a minimum of 285 N-m (210 ft. lbs.)
torque (Fig. 28).
When using original pinion rear bearing and a
replacement front bearing. The correct preload
torque is 1 N-m (10 in. lbs.) torque in addition to
the torque m e a s u r e d a n d recorded during disas
sembly.
Fig. 29 Bearing Caps & Bolts
(3) Install the bearing cap bolts (Fig. 29). Tighten
the upper bolts to 14 N-m (10 ft. lbs.) torque. Tighten
the lower bolts finger-tight until the bolt head is
lightly seated.
DIFFERENTIAL BEARING PRELOAD AND RING

GEAR BACKLASH ADJUSTMENT
The following must be considered when adjusting
bearing preload and gear backlash:
• The maximum ring gear backlash variation is
0.003 inch (0.076 mm)
• Mark the gears so the same teeth are meshed dur
ing all backlash measurements
• Maintain the torque while adjusting the bearing
Fig. 28 Bearing Preload Torque Measurement preload and ring gear backlash
• Excessive adjuster torque will introduce a high
The bearing preload torque should be constant bearing load and cause premature bearing failure.
during a complete revolution of the drive pinion Insufficient adjuster torque can result in excessive
gear shaft. If the preload torque varies during differential case free-play and ring gear noise
• Insufficient adjuster torque will not support the
ring gear correctly and can cause excessive differen
tial case free-play and ring gear noise
T h e differential b e a r i n g c u p s will n o t a l w a y s
i m m e d i a t e l y follow t h e t h r e a d e d a d j u s t e r s a s
they are moved during adjustment. E n s u r e accu
rate bearing cup responses to the adjustments.
M a i n t a i n t h e g e a r t e e t h e n g a g e d (meshed) a s
marked. The bearings must be seated by rapidly
rotating the pinion gear a half t u r n b a c k a n d
forth. D o t h i s five t o t e n t i m e s e a c h t i m e t h e
threaded adjusters are adjusted.
(1) Use Wrench C-4164 to adjust each threaded ad
juster inward (Fig. 30). Adjust until the differential
bearing free-play is eliminated. Allow some ring gear
backlash (approximately 0.01 inch/0.25 mm) between
the ring and pinion gear. Seat the bearing cups with Fig. 31 Ring Gear Backlash Measurement
the procedure described above. Continue to tighten the right-side adjuster and seat
bearing cups until the torque remains constant at
102 N-m (75 ft. lbs.)
(7) Measure the ring gear backlash. The range of
backlash is 0.006 to 0.008 inch (0.15 to 0.203 mm).
Continue increasing the torque at the right-side
threaded adjuster until the specified backlash is ob
tained.
T h e left-side t h r e a d e d a d j u s t e r t o r q u e s h o u l d
h a v e a p p r o x i m a t e l y 102 N-m (75 ft. lbs.) t o r q u e .
If t h e t o r q u e is c o n s i d e r a b l y less, t h e c o m p l e t e
adjustment procedure must be repeated.
(8) Tighten the left-side threaded adjuster until
102 N-m (75 ft. lbs.) torque is indicated. Seat the
bearing rollers with the procedure described above.
Do this until the torque remains constant.
(9) Install the threaded adjuster locks . Ensure the
Fig. 30 Threaded Adjuster Tool lock finger is engaged with the adjuster hole.
(2) Install Dial Indicator (Fig. 31). Position the Tighten the lock screws to 10 N-m (90 in. lbs.)
plunger against the drive side of a ring gear tooth. torque.
Measure the backlash at 4 positions (90 degrees
SIDE GEAR CLEARANCE MEASUREMENT AND
apart) around the ring gear. Locate and mark the
ADJUSTMENT
area of minimum backlash. When measuring side gear clearance, check each
(3) Rotate the ring gear to the position of the least gear independently. If it necessary to replace a side
backlash. Mark the gear so t h a t all future backlash gear, replace both gears as a matched set.
measurements will be taken with the same gear (1) Install the axle shafts and C-clip locks and pin
teeth meshed. ion mate shaft. If necessary, refer to the installation
(4) Loosen the right-side, tighten the left-side located within this group.
threaded adjuster. Obtain backlash of 0.003 to 0.004 (2) Measure each side gear clearance. Insert a
inch (0.076 to 0.102 mm) with each adjuster tight matched pair of feeler gauge blades between the gear
ened to 14 N-m (10 ft. lbs.) torque. Seat the bearing and differential housing on opposite sides of the hub
cups with the procedure described above. (Fig. 32).
(5) Tighten the differential bearing cap bolts; (3) If side gear clearances is no more t h a n 0,005
• 8 3/8 axles to 95 N-m (70 ft. lbs.) torque inch. Determine if the shaft is contacting the pinion
• 9 1/4 axles to 136 N-m (100 ft. lbs.) torque gear mate shaft. D o n o t r e m o v e t h e feeler g a u g e s ,
(6) Use Wrench C-4164 to tighten the right-side i n s p e c t t h e axle shaft w i t h t h e feeler g a u g e in
threaded adjuster to 102 N-m (75 ft. lbs.) torque. Seat s e r t e d b e h i n d t h e s i d e g e a r . If the end of the axle
the bearing cups with the procedure described above. shaft is not contacting the pinion gear mate shaft,
the side gear clearance is acceptable.
REAR SUSPENSION AND AXLE 3 - 2§
measure t h e t h r u s t washer thickness. Record the

thickness and re-install t h e thrust washer. Assemble
the differential case without the C-clip lock installed
and re-measure t h e side gear clearance.
(6) Compare both clearance measurements. If the
difference is less than 0,012 inch (0.305 mm), add
clearance recorded when the C-clip lock was installed
to thrust washer thickness measured. The sum will
determine the required thickness of the replacement
thrust washer.
(7) If clearance is 0.012 inch (0.305 mm) or
greater, both side gears must be replaced (matched
set) and t h e clearance measurements repeated.
(8) If clearance (above) continues to be 0.012 inch
(0.305 mm) or greater, t h e case must be replaced.
Fig. 32 Side Gear Clearance Measurement RING GEAR TEETH CONTACT PATTERN
ANALYSIS
(4) If clearance is more t h a n 0.005 inch (axle shaft
The ring gear teeth contact patterns will show if
not contacting mate shaft), record the side gear clear the pinion gear depth shim(s) have t h e correct thick
ance. Remove the thrust washer and measure its ness. It will also show if the ring gear backlash h a s
thickness with a micrometer. Add t h e washer thick been adjusted correctly. The backlash must be main
ness to the recorded side gear clearance. The sum of tained within the specified limits until the correct
gear clearance and washer thickness will determine teeth contact patterns are obtained.
required thickness of replacement thrust washer • Excessive backlash is corrected by moving the ring
(Fig. 33). gear teeth closer to the pinion gear teeth
• Insufficient backlash is corrected by moving the
SIDE GEAR CLEARANCE 0.007
THRUST WASHER THICKNESS + 0.033
ring gear away from the pinion gear
TOTAL 0.040 (1) Apply yellow ferrous (iron) oxide compound to
I ^ ^ 0.040
both drive and coast sides of ring gear teeth.
REPLACEMENT WASHER THICKNESS - 0.037 (2) Rotate the ring gear one complete revolution in
NEW SIDE GEAR CLEARANCE 0.003 both directions.
J9203-31 (3) Note patterns in compound. Refer to (Fig. 34)
Fig. 33 Side Gear Calculations
cordingly.
In some cases, the end of the axle shaft will move (4) Install t h e axle shafts. Refer to Axle Shaft In
and contact the mate shaft when the feeler gauge is stallation within this group.
inserted. The C-clip lock is preventing the side gear (5) Install t h e housing cover. Refill the differential
from sliding on the axle shaft. with lubricant. Refer to Axle Shaft Installation.
(5) If there is no side gear clearance, remove the (6) Install the RWAL brake speed sensor and cover
C-clip lock from t h e axle shaft. Use a micrometer to onto the axle housing. Tighten the sensor to 24 N*m
DRIVE SIDE C O A S T SIDE

OF RING O F RING
DESIRABLE C O N T A C T PATTERN.
PATTERN S H O U L D BE CENTERED
O N THE DRIVE SIDE O F T O O T H .
HEEL TOE TOE HEEL PATTERN S H O U L D BE CENTERED O N
THE COAST SIDE O F T O O T H ,
BUT M A Y BE SLIGHTLY T O W A R D
THE TOE. THERE S H O U L D ALWAYS
C O N T A C T PATTERN A N D T O P O F
THE T O O T H .
R I N G GEAR BACKLASH CORRECT.

T H I N N E R P I N I O N GEAR DEPTH
S H I M REQUIRED.
R I N G GEAR BACKLASH CORRECT.

THICKER P I N I O N GEAR DEPTH
S H I M REQUIRED.
P I N I O N GEAR DEPTH S H I M
CORRECT. DECREASE R I N G
GEAR BACKLASH.
P I N I O N GEAR DEPTH S H I M
CORRECT. I N C R E A S E R I N G
GEAR BACKLASH.
J9003-24

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

3.55:1. .......39/11
3.90:1.............. 39/10
S U R E - G R I P DIFFERENTIAL SERVICE
GENERAL INFORMATION desirable and normal function of a differential. A
The Sure-Grip differential is an option available in Sure-Grip differential transfers additional engine
the 8 1/4 and 9 1/4 inch rear axles (Fig. 1). torque to the rear wheel t h a t h a s t h e better traction
surface. The Sure-Grip differential allows the driving
EXCITER RING
RING GEAR wheel with better traction to develop more driving
torque t h a n the other wheel. The Sure-Grip is not a
DIFFERENTIAL locking type differential.
CASE
IDENTIFICATION
Raise both rear wheels off the surface and rotate
them. If both rear wheels rotate in t h e same direc
tion, t h e vehicle is equipped with a Sure-Grip differ
ential. Another method of identification is by
removing the housing cover fill hole plug. Examine
(with a flashlight) the differential case components
BEARING through the lubricant fill hole.
SERVICE INFORMATION
BEARING J9003-119 When Sure-Grip differential service is necessary,
both rear wheels must be raised off the surface so
Fig. 1 Sure-Grip Differential they are free to rotate.
With the exception of the Sure-Grip differential A Sure-Grip differential case is not repairable.
case, all t h e axle components are identical to the If defective, it must b e replaced a s a complete
unit only. D o not attempt to disassemble a n d re
standard axle. The Sure-Grip has a two-piece differ
pair t h e case components.
ential case. The case is completely interchangeable
Follow the same procedure outlined under Stan
with a standard differential case (Fig. 2). Sure-Grip
dard Differential for Removal and Installation.
differential removal and installation is same as stan
dard differential. DIFFERENTIAL TEST
DIFFERENTIAL
CASE C A U T I O N : Whenever a rear axle is being serviced,
R A I S E B O T H R E A R W H E E L S off the surface.
SIDE GEAR
PINION A Sure-Grip differential can be tested without re

GEAR moving the differential case from the housing.
(1) Position the vehicle on a hoist with the ignition
OFF. P u t the transmission selector lever in PARK
(automatic transmission) or in first gear (manual
transmission).
(2) Attempt to manually rotate each rear wheel.
(3) If difficult to manually rotate either wheel, the
Sure-Grip differential is functioning normally. If
easy, t h e differential is not functioning normally and
COIL SPRING should be replaced.
CLUTCH
A Sure-Grip differential c a s e is n o t repairable.
If defective, it must b e replaced a s a complete
unit only. D o not attempt to disassemble a n d re
LUBRICATION
GROOVES
pair the case components.
LUBRICATION DIFFERENTIAL NOISE

WELL J9003-120
Noise complaints involving a Sure-Grip should be
evaluated to determine the source of the noise. If a
Fig. 2 Sure-Grip Differential Components noise occurs while the vehicle is turning, t h e proba
The action of a standard differential will allow the ble cause is incorrect or insufficient gear lubricant.
rear wheels to rotate a t different speeds when the ve The drain and clean procedure should be used for
hicle is turning. This differential will divide the en possible elimination of the noise before replacing the
gine torque equally between them. This is a differential.
• REAR SUSPENSION AND AXLE 3-29
WARNING: WHEN SERVICING VEHICLES WITH In Sure-Grip differentials 4 ounces of MOPAR Hy
SURE-GRIP, DO NOT USE THE ENGINE TO ROTATE poid Gear Lubricant Additive m u s t be added with
THE AXLE AND WHEELS. BOTH REAR WHEELS each re-fill.
MUST BE RAISED AND THE VEHICLE SUPPORTED. It is recommended the vehicle be driven through 10
A SURE-GRIP AXLE CAN EXERT ENOUGH FORCE to 12 slow, figure-eight turns. This ensures t h e lubri
(IF ONE WHEEL IS IN CONTACT WITH THE SUR cant is thoroughly pumped through the Sure-Grip
FACE) TO CAUSE THE VEHICLE TO MOVE. differential clutches.
LUBRICATION
Multi-Purpose Gear Lubricant, as defined by MIL-
L-2105-B (API GL-5) should be used in all axles.
MOPAR Hypoid Lubricant is recommended or equiv
alent.
MODEL 6 0 a n d 7 0 AXLES
INDEX
page page
Axle Shaft Removal/Installation 32 Pinion Gear Depth Measurement and Adjustment with
Complete Axle Removal/Installation . . . . . . . . . . . 33 Tool Set C-758-D6 43
Differential Assembly 38 Pinion Gear Depth Measurement and Adjustment with
Differential Disassembly 34 Tool Set D-116 . 40
Lubricant 31 Wheel Bearing Service 33
GENERAL INFORMATION The removable, stamped steel cover provides a

The housing (Fig. 1) consists of an iron center cast means for inspection and service without removing
ing with axle shaft tubes extending from either side. the complete axle from the vehicle.
The tubes are pressed in to form a one-piece axle A small, stamped metal axle gear ratio identifica
housing. tion tag is attached to the housing cover via one of
The integral type housing, hypoid gear design has the cover bolts. This tag also identifies the number of
the centerline of the pinion set below the centerline ring and pinion teeth.
of the ring gear. The differential case is a one-piece design. The dif
The axles are equipped with full-floating axle ferential pinion mate shaft is retained with a roll
shafts, meaning t h a t loads are supported by the axle pin. Model 70 axles with the optional Powr-Lok use a
housing tubes. The full-float axle shafts are retained two piece differential case. Differential bearing pre
by bolts attached to the hub. The hub rides on two load and ring gear backlash are adjusted by the use
bearings at the outboard end of the axle tube. The of shims located between t h e differential bearing
axle shafts can be removed without disturbing or re
cones and case.
moving the wheel bearings. The wheel bearings are
opposed tapered roller bearings t h a t are part of the
hub/drum assembly.
CO
Fig. 1 Model 60 and 70 Rear Axle

LUBRICANT (7) Install the cover on the differential. Install the

e
Hypoid gear lubricant, as defined by MIL-L-2105-B identification tag. Tighten the cover bolts to 47 N m
and API GL 5 is the specified lube. MOPAR Hypoid (35 ft. lbs.) torque.
Gear Lubricant conforms with both of these specifica
tions and is highly recommended. C A U T I O N : Overfilling the differential" c a n result in
the lubricant foaming a n d overheating.
C A U T I O N : If a rear axle i s s u b m e r g e d in water, the
(8) Refill the differential housing with the speci
axle lubricant must be replaced immediately,
With Trac-Lok differentials, add a container of Trac-
DRAIN AND REFILL Lok Lubricant additive.
(1) Drive the vehicle until the gear lubricant (9) Install the fill hole plug. Tighten to 34 N-m (25
reaches normal operating temperature. ft. lbs.) torque.
(2) Raise and support the vehicle. (10) Road test the vehicle. Drive the vehicle and
(3) Remove the lubricant fill hole plug from t h e make 10 to 12 slow, figure-eight turns. This maneu
ver will pump lubricant through clutch discs.
differential housing cover.
(4) Remove the differential housing cover. Allow
PINION SHAFT SEAL
the lubricant to completely drain from the housing
and axle shaft tubes. REMOVAL
(5) Flush the differential and the housing cavity (1) Raise and support the vehicle.
with a flushing oil to remove residual lubricant and (2) Mark the U-joint, pinion yoke, and pinion shaft
foreign matter. D o n o t u s e w a t e r , s t e a m , k e r o s e n e for reference.
or g a s o l i n e for flushing, (3) Disconnect the drive shaft from the pinion
(6) Scrape the residual gasket from the housing yoke. Secure the drive shaft in an upright position to
and cover mating surfaces. Clean the mating sur prevent damage to t h e rear U-joint.
faces with mineral spirits. Install a new cover gas (4) Remove the pinion yoke nut and washer. Use
ket. Apply a bead of MOPAR® Silicone Rubber Remover C-452 and Wrench C-3281 to remove the
Sealant on the housing cover (Fig. 2). Allow the seal pinion yoke (Fig. 3).
ant to cure for a few minutes. (5) Mark the positions of the yoke and pinion gear
for installation alignment reference.
SURFACE SPECIAL TOOL
C-3281
SPECIAL TOOL
C-452 J9102-31

BEAD (6) Use Remover C-748 to remove the pinion gear
THICKNESS seal (Fig. 4).
6.35mm (1/4")
J9302-30
INSTALLATION
Fig. 2 Sealant On Housing Cower (1) Apply a light coating of gear lubricant on the
lip of pinion seal. Install the new seal (Fig. 5);
I n s t a l l the h o u s i n g c o v e r w i t h i n 5 m i n u t e s af
• Model 60 use Installer C-3719-A and Handle
ter a p p l y i n g the sealant. I f n o t i n s t a l l e d , the
C-4735
sealant m u s t b e r e m o v e d a n d a n o t h e r b e a d a p
• Model 70 use Installer C-359 and Handle C-4735
plied.
(2) Align the installation reference marks and po-
PINION SEAL DIFFERENTIAL
J9203-55
Fig. 4 Pinion Seal Removal

SPECIAL TOOL
C-4735 AXLE SHAFT REiOWAL/INSTALLATlON
C A U T I O N : R A I S E B O T H R E A R W H E E L S off the sur
face whenever a rear axle is being serviced.
REMOVAL-MODEL 60
(1) Remove the axle shaft flange bolts.
(2) Slide the axle shaft out from the axle tube (Fig.
1).
INSTALLATION-MODEL 60
(1) Clean the gasket contact surface area on the
flange with an appropriate solvent. Install a new
flange gasket and slide the axle shaft into the tube
(Fig. 1).
(2) Install the bolts and tighten to 95 N»m (70 ft.
lbs.) torque.
REMOVAL-MODEL 70
J9203-56 (1) Remove the axle shaft flange lock nuts.
(2) Strike the axle shaft sharply in the center of
the flange with a hammer to the loosen the tapered
sition the yoke on the pinion gear. dowels. Slide the axle shaft out from the axle tube
(3) Install the pinion yoke, washer, and n u t on (Fig. 1).
shaft. Tighten the nut to 339-366 N-m (250-270 ft.
lbs.) torque (Fig. 6). INSTALLATION-MODEL 70
(4) Align the installation reference marks and at (1) Clean the gasket contact surface area on the
tach the drive shaft to the yoke. flange with an appropriate solvent. Install a new
(5) Add API grade GL 5 hypoid gear lubricant to flange gasket and slide the axle shaft into the tube
the differential housing, if necessary. (Fig. 1).
(6) Lower the vehicle. (2) Install the tapered dowels and the lock nuts.
Tighten the lock nuts to 95 N*m (70 ft. lbs.) torque.
WHEEL BEARING SERVICE threads during installation. Otherwise, the threads,

bearing, and seal could be damaged.
REMOVAL
(1) Remove the axle shaft, refer to the removal (6) Carefully slide the hub onto t h e axle. Install
procedure. the outer wheel bearing, the locktab and outer wheel
(2) Remove the nut lock and adjustment nut. bearing locknut.
(3) Remove the hub and drum assembly. The outer (7) Tighten the adjustment nut to 163-190 Nnn
wheel bearing will slide out as the hub is being re (120-140 ft. lbs.) torque while rotating the wheel.
moved. (8) Loosen the adjustment n u t 1/3 of-a-turn (120
(4) Place hub on bench and remove inner grease degrees) to provide 0.001-inch to 0.008-inch wheel
seal. Discard seal. bearing end play.
(5) Remove inner wheel bearing. Inspect wheel (9) Tap the n u t lock into the spindle keyway and
bearings for wear. Replace as necessary. adjustment nut.
(10) Install the axle shaft, refer to the installation
CLEANING AND INSPECTION procedure.
(1) Thoroughly clean both wheel bearings and in
terior of the hub. Remove all of the residual lubri COMPLETE AXLE REMOVAL/INSTALLATION
cant.
(2) To clean the bearings: REMOVAL
• Soak them in an appropriate cleaning solvent It is not necessary to remove the complete axle
• Strike the flat of each bearing against a hardwood from the vehicle for routine or differential service. If
block several times the differential housing or axle shaft tubes are dam
• Flush bearing between strikes aged, the complete axle can be removed and in
• Repeat the procedure above until each bearing is stalled.
clean (1) Raise the rear of the vehicle until the rear
• Dry the bearings with compressed air but do not wheels are not contacting the surface. Support the
spin them vehicle body at the front of the rear springs.
(3) After cleaning, apply engine oil to each bear (2) Use a wooden block to retain the brake pedal
ing. in the up position.
(4) Rotate each bearing slowly while applying (3) Remove the axle shafts, wheels, hubs and
downward force. Examine the rollers for pitting and brake drums. If necessary, refer to the applicable re
roughness. Replace worn or otherwise defective bear moval procedures.
ings. If a bearing has pitted and/or rough surfaced (4) Disconnect the brake line and cap the fittings
rollers, replace both the bearing and bearing cup.
to prevent loss of brake fluid.
(5) If reusable, remove the engine oil from each
(5) Disconnect the parking brake cables.
bearing. Pack each bearing with multi-purpose
Scribe installation alignment reference m a r k s
NLGI, grade 2, EP-type lubricant.
Ensure that lubricant is forced into all the cav on drive shaft U-joint and on pinion yoke.
ities b e t w e e n the bearing cage and rollers. (6) Disconnect the drive shaft U-joint from the pin
ion yoke. Secure it in an upright position to prevent
INSTALLATION damage to the U-joint.
(1) If a bearing and cup must be replaced, remove (7) Remove the rear shock absorbers and the rear
the cup from the hub bore. Use a brass drift or an spring U-bolts from the axle.
appropriate removal tool to tap out the cup. (8) Remove the rear axle from the vehicle.
(2) Install the replacement bearing cup(s) with an
appropriate installation tool. INSTALLATION
(3) Apply lubricant to surface area of the hub bore. (1) If the differential housing cover was removed,
Install the inner wheel bearing in the hub. Install a ensure differential housing and cover mating sur
replacement bearing seal with an appropriate seal faces are clean.
installation tool. (2) If cover was removed, apply a bead of MOPAR
(4) Inspect the bearing and seal contact surfaces on Silicone Rubber Sealant around the cover bolt circle.
the axle for burrs and/or roughness. Install the differential housing cover. Tighten the
(5) Remove all the rough contact surfaces from the cover bolts to 47 N»m (35 ft. lbs.) torque. Install the
axle. Apply a coating of multi-purpose NLGI, grade axle gear ratio identification tag under one o f
2, EP-type lubricant to the axle. the cover bolts.
(3) With the vehicle body supported at the front of
C A U T I O N : Use care to prevent the inner wheel bear the rear springs, position the axle under the rear
ing and bearing seal from contacting the axle springs.
(4) Install the spring U-bolts and tighten the nuts (3) Position Spreader D-167 with the tool dowel
with the specified torque. pins seated in the locating holes (Fig. 8). Install the
(5) Install the shock absorbers. holddown clamps and tighten the tool turnbuckle fin
(6) Connect the parking brake cables. ger-tight.
(7) Connect the brake lines. Install the hubs and
SPECIAL TOOL DIAL
brake drums. Adjust the wheel bearings (refer to MODEL 44-W-129-A INDICATOR
Wheel Bearing Adjustment).
(8) Remove the block from the brake pedal. Bleed
and adjust the brakes.
(9) Connect the drive shaft to the pinion yoke with
the reference marks aligned. Tighten the U-joint
clamp bolts to 21 N-m (16 ft. lbs./186 in. lbs.) torque.
(10) Install the rear wheels and tighten the lug
nuts with the specified torque (refer to Group 22,
Wheels And Tires).
(11) Raise the rear of the vehicle, remove the sup
ports, level the vehicle and position the supports.
(12) Remove the fill hole plug from the differential
housing cover. Fill the differential housing to the
correct level with MOPAR Hypoid Gear Lubricant, or
an equivalent product. Fig. 8 Differential Housing Separation
A d d 4 o u n c e s of M O P A R H y p o i d G e a r L u b r i (4) Install a pilot stud at the left side of the differ
c a n t A d d i t i v e for T r a c - L o k e q u i p p e d a x l e s . ential housing. Attach Dial Indicator to housing pilot
(13) Install the fill hole plug. Remove the supports stud. Load the indicator plunger against the opposite
and lower the vehicle. side of the housing (Fig. 8) and zero the indicator.
(14) Road test the vehicle to evaluate the results of
the repair. C A U T I O N : Do not spread over the specified dis
tance. If the housing is over-separated, it could be
DIFFERENTIAL DISASSEMBLY
distorted or damaged.
RE MO VA L/DISA SSEMBL Y
R e m o v e t h e R W A L b r a k e s e n s o r hold-down (5) Separate the housing enough to remove the
b o l t a n d p u l l t h e s e n s o r from t h e differential case from the housing. S e p a r a t e h o u s i n g a m a x i
h o u s i n g . T h e s e n s o r m u s t b e r e m o v e d to p r e v e n t m u m d i s t a n c e of 0.38 m m (0.015 in) w i t h t h e
damage when disassembling or assembling the s p r e a d e r tool. Measure the distance with the dial
differential c o m p o n e n t s . indicator (Fig. 8).
(1) N o t e t h e i n s t a l l a t i o n r e f e r e n c e letters (6) Remove the dial indicator.
stamped on the bearing caps a n d housing ma (7) Pry the differential case loose from the hous
c h i n e d s e a l i n g s u r f a c e (Fig. 7). ing. To prevent damage, pivot on housing with the
(2) Remove the differential bearing caps. end of the pry bar against case.
(9) Clamp the differential case in a vise equipped
with soft jaws. Remove and discard the ring gear
remove (Fig. 9).
seal (Fig. 4).
save time if they should become misplaced.
(13) The excitor ring can be removed with a soft-
Fig. 7 Bearing Cap identification faced hammer (Fig. 12). Discard after removal.
SPECIAL TOOL
C-3281
EXCITOR
RING
SPECIAL TOOL
C-452 J9102-31

• Model 70 use Remover D-159 and Handle C-4171
(16) Remove the depth shims from t h e housing
RING bore. Record the thickness of the depth shims.
GEAR 8903-32
(17) Remove the pinion rear bearing (Fig. 15);
• Model 60 use Puller DD-914-P, Adapter Ring DD-
Fig. 9 Ring Gear Removal
914-9 and Plate C-293-37
(14) Remove the front pinion bearing cup with Re • Model 70 use Puller DD-914-P, Adapter Ring DD-
mover D-158 and Handle C-4171 (Fig. 13). 914-9 and Plate DD-914-95
(15) Remove the rear bearing cup from housing (18) Remove the differential side gears and thrust
(Fig. 14). washers.
• Model 60 use Remover D-162 and Handle C-4171
PINION WASHER
YOKE
PINION
NUT
SLINGER
FRONT
BEARING
CUP
PINION
PRELOAD
SHIMS PINION
OIL SEAL
PINION PRELOAD
SPACER FRONT
BEARING
CONE
SHOULDER FOR J9203-63

' PINION PRELOAD SPACER

PINION
SPECIAL TOOL
DD-914-9
FRONT
BEARING CUP
J9203-57
SPECIAL TOOL
G293-37
Fig. 13 Front Bearing Cup Removal
(19) Remove the case from the vise. J9203-59
(20) Remove the bearings (Fig. 16) with:
• Remover DD-914-P Fig. 15 Pinion Rear Bearing Removal
• Adapter Ring DD-914-8 (22) Clamp the differential case in a vise equipped
• Plate DD-914-62 with soft jaws. Use a pin punch to remove the pinion
• Screw Extension DD-914-7 gear mate shaft lock pin (Fig. 17).
• Button DD-914-42 (23) Remove the mate shaft with a drift and ham
U s e care that adapter rings are placed so they mer (Fig. 18).
d o not d a m a g e the bearing cage. (24) Rotate the differential side gears and remove
(21) Remove bearing shims from case hubs and the pinion mate gears and thrust washers (Fig. 19).
mark t h e m (with hub identity) for assembly refer
ence. Record the thickness of the shims. GLEANING/INSPECTION
(1) Wash and clean all components with cleaning
solvent and dry with compressed air.
THRUST
WASHER
Fig. 16 Differential Bearing Removal MATE GEAR SIDE GEAR J9203-61
Fig. 19 Pinion Mate Gear Removal

housing opening. Draw the wire (and cloth) from the
housing outward through the tube.
(3) Inspect the differential and pinion gear bear
ings. Inspect the differential case and housing.
• Bearings and cups should have a smooth appear
ance with no broken/dented surfaces on the bearing
rollers or the roller contact surfaces
• Bearing races must not be distorted or cracked
Cup and bearing must be replaced as a
m a t c h e d sets only.
• All machined surfaces in the housing and on bear
Fig. 17 Mate Shaft Lock Pin Removal
ing caps should be smooth and without any raised
edges
• Pinion gear front and rear bearing cup bores
should be smooth
• Raised metal on shoulders of cup bores should be
removed with a hand stone
(4) Examine the differential pinion gear mate
shaft, pinion gears, side gears and thrust washers for
wear and damage. Replace all defective components.
If either of the differential pinion g e a r s is not
reusable, both gears must b e replaced as a
matched set only. Do not replace only o n e gear.
(5) Examine the ring gear and the pinion gear for
worn and chipped teeth. Examine the ring gear for
damaged attaching bolt threads.
If replacement of either gear is necessary, both
Fig. 18 Mate Shaft Removal must be replaced as a m a t c h e d set only.
(6) Inspect the pinion yoke for cracks, worn
Do n o t s t e a m c l e a n t h e differential c o m p o splines, pitted areas, and a rough/corroded seal con
nents. tact surface. Repair or replace the yoke as necessary.
(2) Clean the axle shaft tubes. Insert a stiff wire
into each tube, attach a clean cloth to the wire at the
(7) Inspect the pinion bearing preload shims (Fig.
1) for cracks, damage and distortion. Install replace
ment shims (if necessary) for the preload torque ad
justment.
(8) Inspect the RWAL brake exciter ring for dam
age and missing teeth. If not removed, ensure the
ring is firmly pressed onto the differential case. Re
place the ring if loose or damaged.
DIFFERENTIAL ASSEMBLY
ASSEMBLY
(1) Align the exciter ring tab with the slot in dif
ferential case (Fig. 20).
SLOT 8903-36
Fig. 22 Ring Gear Bolt Hole Alignment

(4) Install new ring gear bolts and alternately
tighten to;
• Grade 8 bolts to 136-163-N-m (100-120 ft. lbs.)
torque
• Grade 9 bolts (7 radial lines) to 169-183 N»m (125-
135 ft. lbs.) torque
(5) Lubricate all differential components with hy
poid gear lubricant.
(6) Install the following components in the differ
ential case (Fig. 23).
• Differential side gears and thrust washers
• Pinion gears and thrust washers
• Pinion gear mate shaft (align holes in shaft and
case)
Fig. 20 Exciter Ring Alignment case and mate shaft with a punch and hammer (Fig.
(2) Invert the differential case and start two ring 23). Peen metal part of case over pin in two places.
gear bolts. This will provide case-to-ring gear bolt If r e p l a c e m e n t g e a r s a n d t h r u s t w a s h e r s w e r e
hole alignment (Fig. 21). i n s t a l l e d , It is n o t n e c e s s a r y t o m e a s u r e t h e g e a r
b a c k l a s h . C o r r e c t fit is d u e t o close m a c h i n i n g
(8) Place Master Differential Rearing D-343
(D-117) on the case hubs (Fig. 24).
indicator plunger against the back of the ring gear
(Fig. 25).
(10) Insert a small pry bar between the bearing
cap and left side of differential case. Pry the case as
far as possible to right side (Fig. 25). Zero the dial
indicator pointer.
(11) Pry the case to left side and record the travel
distance.
T h e m e a s u r e m e n t a b o v e is t h e s h i m t h i c k n e s s
n e c e s s a r y for c a s e z e r o e n d - p l a y . T h e t o t a l
Fig. 21 Ring Gear Bolt Hole Alignment t h i c k n e s s will b e d e t e r m i n e d d u r i n g t h e r i n g
gear backlash adjustment.
(3) Press the exciter ring onto the differential case
using the ring gear as a pilot (Fig. 22). (12) Remove indicator and pilot stud.
PUNCH TOOL C-3339
MATE
SHAFT
LOCKPIN
J9203-64 8903-29
Fig. 23 Mate Shaft Pin installation Fig. 25 Differential Case End Play Measurement
SPECIAL TOOL DIFFERENTIAL DRIVE PINION

D-343 CASE PRODUCTION GEAR DEPTH
(D-117) NUMBERS VARIANCE
SPECIAL TOOL
D-343
(D-117)
GEAR MATCHING NUMBER

(SAME AS RING GEAR NUMBER) J9003-100
Fig. 26 Pinion Gear ID Numbers
shoulder of the rear pinion bearing.
J9103-20 • Model 60 axle, the standard depth/distance is
5.000 inches (127.00 mm)
Fig. 24 Master Bearing Tools On Hubs • Model 70 axle, the standard depth/distance is
PINION GEAR DEPTH INFORMATION 5.375 inches (136.525 mm)
Gears are supplied as matched sets only. The iden Compensation for depth variance is achieved by
tifying numbers for the ring and pinion gear are shims placed adjacent to the pinion gear rear bearing
etched into the face of each gear (Fig. 26). A plus ( + ) cup (Fig. 28).
number, minus (-) number or zero (0) is etched into If a new gear set is being installed, note the depth
the face of the pinion gear. This number is the variance etched into the original and new pinion
amount (in thousandths of an inch) the depth varies gear. Add or subtract the thickness of the original
from the standard depth setting. The standard depth depth shims to compensate for the difference in the
provides the best teeth contact pattern. depth variances. Refer to the Depth Variance charts.
For Example:
DEPTH DRIVE
SETTING PINION
5.000- BEARING
PRELOAD
SPACER/SHIM
\ DRIVE
\ ^ PINION GEAR
DEPTH
CENTER LINE
BEARING OF AXLESHAFT'
SHOULDER RING GEAR J9302-75

• If a positive marking, this means the shim pack
must decrease by the same number of thousandths DIFFERENTIAL
• If a negative marking, this means the shim pack BEARING
SHIM J9002-32
must increase by the same number of thousandths
• If marked zero will use the nominal setting as de Fig. 28 Shim Locations
termined in this procedure
If equipped, the oil slinger must be measured
Individual depth shims are available in
and the thickness included with the total shim
• 0.003-inch
pack thickness.
• 0.005-inch
Depth shim thickness for the new pinion gear must
• 0.010-inch
be determined before installing differential case in
• 0.030-inch
housing.
If original gear set is installed but the depth shims
replaced, measure the thickness of the original depth
ADJUSTMENT WITH TOOL SET D-116
the same thickness.
ment procedure involves using Tool Set D-271.
OrlflfMil M i i t o n
-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 + 0006 + 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 -0001 -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

J8902-46
(1) Insert Master Pinion Block into the differential

housing (Fig. 29);
• Model 60 use Tool D-120
• Model 70 use Tool D-137
Fig. 29 Pinion Block In Shaft Bore

(2) Place Disc D-116-2 on Arbor D-115-3 and posi
tion in the bearing cradles (Fig. 30). This is the cen
terline of the ring gear/axle shaft.

(6) Measure the thickness of each depth shim with
a micrometer and combine the shims necessary for
total required pack thickness. Include oil slinger
t h i c k n e s s with the total shim p a c k thickness.
(7) Remove the measurement tools from the differ
ential housing.
Fig. 30 Disc & Arbor In Housing (8) Place the depth shims in the pinion gear rear
bearing bore. Install the bearing cup (Fig. 33);
(3) Place Pinion Height Block D-116-1 on top of
• Model 60 use Installer D - l l l and Handle C-4171
master pinion block tool and against arbor tool (Fig.
31).
(4) Firmly place Gauge Block D-115-2 and Dial In
dicator D-106-5 on the lowest step of pinion height (9) Install the pinion front bearing cup with In
block tool (Fig. 32). Zero the dial indicator pointer. staller C-4203 and Handle C-4171 (Fig. 34).
(5) Move the gauge block toward the arbor until (10) Install the rear bearing (and slinger if used)
the indicator plunger contacts the arbor tool (Fig. on the pinion gear with Installer C-3095-A until
32). Slide the gauge block across along the arbor completely seated (Fig. 35).
while observing indicator. Record the longest travel (11) Assemble preload shims onto pinion and in
distance, whether inward (-) or outward ( + ), indi stall the pinion gear in housing.
cated by the pointer. (12) Install pinion front bearing, oil slinger, yoke,
The plunger travel distance indicated, plus or washer and nut. Install the yoke with Installer
minus the variance etched in the gear is the re C-3718 and Wrench C-3281 (Fig. 36).
quired thickness for the depth shims.
SPECIAL TOOL
D-111 PRESS
INSTALLATION
TOOL
DRIVE
PINION GEAR
SHAFT
REAR BEARING"
OIL
SLINGER
SPECIAL
TOOL DRIVE
C-4171 J9203-65 PINION GEAR J9302-68
Fig. 33 Pinion Rear Bearing Cup installation Fig. 35 Pinion Rear Bearing Installation
BEARING CUP DRIVER SPECIAL DIFFERENTIAL
INSTALLATION TOOL C-4203 HANDLE TOOL HOUSING
TOOL C-3718
C-4171
SPECIAL
TOOL
C-3281
Fig. 34 Pinion Front Bearing Cup Installation
(13) Tighten the yoke nut to 339-366 N-m (250-270
ft. lbs.) torque.
(14) Check bearing preload torque with an inch
J9103-21
pound torque wrench (Fig. 37). The torque necessary
to rotate the pinion gear should be; Fig. 36 Pinion Yoke Installation
• Original Bearings — 1-3 Nnn (10-20 in. lbs.)
(15) Remove the pinion yoke n u t and washer. Use
• New Bearings — 2-5 Nnn (20-40 in. lbs.)
If the preload torque is not within the specified tol
erance, correct the shim thickness accordingly (Fig.
38);
lip of pinion seal. Install the new seal (Fig. 40);
© Model 60 use Installer C-3719-A and Handle
thickness
C-4735
thickness
C-452 J9102-31

SPECIAL TOOL
C-4735
J9203-56

A s s e m b l e C-758-D6 Tool Set a s d e s c r i b e d (Fig.
Fig. 38 Shim Locations 41);
• Position Spacer (SP-5814 for Model 60) or (SP-5587
(18) Install a new yoke n u t and tighten to 339-366 for Model 70) over Shaft (SP-526)
Nnn (250-270 ft. lbs.) torque. • Position pinion rear bearing on shaft
PINION GEAR DEPTH MEASUREMENT AND • Install pinion front bearing
ADJUSTMENT WITH TOOL SET C-758-D6 • Install Sleeve (SP-535-A), Washer (SP-534) and
The alternate measurement and adjustment proce
N u t (SP-533)
dure involves using Pinion Depth Measurement
Gauge Set C-758-D6 (Fig. 41).
with Wrench C-3281.
(1) Install t h e pinion rear bearing cup (Fig. 42);
Tighten the n u t to seat the pinion bearings in the
housing (Fig. 44). Allow the sleeve to t u r n several
times during the tightening to prevent brinelling the
bearing cups or the bearings.
(2) Install the pinion front bearing cup with In
staller C-4203 and Handle C-4171 (Fig. 43).
3 - 44 REAR SUSPENSION AND AXLE — _ _ — _ . _ •
SPECIAL TOOL SET BEARING CUP DRIVER

INSTALLATION TOOL C-4203 HANDLE
Fig. 41 Pinion Adjustment Tools

SPECIAL TOOL

tool. Install the attaching bolts. Tighten the cap bolts
to 14 N-m (10 ft. lbs.) torque.
C-4171 J9203-65 (7) Trial fit depth shim(s) between the crossbore
arbor and gauge block (Fig. 45). The depth shim(s)
Fig. 42 Pinion Rear Bearing Cup Installation fit must be snug but not tight (drag friction of a
Depth shim(s) are positioned b e t w e e n the pin feeler g a u g e blade).
ion gear rear bearing a n d pinion g e a r to provide Depth shims are available in 0.001-inch incre
the separation distance. The required thickness ments from 0.020 inch to 0.038 inch.
of the depth shim(s) is determined according to (8) Note the etched number on the face of the drive
the following information. pinion gear (e.g., -0, - 1 , -2, + 1 , + 2 , etc.). The num
(4) Loosen the compression n u t tool. Lubricate the bers represent thousands-of-an-inch deviation from
pinion gear front and rear bearings with gear lubri the standard. If the number is - (negative), add t h a t
cant. Re-tighten the compression n u t tool to 1-3 N-m value to the required thickness of the depth shim(s).
(15-25 in. lbs.) torque. Rotate the pinion gear several If the number is + (positive), subtract t h a t value
complete revolutions to align the bearing rollers. from the thickness of the depth shim(s). If the num
(5) Install Gauge Block SP-5260 at the end of SP- ber is 0, no change is necessary.
526. Install Cap Screw (SP-536) and tighten with (9) Remove the tools from the differential housing.
Wrench SP-531. (10) Remove the rear bearing cup from housing
(6) Position Crossbore Arbor (SP-5183) in the dif (Fig. 46),
ferential housing. * Model 60 use Remover D-162 and Handle C-4171
Center the arbor in cradles so equal space exists at *> Model 70 use Remover D-159 and Handle C-4171
both ends. Position the bearing caps on the arbor
• REAR SUSPENSION AND AXLE 3 - 4S
SPACER
PRESS
REAR PINION
BEARING
DEPTH SHIMS
HERE SHAFT
INSTALLATION
TOOL
DRIVE
PINION GEAR
SHAFT
REAR BEARING ^

OIL
Fig. 45 Depth Shim(s) Selection SUNGER
HAMMER DRIVER
HANDLE
DRIVE
PINION GEAR J9302-68
Fig. 47 Pinion Rear Bearing Installation

(17) Install pinion front bearing, oil slinger, yoke,
washer and nut. Install t h e yoke with Installer
TOOL HOUSING
C-3718
J9203-58
Fig. 46 Rear Bearing Cup Removal

SPECIAL
(11) Position depth shims in housing rear bearing TOOL
cup bore. C-3281
(12) Install the pinion rear bearing cup (Fig. 42);
(13) If the depth of mesh has been followed accord J9103-21
ing to the instructions above, good gear teeth contact Fig. 48 Pinion Yoke Installation
should exist.
(14) Install the rear bearing (and slinger if used) (18) Tighten the yoke n u t to 339-366 Nnn (250-270
on the pinion gear with Installer C-3095-A until ft. lbs.) torque.
completely seated (Fig. 47). (19) Check bearing preload torque with an inch
(15) Install pinion in housing bore. pound torque wrench (Fig. 49). The torque necessary
(16) Assemble preload shims onto pinion and in to rotate the pinion gear should be;
stall the pinion gear in housing. • Original Bearings — 1-3 Nnn (10-20 in. lbs.)
• New Bearings — 2-5 Nnn (20-40 in. lbs.)
C-452 J9102-31

If t h e preload torque is not within the specified tol • Model 60 use Installer C-3719-A and Handle
erance, correct the shim thickness accordingly (Fig. C-4735
50); • Model 70 use Installer C-359 and Handle C-4735
SPECIAL TOOL
thickness C-4735
thickness
J9203-56

(23) Install a new yoke n u t and tighten to 339-366
N-m (250-270 ft. lbs.) torque.
RING GEAR BACKLASH ADJUSTMENT

(1) Place Master Differential Bearing D-343
(20) Remove the pinion yoke n u t and washer. Use (D-117) on the case hubs (Fig. 24).
Remover C-452 and Wrench C-3281 to remove the (2) Install a pilot stud at the right side of housing.
pinion yoke (Fig. 51). Attach Dial Indicator C-3339 to the pilot stud. Load
(21) Apply a light coating of gear lubricant on the indicator plunger against the back of the ring gear
lip of pinion seal. Install the new seal (Fig. 52); (Fig. 54). Ensure ring and pinion gear teeth are
tightly meshed. Zero the indicator.
SPECIAL DIFFERENTIAL shim thickness. T h e shims must b e placed at the

TOOL HOUSING ring gear side b e t w e e n the c a s e a n d bearing.
(6) Remove the differential case from housing.
(7) Remove the master bearing tools from the dif
ferential case hubs.
(8) Position the backlash shims (with determined
thickness) on case h u b (ring gear side). Install bear
ing on the h u b ;
C-4171 (Fig. 55)
• Model 70 HD use Installer C-4190 and Handle
C-4171
J9103-21
Fig. 53 Pinion Yoke installation

(9) Position t h e remaining zero end-play shims on
hub at opposite side of case. Include an additional
0.015-in (0.38-mm) thick shim on this hub. This will
provide t h e required differential bearing preload
torque.
(10) Install bearing on hub;
C-4171 (Fig. 55)
Fig. 54 Ring Gear Backlash Measurement • Model 70 HD use Installer C-4190 and Handle
(3) Insert a small pry bar between t h e bearing cap C-4171
and right side of differential case. Pry the case as far (11) Match each bearing cup with bearing (origi
as possible to left side (Fig. 19). Zero the dial indica nal). Install the cups on the bearings.
tor pointer. (12) Position Spreader D-167 with the tool dowel
(4) Repeat the measurement several times to check pins seated in t h e locating holes (Fig. 56). Install the
consistency. Record t h e travel distance. holddown clamps and tighten the tool turnbuckle fin
The m e a s u r e m e n t a b o v e s h o w s shim thickness ger-tight.
n e c e s s a r y to eliminate ring gear backlash. Sub (13) Install a pilot stud at the left side of the dif
tract this thickness from case zero end-play ferential housing. Attach Dial Indicator to housing
SPECIAL TOOL (18) Rotate the assembly several revolutions to
.MODEL 44-W-129-A seat bearings. Measure backlash at three equally
MODEL 60-D-167
spaced locations with a dial indicator (Fig. 58).

TOOL
pilot stud. Load the indicator plunger against the op C-3339 8903-31
posite side of the housing (Fig. 56) and zero the indi
cator. Fig. 58 Ring Gear Backlash Measurement
The ring gear backlash must be within 0.004 -
C A U T I O N : D o not spread over the specified dis 0.009 inch (0.10 - 0.23 mm). It cannot vary more
tance. If the housing is over-separated, it could be than 0.002 inch (0.05 mm) b e t w e e n the points
distorted or d a m a g e d . checked.
(19) Excessive backlash is corrected by moving the
(14) Separate the housing enough to install the
ring gear teeth closer to the pinion gear teeth. Insuf
case in the housing. Separate h o u s i n g a m a x i m u m
ficient backlash is corrected by moving the ring gear
distance of 0.38 m m (0.015 in) with the spreader away from the pinion gear. Backlash correction is ac
tool. Measure the distance with the dial indicator. complished by transferring shims from one side to
(15) Remove the dial indicator. the other.
(16) Install case in the housing. Ensure the differ If the mesh and backlash steps have been followed
ential bearings are fully seated. Remove the in the procedures above, good gear teeth contact pat
spreader. terns should exist.
(17) Observe the assembly reference marks and po
sition the bearing caps at their original locations RING GEAR TEETH CONTACT PATTERN
(Fig. 57). Tighten the bearing cap bolts to 95-122 ANALYSIS
N*m (70-90 ft. lbs.) torque. The ring gear teeth contact patterns will show if
the pinion gear depth shim(s) have the correct thick
INSTALLATION
EFERENCE LETTERS ness. It will also show if the ring gear backlash has
been adjusted correctly. The backlash must be main
(1) Apply a thin coat of hydrated ferric oxide, to
the drive and coast side of ring gear teeth.
(2) Rotate the ring gear one complete revolution in
both directions while a load is being applied. Insert a
pry bar between the differential housing and the case
flange. This action will produce distinct contact pat
gear teeth.
(3) Note patterns in compound. Refer to (Fig. 59)
© ^ J9003-92 cordingly.
(4) Install the axle shafts. Refer to Axle Shaft In
Fig. 57 Differential Bearing Cap Reference Letters stallation within this group.
(5) Install the housing cover. Refill the differential
DRIVE SIDE C O A S T SIDE

OF RING OF RING
DESIRABLE C O N T A C T PATTERN.
PATTERN S H O U L D BE CENTERED
O N THE DRIVE SIDE O F T O O T H .
H E E ^ ^ ^ ^ ^ ^ ^ T O E T O E ^ ^ ^ ^ ^ ^ ^ ^ ^ E L PATTERN S H O U L D BE CENTERED O N
THE C O A S T SIDE O F T O O T H ,
BUT M A Y BE SLIGHTLY T O W A R D
THE T O E . THERE S H O U L D ALWAYS
C O N T A C T PATTERN A N D T O P O F
THE T O O T H .
R I N G GEAR BACKLASH CORRECT

T H I N N E R P I N I O N GEAR DEPTH
S H I M REQUIRED.
R I N G GEAR BACKLASH CORRECT

T H I C K E R P I N I O N GEAR DEPTH
S H I M REQUIRED.
P I N I O N GEAR DEPTH SHIM

CORRECT DECREASE R I N G
GEAR BACKLASH.
P I N I O N GEAR DEPTH SHIM

CORRECT. I N C R E A S E R I N G
GEAR BACKLASH.
J9003-24

(6) Install the RWAL b r a k e speed sensor and cover
s
onto the axle housing. Tighten the sensor to 24 N m
SPECIFICATIONS
REAR AXLE MODEL 60 AND 70
Axle Type . . . . . . . . . . . . . . . . . . . . . . Full-Floating Hypoid GAWR (lbs.)

Application D-TRK Mode 60 5800, 6200
Mode 7 0 . 6900*, 7500*, 6200
Ring Gear Diameter *denotes dual rear wheels
Model 6 0 . . . . . . . . . . . . . . .24.76 cm (9.75 in.)
Differential Bearing
Model 70 . . . . . . . . . . . . . . . . . . . . . .26.67 cm (10.5 in.)
Preload Shim. 0.38 mm (0.015 in.)
Lubricants MOPAR Gear Lubricant or
equivalent SAE 75W-90, Differential Side
API Grade GL-5, MIL-L-2105C Gear to Case Clearance .0.00-0.18 mm (0.000-0.007 in.)
Differential Ring Gear Backlash . . . . . .0.12-0.20 mm (0.005-0.008 in.)
Model 60 . . . . . Standard/Track-Lok Drive Pinion Gear Bearing
Model 70 Standard/Powr-Lok Breakaway Preload Torque
Lubricant Capacity Original Bearings 1.2 N-m (10-20 in. lbs.)
Model 60 . . . . . 2.84L (6.0 pts) Replacement Bearings 2-5 N-m (20-40 in. lbs.)
Model 70 .3.31L (7.0 pts)
Drive Pinion Gear Depth . . . . . . . . . . . . . . . . . Select Shims
Axle Model M 60, M 70
Standard Setting
Axle Ratio to 1 Model 60 . . . .79.37 mm (3.125 in.)
Model 60 .4.10, 4.56
Model 7 0 . . . . . . 3.07, 3.54, 4.10,4.56 Model 70 . 88.90 mm (3.50 in.)
Track Side Gear Clearance (max.) 0.015 mm (0.006 in.)
Model 60 . 64.0 in. Case Runout (max.) .0.015 mm (0.006 in.)
Model 70 w/dual rear wheels. . . . . . . . .73.0 in., 68.0 in.
w/single rear wheels . . . . . . . . . . . . . .64.0 in. J9302-77
TRAC-LOK DIFFERENTIAL
SERVICE INFORMATION (4) Place a block of wood t h a t is 2 inches high and
Model 60 rear axles equipped with Trac-Lok differ a minimum of 3 inches wide in front of one of the
ential are optionally available for Ram Truck vehi front tires.
cles. (5) With a gradual throttle opening, attempt to
slowly drive the vehicle over t h e block of wood.
DIFFERENTIAL NOISE (6) If the Kraft paper slips out before the front
Noise complaints involving Trac-Lok should be wheel moves over the block of wood; reposition the
evaluated to determine the source of t h e noise. If a vehicle so paper and board are under the opposite
noise occurs while the vehicle is turning, the proba rear wheel. Attempt to drive over the block of wood
ble cause is incorrect or insufficient gear lubricant. the second time.
Replace the axle gear lubricant and add MOPAR Hy (7) If the front wheel moves over the block of wood,
poid Gear Lubricant Additive. If the chatter persists, the axle can be considered to be functioning nor
clutch disc damage could have occurred. mally.
W A R N I N G : W H E N SERVICING V E H I C L E S WITH A LUBRICANTS

TRAC-LOK DIFFERENTIAL, D O NOT U S E T H E E N The lubricant recommended for Trac-Lok differen
G I N E TO R O T A T E T H E A X L E A N D W H E E L S . B O T H tial is API grade GL 5. A container of Trac-Lok Lu
REAR W H E E L S MUST B E RAISED, FROM THE S U R bricant (friction modifier) should be added after
FACE A N D THE VEHICLE SUPPORTED. TRAC-LOK service.
C A N E X E R T ENOUGH DRIVING F O R C E T O C A U S E Refer to Group 0, Lubrication and Maintenance for
T H E V E H I C L E TO M O V E . additional information.
COMPONENTS
DIFFERENTIAL TEST
The Trac-Lok (limited-slip) differential components
(1) Drive the vehicle to thoroughly warm up the
are illustrated in (Fig. 1). Refer to this illustration
lubricant in the rear axle.
during repair service for component detail and their
(2) Place a large piece of Kraft paper over a
location.
smooth Formica board.
(3) Drive the vehicle over the Formica board until
one rear wheel/tire is in the center of the board and
paper.
DIFFERNTIAL THRUST WASHER

CASE
PINION
SNAP RING
SHAFT
LOCK
PIN
CLUTCH PACK
PINION
MATE
SHAFT J9203-13
Fig. 1 Trac-Lok Differential

DISASSEMBLY (3) Position the differential case on the axle shaft

Service to the Trac-Lok differential requires the (Fig. 3).
use of Tool Set C-4487 (J-23781). Refer to differential (4) Remove and discard the ring gear bolts. They
overhaul in the Model 60 section for differential case are not reusable.
removal and installation. (5) Remove the case from the fixture. Remove the
(1) Clamp one axle shaft in a vise (with protective ring gear from the case by tapping it with brass drift
jaws) with the splined end upward (Fig. 2). and a hammer.
(6) Position the case on the fixture.
(7) Remove the pinion gear mate shaft retaining
USE
AXLE roll pin (Fig. 4).
SHAFT
A S HOLDING DIFFERENTIAL
FIXTURE CASE
(EXTEND N O
MORE T H A N
2 3/4 IN.) PINION
GEAR MATE
SHAFT
PUNCH
LOCKPIN
J9003-95
Fig. 4 Pinion Gear Mate Shaft Lock Pin Removal

J8903-42 (8) Remove the pinion gear mate shaft. Use a ham
mer and a brass drift and tap the shaft out.
~ Fig. 2 Axle Shaft As Holding Fixture
(9) Install and lubricate Step Plate C-4487-1 (Fig.
(2) Place shop towels under the differential gear to 5).
avoid gear damage during removal of the ring gear
SPECIAL
(Fig. 3). TOOL
C-4487-1
RING GEAR
BOLTS UPWARD
DIFFERENTIAL
O N AXLE
SHAFT
LOWER
DIFFERENTIAL SIDE
CASE GEAR J9203-4
Fig. 5 Step Plate Tool Installation

J8903-43
Fig. 3 Differential Case On Shaft

• REAR SUSPENSION AND AXLE 3 - §3
(10) Assemble Threaded Adapter C-4487-3 into top (13) Loosen the forcing screw tool until the clutch
side gear. Thread forcing Screw C-4487-2 into pack tension is relieved.
adapter until it becomes centered in adapter plate. (14) Insert Turning Bar C-4487-4 in case. Rotate
(11) Use a small screw driver, position it in slot of case with tool until pinion gears can be removed
Threaded Adapter C-4487-3 (Fig. 6). This will pre (Fig. 8). Remove tools from the case.
vent adapter from turning.
SOCKET
THREADED
ROD
THREADED C-4487-2
ADAPTER SPlCIAL
DISC tOOL
C-4487-3 C-4487-4
THREADED
ROD
C-4487-2
J9203-2
DISC J9203-1
C-4487-1 Fig. 8 Pinion Gear Removal
Fig. 6 Threaded Adapter Installation (15) Remove top side gear and clutch pack. Keep
plates in correct order during removal (Fig. 9).
(12) Tighten forcing screw tool enough to relieve (16) Remove case from fixture. Remove remaining
clutch pack tension. Remove both pinion thrust clutch pack.
washers (Fig. 7).
SIDE GEAR DIFFERENTIAL
SPECIAL AND CLUTCH DISC CASE
TOOL PACK
C-4487-2
PINION GEAR FEELER

THRUST "GAUGE
WASHER
33
/
X
SPECIAL TOOL
RETAINER C-4487-1 J9203-5
J9203-3
Fig. 9 Side Gear & Clutch Disc Removal
Fig. 7 Remove Pinion Thrust Washer (17) Remove clutch pack retaining clips. Mark
each clutch pack for installation reference.
3 - 54 REAR SUSPENSION A I D AXLE •
CLEANING AND INSPECTION
(1) Clean all components in cleaning solvent. Dry
components with compressed air.
(2) Inspect clutch pack plates for wear, scoring or
damage. Replace both clutch packs if any one compo
nent in either pack is damaged.
(3) Inspect side and pinion gears. Replace any gear
t h a t is worn, cracked, chipped or damaged.
(4) Inspect differential case and pinion shaft. Re
place if worn or damaged.
ASSEMBLY
(1) The clutch discs are replaceable as complete
sets only. If one clutch disc pack is damaged,
both p a c k s must be replaced. Lubricate each com
ponent with gear lube before assembly and installa Fig. 11 Clutch Discs & Lower Side Gear Installation
tion.
(2) Assemble the clutch discs into packs (Fig. 10). UPPER SIDE
(3) Secure disc packs with retaining clips (Fig. 10). GEAR AND CLUTCH
DISC PACK
(4) Position assembled clutch disc packs on the
side gear hubs.
CLUTCH PACK
Installation
RETAINER
J8903-50 (10) Tighten forcing screw tool to compress clutch
discs.
Fig. 10 Clutch Disc Pack (11) Install pinion gears. Rotate case with Turning
(5) Position case on fixture (Fig. 3). Bar C-4487-4. Make sure holes of pinion mate gears
(6) Install clutch pack and side gear in lower bore are aligned with case.
(Fig. 11). B e sure clutch p a c k retaining clips re
main in position and are seated in the c a s e
pockets.
(7) Install lubricated Step Plate C-4487-1 on first
clutch pack (Fig. 12).
(8) Install the upper side gear and clutch disc pack
(Fig. 12).
(9) Hold assembly in position. Insert Threaded
Adapter C-4487-3 into top side gear, insert forcing
Screw C-4487-4 (Fig. 6).
(12) Tighten forcing screw to compress t h e conned

plates. Lubricate and install pinion gear thrust
washers with a small screw driver.
(13) Insert and tap t h e pinion shaft into the differ
ential case (Fig. 13).
(14) Secure pinion shaft with new roll pin. Stake
roll pin to differential case.
Fig. 13 Pinion Gear Mate Shaft installation
POWER-LOK DIFFERENTIAL
SERVICE INFORMATION gear lubricant and add MOPAR Hypoid Gear Lubri
Model 70 rear axles equipped with a Power-Lok cant Additive. This will correct the condition in most
differential are optionally available for Ram Truck instances. However, if t h e chatter persists, clutch
vehicles (Fig. 1). disc damage could have occurred.
FLANGE BUTTON BOLTS WARNING: WHEN SERVICING VEHICLES WITH A
POWER-LOK DIFFERENTIAL, DO NOT USE THE EN
GINE TO ROTATE THE AXLE AND WHEELS. BOTH
REAR WHEELS MUST BE RAISED FROM THE SUR
FACE AND THE VEHICLE SUPPORTED. POWER-
LOK CAN EXERT ENOUGH DRIVING FORCE (IF
ONE WHEEL IS IN CONTACT WITH THE SURFACE)
TO CAUSE THE VEHICLE TO MOVE.
DIFFERENTIAL TEST
(1) Drive t h e vehicle to thoroughly warm up t h e
lubricant in t h e rear axle.
(2) Place a large piece of Kraft paper over a
smooth Formica board. Ensure Formica board is on a
flat and level surface.
(3) Drive t h e vehicle over the Formica board until
one rear wheel is in t h e center of the board and pa
per.
(4) Place a block of wood that is 2 inches high a n d
a minimum of 3 inches wide in front of one of t h e
PINION front tires.
AAATE SHAFT J9203-71 (5) With a gradual throttle opening, attempt to
slowly drive t h e vehicle over t h e block of wood.
Fig. 1 Power-Lok Differential (6) If the Kraft paper slips out from under the rear
DIFFERENTIAL NOISE wheel before t h e front tire moves over t h e block of
Noise complaints involving a Power-Lok should be wood; reposition t h e vehicle so paper and board a r e
evaluated to determine t h e source of the noise. If a under t h e opposite rear wheel. Attempt to drive over
noise occurs while t h e vehicle is turning, t h e proba the block of wood t h e second time.
ble cause is incorrect gear lubricant. Replace axle
BUTTON
HALF
CLUTCH
PLATES
FLANGE
HALF
J9203-72
J9203-73
Fig. 2 Case Marked Fig. 3 Cover Half Removal

(7) If the front wheel moves over the block of wood,
DISASSEMBLY
the axle can be considered to be functioning normally.
(1) Mark the ring gear half and cover half for in
stallation reference (Fig. 2).
LUBRICANTS
(2) Remove the case attaching bolts and remove
The lubricant recommended for Power-Lok differ
ential is API grade GL 5. A container of Trac-Lok the button cover half (Fig. 3).
Lubricant (friction modifier) should be added after (3) Remove the pinion mate gear, side gear (clutch)
service. ring and clutch pack shaft (Fig. 4). Keep these parts
Refer to Group 0, Lubrication and Maintenance for with the button cover half for correct installation in
additional information. their original positions.
FLANGE HALF CLUTCH PINION MATE

RING GEAR
SCREW
PLATE DISHED PLATE DISHED PINION AAATE

DISC DISC CROSS SHAFT BUTTON HALF
J9203-74
Fig. 4 Power-Lok Components

(4) Remove the same parts listed above from the

ring gear flange half of the case. (Fig. 4). Keep these
parts with the flange cover half for correct installa
tion in their original positions.

(1) Clean all components (Fig. 4) in cleaning sol
vent. Dry components with compressed air.
(2) Inspect clutch pack plates for wear, scoring or
damage. Replace both clutch packs if any one compo
nent in either pack is damaged.
(3) Inspect side and pinion gears. Replace any gear
that is worn, cracked, chipped or damaged.
(4) Inspect differential case and pinion shaft. Re
place if worn or damaged.
ASSEMBLY
(1) The clutch discs are replaceable as complete
sets only. If one clutch disc pack is damaged,
both p a c k s must be replaced. Lubricate each com
ponent with gear lube before assembly and installa
tion.
Fig. 6 Clutch Pack Assembly
(2) Clamp one axle shaft in a vise (with protective
jaws). Tighten shaft in vise with the splined end ex the clutch plate lugs enter the slots in the case.
tending approximately 76.2 mm (3.0 inches) upward Also m a k e sure the clutch p a c k bottoms out o n
(Fig. 5). the case.
Fig. 5 Axle Shaft As Holding Fixture Fig. 7 Clutch Pack Installation

(3) Saturate the clutch plates with Hypoid Gear (5) Install pinion mate shafts and pinion mate
Lubricant or Additive. Assemble clutch packs into gears (Fig. 8). Make sure shafts are correctly in
the side gear plate in exactly the same position as re stalled according to the alignment marks.
moved (Fig. 6). (6) Lubricate and install the other side gear and
(4) Line up the plate ears and install the assem clutch pack as done above in Step 3 (Fig. 8).
bled pack into the flange half (Fig. 7). Make sure
SIDE GEAR
ALIGNMENT PINION GEARS

MARKS A N D MATE SHAFT J9203-78
Fig. 8 Clutch Pack Installation

(7) Correctly align and assemble button half to Fig. 9 Case Half Installation
flange half. Install case body screws finger tight.
(8) Place case assembly onto axle shaft fixture
(Fig. 9). Install another axle shaft into opposite side
gear. Tighten body screws alternately and evenly.
Tighten screws to 89-94 N«m (65 to 70 ft. lbs.) torque.
Both axle shafts must b e inserted ALL the w a y
on e a c h side to align BOTH splines.
If bolt heads have 7 radial lines stamped on the
head, tighten these to 122-136 N-m (90 to 100 ft. lbs.)
torque.
(9) Remove differential assembly from axle shaft.
I n s p e c t t h a t e a c h pinion mate cross shaft is tight
on its ramp. Or clearance should not be more
than 0.254 m m (0.010 in.) a n d equal at all four
shaft ends.
REAR SUSPENSION COMPONENTS 8 3/8 AND 9 1/4 INCH AXLE
REAR SUSPENSION COMPONENTS

DESCRIPTION TORQUE
DESCRIPTION TORQUE
Jounce Bumper to Bracket 20 N-m (180 in. lbs.) 8-3/8 Axle Differential
Jounce Bumper/Bracket to Bearing Cap Bolt 95 N*m (70 ft. lbs.)
Frame (Round) 41 N-m (30 ft. lbs.) 9-1/4 Axle Differential
Bearing Cap Bolt 136 N*m(100 ft. lbs.)
Jounce Bumper/Bracket to
Brake Backing Plate , ... 64 N*m (48 ft. lbs.)
Frame (Block)......... 23 N-m (200 ft. lbs.)
Differential Housing Cover
Shock Lower Nut 82 N-m (60 ft. lbs.) Bolt 47 N*m (35 ft. lbs.;
Shock Upper Nut 82 N-m (60 ft. lbs.) Pinion Yoke Nut (Minimum
Spring Center Bolt 20 N-m (15 ft. lbs.) Torque) 2 8 5 N t t i (210 ft. lbs.)
Ring Gear Bolt... ... 95 N*m (70 ft. lbs.)
Spring U-Bolt Nut (1/2-20) 88 N-m (65 ft. lbs.)
RWAL Brake Sensor ... 24 N*m (18 ft. lbs.)
Spring U-Bolt Nut (9/16-18) 149 N-m (110 ft. lbs.)
Spring Front and Rear Pivot J9203-69
Bolt/Nut (1/2-20) 88 N-m (65 ft. lbs.)
Spring Front and Rear Pivot
Bolt/Nut(5/8-18).... 135 N-m (100ft. lbs.)
Spring Front and Rear Pivot
Bolt/Nut (3/4-16) 183 N-m (135 ft. lbs.)
MODEL 60 AND 70 AXLE
Spring Pad to Frame (Aux) 41 N-m (30 ft. lbs.)
J9203-82
REAR AXLE MODEL 6 0 a n d 7 0
DESCRIPTION TORQUE
Axle Flange to Hub Bolts. 95 N-m (70 ft. lbs.)
Bearing Cap Bolts to 122 N-m
... 9 5
(70 to 90 ft. lbs.)
Case Half Bolts (Powr-Lok) .. 89 to 94 N-m
(65 to 70 ft. lbs.)
Case Half Bolts Heavy Duty
(Powr-Lok) 122 to 136 N-m
(90 to 100 ft. lbs.)
Differential Cover Bolts
47 N-m (35 ft. lbs.)
Fill Hole Plug
34 N-m (25 ft. lbs.)
Ring Gear Bolts (Grade 8)
136 to 163 N-m
(100 to 120 ft. lbs.)
Ring Gear Bolts (Grade 9) 169 to 183 N-m
(125 to 135 ft. lbs.)
RWAL Brake Sensor 24 N-m (18 ft. lbs.)
J9203-83
• BRAKES 5 - 1
BRAKES
CONTENTS
page page
BENDIX DISC BRAKE 37 VALVE-BRAKE LINES 10

BRAKE ADJUSTMENTS-BRAKE BLEEDING .. 7 PARKING BRAKES 56
BRAKE DIAGNOSIS 3 POWER BRAKE BOOSTER-BRAKE PEDAL . . 20
CHRYSLER DISC BRAKE 27 POWER BRAKE VACUUM PUMP-DIESEL
DRUM BRAKES-ELEVEN INCH 46 ENGINE ...22
DRUM BRAKES-TWELVE INCH 50
REAR WHEEL ANTILOCK (RWAL) BRAKES . . 59
SPECIFICATIONS 65
MASTER CYLINDER-COMBINATION
GENERAL INFORMATION
INDEX
page page
Antilock Rear Wheel Brakes 1 Brake Fluid/Lubricants/Cleaning Solvents 1
Brake Components 1 Brake Safety Precautions 2
BRAKE COMPONENTS same side of the instrument cluster as the red indi
AD models are equipped with front disc and rear cator light. The antilock light alerts the driver if a
drum brakes. Power assist brakes and rear wheel an system fault occurs.
tilock brakes are standard equipment on all models.
A dual reservoir master cylinder and single or dual ANTILOCK REAR WHEEL BRAKES
diaphragm, vacuum operated power brake booster is All AD models are equipped with antilock r e a r
used for all applications. Models with the Cummins brakes. The system is designed to retard wheel
diesel engine option are also equipped with a vacuum lockup during periods of high wheel slip when brak
pump assembly to operate the power brake booster. ing.
Front disc brake units consist of single piston, slid- Retarding wheel lockup is accomplished by modu
ing-type calipers with semi metallic brakeshoe lin lating fluid pressure to the wheel brake units. Refer
ing. Vented disc brake rotors are used on all models. to the Rear Wheel Anti-Lock Brake section for oper
Bendix calipers are used on 4-wheel drive models ation and service information.
and on diesel engine models. Chrysler disc brake cal
ipers are used for all other applications. BRAKE FLUID/LUBRICANTS/CLEANING SOLVENTS
Rear drum brakes are dual shoe units with an au Recommended fluid for all AD models is Mopar
tomatic adjustment mechanism. Bendix and Chrysler brake fluid or equivalent meeting SAE J1703 and
drum brake assemblies are used. DOT 3 standards.
A combination valve is used on all models. The Use Mopar multi mileage grease to lubricate cali
valve consists of a front brake metering (hold-off)
per slide surfaces, drum brake pivot pins and shoe
valve and a front/rear pressure differential switch.
contact points on the backing plates. Use GE 661 or
A red, brake indicator and warning light is used to
Dow 111 silicone grease (or equivalent) on caliper
alert the driver if a pressure differential exists be
bushings and slide pins.
tween the front and rear hydraulic systems. The
light also alerts the driver when the parking brakes Use fresh b r a k e fluid or Mopar brake cleaner to
are applied. The light is located at the left side of the clean or flush brake system components. These are
instrument cluster. the only cleaning materials recommended.
An additional indicator light is used for the anti-
lock system. This light is amber and is located in the
5 - 2 BRAKES •
C A U T I O N : Never use gasoline, kerosene, alcohol, UUM C L E A N E R S P E C I F I C A L L Y D E S I G N E D FOR
motor oil, transmission fluid, or any fluid containing R E M O V I N G B R A K E D U S T THAT M A Y A S B E S T O S
mineral oil to clean the system components. These F I B E R S . IF A S U I T A B L E V A C U U M C L E A N E R I S NOT
fluids d a m a g e rubber c u p s and seals. If system AVAILABLE, CLEANING SHOULD BE DONE USING
contamination is suspected, check the fluid for dirt, A W A T E R D A M P E N E D C L O T H . D O NOT C R E A T E
discoloration, or separation into distinct layers. DUST BY SANDING, GRINDING, OR SHAVING
Drain and flush the system with new brake fluid if
B R A K E LININGS U N L E S S PROPERLY VENTED
contamination is suspected.
EQUIPMENT IS U S E D . D I S P O S E OF ALL DUST A N D
DIRT THAT M A Y C O N T A I N A S B E S T O S F I B E R S IN
BRAKE SAFETY PRECAUTIONS S E A L E D B A G S O R C O N T A I N E R S . THIS W I L L MINI
MIZE E X P O S U R E TO Y O U R S E L F A N D O T H E R S .
W A R N I N G : D U S T A N D DIRT O N B R A K E P A R T S FOLLOW ALL R E C O M M E N D E D PRACTICES PRE
THAT A C C U M U L A T E S D U R I N G N O R M A L U S E M A Y
S C R I B E D BY THE OCCUPATIONAL SAFETY AND
CONTAIN A S B E S T O S FIBERS. BREATHING E X C E S
HEALTH ADMINISTRATION AND THE ENVIRON
SIVE C O N C E N T R A T I O N S OF A S B E S T O S F I B E R S
M E N T A L P R O T E C T I O N A G E N C Y FOR T H E H A N
CAN C A U S E S E R I O U S BODILY HARM. E X E R C I S E
CARE WHEN SERVICING B R A K E COMPONENTS. DLING, P R O C E S S I N G , A N D DISPOSITION OF DUST
D O NOT C L E A N B R A K E C O M P O N E N T S WITH C O M O R DIRT W H I C H M A Y C O N T A I N A S B E S T O S FI
P R E S S E D AIR OR BY D R Y B R U S H I N G . U S E A V A C BERS.
• BRAKES i -3
BRAKE DIAGNOSIS
INDEX
page page
Brake Warning Lights 3 Master Cylinder/Power Booster Test 5
Diagnosing Brake Problems ................. 4 Power Booster Check Valve Test ............. 6
Diagnosis Procedures 3 Power Booster Vacuum Test . . . . . . . . . . . . . . . . . 6
Low Vacuum Switch—Diesel Models 3 Testing Diesel Engine Vacuum Pump Output .... 6
DIAGNOSIS PROCEDURES light is designed to differentiate between a low vac

Brake diagnosis involves determining if the prob uum condition and a hydraulic circuit fault.
lem is related to a mechanical, hydraulic or vacuum
operated component. A preliminary check, road test PRELIMINARY BRAKE CHECK
ing and component inspection can all be used to de (1) Check condition of tires and wheels. Damaged
termine a problem cause. wheels and worn, damaged, or underinflated tires can
Road testing will either verify proper brake opera cause pull, shudder, tramp, and a condition similar to
grab.
tion or confirm t h e existence of a problem. Compo
(2) If complaint was based on noise when braking,
nent inspection will, in most cases, identify t h e
check suspension components. Jounce front and rear of
actual part causing a problem.
vehicle and listen for noise that might be caused by
The first diagnosis step is the preliminary check. This
loose, worn or damaged suspension or steering compo
involves inspecting fluid level, parking brake action, nents.
wheel and tire condition, checking for obvious leaks or (3) Inspect brake fluid level and condition. Note
component damage and testing brake pedal response. t h a t t h e front disc brake reservoir fluid level will
A road test will confirm the existence of a problem. drop in proportion to normal lining wear. A l s o note
Final diagnosis procedure involves road test analysis that brake fluid tends to darken over time. This
and a visual inspection of brake components. is normal a n d should not b e mistaken for con
tamination. If the fluid is still clear a n d free of
BRAKE WARNING LIGHTS foreign material, it is OK.
The red brake warning light is connected to t h e (a) If fluid level is abnormally low, look for evi
parking brake switch and to t h e pressure differential dence of leaks at calipers, wheel cylinders, brake-
switch in the combination valve. lines and master cylinder.
The red light will illuminate when the parking (b) If fluid appears contaminated, drain out a
brakes are applied or when a fluid pressure drop oc sample. If fluid is separated into layers, or obvi
curs in t h e front or r e a r brake circuit. The light will ously contains oil or a substance other t h a n brake
also illuminate for approximately 2-4 seconds at en fluid, the system seals and cups will have to be re
gine start up. This is a self test feature designed to placed and the hydraulic system flushed.
check bulb and circuit operation each time the en (4) Check parking brake operation. Verify free
gine is started. movement and full release of cables and pedal. Also
The amber antilock light is connected to the anti- note if vehicle was being operated with parking
lock rear brake hydraulic valve. The light will illu brake partially applied.
minate if a fault occurs within the antilock system. (5) Check brake pedal operation. Verify t h a t pedal
does not bind and has adequate free play. If pedal
LOW VACUUM SWITCH-DIESEL MODELS lacks free play, check pedal and power booster for be
On diesel models, the red brake warning light is also ing loose or for bind condition. Do not road test until
used to alert the driver of a low brake booster vacuum condition is corrected.
condition. The warning light is in circuit with a vacuum (6) If components checked appear OK, road test the
warning switch mounted on the driver side fender vehicle.
panel. The vacuum side of the switch is connected to the
power brake booster. The electrical side of the switch is ROAD TESTING
connected to the brake warning light. (1) If complaint involved low brake pedal, pump
The low vacuum switch monitors booster vacuum the pedal and note if the pedal comes back up to nor
level whenever the engine is running. If booster vac mal height.
uum falls below 8.5 inches vacuum for a minimum of (2) Check brake pedal response with transmission
10 seconds, the switch completes t h e circuit to the in Neutral and engine running. Pedal should remain
warning light causing it to illuminate. The warning firm under steady foot pressure.
5 - 4 BRAKES •
(3) During road test, make normal and firm brake On diesel engine models, high pedal effort may be
stops in 25-40 mph (40-64 Km/h) range. Note faulty the result of a low vacuum condition. If the booster
brake operation such as pull, grab, drag, noise, low and check valve are OK, the problem may be related
pedal, etc. to a vacuum pump hose, hose connection, hose fit
(4) Inspect suspect brake components and refer to ting, pump diaphragm, or drive gear. Vacuum pump
problem diagnosis information for causes of various output can be checked with a standard vacuum
brake conditions. gauge. Vacuum output should range from 8.5 to 25
inches vacuum. If vacuum pump output is within
COMPONENT INSPECTION limits, check the power booster and check valve as
Fluid leak points and dragging brake units can usu described in this section.
ally be located without removing any components. The
area around a leak point will be wet with fluid. The BRAKE DRAG
components at a dragging brake unit (wheel, tire, rotor) Brake drag occurs when the lining is in constant
will be quite warm or hot to the touch. contact with the rotor or drum. Drag can occur at
Other brake problem conditions will require compo one wheel, all wheels, fronts only, or rears only. It is
nent removal for proper inspection. Raise the vehicle a product of incomplete brakeshoe release. Drag can
and remove the necessary wheels for better visual ac be minor or severe enough to overheat the linings,
cess. rotors and drums.
Brake drag can also effect fuel economy. If undetec
DIAGNOSING BRAKE PROBLEMS ted, minor brake drag can be misdiagnosed as an en
gine or transmission/torque converter problem.
PEDAL FALLS AWAY Minor drag will usually cause slight surface charring
A brake pedal that falls away under steady foot of the lining. It can also generate hard spots in rotors
pressure is the result of a system leak. The leak and drums from the overheat-cool down process. In most
point could be at a brakeline, fitting, hose, or caliper. cases, the rotors, drums, wheels and tires are quite
Internal leakage in the master cylinder caused by warm to the touch after the vehicle is stopped.
worn or damaged piston cups, may also be the prob Severe drag can char the brake lining all the way
lem cause. through. It can also distort and score rotors and
If leakage is severe, fluid will be evident at or around drums to the point of replacement. The wheels, tires
the leaking component. However, internal leakage in and brake components will be extremely hot. In se
the master cylinder may not be physically evident. Re vere cases, the lining may generate smoke as it chars
from overheating.
fer to the cylinder test procedure in this section.
Some common causes of brake drag are:
LOW PEDAL • seized or improperly adjusted parking brake cables
If a low pedal is experienced, pump the pedal sev • loose/worn wheel bearing
eral times. If the pedal comes back up, worn lining • seized caliper or wheel cylinder piston
• caliper binding on corroded bushings or rusted
and worn rotors or drums are the likely causes.
slide surfaces
A decrease in fluid level in the master cylinder res
• loose caliper mounting bracket
ervoirs may only be the result of normal lining wear.
• drum brakeshoes binding on worn or damaged sup
Fluid level can be expected to decrease in proportion
port plates
to wear. It is a result of the outward movement of • misassembled components.
caliper and wheel cylinder pistons to compensate for If brake drag occurs at all wheels, the problem may
normal wear. Top off the reservoir fluid level and be related to a blocked master cylinder return port, or
check brake operation to verify proper brake action. faulty power booster that binds and does not release.
SPONGY PEDAL. BRAKE FADE
A spongy pedal is most often caused by air in the sys Brake fade is a product of overheating caused by
tem. Thin brake drums or substandard brake lines and brake drag. However, brake overheating and subse
hoses can also cause a spongy pedal. The proper course quent fade can also be caused by riding the brake
of action is to bleed the system and replace thin drums pedal, making repeated high deceleration stops in a
and suspect quality brake lines and hoses. short time span, or constant braking on steep moun
tain roads. Refer to the Brake Drag information in
HARD PEDAL OR HIGH PEDAL EFFORT this section for additional causes.
A hard pedal or high pedal effort may be due to
lining t h a t is water soaked, contaminated, glazed, or PEDAL PULSA TION
badly worn. The power booster or check valve could Pedal pulsation is caused by components t h a t are
also be faulty. loose, out of round, or worn beyond tolerance limits.
• BRAKES 5 - 5
Disc brake rotors with excessive lateral runout or Thump/Clunk

thickness variation, or out of round brake drums are Thumping or clunk noises during braking are fre
the primary causes of pulsation. Other causes are loose quently n o t caused by brake components. In many
wheel bearings or calipers and worn, damaged tires. cases, such noises are caused by loose or damaged
steering, suspension, or engine components. How
PULL ever, calipers t h a t bind on t h e slide pins, or slide sur
A front pull condition could be the result of con faces, can generate a thump or clunk noise. Worn
taminated lining in one caliper, seized caliper piston, out, improperly adjusted, or improperly assembled
binding caliper, loose caliper, loose or corroded slide rear brakeshoes can also produce a t h u m p noise.
pins, improper brakeshoes, or a damaged rotor.
A worn, damaged wheel bearing or suspension compo Chatter
nent are further causes of pull. A damaged front tire Brake chatter is usually caused by loose or worn
(bruised, ply separation) can also cause pull. components, or glazed/burnt lining. Rotors with hard
A common and frequently misdiagnosed pull condi spots can also contribute to chatter. Additional
tion is where direction of pull changes after a few causes of chatter are out of tolerance rotors, brake
stops. The cause is a combination of brake drag fol lining not securely attached to the shoes, loose wheel
lowed by fade at one of the brake units. bearings and contaminated brake lining.
As the dragging brake overheats, efficiency is so
reduced t h a t fade occurs. Since the opposite brake Brakelining Contamination
unit is still functioning normally, its braking effect is Brakelining contamination is usually a product of
magnified. This causes pull to switch direction in fa leaking calipers or wheel cylinders, driving through
vor of the normally functioning brake unit. deep water puddles, or lining t h a t has become cov
When diagnosing a change in pull condition, re ered with grease and grit during repair.
member t h a t pull will return to the original direction
if the dragging brake unit is allowed to cool down Wheel and Tire Problems
(and is not seriously damaged). Some conditions attributed to brake components
may actually be caused by a wheel or tire problem.
REAR BRAKE GRAB OR PULL A damaged wheel can cause shudder, vibration and
Rear grab or pull is usually caused by an improperly pull. A worn or damaged tire can also cause pull.
adjusted or seized parking brake cable, contaminated Severely worn tires with very little tread left can
lining, bent or binding shoes and support plates, or im produce a grab-like condition as the tire loses and re
properly assembled components. This is particularly covers traction.
true when only one rear wheel is involved. However, Flat-spotted tires can cause vibration and wheel
when both rear wheels are affected, the master cylinder t r a m p and generate shudder during brake operation.
or proportioning valve could be at fault. A tire with internal damage such as a severe
bruise or ply separation can cause pull and vibration.
BRAKES DO NOT HOLD AFTER DRIVING
THROUGH DEEP WATER PUDDLES MASTER CYLINDER/POWER BOOSTER TEST
This condition is generally caused by water soaked (1) Start engine and check booster vacuum hose
lining. If the lining is only wet, it can be dried by driv connections. Hissing noise indicates a vacuum leak.
ing with the brakes very lightly applied for a few min Correct any leaks before proceeding.
utes. However, if the lining is thoroughly wet and dirty, (2) Stop engine and shift transmission into Neu
disassembly and cleaning will be necessary. tral
(3) Pump brake pedal until all vacuum reserve in
BRAKE NOISE booster is depleted.
(4) Press and hold brake pedal under light foot
Squeak/Squeal pressure.
Brake squeak or squeal may be due to linings that (a) If pedal holds firm, proceed to step (5).
are wet or contaminated with brake fluid, grease, or oil. (b) If pedal does not hold firm and falls away,
Glazed linings and rotors with hard spots can also con master cylinder is faulty (internal leakage).
tribute to squeak. Dirt and foreign material embedded (5) Start engine and note pedal action.
in the brake lining can also cause squeak/squeal. (a) If pedal falls away slightly under light foot
A very loud squeak or squeal is frequently a sign of pressure then holds firm, proceed to step (6).
severely worn brake lining. If the lining has worn (b) If pedal is effort is high, or no pedal action is
through to the brakeshoes in spots, metal-to-metal con discernible, power booster or vacuum check valve is
tact occurs. If the condition is allowed to continue, ro faulty. Install known good check valve and repeat
tors can become so scored that replacement is necessary. steps (2) through (5).
5 - 6 BRAKES •
(c) On diesel models, vacuum pump hose or (2) Start and run engine at idle speed for one
pump component may have malfunctioned. Check minute.
pump output with vacuum gauge and repair as (3) Clamp hose shut between vacuum source and
necessary. Refer to service procedures in Power check valve (Fig. 3).
Booster/Vacuum Pump section. (4) Stop engine and observe vacuum gauge.
(6) Rebuild booster vacuum reserve as follows: Re (5) If vacuum drops more t h a n one inch vacuum
lease brake pedal. Increase engine speed to 1500 (33 millibars) within 15 seconds, either booster dia
rpm, close throttle and immediately t u r n off ignition. phragm or check valve are faulty.
(7) Wait a minimum of 90 seconds and try brake ac
SHORT
tion again. Booster should provide two or more vacuum CONNECTING CHECK
assisted pedal applications. If vacuum assist is not pro
vided, perform booster and check valve vacuum tests.
Also check vacuum output on diesel models.
POWER BOOSTER CHECK VALVE TEST

(1) Disconnect vacuum hose from check valve.
(2) Remove check valve and valve seal from
booster (Fig. 1).
(3) Hand operated vacuum pump can be used for
test (Fig. 2).
(4) Apply 15-20 inches (50-67 kPa) vacuum at
large end of check valve (Fig. 1).
(5) Vacuum should hold steady. If gauge on pump
indicates any vacuum loss, valve is faulty and must
be replaced.
BOOSTER
CHECK VACUUM
VALVE APPLY TEST GAUGE
\ VACUUM HERE
J9005-81
Fig. 3 Booster Vacuum Test Connections

TESTING DIESEL ENGINE VACUUM PUMP OUTPUT
On models with a Cummins turbo diesel engine, a
low vacuum condition in the brake booster will cause
the brake warning light to illuminate.
The following test checks output and condition of the
vacuum pump and interconnecting hoses. However, a
more comprehensive testing procedure is provided in
the Power Brake Booster-Brake Pedal-Vacuum Pump
section. Refer to the procedure for "Diagnosing A Low
Fig. 1 Vacuum Check Vaive And Seal Vacuum Condition" in that section.
(1) Check pump vacuum and booster hoses and
connections. Make sure hoses are in good condition
and securely attached. Run engine and check for vac
u u m leaks. Replace leaking hoses before proceeding.
(2) Disconnect vacuum hose at booster and connect
vacuum gauge to hose end.
(3) Run engine at curb idle speed and note vacuum
reading. Then run engine at 1/2 to 3/4 throttle and
note vacuum reading again.
J9005-80
(4) Vacuum should range from 8.5 to 25 inches
vacuum at various throttle openings. Vacuum should
Fig. 2 Typical Hand Operated Vacuum Pump
hold steady and not drop below 8.5 inches.
POWER BOOSTER VACUUM TEST (5) If vacuum output is OK, check booster and
(1) Connect a vacuum gauge to the booster check check valve as described in this section. However, if
valve with a short length of hose and a T-fitting (Fig. vacuum is low, or does not hold steady, vacuum
3). hoses or pump components are faulty.
• BRAKES i - 7
B R A K E A D J U S T M E N T S - B R A K E BLEEDING
INDEX
page page
Brake Fluid and Level 7 Stop Light Switch Adjustment 9
Brake System Bleeding 8 Wheel Nut Tightening 9
Rear Brake Adjustment 7
BRAKE FLUID AND LEWEL shoes are replaced; removed for access to other parts;
or when one or both drums are replaced.
RECOMMENDED FLUID Adjustment can be performed with a standard
The only brake fluid recommended for AD models brake gauge or with adjusting tool C-3784.
is Mopar brake fluid, or an equivalent fluid meeting
SAE J 1 7 0 3 and DOT 3 standards. ADJUSTMENT WITH STANDARD BRAKE GAUGE
Use n e w brake fluid only, to top off the master (1) Verify t h a t left/right automatic adjuster lever
cylinder or refill the system* N e v e r u s e re and cable are properly connected and t h a t parking
claimed fluid, fluid not meeting the S A E / D O T brakes are fully released. Be sure there is slack in
standards, fluid marked 70R1, or fluid from a cables.
container that h a s b e e n left open for a n y length (2) Insert brake gauge in drum. Expand gauge un
til gauge inner legs contact drum braking surface.
of time. Using n o n r e c o m m e n d e d or unspecified
Then lock gauge in position (Fig. 1).
fluid c a n result in brake failure after h a r d pro
longed braking.
BRAKE FLUID LEWEL

Always clean the master cylinder cover before
checking fluid level. If not cleaned, dirt from the
cover could enter the fluid. Also check the cover seal
and replace it if torn or distorted.
Correct fluid level is to the bottom of the ring in
dicators on models with a plastic reservoir and to
within 1/4 inch of the reservoir rim on all others.
If necessary, add fluid to bring up to the proper level.
Note that on disc brake equipped vehicles, fluid level
can be expected to fall as the brake pads wear.
BRAKE FLUID CONTAMINATION
Oil in the fluid will cause brake system rubber
seals to soften and swell. The seals may also become Fig. 1 Adjusting Gauge To Brake Drum
porous and begin to deteriorate. (3) Reverse gauge and install it on brakeshoes
If fluid contamination is suspected, drain off a sam (Fig. 2). Position gauge legs at shoe centers as
ple from the master cylinder. A suction gun or simi shown. If gauge does not fit (too loose/too tight), ad
lar device can be used for this purpose. just shoes.
Empty the drained fluid into a glass container. (4) Pull t h e shoe adjuster star wheel away from
Contaminants in the fluid will cause the fluid to sep the automatic adjuster lever.
arate into distinct layers. If contamination has oc (5) Turn the adjuster star wheel (by hand) to ex
curred, the system rubber seals, hoses and cups must pand or retract the brakeshoes. Continue adjustment
be replaced and the system thoroughly flushed with until the gauge outside legs are a light drag-fit on
clean brake fluid. the shoes (Fig. 2).
Remember that brake fluid tends to darken (6) Repeat adjustment a t the opposite brakeshoe
over time. Do n o t confuse this normal condition assembly.
with contamination. (7) Install the brake drums and wheels and lower
the vehicle.
REAR BRAKE ADJUSTMENT (8) Make final adjustment. Drive vehicle and make
The rear drum brakes are equipped with a self ad one forward stop followed by one reverse stop. Repeat
justing mechanism. Under normal circumstances, the procedure 8-10 times to actuate adjuster mechanism
only time adjustment is required is when the brake- and equalize adjustment. Bring vehicle to complete
i - 8 BRAKES •
BRAKE SHOE'S
Fig. 2 Adjusting Brakeshoes To Gauge

standstill at each stop. Incomplete, rolling stops will Fig. 3 Rear Brake Adjustment With Tool C-3784
not activate the automatic adjusters. (5) Have helper apply brakes firmly. Firm applica
tion will cause secondary shoe to move and engage
ADJUSTMENT WITH TOOL C-3784 rotating drum.
(1) Release parking brakes fully. Be sure there is (6) Normal shoe "wrap-up" effect should move sec
slack in cables. ondary shoe enough to cause adjuster cable to pull
(2) Raise vehicle so all wheels are free to turn. adjuster lever up and t u r n star wheel.
(3) Remove rubber plugs from access holes in sup
port plates. BRAKE SYSTEM BLEEDING
(4) Insert adjusting Tool 0-3784 into star wheel of The brake system can be bled manually or with
adjuster screw. Turn star wheel counterclockwise pressure equipment. Manual bleeding requires the
(move tool upward) until slight drag is felt when aid of a helper. Pressure equipment allows the sys
road wheel is rotated. tem to be bled by one person.
(5) Insert thin screwdriver or length of welding rod All models are equipped with a front brake meter
into support plate access hole and push adjuster lever ing (hold off) valve. The metering valve is located
out of engagement with star wheel (Fig. 3). Do not within the combination valve. The metering valve
bend lever or distort lever spring. balances brake action between the front disc and
(6) Hold adjuster lever away from star wheel. Then rear drum brakes during initial brake application.
back off star wheel until shoe drag on drum is elim The metering valve is designed to hold off fluid
inated. flow to the front disc brakes at pressures between 3
(7) Repeat above adjustment at opposite wheel. Be and 135 psi (20.68 and 930.8 kPa).
sure adjustment is equal. Pressures generated by gravity or manual type
(8) Install access hole plugs in support plate. bleeding techniques will not affect the valve. How
(9) Adjust the parking brake after wheel brake ad ever, pressure bleeding equipment will generate
justment. enough fluid pressure (20 to 30 psi) to close the valve
(10) Make final adjustment. Drive vehicle and and prevent fluid flow to the front brakes. As a re
make one forward stop followed by one reverse stop. sult, the valve must be held open with special tool
Repeat procedure 8-10 times to actuate adjuster C-4121 when using pressure bleeding equipment.
mechanism and equalize adjustment. Bring vehicle to
complete standstill at each stop. Incomplete, rolling BLEEDING PROCEDURE
stops will not activate adjuster mechanism. (1) If new or overhauled master cylinder will be used,
be sure to bleed cylinder before installation. Refer to
CHECKING DRUM BRAKE ADJUSTER bleeding procedure in Master Cylinder section.
OPERATION (2) If master cylinder has not been serviced, clean
(1) Place vehicle on hoist, with helper in driver master cylinder and cover to prevent dirt entering
seat to apply brakes. reservoirs. Then remove cover.
(2) Remove access plugs from support plates. (3) If pressure bleeding t a n k C-3496-B will be
(3) Back off adjuster screw star wheel approxi used, install adapter C-4578 on master cylinder.
mately 20-30 notches. Then prepare tank for bleeding according to instruc
(4) Observe adjuster screw star wheel and spin tions provided by supplier. Be sure to purge air from
drum and road wheel rapidly in a reverse direction. t a n k lines before use.
BRAKES i - 9
Fig. 4 Metering Valve Hold Off Tool

(4) If pressure bleeding equipment will be used, hold
metering valve open with tool C-4121. Tool is installed
on valve stem to hold it (and valve) open (Fig. 4).
in clear container partially filled with brake fluid.
C A U T I O N : Under no condition should a rigid clamp, Be sure hose end is immersed in brake fluid or air
wedge or block be used to press the valve stem in will be drawn back into valve.
ward to hold the valve open. This practice could dam (b) Open bleed screw at RWAL valve and allow
age the valve resulting in valve failure and loss of fluid to flow through valve.
front brake action. Note that the valve stem is in its in
(c) Stop bleeding when only clear, bubble free
nermost position when there is no pressure present.
fluid flows into fluid container.
No attempt should be made to further depress the
(d) Continue bleeding operations in recom
valve stem.
mended sequence at wheel brake units. Start with
(5) Bleed system in following sequence and bleed left rear wheel.
only one wheel or valve at a time: (9) Repeat bleeding procedure if system indicator
• master cylinder lights remain on or if pedal still feels spongy.
• RWAL hydraulic valve
• right rear wheel WHEEL NUT TIGHTENING
• left rear wheel The wheel attaching nuts must be tightened properly
• right front wheel to ensure efficient brake operation. Overtightening the
• left front wheel nuts or tightening them in the wrong sequence could
(6) Bleed master cylinder first. If replacement cylin cause distortion of the brake rotors and drums.
der will be installed, bleed cylinder on bench before in Impact wrenches are not the best tools for tighten
stalling it. ing wheel nuts. A torque wrench should be used for
(7) If m a n u a l b l e e d i n g : this purpose at all times.
(a) Fill master cylinder with fresh fluid and open The correct tightening sequence is important in
all bleed screws. Close bleed screws when fluid be avoiding rotor and drum distortion. The correct se
gins to trickle from each bleed screw opening. quence is in a diagonal crossing pattern (Fig. 5).
(b) Top off master cylinder with fresh fluid. Seat the wheel and install the wheel nuts finger
(c) Clean bleed screw on RWAL valve. Then in tight. Tighten the nuts in the sequence to 1/2 re
stall bleed hose on bleed screw. Insert end of hose quired torque. Then repeat the tightening sequence
in clear container partially filled with brake fluid. to final specified torque.
Be sure hose end is immersed in brake fluid or air
will be drawn back into valve. STOP LIGHT SWITCH ADJUSTMENT
(d) Have helper press and hold brake pedal to The plunger-type stop light switch is attached to
floorpan. Then tighten bleed screw at this point the brake pedal bracket. The switch is directly actu
and have helper release pedal. ated by a t a n g on the brake pedal. Switch adjust
(e) Open bleed screw and have helper press pedal ment is as follows:
down again. Continue bleeding until only clear, (1) Push switch through clip in mounting bracket
bubble free fluid flows into glass container. until switch is sealed against bracket. Brake pedal
(f) Continue bleeding operations at remaining will move forward slightly.
wheel brake units. (2) Gently pull back on brake pedal as far as it will
(8) If p r e s s u r e b l e e d i n g : go.
(a) Clean bleed screw on RWAL valve. Then in (3) Switch will ratchet rearward to correct posi
stall bleed hose on bleed screw. Insert end of hose tion. F u r t h e r adjustment is not required.
S - 10 BRAKES •
MASTER CYLINDER—COMBINATION VALVE—BRAKE LINES
INDEX
page page
Bleeding New or Overhauled Master Cylinder . . . 12 General Information . 10
Brake Lines and Hoses 13 Master Cylinder Installation 12
Combination Valve Operation 13 Master Cylinder Removal 10
Combination Valve Removal/Installation . . . . . . . . 13 Master Cylinder Service—Integral Cylinder 11
Combination Valve Testing . . . . . . . . . . . . . . . . . 13 Master Cylinder Service—Two-Section Cylinder . . 11
GENERAL INFORMATION
Two types of master cylinder are used on AD mod
els. A two-section master cylinder with a removable
reservoir is used on D and W150/250 models (Fig. 1).
An integral (one-piece) master cylinder with built-in
fluid reservoirs is used on D and W 250/350 heavy
duty models (Fig. 2).
Two-Section Master Cylinder

The two-section master cylinder consists of the cyl
inder body and a removable fluid reservoir. The pri
mary and secondary pistons are located in t h e
aluminum body section. The removable reservoir is
made of nylon reinforced with glass fiber and is t h e
only serviceable component.
The fluid compartments of t h e nylon reservoir are
interconnected to permit fluid level equalization.
However, t h e equalization feature does not affect cir
cuit separation in t h e event of a front/rear hydraulic
system malfunction. The reservoir compartments are
designed to retain t h e necessary quantity of fluid
needed to operate t h e functioning circuit.
Care must be exercised when removing/installing
the master cylinder connecting lines. The threads in
the fluid ports can be damaged if care is not prac
ticed. Start all brake line fittings by hand to avoid
cross threading.
The aluminum b o d y section of t h e master cyl
inder i s n o t a repairable component. If diagnosis
indicates that a n internal malfunction h a s oc OUTLETS MASTER CYLINDER BODY RF494
curred, t h e aluminum b o d y section must b e re
placed a s a n assembly. Fig. 2 Integral Master Cylinder
Integral Master Cylinder MASTER CYLINDER REMOVAL

The one-piece master cylinder is a venting type (1) Disconnect primary and secondary brake tubes
with integral fluid reservoirs. The primary and sec at master cylinder.
ondary piston assemblies a r e located in t h e cylinder (2) Install plugs in cylinder outlet ports and brake
bore. The cylinder is a fully serviceable component tubes to prevent dirt entry.
and can be overhauled when necessary. (3) Remove nuts attaching master cylinder to
power brake booster.
Combination Valve (4) Remove master cylinder from power brake
A two-way combination valve is used on all AD booster mounting studs.
models (Fig. 3). The two-way valve contains a front
brake metering valve and a pressure differential
valve and switch.
• BRAKES 5 - 11
F R O M M A S T E R CYLINDER ^ S W I T C H ASSEMBLY (7) Install new reservoir grommets in cylinder

body.
(8) Lubricate new reservoir grommets with clean
brake fluid.
C A U T I O N : The reservoir can be installed back

wards if care is not exercised. Install the reservoir
s o the fluid fill information (on the reservoir side) is
on the s a m e side a s the fluid outlet ports in the cyl
inder body (Fig. 4).
(9) Start reservoir into grommets. Then rock reser

voir side to side until fully seated. Reservoir bottom
surface should touch grommets after installation.
(10) Bleed master cylinder before installing it in
vehicle. Refer to procedure in this section.
Fig. 3 Two-Way Combination Valve
MASTER CYLINDER SERVICE-TWO-SECTION MASTER CYLINDER SERVICE-INTEGRAL
CYLINDER CYLINDER
The integral (one-piece) cylinder is a fully service
The only serviceable component on the two-
able component. It can be overhauled to restore per
section cylinder is the n y l o n reservoir. If the cyl
formance when necessary. Overhaul procedure is as
inder b o d y or internal components are w o r n or
follows.
damaged, the cylinder b o d y must be replaced as
an assembly. INTEGRAL CYLINDER DISASSEMBLY AND
INSPECTION
RESERVOIR REPLACEMENT- TWO-SECTION
(1) Remove cylinder cover (Fig. 5).
CYLINDER
(2) Drain fluid from cylinder reservoirs.
(1) Clean reservoir exterior and master cylinder
(3) Mount cylinder in vise.
body.
(4) Press cylinder pistons inward with wood dowel
(2) Remove reservoir caps and drain fluid from cyl
and remove piston snap ring (Fig. 6).
inder.
(5) Remove primary piston assembly from cylinder
(3) Mount master cylinder in vise. Clamp vise jaws
bore. Discard piston assembly.
on aluminum body.
(6) If cylinder is equipped with piston stop screw
(4) Note position of reservoir before removal. This
for secondary piston, remove stop screw before pro
is important as reservoir can be installed backwards
ceeding.
if care is not exercised.
(7) Remove secondary piston with compressed air
(5) Remove reservoir by firmly rocking it from side
applied through brakeline port or compensator port
to side (Fig. 4). Continue rocking until reservoir is
at bottom of reservoir. Discard piston assembly after
free of grommets.
removal.
COVER COVER
Fig. 4 Removing/Installing Cylinder Reservoir

(6) Remove and discard grommets securing reser CLAMP RF495
voir in cylinder body.
Fig. 5 Removing/Installing Cylinder Cover
i - 12 BRAKES •
BLEEDING NEW OR OVERHAULED MASTER
CYLINDER
A new or overhauled master cylinder should be
purged of all air before installation on the vehicle.
Cylinder bleeding is performed on the bench.
Bleeding tools for the integral master cylinder in
clude fabricated bleed tubes and a wood dowel.
Bleeding tools for the two-section master cylinder in
clude bleed tubes C-4029 and a wood dowel (Fig. 7).
CYLINDER BLEEDING PROCEDURE

(1) Mount master cylinder assembly in vise.
(2) Attach bleed tubes to cylinder outlet ports and
Fig. 6 integral Cylinder Components insert tubes in reservoir fluid compartments (Fig. 7).
Cylinder Cleaning And Inspection Bleed tubes can be fabricated from steel or copper
Clean the cylinder body and cover with brake fluid tubing and appropriate size fittings.
or brake cleaner only. Do not use any other type of (3) Fill reservoir with fresh brake fluid.
solvents, or cleaning agent. (4) Press cylinder pistons inward with wood dowel.
Inspect the cylinder body and bore. Light discolor Then release pistons and allow them to return under
ation of the cylinder bore is normal and is an accept spring pressure.
able condition. The bore should be smooth and free of (5) Continue bleeding operations until air bubbles
scores, scratches, corrosion and rust. Replace the cyl are no longer visible in fluid.
inder if the bore is worn, scored, or corroded.
D o n o t h o n e t h e b o r e in an attempt to restore the
surface finish. Replace the cylinder if the bore is
damaged in any way. Also replace the cylinder if the
body is cracked, porous, or the compensator port at
the bottom of each reservoir is blocked or damaged.
Inspect the cover and gasket. Replace the gasket if
distorted, cut, or torn. Replace the cover and retain
ing wire if either component is distorted or damaged
in any way.
Do not reuse the old piston assemblies. Discard
these parts as soon as they are removed. Install re
placement primary and secondary piston assemblies
only.
INTEGRAL CYLINDER ASSEMBLY

Fig. 7 Master Cylinder Bleeding— Two-Section
(1) Coat cylinder bore and replacement piston as
Cylinder Shown
semblies with liberal quantity of clean brake fluid.
(2) Install secondary piston assembly in bore with MASTER CYLINDER INSTALLATION
a turning motion. Do not use metal tools of any kind (1) Bleed master cylinder on bench before installa
to help ease piston into bore. Sharp edge tools will tion.
scratch bore and cut piston seals. (2) Position master cylinder on studs of power
(3) If cylinder is equipped with stop screw for sec brake unit.
ondary piston, press piston to bottom of bore and in (3) Align power brake push rod with master cylin
stall screw. der piston.
(4) Install primary piston in bore. (4) Install and tighten cylinder attaching nuts to
(5) Press pistons inward with wood dowel and in 23 N-m (200 in. lbs.).
stall piston snap ring. Be sure snap ring is fully (5) Connect front and rear brakelines to cylinder.
seated. Start brakeline fittings by hand.
(6) Install new gasket on cover if necessary. (6) Tighten brakeline fittings to 19 N«m (170 in.
(7) Install cover retaining wire on cylinder if re lbs.).
moved. (7) Bleed brakes.
(8) Fill and bleed master cylinder on bench before
installing it in vehicle. Refer to following procedure.
• BRAKES 5 - 13
COMBINATION VALVE OPERATION (b) If light fails to illuminate, check circuit fuse,
bulb and wiring. Repair as necessary and repeat
METERING (HOLD-OFF) VALVE test steps (3) and (4).
The metering valve is used to balance brake action (5) If warning light still fails to illuminate, check
between the front disc and rear drum brakes. The brakelight and park brake switches (and wiring)
valve meters (holds-off) full apply pressure to the with test lamp. Repair or replace parts as necessary
front disc brakes until the rear brakeshoes are in full and test differential pressure switch operation again.
contact with t h e drums. (6) If warning light still does not illuminate,
The valve is designed to maintain front brake fluid switch is faulty. Replace combination valve, bleed
pressure at 3-30 psi until the hold-off limit of 117 psi brakes and verify proper switch and valve operation.
is reached. At this point, the metering valve opens
completely permitting full fluid apply pressure to the COMBINATION VALVE REMOVAL/INSTALLATION
front disc brakes.
VALVE REMOVAL
PRESSURE DIFFERENTIAL SWITCH AND (1) Raise vehicle on hoist.
VALVE (2) Mark or tag brake lines connected to valve for
The pressure differential switch is connected to the assembly reference.
brake warning light. The switch is triggered by (3) Disconnect lines at valve (Fig. 8).
movement of the switch valve. The purpose of the (4) Disconnect wires from differential pressure
switch is to monitor fluid pressure in the separate switch.
front/rear brake hydraulic circuits. (5) Remove bolts attaching valve to frame bracket
A decrease or loss of fluid pressure in either hy and remove valve.
draulic circuit will cause the switch valve to shuttle
forward or rearward in response to a pressure differ VALVE INSTALLATION
ential. (1) Mount new valve on bracket and tighten valve
Movement of the switch valve will push the switch and bracket screws/nuts securely.
plunger upward. This closes the switch internal con (2) Connect brakelines to valve. Tighten fittings to
tacts completing the electrical circuit to the warning 16 N*m (145 in. lbs.)
light. The switch valve will remain in an actuated (3) Connect wires to pressure differential switch
position until repair restores system pressures to nor terminal.
mal levels. (4) Bleed brakes.
(5) Lower vehicle and verify proper brake opera
COMBINATION VALVE TESTING tion.
TESTING METERING VALVE BRAKE LINES AND HOSES

Metering valve operation can be checked visually
and with the aid of a helper. BRAKE LINE AND HOSE INSPECTION
Observe the metering valve stem while a helper Flexible rubber hose is used at both front brakes
applies and releases the brakes. If the valve is oper and at the rear axle junction block. Inspect the hoses
ating correctly, the stem will extend slightly when whenever the brake system is serviced, at every en
the brakes are applied and retract when the brakes gine oil change, or whenever the vehicle is in for ser
are released. vice.
If the valve is faulty, replace the entire combina Inspect the hoses for surface cracking, scuffing, or
tion valve as an assembly. worn spots. Replace any brake hose immediately if
the fabric casing of the hose is exposed by cracks or
TESTING PRESSURE DIFFERENTIAL SWITCH abrasion.
(1) Have helper sit in drivers seat to observe brake Also check brake hose installation. Faulty installa
warning light and to operate brake pedal. tion can result in kinked, twisted hoses, or contact
(2) Raise vehicle on hoist. with the wheels and tires or other chassis compo
(3) Connect bleed hose to left or right rear wheel nents. All of these conditions can lead to scuffing,
cylinder. Then immerse hose end in glass jar par cracking and eventual failure.
tially filled with brake fluid. The steel brake lines should be inspected periodi
(4) Have helper press and hold brake pedal all the cally for evidence of corrosion, twists, kinks, leaks, or
way down and observe warning light. other damage. Heavily corroded lines will eventually
(a) If warning light illuminates, switch is operat rust through causing leaks. In any case, corroded or
ing correctly. damaged brake lines should be replaced.
5 - 14 BRAKES •
Fig. 8 Combinat Valve Mounting

BRAKE LINE AND HOSE REPLACEMENT clean and free from nicks and burrs. Also remember
Factory replacement brake lines and hoses are rec t h a t right and left brake hoses are not interchange
ommended to ensure quality, correct length and su able.
perior fatigue life. Care should be taken to make Use new copper seal washers at all caliper connec
sure t h a t brake line and hose mating surfaces are tions (Fig. 9). Be sure brake line connections are
properly made (not cross threaded) and tightened to
recommended torque.
Brake line routing, connections and tightening ref
erence information is outlined in Figures 9 through
12.
Fig. 9 Front Brake Lines
Fig. 10 Rear Brake Lines And RWAL Components
TUBE ASSEMBLY MASTER
BRACKET AND SHIELD TORQUE
CYLINDER TO BRAKE
VALVE REAR (SECONDARY) LET. NEWTON
POUNDS
METRES
x!^ 145 IN. 16
35 FT. 47
XX
BRAKE HOSE AND RWAL
SENSOR WIRING 170 IN. 19
100 IN. 11
125 IN. 14
BRAKE VALVE TUBE

TO RIGHT FRONT
BRAKE HOSE
GASKET
VIEW IN DIRECTION SCREW <§>

OF ARROW A
8905-54
Fig. 11 Brake Lines—Two-Wheel Drive Models

TORQUE
LET. NEWTON
POUNDS
METRES
145 IN. 16
125 IN. 14
100 IN. 11
170 IN. 19
<C> SCREW
RIGHT BRAKE
<A> TUBE
<A> RIGHT
BRAKE TUBE <C>
BRAKE HOSE
BRAKE VALVE TUBE

TO FRONT BRAKE HOSE VALVE
VIEW IN DIRECTION OF ARROW B ASSEMBLY 8905-55
Fig. 12 Brake Lines—Four-Wheel Drive Models

• BRAKES 5-19
BRAKE LINE EMERGENCY REPAIR compression disc over gauge and center tapered flar
Mopar preformed metal brake line is recommended ing screw in recess of compression disc
and preferred for all repairs. However, double-wall (9) Tighten tool handle until plug gauge is seated
steel line can be used for emergency repair when fac on jaws of flaring tool. This starts inverted flare (Fig.
tory replacement parts are not readily available. 13).
Special, heavy duty tube bending and flaring (10) Remove plug gauge and complete inverted
equipment is required to prepare double wall brake flare (Fig. 8).
line. Special bending tools are needed to avoid kink (11) Remove flaring tools and verify t h a t inverted
ing or twisting metal brake line. In addition, special flare is correct. Flared end must be even, not dis
flaring tools are needed to provide the inverted-type, torted, too thin, or cracked.
double flare required on metal brake lines.
Use tool C-4047 to provide the inverted, double
flare (Fig. 8). Heavy duty tube bending tools are
available through the dealer tool program.
Flaring Procedure
(1) Cut off damaged tube with tool C-3478-A or an
equivalent tubing cutter.
(2) Ream cut edges of tubing to ensure proper
flare.
(3) Install replacement tube n u t on section of tube
to be repaired.
(4) Insert tube in flaring tool. Center tube in area
between vertical posts.
(5) Place gauge form A over the end of the tube
(Fig. 13).
(6) Push tubing through flaring tool jaws until
tube contacts recessed notch in gauge t h a t matches
tube diameter.
(7) Squeeze flaring tool jaws to lock tubing in RH222
place.
(8) Insert plug on gauge A in the tube. Then swing Fig. 13 Brakeline Flaring Tools
5 - 20 BRAKES •
POWER BRAKE BOOSTER—BRAKE PEDAL
INDEX
page page
Brake Pedal Installation 21 Power Brake Booster Installation . . . . . . . . . . . . . 21
Brake Pedal Removal 21 Power Brake Booster Removal 21
General Information . . . . . . . . . . . . . . . . . . . . . . . 20
GENERAL INFORMATION The p o w e r brake booster is n o t a repairable

Power brakes are standard on all AD models. A component. The booster must b e replaced a s a n
single or dual diaphragm, vacuum power brake assembly if diagnosis indicates a malfunction
booster is used. h a s occurred.
AD and W150 models are equipped with a single AD models with the Cummins diesel engine are
diaphragm booster unit (Fig. 1). D and W250/350 equipped with a dual diaphragm power brake
models are equipped with a dual diaphragm booster. booster. A separate vacuum pump assembly supplies
The booster unit consists of a single housing di the vacuum needed for booster operation (Fig. 2).
vided into separate chambers by one or two internal
The diesel vacuum pump and t h e power steering
diaphragms. The outer edge of the diaphragm is se
cured to t h e housing. pump are combined into a single assembly. Both
The booster push rod, which connects the booster to pumps are operated by a drive gear pressed onto the
the brake pedal and master cylinder, is attached to vacuum pump shaft. The drive gear is operated by
the center of t h e diaphragm. A check valve is used in the camshaft gear.
the booster outlet connected to t h e engine intake A suspended-type brake pedal is used for all appli
manifold. cations. The pedal is attached to the pedal support
Power assist is produced by a combination of vac bracket with a pivot shaft. The pedal, bolt and bush
u u m and atmospheric pressure to boost brake assist. ings are all serviceable components.
RESERVOIR PEDAL SHAFT
RETAINER
SCREW
<5>
MASTER CYLINDER
AND BOOSTER ASSEMBLY
I RETAINER
CLIP
TIGHTENING TORQUE
'A> 200 IN.-LBS. (23 N-m)
¥> 35 IN.-LBS. (4 N.m)

LOCKNUT «
RK721
Fig. 1 Power Brake Booster And Pedal Mounting

• BRAKES 5 - 21
VACUUM POWER BRAKE BOOSTER INSTALLATION

(1) If new booster is not equipped with check valve
and seal, transfer these parts to new booster.
(2) Align and position booster on dash panel.
(3) Install locknuts on booster mounting studs fin
ger tight.
(4) Install booster push rod on brake pedal pin and
secure the rod with a n e w retaining clip.
(5) Tighten booster locknuts to 25 N t h (220 in.
lbs.) torque.
(6) Install master cylinder on booster. Then install
and tighten cylinder mounting nuts to 19-23 Nnn
(170-200 in. lbs.) torque.
(7) Connect vacuum hose to booster check valve.
BRAKE PEDAL REMOVAL

(1) Disconnect booster push rod from pedal.
(2) Remove screw attaching pedal shaft to brake
GEAR ADAPTER support.
J9105-94 (3) Pull pedal shaft out of support just enough to
remove brake pedal.
Fig. 2 Diesel Vacuum And Power Steering Pump
(4) Slide pedal off shaft and remove it from vehi
Assembly
cle.
POWER BRAKE BOOSTER REMOVAL
(1) Disconnect vacuum hoses from booster check BRAKE PEDAL INSTALLATION
valve. (1) Lubricate pedal shaft and bore in brake pedal
(2) Remove nuts attaching master cylinder to with Mopar multi-mileage grease.
booster and move cylinder away from booster. (2) Position pedal on shaft. Then slide shaft
(3) Inside vehicle, remove clip t h a t secures booster through pedal and into support.
push rod to brake pedal (Fig. 1). Use screwdriver to (3) Secure pedal shaft to support with retaining
ease clip off pedal pivot pin. screw.
(4) Remove locknuts from booster mounting studs. (4) Attach push rod to pedal.
(5) Slide booster away from dash and out of engine (5) Verify correct pedal and brake operation before
compartment. moving vehicle.
5 - 22 BRAKES
P O W E R B R A K E VACUUM P U M P — D I E S E L E N G I N E
INDEX
page page
General Information 22 Vacuum Pump Replacement 24
Low Vacuum Warning Switch 22 Vacuum Pump Serviceability 22
Pump Adapter Replacement . 25 Vacuum—Steering Pump Assembly Installation . . 26
Vacuum Pump Diagnosis . . . . . . . . . . . . . . . . . . 23 Vacuum—Steering Pump Assembly Removal ... 23
Vacuum Pump Operation . . . . . . . . . . . . . . . . . . 23
GENERAL INFORMATION VACUUM

The power brake booster vacuum pump and the PUMP
power steering pump are combined into a single as
sembly on diesel models (Fig. 1). Both pumps are op
erated by a drive gear attached to the vacuum pump
shaft.
The vacuum pump is a constant displacement,
vane-type pump. Vacuum is generated by four vanes
mounted in the pump rotor. The rotor is located in
the pump housing and is pressed onto the pump
shaft.
The vacuum and steering pumps are operated by a
single drive gear pressed onto the vacuum pump
shaft. The drive gear is operated by the camshaft
gear.
The vacuum and power steering pump shafts are POWER
STEERING
connected by a coupling. Each pump shaft h a s an PUMP
adapter with drive lugs t h a t engage in the coupling. DRIVE PUMP
GEAR ADAPTER
The vacuum pump rotating components are lubri J9105-94
cated by engine oil. Lubricating oil is supplied to the
pump through an oil line at the underside of the Fig. 1 Diesel Vacuum And Power Steering Pump
pump housing. Assembly
The complete assembly must be removed in order A vacuum hose connects the switch to the power
to service either pump. However, the power steering
brake booster. A wire harness connects the switch to
pump can removed and serviced separately when
the brake warning light.
necessary.
The switch is mounted on the driver side inner
VACUUM PUMP SERVICEABILITY fender panel just below the hood hinge (Fig. 2),
The vacuum pump is not a serviceable component.
If diagnosis indicates a pump malfunction, the pump
must be replaced as an assembly. Do not disassemble
or attempt to repair the pump.
The combined vacuum and steering pump assembly
must be removed for access to either pump. However,
LOW
VACUUM
b
WARNING
the vacuum pump can be removed without having to SWITCH
disassemble the power steering pump.
If the power steering pump requires service, simply
remove the assembly and separate the two pumps.
Refer to the pump removal and installation proce
dures in this section. SWITCH
HARNESS
LOW VACUUM WARNING SWITCH
A vacuum switch is used to monitor output of the J9105-95
vacuum pump. The switch is in circuit with the
brake warning light. Fig. 2 Diesel Vacuum Switch Location
• BRAKES 5 - 23
VACUUM PUMP OPERATION (5) Start and run engine.

Vacuum pump output is transmitted to the power (6) Apply 8.5 to 9 inches of vacuum to warning
brake booster through a supply hose. The hose is con switch and observe warning light. If light goes out,
nected to an outlet port on the pump housing and to switch vacuum hose is either loose or leaking. If
the check valve in the power brake booster. light remains on, leave engine running and continue
Pump output ranges from a m i n i m u m of 8.5 to 25 testing.
inches vacuum. (7) Apply 20-25 inches vacuum to switch and ob
The pump rotor and vanes are rotated by the pump serve warning light operation. If light now goes out,
drive gear. The drive gear is operated by the cam switch is at fault and should be replaced. If light re
shaft gear. mains on, continue testing.
Booster vacuum level is monitored by a warning (8) Reconnect vacuum hoses and replace original
switch (Fig. 2). The switch consists of a vacuum warning switch with known good switch. Run engine
chamber t h a t measures vacuum level and a sensor in and observe warning light operation. If light is now
circuit with the brake warning light. off, old switch is faulty. If light remains on, problem
The vacuum chamber is connected to the booster is in wiring between switch and warning light.
check valve by a vacuum supply hose. A wire har
ness connects the switch sensor to the brake warning VACUUM-STEERING PUMP ASSEMBLY REMOVAL
light. If booster vacuum falls below 8.5 inches for (1) Disconnect battery negative cable.
8-10 seconds or more, the switch sensor completes (2) Position drain pan under power steering pump.
the circuit to the warning light causing it to illumi (3) Disconnect vacuum and steering pump hoses
nate. from respective pumps (Fig. 3).
VACUUM PUMP DIAGNOSIS

Vacuum pump diagnosis involves checking pump
output with a vacuum gauge. The low vacuum warn
ing switch can also be checked with a vacuum gauge.
Refer to the diagnosis procedure in this section.
A standard vacuum gauge can be used to check
pump output when necessary. Simply disconnect the
pump supply hose and connect a vacuum gauge to
the outlet port for testing purposes. Vacuum should
hold steady in a range of approximately 8.5 to 25
inches at various engine speeds.
DIAGNOSING LOW VACUUM OUTPUT

CONDITION
A low booster vacuum condition or a faulty low
vacuum warning switch will cause the brake warn
ing light to illuminate. If the light does go on and in
dicates the existence of a low vacuum condition,
check the vacuum pump, booster and warning switch
as follows:
(1) Check vacuum pump oil feed line. Verify t h a t
line connections are secure and not leaking. If leak
age is noted and pump is noisy, replace pump. Fig. 3 Vacuum And Steering Pump Hose
(2) Disconnect supply hose to booster. Connect vac Connections
uum gauge to this hose and run engine at various (4) Disconnect oil pressure sender wires at sender
throttle openings. Output should range from 8.5 to (Fig. 4).
25 inches vacuum. If vacuum is consistently below (5) Remove oil pressure sender (Fig. 4).
8.5 inches, problem is with vacuum hoses or pump (6) Disconnect lubricating oil feed line from fitting
component. If output is within specified limits, con at underside of vacuum pump (Fig. 5).
tinue testing. (7) Remove lower bolt t h a t attaches pump assem
(3) Check booster operation as described in diagno bly to engine block (Fig. 6).
sis section. Replace check valve, vacuum hoses, or (8) Remove bottom, inboard nut t h a t attaches
booster if necessary. However, if booster operation is adapter to steering pump (Fig. 6). This nut secures a
correct but warning light is still on, continue testing. small bracket to engine block. Nut and bracket must
(4) Disconnect vacuum hose at warning switch. be removed before pump assembly can be removed
Plug hose and connect hand vacuum pump to switch. from block.
S - 24 BRAKES •
PUMP ASSEMBLY
SOTTOM-INIOAiD
ADAPTER BRACKET NUT J9105-97
Fig. 6 Adapter And Pump Mounting Fastener

Location
LINE J9105-96
Fig. 5 Oil Feed Line Connection At Pump

(9) Remove upper bolt t h a t attaches pump assem
bly to engine block (Fig. 7). Fig. 7 Removing Pump Assembly Upper Mounting
(10) Remove pump assembly from vehicle (Fig. 8). Bolt
(4) Lubricate adapter O-ring with engine oil.
VACUUM PUMP REPLACEMENT
(5) Note position of drive slots in coupling. Then
(1) Remove nuts attaching vacuum pump to
rotate drive gear to align tangs on vacuum pump
adapter (Fig. 8).
shaft with coupling (Fig. 10).
(2) Remove vacuum pump from adapter (Fig. 9).
(6) Verify t h a t pump is seated in adapter and cou
Turn pump gear back and forth to disengage pump
pling.
shaft from coupling if necessary.
(7) Install and tighten pump attaching nuts and
(3) Inspect adapter O-ring (Fig. 9). Replace O-ring
washers.
if cut or torn.
• BRAKES 5 - 25
PUMP ADAPTER REPLACEMENT

(1) Remove coupling from adapter (Fig. 11).
(2) Remove remaining adapter attaching n u t s and
remove adapter from steering pump (Fig. 12).
(3) If steering pump will be serviced, remove
spacer from each inboard mounting stud on pump
(Fig, 12).
ADAPTER
J9105-98
Fig. 8 Pump Assembly Removal

COUPLING
O-RING PUMP Fig. 11 Removing/Installing Pump Drive Coupling

ADAPTER
J9105-99
Fig. 9 Vacuum Pump Removed From Adapter
ROTATE DRIVE
GEAR TO ALIGN
Fig. 12 Steering Pump Mounting Stud Spacer

Locations
TANGS J9105-102
Fig. 10 Aligning Pump Shaft Drive Tangs

5 - 26 BRAKES •
(4) Clean and lubricate pump shaft with engine
oil.
(5) Install spacers on steering pump studs (Fig.
12).
(6) Install O-ring on adapter (Fig. 11).
(7) Position adapter on pump studs.
(8) Install attaching nuts on outboard stud and on
the two upper pump studs. Do n o t install nut on
lower, inboard stud at this time. Tighten nuts to 24
N-m (18 ft. lbs.) torque.
(9) Install coupling on pump shaft. Be sure cou
pling is securely engaged in shaft drive tangs.
(10) Install vacuum pump on adapter. Rotate drive
gear until tangs on pump shaft engage in coupling.
Verify t h a t pump is seated before installing attach
ing nuts.
(11) Install and tighten vacuum pump attaching
nuts.
VACUUM-STEERING PUMP ASSEMBLY

INSTALLATION
(1) Position new gasket on vacuum pump mount
Fig. 14 Installing Pump Assembly On Engine
ing flange (Fig. 13). Use Mopar perfect seal, or sili
cone adhesive/sealer to hold gasket in place. (4) Working from under vehicle, install pump as
sembly lower attaching bolt. Then tighten upper and
lower bolt to 77 N»m (57 ft. lbs.) torque.
(5) Position bracket on steering pump inboard
stud. Then install remaining adapter attaching n u t
on stud. Tighten n u t to 24 N«m (18 ft. lbs.) torque.
(6) Connect oil feed line to vacuum pump connec
tor. Tighten line fitting securely.
(7) Install oil pressure sender and connect sender
wires.
(8) Connect steering pump pressure and return
lines to pump. Tighten pressure line fitting to 30
(9) Connect vacuum hose to vacuum pump.
(10) Connect battery cables, if removed.
(11) Fill power steering pump reservoir.
(12) Purge air from steering pump lines. Start en
gine and slowly t u r n steering wheel left and right to
Fig. 13 Positioning Gasket On Pump Mounting circulate fluid and purge air from system.
Flange (13) Stop engine and top off power steering reser
(2) Insert pump assembly upper attaching bolt in voir fluid level.
mounting flange and gasket. Use sealer or grease to (14) Start engine and check brake and steering op
hold bolt in place if necessary. eration. Verify t h a t power brake booster is providing
(3) Position pump assembly on engine and install vacuum assist and firm brake pedal is obtained.
upper bolt (Fig. 14). Tighten upper bolt only enough Then verify t h a t steering action is correct. Do this
to hold assembly in place at this time. before moving vehicle.
• BRAKES 5 - 27
CHRYSLER D I S C BRAKE
INDEX
page page
Caliper Installation . 33 Disc Brakeshoe Removal 29
Caliper Overhaul 32 General Information . . . . . . . . . . . . . . . . . . . . . . . 27
Caliper Removal 31 Rotor Inspection and Service . . . . . . . . . . . . . . . . 34
Disc Brake Inspection 29 Rotor Installation . 35
Disc Brakeshoe Installation , 31 Rotor Removal 34
GENERAL INFORMATION
DISC BRAKE COMPONENTS
The Chrysler disc brake consists of a sliding type,
single piston caliper and a ventilated disc brake rotor
(Figs. 1 and 2).
Each caliper is mounted on an adapter attached to
the steering knuckle (Fig. 2). Each- caliper slide lat
erally on surfaces machined on the caliper and
mounting adapter. The adapters support the caliper
and maintain fore and aft alignment of the caliper
and brakeshoes. Two retainer clips are used to main
tain caliper alignment but permit lateral movement
needed for caliper operation.
Non-metallic caliper pistons are used for all applica
tions. The pistons are made of a phenolic resin material.
Ventilated, cast iron disc brake rotors are used for all SHIELD RK72
applications. The rotors are serviceable and can be ma
chined to restore surface finish when necessary. Fig. 2 Chrysler Disc Brake Caliper Mounting—Front
View
The outboard brake shoe has flanges t h a t locate
and position the shoe on the caliper fingers (Fig. 3).
Braking force on this shoe is taken by the caliper.
The inboard shoe is held in position by the adapter
and reacts directly on the adapter.
The caliper is a one-piece casting with the inboard
side containing the single piston cylinder bore (Fig.
3). A square cut piston seal is located in a machined
groove in the cylinder bore. A rubber dust boot is
used to prevent dirt, water, road splash from enter
ing the caliper piston bore. The boot is located in a
counterbore machined into the outboard end of the
caliper piston bore.
DISC BRAKE OPERATION

The significant feature of caliper operation is that the
caliper is free to move laterally on the slide surfaces.
At brake application, fluid pressure is exerted
RETAINER CLIP \ equally against the caliper piston and all surfaces of
SPLASH the caliper piston bore.
SHIELD RK71 Pressure applied to the piston is transmitted di
Fig. 1 Chrysler Disc Brake Caliper Mounting—Rear rectly to the inboard brakeshoe to press the shoe lin
View ing against the rotor. At the same time, pressure
applied to the caliper bore surfaces, causes the cali
per to slide inward laterally. The inward movement
RK48
• BRAKES 5 - 29
presses the outboard shoe lining against the opposite Check condition of the rotor, brakeshoe lining, caliper
side of the rotor to complete braking action. and brake hoses. Front wheel bearing adjustment and
The application or release of fluid pressure causes condition can also be checked at this time. The bearings
only a very slight movement of the caliper and pis should be repacked and adjusted if necessary.
ton. At brake release, the piston and caliper return
to the non-applied position. Brakeshoes
The brakeshoes do not retract an appreciable dis With the caliper and brakeshoes on the vehicle,
tance from the rotor. The minimal running clearance check running clearance between the rotor and
between the lining and rotor provides improved re brakeshoes. The shoe lining should either be in very
sponse and reduced pedal travel. It also helps in pre light contact with the rotor or have a maximum of
venting dirt and foreign material from lodging 0.127 mm (0.005 in.) running clearance. If clearance
between the shoe and rotor surfaces. exceeds the stated amount, apply the brakes several
times and recheck clearance. If clearance is still ex
DISC BRAKE LINING WEAR COMPENSATION cessive, either the shoes are severely worn or the cal
Normal lining wear is compensated for by extension iper piston could be binding in the bore.
of the caliper piston and by lateral movement of the cal
iper in the adapter. Piston position is also determined Hoses And Adapter
in part by the square cut piston seal (Fig. 4). Inspect condition of the brake lines and hoses. Re
Normal disc brake lining wear will cause the cali place either front hose if cut, torn, or the reinforcing
per piston to extend enough to maintain proper pedal fabric is visible. Check condition of the metal brake-
height and brake response. The caliper bore will re lines. Replace any line t h a t is badly rusted, leaking
ceive the extra fluid needed to compensate for the ad or damaged in any way.
ditional piston extension. Clean and lubricate the slide surfaces of the caliper
As the piston extends during brake application, the and adapter. Use Mopar high temperature grease for
square-cut seal is deflected outward (Fig. 4). When this purpose. Also verify t h a t the caliper adapter
brake pressure is released, the seal straightens and bolts are secure and tightened to proper torque.
returns to a normal relaxed position. Although the
amount of seal movement is quite small, it is enough Fluid Level
to retract the piston to the necessary minimum run Check the master cylinder fluid level. Maintain
ning clearance. fluid level to the bottom of the indicator rings on the
As lining wear occurs, the fluid level in the front reservoir. Note t h a t front disc brake fluid level can
brake reservoir will decrease. This is a normal con be expected to drop slightly as normal lining wear
dition and only requires adding enough fluid to re occurs. Use Mopar brake fluid or equivalent meeting
store proper level. However, when the brakeshoes are SAE and DOT standards J1703 and DOT 3. Use
replaced and the caliper pistons bottomed in the clean brake fluid from a sealed container only.
bores, the added fluid must be compensated for to
avoid overfill and overflow. Removing a small Rotors
amount of fluid from the front brake reservoir before Check the rotor surfaces for excessive wear, discol
hand will prevent this condition. oration, scoring, rust, scale, or cracks. Also look for
damaged or severely rusted ventilating segments. If
PISTON CALIPER pedal pulsation was experienced, check wheel bear
ing adjustment and condition. If the bearings are
OK, also check rotor runout and thickness variation.
DISC BRAKESHOE REMOVAL

(1) If front brakeshoes are to be replaced, remove
approximately 1/3 of fluid from master cylinder front
brake reservoir with suction gun.
(2) Raise and support vehicle.
(3) Remove front wheels.
DUST BOOT RN102
(4) Press caliper pistons to bottom of bore with
Fig. 4 Caliper Piston Seal Operation large C-clamp. Position clamp screw on outboard
brakeshoe and position clamp frame on rear of cali
DISC BRAKE INSPECTION per.
Inspect the disc brake components whenever the (5) Remove bolts securing caliper retainer clips to
caliper and brakeshoes are removed during service caliper. Then remove clips and anti-rattle springs
operations or routine maintenance. (Fig. 5).
5 - 31 BRAKES •
Fig. 7 Removing Outboard Brakeshoe
Fig. 5 Removing/installing Retainer Clips and

Anti-Rattle Springs
(6) Remove caliper by tilting it rearward and lift
ing up and off rotor (Fig. 6).
Fig. 8 Removing/Installing Inboard Brakeshoe

Replace bonded disc brakeshoes if the lining is
Fig. 6 Caliper Removal/Installation worn to a thickness of 4 mm (3/16 in.) or less. Re
(7) Remove outboard brakeshoe from caliper (Fig. place riveted shoes if the lining is worn to within 1.5
7). Use pry tool to remove shoe from caliper if mm (1/16 in.) of the rivet heads.
flanges are tight, If shoe replacement is necessary, replace the shoes
(8) Remove inboard brakeshoe from caliper mount on both sides at the same time. Do not replace the
ing adapter (Fig. 8). shoes on one side only. This practice could result in
(9) Support caliper on box, stool, or front control unequal braking effort and brake pull. Note t h a t it is
arm. Do not allow brake h o s e to support weight normal for the inboard shoe lining to exhibit slightly
of caliper. This practice could d a m a g e hose. more wear than the outboard shoe lining.
(10) Remove O-ring from caliper adapter. Check for piston seal leaks which will be evident
by brake fluid in and around the boot area and in-
• BRAKES 5 - 31
board lining. Also check condition of the caliper pis

ton dust boot. If leakage is evident or if the boot is
cut, torn, or damaged in any way, it will be neces
sary to overhaul the caliper.
Remove the O-ring from the caliper adapter and clean
the slide surfaces of the adapter and the machined ways
on the caliper with a wire brush and sandpaper.
DISC BRAKESHOE INSTALLATION

(1) Install inboard brakeshoe in adapter (Fig. 8).
(2) If new brakeshoes are being installed, remove
protective paper from noise suppression gasket on
outboard shoe.
(3) Install and adjust outboard brakeshoe in cali
per as follows:
(a) Check vertical movement of outboard shoe in
caliper. Shoe should fit tightly and not exhibit ver
tical movement (free play). Flange must also fit
tightly on caliper finger to eliminate free play and
Fig. 10 Adjusting Outboard Brakeshoe Retaining
prevent shoe rattle (Fig. 9).
Flange
(b) If free play is evident, remove shoe from cal
iper.
(c) Bend shoe retaining flange and trial fit shoe
in caliper. Continue bending flange until shoe is
light interference fit in caliper (Fig. 10).
(d) Reinstall outboard brakeshoe in caliper. If
shoe is difficult to install, use C-clamp to seat shoe
(Fig. 11).
OUTBOARD SHOE MACHINED
Fig. 11 Seating Outboard Brakeshoe

(7) Align caliper in adapter and install caliper re
tainer clips and anti-rattle springs (Fig. 5). Tighten
retainer screws to 20 N«m (180 in. lbs.) torque.
(8) Install wheels and lower vehicle.
(9) Top off master cylinder fluid level.
(10) Apply brakes several times to seat caliper pis
tons and brakeshoes and obtain firm pedal. Do this
before moving vehicle.
Fig. 9 Outboard Brakeshoe Positioned On Caliper CALIPER REMOVAL

Finger (1) Raise vehicle and remove front wheels.
(2) If caliper will only be removed for shoe replace
(4) Lubricate slide surfaces of caliper mounting ment or access to other component, press caliper pis
adapter and machined ways on caliper with Mopar ton to bottom of bore with large C-clamp.
high temperature, or multi-mileage grease. (3) Remove caliper retainer clips and anti-rattle
(5) Install O-ring in adapter, if removed. springs.
(6) Carefully install caliper over rotor and into (4) Disconnect brake hose fitting at caliper.
adapter. D o not displace or d a m a g e the piston (5) Remove caliper from rotor.
dust boot w h e n i n s t a l l i n g the caliper. (6) Remove brakeshoes from caliper and adapter.
5 - 32 BRAKES •
CALIPER OVERHAUL
CALIPER DISASSEMBLY
(1) Drain old fluid out of caliper.
(2) Pad outboard shoe side of caliper interior with
a minimum 2.54 cm (1 in.) thickness of shop towels
(Fig. 12). Towels will prevent piston damage when
piston comes out of bore.
(3) Remove caliper piston with short bursts of com
pressed air. Apply air pressure through fluid inlet
port of caliper (Fig. 12).
C A U T I O N : D o not blow the piston out of the caliper.

This practice will usually result in severe piston
damage. U s e only e n o u g h air pressure to e a s e the
piston out of the bore. In addition, d o not attempt to
catch the piston as it leaves the caliper bore. T h i s
practice will result in personal injury.
Fig. 12 Caliper Piston Removal

(4) Remove piston dust boot. Collapse boot with
screwdriver or punch and remove boot (Fig. 13).
(5) Remove caliper piston seal with wood pencil or
plastic tool (Fig. 14). Do not use metal tools as they
Fig. 14 Removing Caliper Piston Seal
could scratch piston bore.
Inspect the caliper piston. The piston is made from
CLEANING AND INSPECTION a phenolic resin (plastic material) and should be
Clean the caliper components (Fig. 15) with Mopar smooth and clean. Replace the piston if cracked or
brake cleaner, fresh brake fluid, or denatured alcohol scored. Do not attempt to restore a scored piston by
only. Do not use gasoline, kerosene, thinner, or any sanding or polishing. The piston must be replaced if
similar type of solvent. These products can leave a damaged.
residue t h a t is damaging to pistons and seals. If t h e caliper p i s t o n m u s t be r e p l a c e d , install
Dry the caliper and piston with compressed air or t h e s a m e type o f piston i n the caliper. N e v e r in
allow them to air dry. Do not use rags or shop tow terchange phenolic resin a n d steel p i s t o n s . T h e
els. Lint from such materials can adhere to the cali p i s t o n seals, seal g r o o v e s , caliper bore a n d pis-
per and piston.
• BRAKES 5 - 33
BLEEDER CALIPER INBOARD ANTI-RATTLE
PISTON SPRING RH242A
Fig. 15 Caliper Components

t o n t o l e r a n c e s a r e different for r e s i n a n d steel
p i s t o n s a n d c a l i p e r s . D o n o t i n t e r m i x t h e s e com Fig. 17 Installing Caliper Piston Seal
p o n e n t s a t a n y time.
Inspect the caliper piston bore. The bore can be
lightly polished with Honing Tool C-4095 to remove
very minor surface imperfections (Fig. 16). H o w
ever, t h e c a l i p e r m u s t b e r e p l a c e d if t h e b o r e is
severely c o r r o d e d , r u s t e d , s c o r e d , o r if p o l i s h i n g
w o u l d i n c r e a s e b o r e d i a m e t e r m o r e t h a n 0.025
m m (0.001 in.).
Fig. 18 Installing Caliper Piston

(5) Press caliper piston to bottom of bore and seat
piston dust boot with Installer C-4690 and Tool Han
Fig. 16 Lightly Polishing Piston Bore With Tool dle C-4171 (Fig. 19).
C-4095 (6) Install caliper bleed screw if removed.
CALIPER ASSEMBLY
CALIPER INSTALLATION
(1) Coat caliper piston bore, new piston seal and
(1) Clean slide surfaces of caliper mounting
piston with brake fluid. adapter with wire brush. Then lubricate adapter
(2) Install new piston seal in caliper bore. Be sure slide surfaces with Mopar multi-mileage, or high
seal is fully seated in groove (Fig. 17). temperature grease.
(3) Install new dust boot on caliper piston. Seat (2) Install inboard brakeshoe in adapter.
boot in piston groove. (3) Install outboard brakeshoe in caliper. Be sure
(4) Start caliper piston in bore with a rotating mo shoe is light press fit in caliper. Refer to installation
tion. When piston is started in seal, push piston only procedure in Brakeshoe Replacement section.
part way into bore (Fig. 18). Maintain uniform pres (4) Lubricate caliper slide surfaces Mopar multi-
sure on piston to avoid cocking it in bore. mileage, or high temperature grease.
(5) Install O-ring in adapter, if removed.
5 - 34 BRAKES •
ROTOR INSPECTION AND SERVICE
rotor condition
The rotor braking surfaces should not be refinished
unless actually necessary. Light surface rust and
scale can be removed in a lathe equipped with dual
sanding discs.
Rotor surfaces can be restored by machining in a
disc brake lathe if surface scoring and wear are light.
The rotor should be replaced if:
• severely scored
• tapered
• has hard spots
• is cracked
• too thin
boot • machining would cause rotor thickness to fall be
>TALLir low minimum thickness requirements
TOOL
Check rotor lateral runout and thickness variation
if pedal pulsation or an occasional low pedal condi
tion was experienced. Measure runout with a dial in
dicator. Measure thickness with a micrometer at a
minimum of four points around the braking surfaces.
Fig. 19 Seating Piston Dust Boot
CHECKING ROTOR MINIMUM THICKNESS
(6) Install caliper over rotor and into adapter.
Measure rotor thickness at the center of the brake-
(7) Align caliper in adapter and install caliper re shoe contact surface. Replace the rotor if it is worn
tainer clips and anti-rattle springs. Tighten retainer below minimum thickness, or if refinishing would re
clip screws to 20 N*m (180 in. lbs.) torque. duce thickness below the allowable minimum. Rotor
(8) Connect brake hose to caliper. Tighten fitting minimum thickness is usually specified on the rotor
bolt to 47 N»m (35 ft. lbs.) torque. Be s u r e h o s e is hub (Fig. 20).
clear of c h a s s i s a n d s u s p e n s i o n c o m p o n e n t s a n d
u s e n e w seal w a s h e r s t o s e c u r e h o s e fitting t o
caliper. D o not reuse old w a s h e r s .
(9) Fill master cylinder with Mopar brake fluid or
equivalent meeting SAE and DOT standards J1703
and DOT 3.
(10) Bleed brakes. Refer to procedure in Service
And Adjustments section.
(11) Install wheels and lower vehicle.
(12) Apply brakes several times to seat caliper pis
tons and brakeshoes. Be sure firm pedal is obtained
before moving vehicle.
ROTOR REMOVAL
(2) Remove wheel and tire assembly.
(3) Remove caliper assembly. Do not allow brake
hose to support caliper. Support caliper on stool, or
suspend caliper with wire attached to nearby body or
suspension component.
(4) Remove grease cap, cotter pin, n u t lock, adjust
ing nut, t h r u s t washer and outer wheel bearing.
(5) Remove rotor from spindle. Fig. 20 Typical Location Of Rotor Minimum
(6) Remove rotor shield and seal if either is to be Thickness Limit
serviced. ROTOR RUNOUT
Check rotor lateral runout with Dial Indicator
C-3339 as shown in the top view (Fig. 21). Excessive
• BRAKES 5 - 35
lateral runout will cause brake pedal pulsation and CAUTION: D o not refinish a rotor if machining
rapid, uneven wear of t h e brakeshoes. Position the would cause rotor thickness to fall below minimum
dial indicator plunger approximately 25.4 m m ( 1 in.) allowable.
from the rotor outer edge.
Be s u r e w h e e l b e a r i n g a d j u s t m e n t is c o r r e c t
before c h e c k i n g r o t o r r u n o u t . I n c o r r e c t adjust
m e n t c a n c r e a t e a c o n d i t i o n similar t o e x c e s s i v e
lateral runout-
Maximum allowable rotor runout for all models is
0.102 mm (0.004 in.).
Fig. 21 Checking Rotor Runout And Thickness

Variation
ROTOR THICKNESS VARIATION
Variations in rotor thickness will cause pedal pul
sation, noise and shudder.
Measure rotor thickness at 6 to 12 points around
the rotor face (Fig. 21). Position the micrometer ap
proximately 19,05 to 25.4 mm (3/4 to 1 in.) from the
rotor outer circumference for each measurement as
shown in the bottom view (Fig. 21).
Thickness should not vary by more t h a n 0.013 mm
(0.0005 in.) from point-to-point on the rotor. Refinish
or replace the rotor if necessary.
ROTOR REFINISHING
Rotor braking surfaces can be refinished by sand
ing and/or machining in a disc brake lathe. The lathe
must be capable of machining both rotor surfaces si Fig. 22 Rotor Refinishing Equipment
multaneously with dual cutter heads (Fig. 22). A
ROTOR INSTALLATION
brake lathe capable of machining only one side at a
(1) Inspect and repack wheel bearings if necessary.
time will produce a tapered rotor.
Install new grease seal if inner bearing is removed
The disc brake lathe should also be equipped with
for repacking.
a grinder attachment, or dual sanding discs for final
cleanup or light refinishing (Fig. 22). (2) Install rotor on spindle.
If the rotor surfaces only need minor cleanup of (3) Install outer bearing, thrust washer and nut.
rust, scale, or scoring, use abrasive discs to clean up (4) Tighten wheel bearing adjusting n u t to 27-34
the rotor surfaces. However, when a rotor is scored or N t h (240-300 in. lbs.) while turning rotor.
worn, machining with cutting tools will be required. (5) Recheck rotor runout as described previously.
5 - 36 BRAKES •
(6) Loosen wheel bearing adjusting nut completely. with wheel bearing grease.
Then retighten n u t finger tight. Wheel bearing end (9) Install caliper, wheel and tire assembly and
play should be maximum of 0.002 to 0.076 mm lower vehicle.
(0.0001 to 0.003 in.). (10) Check and adjust master cylinder fluid level.
(7) Install n u t lock on bearing adjusting nut. Align (11) Apply brakes several times to seat brake-
lock slots with cotter pin hole and secure n u t and shoes. Be sure to obtain firm pedal before moving ve
lock with new cotter pin.
hicle.
(8) Clean grease cap. Then coat interior of cap
• BRAKES 5 - 37
BENDIX DISC BRAKE
INDEX
page page
Caliper Overhaul 41 General Service Information 37
Disc Brake Inspection 39 Rotor Inspection and Service . . . . . . . . . . . . . . . . 43
Disc Brakeshoe Installation 40 Rotor Installation 45
Disc Brakeshoe Removal . 39 Rotor Removal 45
GENERAL SERVICE INFORMATION

The Bendix disc brake assembly consists of a single
piston, sliding type caliper and ventilated rotor (Fig. 1).
A splash shield is used to protect the rotor. The
shield is bolted to the adapter and protects the bear
ings and inboard surface of the rotor from road
splash. The wheel protects the outboard surface of
the rotor and brake assembly.
The caliper slides laterally on surfaces machined
into the caliper and mounting adapter. The adapter
is bolted to the steering knuckle (Fig. 2). The caliper
is positioned in the adapter with a support key and
spring (Fig. 1). A retaining screw is used to secure
the support key.
The inboard brakeshoe is mounted in the caliper
adapter. The outboard brakeshoe is mounted in the
caliper. The linings are riveted to the shoes, and the
inner and outer shoes are not interchangeable.
DISC BRAKE OPERATION

The significant feature of caliper operation is t h a t
the caliper is free to move laterally on the adapter Fig. 2 Caliper Mounting Adapter Attachment
slide surfaces (Fig. 3).
At brake application, fluid pressure is exerted
equally against the caliper piston and all surfaces of
the caliper piston bore.
Pressure applied to the piston is transmitted di
rectly to the inboard brakeshoe pressing the shoe lin
ing against the rotor. At the same time, pressure
applied to the caliper bore surfaces, causes the cali
per to slide inward laterally. The inward movement
presses the lining of the outboard shoe against the
opposite side of the rotor to complete braking action
(Fig. 3).
Any application or release of brake fluid pressure
causes only a very modest movement of the caliper
and piston. At brake release, the piston and caliper
return to the non-applied position.
The brakeshoes do not retract an appreciable dis
tance from the rotor. The minimal running clearance
provides the improved response and reduced pedal
travel; It also helps in preventing dirt and foreign
material from lodging between the shoe and rotor
surfaces.
Fig. 1 Bendix Disc Brake Caliper

BRAKES 5 - 39
DISC BRAKE LINING WEAR COMPENSATION times and recheck clearance. If clearance is still ex
Normal lining wear is compensated for by exten cessive, either the shoes are severely worn or the cal
sion of the caliper piston and by lateral movement of iper piston could be binding in the bore.
the caliper in the adapter. Piston position is also de
termined in part by the square cut piston seal (Fig. Hoses And Adapter
4). Inspect condition of t h e brake lines and hoses. Re
Normal disc brake lining wear will cause the cali place either front hose if cut, torn, or the reinforcing
per piston to extend enough to m a i n t a i n proper pedal fabric is visible. Check condition of the metal brake-
height and brake response. The caliper bore will re lines. Replace any line t h a t is badly rusted, leaking
ceive the extra fluid needed to compensate for the ad or damaged in any way.
ditional piston extension. Clean and lubricate t h e adapter slide surfaces. Use
As the piston extends during brake application, the Mopar multi-mileage or high temperature grease for
square-cut seal is deflected outward (Fig. 4). When this purpose. Also verify t h a t the caliper adapter
brake pressure is released, the seal straightens and bolts are secure and tightened to proper torque.
returns to a normal relaxed position. Although the
amount of seal movement is quite small, it is enough Fluid Level
to retract the piston to the necessary minimum run Check the master cylinder fluid level. Maintain
ning clearance. fluid level to t h e bottom of the indicator rings on the
Fluid level in the front brake reservoir will de reservoir. Note t h a t front brake fluid level can be ex
crease as lining wear occurs, the. This is a normal pected to drop slightly as normal lining wear occurs.
condition and only requires adding enough fluid to Use Mopar brake fluid or equivalent meeting SAE
restore proper level. However, when t h e brakeshoes and DOT standards J1703 and DOT 3. Use clean
are replaced and the caliper pistons bottomed in the brake fluid from a sealed container only.
bores, the added fluid must be compensated for. This
is necessary to avoid overfill and overflow. Removing Rotors
a small amount of fluid from the front brake reser Check rotor surfaces for excessive wear, discolora
voir beforehand will prevent this condition. tion, scoring, rust, scale, or cracks. Also look for
damaged or severely rusted ventilating segments. If
pedal pulsation was experienced, check wheel bear
ing adjustment and condition. If the bearings are
OK, also check rotor runout and thickness variation.
DISC BRAKESHOE REMOVAL

(1) Remove approximately 1/3 of fluid from master
cylinder front brake reservoir with a suction gun.
(3) Remove wheel and tire assemblies.
(4) Press caliper pistons to bottom of bore with
large C-clamp (Fig. 5). Position clamp screw on out
Fig. 4 Caliper Piston Seal Operation board shoe and clamp frame or rear of caliper hous
ing.
DISC BRAKE INSPECTION (5) Remove support key retaining screw (Fig. 6).
Inspect the disc brake components whenever the (6) Remove caliper support key and spring. Use
caliper and brakeshoes are removed during service pin punch or drift to t a p key out of caliper (Fig. 7).
operations or routine maintenance. (7) Lift caliper out of adapter.
Check condition of the rotor, brakeshoe lining, cal (8) Remove outboard shoe from caliper (Fig. 8).
iper and brake hoses. Front wheel bearing adjust (9) Secure caliper to convenient chassis component
ment and condition can also be checked at this time. with wire. Do not allow brake hose to support caliper
The bearings should be repacked and adjusted if nec weight.
essary. (10) Remove inboard shoe and anti-rattle spring
from caliper adapter (Fig. 9). Note position of spring
Brakeshoes for installation reference.
With the caliper and brakeshoes on the vehicle,
check running clearance between the rotor and CLEANING AND INSPECTION
brakeshoes. The shoe lining should either be in very Inspect the shoe lining for wear. Replace riveted
light contact with the rotor or a maximum of 0.127 shoes if the lining is worn to within 1.5 m m (1/16 in.)
mm (0.005 in.) running clearance. If clearance ex of the rivet heads. Replace bonded lining if thickness
ceeds the stated amount, apply the brakes several is 3 mm (3/16 in.) or less.
5 - 40 BRAKES •
BRASS ROD
Fig. 7 Removing Caliper Support Key And Spring
Fig. 6 Removing/Installing Support Key Retaining

Screw
If the shoe lining will be reused, do not intermix
the shoes. Keep them with the caliper they were re
moved from.
Examine the caliper piston area for evidence of
Fig. 8 Removing/Installing Outboard Brakeshoe
leaks. Also check condition of the piston boot. Over
haul the caliper if leakage is evident or the boot is (2) Install outboard shoe in caliper. Free play
cut or torn. should not exist between shoe retaining flanges and
Clean rust and corrosion from the support key and machined surfaces on caliper. If shoe cannot be
the caliper and adapter slide surfaces (machined pressed into place by hand, use a C-Clamp. If a
ways) with a wire brush. Then lubricate the slide C-Clamp is used, protect shoe with wood block (Fig.
surfaces with Mopar multi-mileage grease, or equiv 10).
alent. (3) Position caliper over rotor and in adapter (Fig.
11). Be careful to avoid damaging piston dust boot
DISC BRAKESHOE INSTALLATION during installation.
(1) Install anti-rattle spring on inboard brakeshoe
and install shoe in adapter. Be sure spring remains C A U T I O N : Verify that the brake hose is straight
in place and is positioned as shown (Fig. 9). Loop and not twisted, kinked, or touching any c h a s s i s
portion of spring should face away from the rotor. components.
• BRAKES 5 - 41
CALIPER
Fig. 11 Caliper Installation

CALIPER
Fig. 9 Removing/Installing Inboard Brakeshoe
Fig. 10 Seating Outboard Brakeshoe In Caliper Fig. 12 Installing Support Key And Spring
(4) Seat caliper in adapter. CALIPER OVERHAUL
(5) Place support spring on support key. Then in
sert spring and key between caliper and adapter. CALIPER REMOVAL
(6) Tap support key and spring into place with pin (1) Raise vehicle and support on hoist or jack-
punch or drift (Fig. 12). stands.
(7) Align notch in support key with screw hole in (2) Remove wheel and tire assemblies.
caliper. (3) Clean brake hose and tubing connections at
(8) Install support key retaining screw. Tighten calipers and brake hoses.
screw to 20 N»m (15 ft. lbs.) torque. B e sure shoul (4) Remove screw retaining caliper support key
der on screw is fully s e a t e d in s u p p o r t k e y and spring and tap support key and spring out with
notch. a drift or pin punch.
(9) Install wheel and tire assembly and lower vehi (5) Remove calipers and brakeshoes from adapters
cle.
(6) Disconnect caliper brake hoses at frame brack
(10) Top off master cylinder fluid level.
ets and remove calipers.
(11) Pump brake pedal to seat shoes and restore
(7) Cover brake lines to prevent dirt entry.
normal pedal height. Do not move vehicle until firm
pedal is obtained.
5 - 42 BRAKES •
CALIPER DISASSEMBLY. Inspect the caliper piston, piston bore and the seal
(1) Drain old fluid out of caliper. and boot grooves. Replace the piston if corroded, pit
(2) Pad outboard shoe side of caliper interior with ted, scored, or worn. Do not attempt to restore the
a minimum 2.54 cm (1 in.) thickness of shop towels piston surface by sanding. Replace the piston if nec
(Fig. 13). Towels will prevent piston damage when it essary.
comes out of bore. Very light scratches or corrosion in the piston bore
(3) Remove caliper piston with short bursts of com can usually be cleaned up with a fiber brush, or by
pressed air. Apply air pressure through fluid inlet polishing with a honing tool or crocus cloth. How
port of caliper (Fig. 13). ever, the caliper should be replaced if the bore is se
verely corroded, scored, or if honing and polishing
CAUTION: Do not blow the piston out of the cali would increase bore diameter by more t h a n 0.050
per. This practice will usually result in severe pis mm (0.002 in.).
ton damage. Use only e n o u g h air pressure to ease Dark brown or black stains on the piston are
the piston out of the bore. In addition, d o not at caused by the piston seal and are a normal condition.
tempt to catch the piston a s it leaves the caliper In addition, light discoloration of the piston bore is
bore. This practice will result in personal injury. also normal. This discoloration is acceptable as long
as the bore and piston surfaces are in good condition.
If t h e c a l i p e r p i s t o n m u s t b e r e p l a c e d , i n s t a l l
t h e s a m e t y p e of p i s t o n in t h e c a l i p e r . N e v e r in
t e r c h a n g e p h e n o l i c r e s i n a n d steel p i s t o n s . T h e
p i s t o n seals, seal g r o o v e s , c a l i p e r b o r e a n d pis
t o n t o l e r a n c e s a r e different for r e s i n a n d steel
p i s t o n s a n d c a l i p e r s . Do n o t i n t e r m i x t h e s e com
p o n e n t s at any time.
The caliper bore can be lightly polished to remove
minor scratches or corrosion. However, polishing op
erations should not remove any more t h a n 0.012 mm
(0.0005 in.) from the bore surface. Replace the caliper
if the bore is severely scored or corroded. Use crocus
cloth or 400 grit honing stones soaked in fresh brake
fluid to polish the bore surface. Be sure to flush and
clean the caliper thoroughly afterward. All residue
generated by polishing must be removed to avoid po
tential damage to the piston, seal and bore after as
sembly.
Inspect and clean the inboard shoe anti-rattle
PISTON J9105-66 spring, support key spring, retaining screw and cali
per support key (Fig. 14). Replace these components
Fig. 13 Caliper Piston Removal
if worn or damaged.
(4) Remove dust boot from caliper.
SHOE AND SHOE AND CALIPER BLEEDER SCREW
(5) Remove caliper piston seal from caliper bore
with small wood or plastic tool. D o n o t u s e m e t a l
tools t o r e m o v e seal. M e t a l tools c a n s c r a t c h o r
score bore surface.
(6) Remove bleed screw from caliper.

Clean the slide surfaces of the caliper with a wire
brush and emery cloth. Then clean the caliper and
piston with Mopar brake cleaner, fresh brake fluid,
or denatured alcohol only. Do not use any other type
of solvent or cleaning agent.
Dry the caliper and piston with compressed air or
allow them to air dry. Do not use rags or towels to SEAL BOOT ANTI-RATTLE SPRING RN1059
dry the caliper and piston. Lint from such materials
can adhere to the piston and caliper. Fig. 14 Caliper Components
• BRAKES 5 - 43
CAMPER ASSEMBLY
(1) Mount caliper in vise equipped with protective
jaws. Do not overtighten vise. Excessive pressure
could cause bore distortion and piston binding.
(2) Lubricate new piston seal and piston bore with
fresh brake fluid.
(3) Install new piston seal in bore groove (Fig. 15).
Position seal in one area of groove and gently work it
around and into remainder of groove until seated. Be
sure seal is not twisted or rolled over.
Fig. 16 Installing Caliper Piston

(2) Connect brake hose to brake line on frame
bracket. Tighten hose fitting to 13-20 N«m (115-175
in. lbs.) torque.
(3) Connect brake hose to caliper. Use new seal
washers when connecting fitting to caliper. Do not
tighten hose fitting at this time.
(4) Lubricate caliper and adapter slide surfaces
with Mopar high temperature grease, or an equiva
lent grease.
(5) Install and secure caliper in adapter.
(6) Fill master cylinder and bleed brakes.
(7) Install wheel and tire assemblies and lower ve
Fig. 15 Installing Caliper Piston Seal hicle.
(4) Lubricate new dust boot with fresh brake fluid
and install it in caliper (Fig. 16). Work boot into ROTOR INSPECTION AND SERVICE
groove with fingers. Boot will seem larger t h a n
ROTOR CONDITION
groove diameter at first but will snap into place
Rotor condition and tolerances can be checked with
when properly positioned.
the rotor mounted on the axle. However, wheel bear
(5) Plug fluid inlet port and install bleeder screw.
ing end play should be reduced to zero before check
(6) Coat caliper piston with brake fluid. ing lateral runout.
(7) Start piston into dust boot and bore (Fig. 16). The rotor braking surfaces should not be machined
Spread dust boot with fingers. Then work piston unless actually necessary. Light surface rust and
through boot and into bore. Air trapped below piston scale can be removed in a lathe equipped with dual
will force boot around it and into groove as piston is sanding discs.
installed. Worn, or scored rotor surfaces can be restored by
(8) Remove plug from inlet port and loosen bleeder machining in a disc brake lathe but only if surface
screw. scoring and wear are light.
(9) Carefully press piston into bore with turning The rotor should be replaced if:
motion until fully bottomed. Apply force uniformly to • severely scored
avoid cocking piston (Fig. 16). • tapered
(10) Seat dust boot with suitable size installer tool • has hard spots
if necessary. • cracked
• warped
CALIPER INSTALLATION • too thin
(1) Install brakeshoes in caliper and adapter. • machining would cause rotor thickness to fall be
low minimum thickness requirements
5 - 44 BRAKES •
Check rotor lateral runout and thickness variation CHECKING ROTOR MINIMUM THICKNESS
if pedal pulsation or an occasional low pedal condi Measure rotor thickness at the center of the brake-
tion was experienced. Measure runout with a dial in shoe contact surface. Replace the rotor if it is worn
dicator. Measure thickness with a micrometer at a below minimum thickness, or if refinishing would re
minimum of four points around the braking surfaces. duce thickness below the allowable minimum. Rotor
The rotor measurement points are shown in Figure minimum thickness is usually specified on the rotor
17. hub.
ROTOR THICKNESS VARIATION

Variations in rotor thickness will cause pedal pul
sation, noise and shudder.
Measure rotor thickness at 6 to 12 points around
the rotor face (Fig. 18). Position the micrometer ap
proximately 25.4 mm (1 in.) from the rotor outer cir
cumference for each measurement (Figs. 17 and 19).
Thickness should not vary by more t h a n 0.025 mm
(0.001 in.) from point-to-point on the rotor. Refinish
or replace the rotor if necessary.
ROTOR RUNOUT
Check rotor lateral runout with Dial Indicator
C-3339 (Fig. 18). Excessive lateral runout will cause
brake pedal pulsation and rapid, uneven wear of the
brakeshoes.
Position the dial indicator plunger approximately
25.4 mm (1 in.) in from the rotor edge. Be s u r e
w h e e l b e a r i n g e n d p l a y is r e d u c e d t o z e r o b e f o r e
c h e c k i n g r u n o u t . Maximum allowable runout is
0.127 mm (0.005 in.).
Fig. 18 Checking Rotor Runout And Thickness

Variation
ROTOR REFINISHING
Rotor braking surfaces can be refinished by sand
ing and/or machining in a disc brake lathe. The lathe
Fig. 17 Rotor Measurement Points must be capable of machining both rotor surfaces si-
• BRAKES 5 - 45
multaneously with dual cutter heads. Equipment ca

pable of machining only one side at a time will
produce a tapered rotor.
The lathe should also be equipped with a grinder
attachment or dual sanding discs for final cleanup or
light refinishing.
If the rotor surfaces only need minor cleanup of
rust, scale, or scoring, use abrasive discs to clean up
the rotor surfaces. However, when a rotor is scored or
worn, machining with cutting tools will be required.
C A U T I O N : Do not refinish a rotor if machining

would cause the rotor to fall below minimum allow
able thickness.
ROTOR REMOVAL
(1) Raise and support front of vehicle. Fig. 20 Removing Drive Flange Snap Ring
(2) Remove wheel and tire assemblies. (12) Remove seal and inner bearing from hub if
(3) Remove support key retaining screw (Fig. 6). bearing or seal requires service.
(4) Remove caliper support key and spring with (13) If wheel bearing races require service, remove
pin punch or drift (Fig. 19). them with suitable remover tools or with brass drift.
(14) Clean rotor and hub and wheel bearings in
solvent.
ROTOR INSTALLATION
(1) Repack wheel bearings and coat spindle with
Mopar high temperature bearing grease.
(2) Install new bearing races, bearings and seals in
hubs if necessary.
(3) Install hub on spindle and install outer bearing
and inner adjusting nut.
(4) Tighten adjusting nut to 68 Nrni (50 ft. lbs.)
with Special Tools DD-1241-JD and C-3952 to seat
bearings.
(5) Adjust wheel bearings as follows:
(a) Back off adjusting nut.
(b) Retighten adjusting n u t to 54 N*m (40 ft. lbs.)
Fig. 19 Removing Caliper Support Key And Spring while rotating hub and rotor.
(c) Back off adjusting n u t approximately 135 to
(5) Remove caliper and brakeshoes from adapter. 150 degrees.
Do not allow brake h o s e to support caliper (d) Install lock ring and locknut.
weight. Support caliper on stool, or secure cali (6) Tighten lock n u t to a minimum of 88 N»m (65
per to n e a r b y frame or chassis c o m p o n e n t with ft. lbs.). Bearing end play should be 0.025 - 0.25 mm
wire. (0.001 - 0.010 in.).
(6) Remove hub cap. (7) Bend one tang of lock ring over adjusting n u t
(7) Remove drive flange snap ring with Tool and another t a n g over locknut to secure them.
C-4020 (Fig. 20). (8) Install new gasket on hub and install drive
flange, lock washers and nuts. Tighten nuts to 41 -
(8) Remove flange nuts and lock washers and re
54 N«m (30 - 40 ft. lbs.).
move drive flange. Discard the flange gasket.
(9) Install flange snap ring with Tool C-4020.
(9) Straighten tang on lock ring. (10) Install hub cap.
(10) Loosen outer locknut and adjusting nut with (11) Install caliper and brakeshoes. Tighten sup
Tool DD-1241-JD (Fig. 19). Then remove outer lock- port retaining screw to 20 Nnn (15 ft. lbs.) torque.
nut, lock ring, inner adjusting nut and outer bearing. (12) Install wheel and tire assembly and lower ve
(11) Remove hub and rotor from spindle. hicle.
i - 46 BRAKES •
DRUM BRAKES—ELEVEN INCH
INDEX
page page
Brake Drum Inspection and Refinishing ........ 48 Brakeshoe Removal . . . . . . . . . . . . . . . . . . . . . . 46
Brake Drum Installation . . . . . . . . . . . . . . . . . . . . 48 Cleaning and Inspection 47
Brake Drum Removal 46 General Information 46
Brake Shoe Installation . 47 Wheel Cylinder Installation 50
Brake Support Plate Installation 49 Wheel Cylinder Overhaul 49
Brake Support Plate Removal . . . . . . . . . . . . . . . 49 Wheel Cylinder Removal 49
GENERAL INFORMATION push self adjusting lever away from adjuster screw
Chrysler eleven inch rear drum brakes are used on star wheel.
D and W150 models (Fig. 1). All applications are two (c) Insert Tool C-3784 into brake adjusting hole
shoe, internal expanding units with a self adjuster and rotate adjuster screw star wheel to retract
mechanism. A single wheel cylinder is used to ex brakeshoes.
pand the dual brakeshoes. The lower ends of the (5) Remove brake drum.
brake shoes are connected by a star wheel adjusting (6) Inspect brakelining for wear, alignment, or ev
screw which is part of the self adjusting mechanism. idence of leakage from axle or wheel cylinder.
SUPPORT RETURN ANCHOR RETURN CABLE
PLATE SPRING PLATE G U D E
BRAKESHOE REMOVAL
SPRING J
(1) Remove rear wheel and drum.
(2) Remove shoe return springs with Tool C-3785
PARKING (Fig. 2).
PARKING BRAKE
BRAKE LEVER SHOE SPECIAL TOOL
STRUT AND RETURN (REMOVING A N D
SPRING SPRING INSTALLING)
ADJUSTER
CABLE
AND
SPRING
PRIMARY SHOE
SHOE AND RETAINER,
LINING SPRING
AND PIN
SHOE SPRING
SECONDARY LEVER
SHOE A N D SPRING
ADJUSTER SCREW
ADJUSTER LINING
ASSEMBLY LEVER SHOE TO SHOE ADJUSTING
LEVER J9005-62
SPRING SPRING LEVER RH225A
Fig. 1 Eleven Inch Drum Brake Assembly Fig. 2 Removing/Installing Shoe Return Springs
BRAKE DRUM REMOVAL (3) Remove adjuster cable. Slide cable eye off an
(1) Raise and support vehicle. chor pin and remove cable from adjuster lever.
(2) Remove wheel and tire. (4) Remove cable guide from secondary shoe and
(3) Remove clip nuts securing brake drum to wheel remove anchor plate from anchor pin.
studs. (5) Remove adjuster lever. Disengage lever from
(4) If drum is difficult to remove, retract brake- spring by sliding lever forward to clear pivot and
shoes as follows: work lever out from under spring.
(a) Remove rear plug from access hole in support (6) Remove adjuster lever spring from pivot.
plate. (7) Disengage and remove shoe spring from brake-
(b) Insert a thin screwdriver into access hole and shoes.
BRAKES 5 - 47
(8) Disengage and remove adjuster screw assembly Replace the brakeshoes if worn to within 1.5 mm
from brakeshoes. (1/16 in.) of the rivet heads or if bonded lining is less
(9) Remove brake shoe retainers, springs and pins t h a n 4 m m (3/16 in.) thick. Examine t h e lining con
with Tool C-4070, (Fig. 3). tact pattern to determine if the shoes are bent or the
drum is tapered. The lining should exhibit contact
across t h e entire width. Shoes exhibiting contact only
on one side should be replaced and the drum checked
for runout or taper.
Clean and inspect the adjuster screw assembly. Re
place t h e assembly if the star wheel threads are
damaged, or the components are severely rusted or
corroded.
Discard the brake springs and retainer components
if worn distorted, or collapsed. Also replace the
springs if a brake drag condition had occurred. Over
heating will distort and weaken the springs.
Inspect the brakeshoe contact surfaces on the sup
port plate (Fig. 5). Remove light rust and scale from
these surfaces with 180 grit emery cloth or sandpa
per. However, replace the support plate if any of the
contact surfaces are worn or rusted through. Also re
Fig. 3 Removing/Installing Shoe Retainers, Springs place the plate if it is bent or distorted.
and Pins
(10) Remove secondary brakeshoe from support
plate.
(11) Remove strut and anti rattle spring (Fig. 4).
Fig. 5 Shoe Contact Surfaces

BRAKE SHOE INSTALLATION
(1) Lubricate anchor pin and brakeshoe contact
pads on support plate (Fig. 5) with Mopar multi-pur
pose, or high temperature grease.
(2) Lubricate adjuster screw socket, nut, button
Fig. 4 Removing/Installing Strut And Spring
and screw thread surfaces with Mopar multi purpose,
(12) Remove parking brake lever from secondary or high temperature grease.
shoe. (3) Attach parking brake cable to lever. Then con
(13) Remove primary shoe from support plate. nect lever to secondary shoe.
(14) Disengage parking brake lever from parking (4) Install primary shoe on support plate. Secure
brake cable. shoe with new spring retainers and pin (Fig. 6).
(5) Install spring on parking brake strut and en
CLEANING AND INSPECTION gage strut in primary shoe (Fig. 6).
Clean the brake components, including the support (6) Install secondary shoe on support plate (Fig. 6).
plate and wheel cylinder exterior, with a water Insert strut in shoe and guide shoe onto anchor pin.
dampened cloth or with Mopar brake cleaner. Do not Temporarily secure shoe with retaining pin.
use any other cleaning agents and do not use com (7) Install anchor plate and adjuster cable eyelet
pressed air to remove dirt and dust. on support plate anchor pin.
5 - 48 BRAKES •
face variation. Final finish cuts of 0.025 to 0.038 mm
(0.001 to 0.0015 in.) are recommended and will gen
erally provide the best surface finish.
Be sure the drum is securely mounted in the lathe
before machining operations. A damper strap should
always be used around the drum to reduce vibration
and avoid chatter marks.
BRAKE DRUM REFINISH LIMITS

The maximum allowable diameter of the drum
braking surface is stamped or cast into the drum
outer edge (Fig. 8). Generally, a drum can be ma
chined to a maximum of 1.52 mm (0.060 in.) oversize.
Always replace the drum if machining would cause
drum diameter to exceed indicated size limit.
Fig. 6 Brakeshoe Installation

(8) Install cable guide in secondary shoe and posi
tion cable in guide.
(9) Assemble adjuster screw (Fig. 7). Then install
and engage adjuster screw in brakeshoes.
C A U T I O N : B e s u r e the adjuster s c r e w s are in

stalled o n the correct brake unit. T h e adjuster
s c r e w s are marked L (left) a n d R (right) for identifi
cation (Fig. 8).
' WASHER SOCKET STAMPED LETTER
BUTTON NUT RH227A
Fig. 7 Adjuster Screw Components

(10) Install adjuster lever and spring and connect Fig. 8 Location Of Brake Drum Maximum Allowable
adjuster cable to lever. Diameter
(11) Install secondary shoe retainers and spring.
(12) Install shoe spring. Connect spring to second BRAKE DRUM RUNOUT
ary shoe first. Then to primary shoe. Measure drum diameter and runout with an accu
(13) Verify adjuster operation. Pull adjuster cable rate gauge. The most accurate method of measure
upward. Cable should lift lever and rotate start ment involves mounting the driim in a brake lathe
wheel. Be sure adjuster lever properly engages start and checking variation and runout with a dial indi
wheel teeth. cator. Variations in drum diameter should not exceed
(14) Adjust brakeshoes to drum with brake gauge. 0.076 m m (0.003 in.). Drum runout should not exceed
Refer to Service Adjustments section for procedure. 0.20 m m (0.008 in.) out of round. Refinish the drum
if runout or variation exceed these values.
BRAKE DRUM INSPECTION AND REFINISHING
BRAKE DRUM INSTALLATION
BRAKE DRUM REFINISHING (1) Clean drum with Mopar brake cleaning solvent
The brake drums can be resurfaced on a drum or with a soap and water solution only. Do not use
lathe when necessary. Initial machining cuts should any other cleaning agents and do not use compressed
be limited to 0.12 - 0.20 mm (0.005 - 0.008 in) at a air to remove dirt and dust.
time as heavier feed rates can produce taper and sur
• BRAKES 5 - 49
(2) Adjust brake shoes to drum with a brake (7) Connect parking brake cable to lever on sec
gauge. ondary shoe and install brakeshoes on support plate.
(3) Install and secure drum to wheel studs with (8) Adjust brakeshoes to drum with brake gauge.
new retaining nuts/clips. (9) Install brake drum and wheel and tire.
(4) Install rubber access plugs in support plate if (10) Bleed brake system.
removed.
(5) Install wheel and tire. WHEEL CYLINDER REMOVAL
(1) Raise vehicle and remove wheel and brake
BRAKE SUPPORT PLATE REMOVAL drum.
(1) Remove wheel and tire and brake drum. (2) Disconnect wheel cylinder brakeline.
(2) Remove axle shaft and retainer. Refer to Group (3) Remove brakeshoe return springs and move
3 for procedures. shoes out of engagement with cylinder push rods.
(3) Remove primary brakeshoe for access to park (4) Remove cylinder attaching bolts and remove
ing brake cable if necessary. cylinder from support plate.
(4) Compress parking brake cable retainer tabs
with a hose clamp (Fig. 9). Then push retainer and WHEEL CYLINDER OVERHAUL
cable through and out of support plate.
WHEEL CYLINDER DISASSEMBLY
(1) Remove push rods and boots (Fig. 10).
(2) Press pistons, cups and spring and expander
out of cylinder bore.
(3) Remove bleed screw.
SPRING PISTON
CYLINDER CUP
BOOT
CUP
EXPANDERS PISTON '
BLEED SCREW PUSH ROD ' J9005-66
AIRCRAFT TYPE
HOSE CLAMP RB763
Fig. 10 Wheel Cylinder Components
Fig. 9 Removing Parking Brake Cable From Support CLEANING AND INSPECTION
Plate Clean the cylinder and pistons with fresh brake
(5) Disconnect brake line at wheel cylinder. fluid or brake cleaner only. Do not use any other
(6) Remove wheel cylinder and brakeshoes from cleaning agents. Dry the cylinder and pistons with
support plate. compressed air. Do not use rags or shop towels to dry
(7) Remove bolts attaching support plate to axle the cylinder components. Lint from such materials
and remove support plate. can adhere to the cylinder bores and pistons.
Inspect the cylinder bore. Light discoloration and
BRAKE SUPPORT PLATE INSTALLATION dark stains in the bore are normal and will not im
(1) If new support plate is being installed, apply pair cylinder operation. If desired, the bore can be
bead of Mopar silicone sealer around wheel cylinder lightly polished but only with crocus cloth. Replace
mounting surface. Then transfer wheel cylinder to the cylinder if the bore is scored, pitted or heavily
new support plate. corroded. Honing the bore to restore the surface is
(2) Apply bead of Mopar silicone sealer around not recommended.
axle mounting surface of support plate.
Inspect the cylinder pistons. The piston surfaces
(3) Install support plate on axle flange. Tighten at
should be smooth and free of scratches, scoring and
taching bolts to 47-68 N-m (35-50 ft. lbs.).
corrosion. Replace the pistons if worn, scored, or cor
(4) Install parking brake cable in support plate.
roded. Do attempt to restore the surface by sanding
(5) Install axle shaft and retainer.
(6) Start brakeline in wheel cylinder and install or polishing.
cylinder on support plate. Tighten brakeline fitting
after cylinder installation.
5 - 50 BRAKES •
Discard t h e old piston cups and the spring and ex maining piston cup and piston.
pander. These parts are not reusable. The original (4) Install boots on each end of cylinder and insert
dust boots may be reused b u t only if they are in good push rods in boots.
condition. (5) Install cylinder bleed screw.
ASSEMBLING WHEEL CYLINDER WHEEL CYLINDER INSTALLATION

(1) Lubricate wheel cylinder bore, pistons, piston (1) Apply bead of Mopar silicone sealer around cyl
cups and spring and expander with clean brake fluid. inder mounting surface of support plate.
(2) Install first piston in cylinder bore. Then in (2) Connect brake line to cylinder. Mount cylinder
stall cup in bore and against piston. B e s u r e lip of on support plate and install cylinder attaching bolts.
piston c u p is facing i n w a r d (toward spring a n d (3) Install wheel brake components.
expander) a n d flat side is against piston. (4) Install brake drum and wheel and bleed
(3) Install spring and expanders followed by re brakes.
DRUM BRAKES—TWELVE INCH
INDEX
page page
Brake Drum Installation 54 General Information 50
Brake Drum Removal 52 Support Plate Installation 55
Brake Drum Service 54 Support Plate Removal 55
Brake Shoe Installation 53 Wheel Cylinder Installation 55
Brakeshoe Removal 52 Wheel Cylinder Overhaul . . . . . . . . . . . . . . . . . . . 54
Cleaning and Inspection 52 Wheel Cylinder Removal . 54
GENERAL INFORMATION pand the dual brakeshoes. The lower ends of the
Twelve inch rear drum brakes are used on D and brake shoes are connected by a star wheel adjuster
W 250/350 models (Fig. 1). All applications are dual screw which is part of the self adjusting mechanism
shoe, internal expanding units with a self adjusting (Fig. 1).
mechanism. A single wheel cylinder is used to ex-
SHOE HOLD- ANCHOR
DOWN PIN BOLT
NUT
WHEEL CYLINDER BOLTS

WHEEL CYLINDER
ADJUSTING
HOLE COVER
PRIMARY SHOE
UPPER
SHOE-TO-SHOE SPRING
SHOE
HOLD-DOWN SPRING
LOWER-SHOE-TO-SHOE
SPRING SHOE HOLD-
D O W N PIN
ANTI-RATTLE SPRING
FLAT WASHER BACKING PLATE
AUTOMATIC ADJUSTER
CABLE
ANCHOR BOLT
ADJUSTER LEVER
PIVOT PIN
ADJUSTER LEVER
RETURN SPRING
SECONDARY SHOE
PARKING AUTOMATIC
BRAKE LEVER ADJUSTER LEVER RN326A
Fig. 1 Twelve Inch Drum Brake Assembly

5 - 52 BRAKES •
BRAKE DRUM REMOVAL
(2) Remove wheel and tire assembly.
(3) Remove axle shaft nuts, washers and cones.
Strike axle shaft in center with copper or dead blow
hammer to loosen retaining cones.
(4) Remove axle shaft.
(5) Remove outer hub nut.
(6) Straighten and remove lock washer.
(7) Remove inner n u t and bearing.
(8) Remove drum. If drum is difficult to remove,
retract brakeshoes as follows:
(a) Remove rear plug from access hole in support
plate.
(b) Insert a thin releasing tool (or screwdriver)
into access hole and push self adjusting lever away
from adjuster screw star wheel (Fig. 2).
(c) Insert thin screwdriver, or Tool C-3784 into RK60A
access hole and rotate adjuster star wheel to re
tract brakeshoes (Fig. 2). Fig. 3 Removing/Installing Shoe-To-Shoe Upper
Spring
Fig. 2 Retracting Brakeshoes

(9) Remove brake drum.
(10) Inspect brakelining for wear, alignment, or
evidence of leakage from axle or wheel cylinder.
Fig. 4 Removing/Installing Shoe Holddown Springs
BRAKESHOE REMOVAL lever, washer, spring, cam plate, anchor bolt bushing
(1) Unhook adjuster lever return spring from lever and adjuster cable (Fig. 1).
(Fig. 1).
(2) Remove lever and return spring from lever CLEANING AND INSPECTION
pivot pin (Fig. 1). Clean the brake components, including the support
(3) Unhook adjuster lever from adjuster cable as plate and wheel cylinder exterior, with a water
sembly (Fig. 1). dampened cloth or with Mopar brake cleaner. Do not
(4) Remove shoe-to-shoe upper spring (Fig. 3). use compressed air.
(5) Remove shoe holddown springs (Fig. 4). Replace the brakeshoes if the lining is worn to
(6) Disconnect parking brake cable from parking within 1.5 mm (1/16 in.) of the rivet heads or if
brake lever. bonded lining is less t h a n 4 mm (3/16 in.) thick. Ex
(7) Remove both brakeshoes, shoe-to-shoe lower amine the lining contact pattern to determine if the
spring and adjuster n u t as assembly (Fig. 5). shoes are bent or the drum is tapered. The lining
(8) If support plate or wheel cylinder are to be ser should exhibit contact across the entire width. Shoes
viced, remove anchor bolt and n u t t h a t attaches exhibiting contact only on one side should be re
parking brake lever to support plate. Then remove placed and the drum checked for runout or taper.
• BRAKES 5 - 53
BRAKE SHOE INSTALLATION

(1) If parking brake lever was removed, install an
chor bolt bushing, cam plate, lever, spring, washer
and anchor bolt and nut (Fig. 1).
(2) Coat contact pads on support plate (Fig. 6) with
Mopar high temperature grease, or equivalent,
(3) If both sets of brakeshoes were removed, verify
t h a t adjusting nuts are installed on correct side of
vehicle. Pivot screw and adjusting nut have left hand
threads on left side brake assembly and right hand
threads on right side assembly.
(4) Lubricate and assemble adjusting nut and pivot
screw.
(5) Assemble adjusting nut, shoe-to-shoe lower
spring and both brakeshoes. Then position the as
sembled components on the support plate.
(6) Install brakeshoe holddown springs and pins
(Fig. 4). Be sure holddown pins are seated in support
plate and springs are connected as shown (Fig. 7).
Fig. 5 Removing/installing Brakeshoes SHOE HOLD DOWN PIN
Clean and inspect the adjusting n u t and pivot HOLD D O W N
SPRING
screw assembly. Replace the assembly if the star
wheel threads on the nut are damaged, or the screw
are severely rusted or corroded.
Discard the brake springs and retainer components
if worn distorted, or collapsed. Also replace the
springs if a brake drag condition had occurred. Over
heating will distort and weaken the springs.
Inspect the brakeshoe contact pads on the support
plate (Fig. 6). Remove light rust and scale from the
pads with fine sandpaper. However, replace the sup BACKING PLATE RN1064
port plate if any of the pads are worn or rusted
Fig. 7 Holddown Spring And Pin Attachment
through. Also replace the plate if it is bent or dis
torted. (7) Connect parking brake cable to parking brake
lever. Be sure cable end is properly secured in lever
(Fig. 8).
Fig. 6 Support Plate Brakeshoe Contact Pads Fig. 8 Connecting Parking Brake Cable
(8) Install shoe-to-shoe upper spring (Fig. 3).
(9) Position adjuster lever return spring on pivot.
(10) Install adjuster lever.
5 - 54 BRAKES •
(11) Attach adjuster cable to adjuster lever. Be
sure cable is properly routed.
(12) Adjust brakeshoes to drum with brake gauge.
BRAKE DRUM INSTALLATION

(1) Position drum on axle housing.
(2) Install bearing and inner nut. Adjust bearing
as described in Group 3.
(3) Install locking washer and outer nut. Bend
locking washer to secure it.
(4) Place new gasket on hub and install axle shaft,
cones, lock washers and nuts.
(5) Install wheel and tire assembly.
(6) Remove support stands and lower vehicle.
BRAKE DRUM SERVICE

BRAKE DRUM REFINISHING
The brake drums can be resurfaced on a drum
lathe when necessary. Initial machining cuts should
be limited to 0.12 - 0.20 mm (0.005 - 0.008 in.) at a
time as heavier feed rates can produce taper and sur
face variation. Final finish cuts of 0.025 to 0.38 mm
(0.001 to 0.0015 in) are recommended and will gen Fig. 9 Location Of Brake Drum Maximum Allowable
erally provide the best surface finish. Diameter
Be sure the drum is securely mounted in the lathe
(6) Disconnect brakeline and remove wheel cylin
before machining operations. A damper strap should
always be used around the drum to reduce vibration der.
and avoid chatter marks.
WHEEL CYLINDER OVERHAUL
BRAKE DRUM REFINISH LIMITS
WHEEL CYLINDER DISASSEMBLY
The maximum allowable diameter of the drum
braking surface is stamped or cast into the drum (1) Remove push rods and boots (Fig. 10).
outer edge (Fig. 9). Generally, a drum can be ma (2) Press pistons, cups and spring and expander
chined to a maximum of 1.5 mm (0.060 in.) oversize. from cylinder bore.
Always replace the drum if machining would cause (3) Remove bleed screw.
drum diameter to exceed indicated size limit.
BRAKE DRUM RUNOUT

Measure drum diameter and runout with an accu
rate gauge. The most accurate method of measure
ment involves mounting the drum in a brake lathe
and checking variation and runout with a dial indi
cator.
Variations in drum diameter should not exceed
0.076 mm (0.003 in). Drum runout should not exceed
0.20 mm (0.008 in.) out of round. Refinish the drum
if runout or variation exceed these values.
Fig. 10 Wheel Cylinder Components
WHEEL CYLINDER REMOVAL
Clean the cylinder and pistons with clean brake
(2) Remove brake drum and brakeshoes as de
scribed in this section. fluid or brake cleaner only. Do not use any other
(3) Remove anchor bolt and n u t and remove cleaning agents. Dry the cylinder and pistons with
washer, spring, parking brake lever, adjuster cable, compressed air. Do not use rags or shop towels to dry
cam plate and anchor pin bushing. the cylinder components. Lint from such materials
(4) Loosen brakeline at wheel cylinder. can adhere to the cylinder bores and pistons.
(5) Remove wheel cylinder bolts.
• BRAKES 5 - 55
Inspect the cylinder bore. Light discoloration and (3) Tighten brakeline fitting and cylinder attach
dark stains in t h e bore are normal and will not im ing bolts.
pair cylinder operation. If desired, the bore can be (4) Install anchor pin bushing, cam plate, adjuster
lightly polished but only with crocus cloth. Replace cable, parking brake lever, spring washer and anchor
the cylinder if t h e bore is scored, pitted or heavily bolt and nut.
corroded. Honing the bore to restore the surface is (5) Install brakeshoes and brake drum as described
not recommended. in this section.
Inspect the cylinder pistons. The piston surfaces (6) Install axle shaft.
should be smooth and free of scratches, scoring and (7) Install wheel and tire.
corrosion. Replace the pistons if worn, scored, or cor (8) Remove supports and lower vehicle.
roded. Do attempt to restore t h e surface by sanding
or polishing. SUPPORT PLATE REMOVAL
Discard the old piston cups and the spring and ex (1) Raise and support vehicle.
pander. These parts are not reusable. The original (2) Remove wheel and tire.
dust boots may be reused but only if they are in good (3) Remove axle shaft.
condition. (4) Remove brake drum, brake shoes and wheel
cylinder as described in this section.
ASSEMBLING WHEEL CYLINDER (5) Remove bolts/nuts attaching support plate to
(1) Lubricate wheel cylinder bore, pistons, piston axle and remove support plate.
cups and spring and expander with ^clean brake fluid.
(2) Install first piston in cylinder bore. Then in SUPPORT PLATE INSTALLATION
stall cup in bore and against piston. Be s u r e lip of (1) Transfer wheel cylinder and parking brake le
p i s t o n c u p is facing i n w a r d ( t o w a r d s p r i n g a n d ver components to replacement support plate.
e x p a n d e r ) a n d flat s i d e is a g a i n s t p i s t o n . (2) Position support plate on axle and install at
(3) Install spring and expanders followed by re taching bolts/nuts.
maining piston cup and piston. (3) Lubricate shoe contact surfaces of support plate
(4) Install boots on each end of cylinder and insert with Mopar multi-purpose, or high temperature bear
push rods in boots. ing grease.
(5) Install cylinder bleed screw. (4) Install brakeshoes. Adjust shoes to drum with
brake gauge.
WHEEL CYLINDER INSTALLATION (5) Install brake drum.
(1) Start brakeline into cylinder. (6) Install axle shaft.
(2) Position cylinder on support plate and install (7) Install wheel and tire.
cylinder attaching bolts. (8) Remove supports and lower vehicle.
5 - 56 BRAKES •
PARKING BRAKES
GENERAL INFORMATION (2) Connect cable to lever on secondary brakeshoe.
The parking brake mechanism on AD models is a (3) Install brakeshoes, parking brake strut and
three cable system operated by a foot pedal assembly spring, shoe return and holddown springs and self
(Figs. 1 and 2). adjuster components.
The foot pedal is mounted on t h e driver side cowl (4) Install cable in cable guide and install cable re
panel. The front cable is attached to t h e pedal assem taining clips, if equipped.
bly. An intermediate cable connects t h e front cable to (5) Connect cable to ratio lever and equalizer.
the rear cables. A n equalizer and ratio lever connect (6) Adjust rear brakes and install brake drum and
the rear cables to t h e intermediate cable. The rear wheel.
cables are connected to t h e secondary brakeshoes by (7) Adjust parking brake cable.
a lever attached to each shoe.
FRONT CABLE REPLACEMENT
PARKING BRAKE CABLE ADJUSTMENT
(1) Adjust rear drum brakes before adjusting park FRONT CABLE REMOVAL
ing brake cables. (1) Remove front cable adjusting nut.
(2) Release parking brakes fully. (2) Remove clip securing cable to anchor bracket
(3) Raise vehicle. and slide cable out of bracket.
(4) Loosen adjusting n u t on front cable until there
(3) Remove retainer attaching cable to pedal as
is slack in all cables.
sembly frame.
(5) Rotate rear wheels and tighten cable adjusting
(4) Disengage cable from pedal clevis.
n u t until slight drag is created a t wheels.
(5) Remove cable grommet (or seal) from floor pan.
(6) Continue rotating rear wheels and loosen cable
adjusting n u t until all drag is eliminated. (6) Remove front cable.
(7) Back off cable adjusting n u t a n additional two
FRONT CABLE INSTALLATION
full turns.
(1) Insert cable through floor pan.
(8) Apply parking brake several times.
(9) Release parking brakes. Then verify t h a t rear (2) Connect cable to pedal clevis and install cable
wheels rotate freely with no evidence of drag. retainer.
(10) Lower vehicle. (3) Seat cable grommet (or seal) in floorpan.
(4) Route cable to anchor bracket and intermediate
REAR CABLE REPLACEMENT cable.
(5) Secure cable in anchor bracket with U-clip.
REAR CABLE REMOVAL (6) Connect cable to adjusting link and install ca
(1) Release parking brakes fully. ble adjusting nut.
(2) Raise vehicle. (7) Adjust rear brakeshoes, if necessary.
(3) Remove adjusting n u t from front cable. (8) Adjust parking brake cable as described in this
(4) Remove rear wheels. section.
(5) Remove brake drums.
(6) Remove brakeshoes a n d parking brake strut INTERMEDIATE CABLE REPLACEMENT
and spring.
(1) Remove adjusting n u t from front cable.
(7) Disconnect cable from parking brake lever on
(2) Disengage intermediate cable from ratio lever
secondary brakeshoe.
or cable equalizer.
(8) Compress cable retainer tabs and remove cable
(3) Remove cable.
from support plate.
(9) Remove cable from guides and retaining clips. (4) Connect new cable to ratio lever or cable equal
(10) Disconnect cable from equalizer and ratio le izer.
ver. (5) Connect cable to adjusting link.
(11) Remove cable. (6) Insert front cable in adjusting link and install
cable adjusting n u t .
REAR CABLE INSTALLATION (7) Adjust brakeshoes if necessary.
(1) Insert cable through support plate hole and (8) Adjust parking brake cable a s described in this
seat cable. section.
• BRAKES 5 - 57
PAGE 1 OF 2 RR05E103
i - i8 BRAKES
CABLE INTERMEDIATE BRACKET BOLT
VIEW E
Fig. 2 Parking Brake Cable Attachment

• BRAKES 5 - 59
REAR WHEEL ANTILOCK (RWAL) BRAKES
page page
Antilock Component Service 63 General Information 59
Antilock Service Diagnosis 62 Hydraulic Valve Replacement 63
Checking Speed Sensor Air G a p . . . . . . . . . . . . . 64 Speed Sensor Replacement ................ 64
Clearing A Fault Code . . . . . . . . . . . . . . . . . . . . . 63 System Components . . . . . . . . . . . . . . . . . . . . . . 59
Electronic Control Module Replacement . . . . . . . . 64 System Fault Codes ...................... 62
Fault Code Capacity 62 System Operation 61
Fault Code Identification 62
GENERAL INFORMATION SYSTEM COMPONENTS

A rear wheel antilock brake system is standard Basic system components include an electronic
equipment on all AD models. It is a n electronically brake control module, a hydraulic pressure control
operated system designed to retard rear wheel lockup valve, a speed sensor and exciter ring and an anti-
during periods of high wheel slip and deceleration. lock warning lamp (Fig. 1).
Retarding lockup is accomplished by modulating A standard master cylinder and vacuum power
fluid pressure to the rear brake units. brake booster are used for all applications.
Rear brake fluid apply pressure is modulated ac
cording to wheel speed, degree of wheel slip and rate ANTILOCK ELECTRONIC CONTROL MODULE
of deceleration. A sensor located in t h e rear axle The electronic module controls all phases of anti-
housing converts differential rotating speed into elec lock mode brake operation. The module is separate
tronic signals. The signals are transmitted to t h e from other electrical circuits in the vehicle and oper
electronic brake control module for processing. The ates independently.
control unit determines rate of deceleration and The module is located on t h e passenger side cowl
wheel slip from these signals. panel under t h e dash (Fig. 2). The system hydraulic
valve, speed sensor and indicator lamps are all in cir-
j3l a
RWAL
ELECTRONIC
CONTROL
MODULE
SPEED
SENSOR HYDRAULIC
AXLE VALVE
HOUSING
EXCITER
RING
J9005-96
Fig. 1 Rear Wheel Antilock Brake System (RWAL)

5 - 60 BRAKES •
cuit with the module. The module contains a micro
processor t h a t operates the system and performs
system diagnostic checks.
Speed sensor inputs are continuously monitored
and interpreted by the module. The module deter
mines wheel speed and rate of deceleration from
these inputs and activates the appropriate solenoid
in the hydraulic valve when necessary.
The module microprocessor also contains a self test
program. The program is activated when the ignition
switch is turned to the On position. In this mode, the
module checks indicator light operation, the system
electrical circuits and the pressure limiting valve so
lenoids.
The brake warning and antilock indicator lamps CONNECTOR J9005-99
are illuminated for approximately two seconds dur
ing the system self test cycle. Fig. 3 RWAL Hydraulic Valve
SPEED SENSOR AND EXCITER RING
A single pole, variable reluctance speed sensor is
used to transmit speed and rate of deceleration in
puts to the control module (Fig. 4). The sensor is ac
tuated by an exiter ring on the differential case.
The sensor is mounted at the top of the rear axle
housing directly over the gear-type exiter ring (Fig.
1). The exciter ring is pressed onto the differential
case next to the ring gear.
The exciter ring is the sensor trigger mechanism.
As the ring rotates, the teeth on the ring will inter
rupt the magnetic field around the sensor pole. The
rate of interruption is converted into speed signals
which are transmitted to the control module.
Fig. 2 Antilock Electronic Control Module

RWAL HYDRAULIC VALVE
The hydraulic valve is a pressure controlling device
and is operated by the electronic module. The valve
controls fluid apply pressure to the rear brake units
during antilock mode braking (Fig. 3). The valve is
mounted on the driver side frame rail at the front of
the vehicle.
The valve contains an accumulator, an isolation
valve and a dump valve. The accumulator is operated
by fluid and spring pressure. The two valves are op
erated by electrical solenoids. The solenoids are oper
ated by the antilock control module.
The hydraulic valve components are inactive dur
ing periods of normal braking effort. The valve com Fig. 4 RWAL Speed Sensor
ponents are activated only when braking effort and ANTILOCK INDICATOR LAMP
rate of wheel slip and deceleration are high (antilock The amber colored indicator lamp is located in the
mode). instrument panel. The lamp alerts the driver if a sys
During normal braking the valve allows free flow tem fault occurs.
of brake fluid to the rear brake units. In antilock The antilock and brake warning lamps are both in
mode, the valve will decrease, hold or increase fluid circuit with the electronic module. The module will
apply pressure as needed.
• BRAKES 5 - 61
cause the two lamps to illuminate or flash to alert ACCUMULATOR CLOSED ISOLATION
the driver t h a t system operation is either normal or VALVE
CLOSED
that a fault has occurred.
SYSTEM OPERATION
During light brake applications, rear wheel decel
eration and/or slip is not sufficient to activate the an FROM
MASTER
tilock system. Brake fluid apply pressure at the rear CYLINDER
wheels is normal. However, when braking effort, de
DUMP
gree of wheel slip and rate of deceleration approach VALVE
programmed limits, sensor inputs will cause the CLOSED
module to activate the system.
TO REAR BRAKES
Normal Braking Mode
In normal braking mode, the hydraulic valve com J9005-94
ponents are inactive. The isolation valve is open and
Fig. 6 Valve Position And Fluid Flow At Start Of
the dump valve and accumulator are closed. Fluid
Anti-Lock Mode Braking
flows unimpeded through the isolation valve directly
to the rear wheel cylinders (Fig. 5). devices. The accumulator and dump valve remain
closed during initial closing of the isolation valve.
ACCUMULATOR CLOSED DUMP ISOLATION
VALVE VALVE However, if pressure exerted by fluid captured in the
CLOSED OPEN wheel cylinders and lines is high enough to lock the
wheels, the dump valve and accumulator are acti
0\m m vated (Fig. 7).
When captured fluid pressure is high, the control
0UUbF t L FROM module opens the dump valve (Fig. 7). Since the
MASTER dump valve is connected to the accumulator, a por
SPRING CYLINDER
tion of the captured fluid is diverted through the
valve and into the accumulator. The amount of fluid
diverted is sufficient to reduce apply pressure to an
tilock levels.
TO REAR BRAKES
When rear brake pressure requirements return to
normal levels, the accumulator spring closes the ac
J9005-93 cumulator. Fluid in the accumulator is forced out
and back into the hydraulic system.
Fig. 5 Valve Position And Fluid Flow-Normal
Braking ACCUMULATOR DUMP ISOLATION
OPEN VALVE VALVE
Start Of Antilock Mode Braking OPEN CLOSED
When high pedal effort braking occurs, the de
crease in exiter wheel rotating speed is converted
into an electronic signal by the sensor. This signal is
transmitted to and processed by, the control module.
FROM
The module determines t h a t acceptable limits of MASTER
wheel slip/deceleration are about to be exceeded. The CYLINDER
module activates the hydraulic valve at this point.
The control module transmits a signal to the isola
tor valve solenoid which closes the valve (Fig. 6).
Closing the valve prevents further fluid flow to the FROM REAR BRAKES TO ACCUMULATOR
rear wheel cylinders. This action isolates the rear
brakes from the master cylinder. The net effect is to J9005-95
decrease rear brake apply pressure to the point
where the wheels will continue to rotate and not Fig. 7 Dump Valve And Accumulator Position In
lock. Pressure Relief Mode
Additional Pressure Relief During Antilock Mode Braking
The dump valve and accumulator are hydraulically
connected and serve as additional pressure limiting
i - 62 BRAKES •
Isolation/Dump Valve Cycle Times If a system fault is detected, the control module il
Activation (opening/closing) of the isolation and luminates the antilock light and stores the fault code
dump valves is continuous during antilock operation. in memory. Fault codes are retained in memory even
The valves cycle rapidly in response to speed sensor after turning the ignition switch to Off position.
inputs and control module signal commands. Cycle
times are measured in milliseconds. FAULT CODES WITH TYPE II CONTROL
As the demand for antilock mode brake operation MODULE
is decreased, the module deactivates the hydraulic The microprocessor in the electronic control module
valve components to restore normal brake operation. has a memory and a self test feature. The self test
feature is activated whenever the ignition switch is
ANTILOCK SERVICE DIAGNOSIS turned to Accessory or Run position.
If a system fault is detected, the control module
GENERAL INFORMATION will illuminate the antilock indicator lamp and store
An antilock system malfunction will be indicated fault codes 1 through 8, 10 and 12 through 15 in the
by illumination of the amber antilock warning lamp. microprocessor memory. When one of these fault
The red brake warning lamp may also illuminate. codes is generated, the control module will retain the
If a problem occurs, system diagnosis should begin code after the ignition switch is turned to the Off po
with a fluid level check followed by a visual exami sition.
nation of the system electrical and hydraulic connec When fault code 9 is generated, the code only re
tions. If obvious defects (low fluid, leaks, loose mains in microprocessor memory while the ignition
connections, etc.) are not evident, road test the vehi switch is in Run position. Turning the ignition
cle. A road test should help determine if a malfunc switch to Off position erases fault code 9. However, if
tion is actually related to an antilock component. the problem still exists when the switch is turned
During the road test, note if other conditions are back to Run position, code 9 will reappear in memory
evident such as a low pedal, pull, grab, or similar after 20 seconds and the antilock light will illumi
condition. Remember t h a t brake malfunctions such nate once again.
as low fluid, system leaks, parking brakes partially When fault code 11 is generated, the antilock light
applied, will also affect the antilock system. The idea will illuminate when vehicle speed exceeds approxi
is to determine if a malfunction is actually related to mately 60.35 km/h (37.5 mph). Code 11 only remains
an anti-lock component. in memory while the ignition switch is in the Run
If a road test does reveal a problem, repeat the position and the fault is present.
road test with the owner driving. Make sure the When the cause of a fault code 11 is corrected, the
owner is not riding the brake pedal, or has forgotten antilock light goes off. Code 11 is erased when the ig
to release the parking brakes. Either situation will nition switch is turned to Off position. However, if
generate a fault and cause the antilock light to illu the problem cause still exists when the ignition
minate. switch is turned to Run position, code 11 will reap
pear when vehicle speed exceeds approximately 60.35
SYSTEM FAULT CODES km/h (37.5 mph).
The antilock control module generates flash codes
to help identify the cause of an antilock system fault. FAULT CODE CAPACITY
Two different control modules are used with the The microprocessor memory will store and display
1992/1993 RWAL system. A type I module is used in only one fault code at a time. The stored code can be
some early production models. All remaining produc displayed by grounding the RWAL diagnostic connec
tion models are equipped with a type II module. tor.
The type I and II modules are identified by the way
fault codes 9 and 11 are processed. If the vehicle has FAULT CODE IDENTIFICATION
a type I module, codes 9 and 11 are n o t erased when To determine what the fault code is, momentarily
the ignition switch is turned to Off position. If the ground the RWAL diagnostic connector and count
vehicle has a type II module, codes 9 and 11 are the number of times the amber antilock lamp
erased when the switch is turned to Off. flashes. Fault codes and typical malfunctions are out
lined in Figure 8. Note t h a t when a fault code is gen
FAULT CODES WITH TYPE I CONTROL erated, the red brake warning lamp will also
MODULE illuminate.
The microprocessor in the electronic control module The initial flash will be a long flash followed by a
has a memory and a self test feature. The self test number of short flashes. The long flash indicates the
feature is activated whenever the ignition switch is beginning of the fault number sequence and the
turned to Accessory or Run position. short flashes are a continuation of t h a t sequence.
• BRAKES 5 - 63
You must count the l o n g flash along with the ANTILOCK COMPONENT SERVICE
short flashes for an accurate fault c o d e count.
GENERAL SERVICE INFORMATION
CLEARING A FAULT CODE The rear wheel antilock (RWAL) components are
To clear a fault code, disconnect the control module serviced as assemblies only. The module, hydraulic
connector or disconnect the battery for a minimum of control valve, speed sensor and exciter ring are not
five seconds. During system retest, wait 30 seconds repairable. These components must be replaced if di
to be sure the fault code does not reappear. agnosis indicates a fault.
FAULT HYDRAULIC VALVE REPLACEMENT

CODE
VALVE REMOVAL
NUMBER TYPICAL FAILURE DETECTED
(1) Raise vehicle.
(2) Disconnect valve-to-sensor harness connector
1 Not used. (Fig. 9).
(3) Disconnect brake lines connecting hydraulic
2 Open isolation valve wiring or bad control valve to rear brakes and to combination valve.
module. (4) Remove hydraulic valve attaching screws and
remove valve from frame bracket (Fig. 9).
3 Open dump valve wiring or bad control
module. VALVE INSTALLATION
(1) Start brake lines in hydraulic valve.
4 Closed RWAL valve switch. (2) Position valve on frame bracket.
(3) Install and tighten valve attaching nuts to
5 Over 16 dump pulses generated in 2WD
vehicles (disabled for 4WD). 22-34 N-m (16-25 ft. lbs.) torque.
(4) Tighten valve brake lines.
6 Erratic speed sensor reading while rolling. (5) Bleed hydraulic valve and brakes. Refer to pro
cedure in Service Adjustments section.
7 Electronic control module fuse pellet open, (6) Lower vehicle.
isolation output missing, or valve wiring
shorted to ground.
8 Dump output missing or valve wiring shorted to

ground.
9 Speed sensor wiring/resistance (usually high

reading).
10 Sensor wiring/resistance (usually low reading).
11 Brake switch always on. RWAL light comes on

when speed exceeds 40 mph.
12 Not used.
13 Electronic control module phase lock loop

failure.
14 Electronic control module program check

failure.
15 Electronic control module RAM failure. J9005-112
J9005-101 Fig. 9 RWAL Hydraulic Valve Attachment

Fig. 8 RWAL System Fault Codes
5 - 64 BRAKES •
SENSOR FLANGE
DIMENSION A
- DIMENSION B
DIMENSION C
SENSOR POLE
PIECE 8905-34
Fig. 10 Checking Sensor Air Gap

CHECKING SPEED SENSOR AIR GAP (4) Install sensor shield.
(1) Remove sensor from differential. (5) Install and tighten sensor attaching bolt to
(2) Measure and record distance from underside of 19-29 Nnn (170-230 in. lbs.).
sensor flange to end of sensor pole piece (Fig. 10). (6) Lower vehicle.
Distance should be 27.17 to 27.43 mm (1.07 to 1.08
in.). This measurement represents dimension B. ELECTRONIC CONTROL MODULE REPLACEMENT
(3) Measure distance between sensor mounting The RWAL control module is at the passenger side
surface of differential case and teeth at top of exciter of the vehicle. On models with A/C, the module is at
ring (Fig. 10). Distance should be 27.56 to 28.45 mm tached to the dash panel near the defroster duct and
(1.085 to 1.12 in,). This distance represents dimen resistor board (Fig. 11).
sion A. To remove the module, remove the attaching
(4) Subtract dimension B from dimension A to de screws, disconnect the module harness connector and
termine sensor air gap which is dimension C (Fig.
remove the module. After installing the new module,
10).
tighten the module attaching screws to 2.3 N»m (21
(5) Air gap should be minimum of 0.12 mm (0.005
in.) and a maximum of 1.27 mm (0.050 in.). in. lbs.) torque.
(6) If air gap is not within stated limits, proceed
as follows:
(a) Replace sensor if dimension B is not within
limits specified in step (2).
(b) Replace exciter wheel or repair differential if
dimension A is not within limits specified in step
(3).
(c) Replace sensor and exciter wheel if both com
ponents are out of tolerance.
SPEED SENSOR REPLACEMENT

SENSOR REMOVAL
(1) Raise vehicle on hoist.
(2) Remove bolt securing sensor to differential
housing.
(3) Remove sensor shield and sensor from differen Fig. 11 Anti-Lock Control Module Mounting
tial housing.
(4) Disconnect sensor wiring and remove sensor.
SENSOR INSTALLATION
(1) Connect wires to sensor. B e sure seal is se
curely in place b e t w e e n sensor a n d wiring con
nector.
(2) Install O-ring on sensor (if removed).
(3) Insert sensor in differential housing.
• BRAKES 5 - 65
SPECIFICATIONS
Description Torque Description Torque
Brake Booster Mounting Nuts 25 N«m (220 in. lbs.) RWAL Valve Bolts/Nuts 22-34 Nrn (16-25 ft. lbs.)
Brakeline/Brake Hose Fittings: Rear Brake Support Plate

Bolts/Nuts:
3/8 or 7/16 13-20 Nrn (115-175 in. lbs.)
7/16 101 N»m (75 ft. lbs.)
1/2 or 9/16 15-23 N«m (140-200 in. lbs.)
1/2 115 N«m (85 ft. lbs.)
Brake Pedal Shaft Retainer
Rear Brake Support Plate
Screw 4 Ntn (35 in. lbs.) Retainer Nut:
Caliper Adapter Mounting Bolts: 8-3/8 axle 44 N«m (33 ft. lbs.)
D150/250 149 N«m (110 ft. lbs.) 9-1/4 axle 47 N-m (35 ft. lbs.)
W150/250 203 N«m (150 ft. lbs.) model 60/70 axle 115 N-m (85 ft. lbs.)
D250/350 (heavy duty) 216 Nrn (160 ft. lbs.) Wheel Cylinder
Mounting Bolts 15-25 N«m (130-230 in. lbs.)
W250/350 216 N»m (160 ft. lbs.)
Caliper-To-Brake Hose Wheel Lug Nuts:
Fitting Bolt 48 N«m (35 ft. lbs.)
8-3/8 axle 142 N»m (105 ft. lbs.)
Caliper Retainer and
Anti-Rattle Spring Screw 25 N«m (200 in. lbs.) 9-1/4 axle 142 Nrn (105 ft. lbs.)
Caliper Retainer Screw model 60/70 axle coned nut 281 N«m (200 ft. lbs.)
(keylock type) 20 N«m (15 ft. lbs.)
model 60/70 flanged 5/8-18 nut. . 441 Nrn (325 ft. lbs.)
Master Cylinder
Mounting Nuts 19-26 N«m (170-230 in. lbs.) model 60/70 flanged 1-1/8 nut . . 644 Nrn (475 ft. lbs.)
J9205-44
CLUTCH 6- 1
CLUTCH
CONTENTS
page
page
CLUTCH DIAGNOSIS 2 CLUTCH SERVICE 11
CLUTCH COMPONENTS CLUTCH LINKAGE FLUID

The clutch fluid reservoir, master cylinder, slave
MECHANICAL COMPONENTS cylinder and fluid lines a r e prefilled with fluid at t h e
The clutch mechanism in A D models with a gas or factory during assembly operations.
diesel engine consists of a single, dry-type clutch disc
The hydraulic system should not require additional
and a diaphragm style clutch cover. A hydraulic
fluid under normal circumstances. In fact, the reser
linkage is used to engage/disengage the clutch disc
voir fluid level will actually increase as normal
and cover.
clutch w e a r occurs. F o r this reason, it is impor
The transmission input shaft is supported in t h e
tant to avoid overfilling, or removing fluid from
crankshaft by a bearing. A sleeve type release bear
ing is used to operate the clutch cover pressure plate. the reservoir.
The release bearing is operated by a release fork in If inspection or diagnosis indicates additional fluid
the clutch housing. The fork pivots on a ball stud may be needed, use Mopar brake fluid, or an equiv
mounted inside the housing. The release fork is actu alent meeting SAE and DOT standards J1703 and
ated by a hydraulic slave cylinder mounted in t h e DOT 3. Do not use any other type of fluid.
housing. The slave cylinder is operated by a clutch
master cylinder mounted on the dash panel. The cyl CLUTCH COMPONENT LUBRICATION
inder push rod is connected to the clutch pedal. Proper clutch component lubrication is important
The clutch disc has cushion springs i n t h e disc hub. to satisfactory operation. The correct lubricant and
The clutch disc facing is riveted to t h e hub. The fac not overlubricating are equally important. Apply rec
ing is made from a non-asbestos material. The clutch ommended lubricant sparingly to avoid disc and pres
cover pressure plate is a diaphragm type with a one- sure plate contamination.
piece spring and multiple release fingers. The pres Clutch and transmission components requiring lu
sure plate release fingers are preset during brication are:
manufacture and are not adjustable. • pilot bearing
A 265 mm clutch disc and cover are used in models • release lever pivot ball stud
with a 3.9L engine. A 280 mm clutch disc and cover • release lever contact surfaces
are used in models with a 5.2L, or 5.9L engine. • clutch disc hub splines
A 330 m m clutch disc and cover are used in models • clutch pedal pivot shaft bore
equipped with the optional 5.9L Cummins diesel en • clutch pedal bushings
gine. Some diesel models are also equipped with a • input shaft splines
clutch pedal interlock switch. The switch is in circuit • input shaft pilot hub
with the starter relay and is actuated by t h e clutch • transmission front bearing retainer slide surface
pedal and push rod. The clutch pedal must be fully D o n o t apply grease to any part of the clutch
depressed in order to start the engine. cover, or disc.
HYDRAULIC LINKAGE COMPONENTS RECOMMENDED LUBRICANTS
The hydraulic linkage consists of a remote reser
Use Mopar multi-purpose grease for the clutch
voir, clutch master cylinder, clutch slave cylinder
pedal bushings and pivot shaft. Use Mopar high tem
and interconnecting fluid lines.
perature grease (or equivalent) for all other lubrica
The clutch master cylinder is connected to t h e
tion requirements. Apply recommended amounts and
clutch pedal and the slave cylinder is connected to
the clutch release fork. The master cylinder is do not over lubricate.
mounted on the drivers' side of the dash panel adja
cent to the brake master cylinder.
6 - 2 CLUTCH •
CLUTCH DIAGNOSIS
INDEX
page page
Clutch Problem C a u s e s , 2 Inspection and Diagnosis Charts 5
General Diagnosis Information 2
GENERAL DIAGNOSIS INFORMATION periods after water contamination, the force exerted
Unless the cause of a clutch problem is obvious, a by the pressure plate may cause the disc to bond it
road test and component inspection will be required self to the flywheel or pressure plate.
for accurate diagnosis. Frequently, the only remedy for the above condi
A road test will help determine the type of fault tion is component replacement. To avoid this prob
while component inspection will identify the problem lem, a vehicle should be driven as soon as possible to
component. heat and dry the clutch components.
During a road test, drive the vehicle at normal Clutch fluid leaks are from a loose or damaged
speeds. Shift the transmission through all gear slave cylinder line or connection. However, clutch
ranges and observe clutch action. fluid leaks will usually be noted and corrected before
If chatter, grab, slip, or improper release is experi severe contamination occurs.
enced, remove and inspect the clutch components.
However, if the problem is noise or hard shifting, CLUTCH MISALIGNMENT
further diagnosis is needed. The transmission or an Clutch components must be in proper alignment
other driveline component may actually be at fault. with the crankshaft and transmission input shaft.
Careful observation during a road test will help Misalignment caused by excessive runout or warpage
narrow the problem area. of any clutch component will cause grab, chatter and
improper clutch release.
CLUTCH PROBLEM CAUSES
Flywheel Runout
CONTAMINATION Common causes of runout are heat warping, im
Fluid contamination is one of the more common proper machining, mounting the flywheel on a dirty
causes of clutch malfunctions. Oil, water, or clutch crankshaft flange, incorrect bolt tightening, or im
fluid on the clutch contact surfaces will result in proper seating on the crankshaft flange shoulder.
faulty operation. The usual result is chatter, slip, or Very light scratches or surface roughness on the
grab. flywheel face can be cleaned up by scuff sanding with
During inspection, note if any components are con 180 grit emery cloth. However, if the surface is
taminated with oil, hydraulic fluid, or water/road warped or severely scored, replace the flywheel.
splash.
Do not machine the flywheel. The flywheel
Oil contamination indicates a leak at either the
face is manufactured with a unique surface con
rear main seal or transmission input shaft.
tour. Machining w o u l d negate this feature and
Oil leakage produces a residue of oil on the hous
could result in unsatisfactory operation.
ing interior and on the clutch cover and flywheel.
Clean the crankshaft flange before mounting the
Heat buildup caused by slippage between the cover,
disc and flywheel, can sometimes bake the oil residue flywheel. Dirt and grease on the flange surface may
onto the components. The glaze-like residue ranges cock the flywheel causing runout.
in color from amber to black. Use new bolts when remounting a flywheel and se
Road splash contamination means dirt and water cure the bolts with Mopar Lock And Seal, or Loctite
are entering the clutch housing due to loose bolts, 242. Tighten flywheel bolts to specified torque only.
housing cracks, vent openings, or through the slave Overtightening could distort the flywheel hub caus
cylinder opening. Driving through deep water pud ing runout.
dles can force water/road splash into the housing
through such openings. Clutch Cover And Disc Runout
An additional problem caused by water contamina Check the clutch disc before installation. Axial
tion and especially by steam cleaning, involves (face) runout of a n e w disc should not exceed 0.5 mm
clutch disc sticking and poor release. (0.020 in.). Measure runout about 6 mm (1/4 in.)
Water and steam vapors can be absorbed by the from the outer edge of the disc facing. Obtain an
clutch facing material. If the vehicle sits idle for long other disc if runout is excessive.
• CLUTCH 6 - 3
Check condition of the clutch before installation. A (9) Subtract each reading from the one 180° oppo
warped cover or diaphragm spring will cause grab site to determine magnitude and direction of runout.
and incomplete release or engagement. Refer to Figure 3 and following example.
Be careful when handling the cover and disc. Im Bore runout example:
pact can distort the cover, diaphragm spring, release 0.000 - (-0.007) = 0.007 in.
fingers and the hub of the clutch disc. + 0.002 - (-0.010) = 0.012 in.
Use an alignment tool when positioning the disc on + 0.004 - (-0.005) = 0.009 in.
the flywheel. The tool prevents accidental misalign -0.001 - ( + 0.001) = -0.002 in. ( = 0.002 inch)
ment which could result in cover distortion and disc In the above example, the largest difference is
damage. 0.012 in. and is called the total indicator reading
A frequent cause of clutch cover distortion (and (TIR). This means t h a t the housing bore is offset
from the crankshaft centerline by 0.006 in. (which is
consequent misalignment) is improper bolt tighten
1/2 of 0.012 in.).
ing. To avoid warping the cover, tighten the bolts al
On gas engines, t h e acceptable maximum TIR for
ternately (in a diagonal pattern) and evenly (2-3
housing bore runout is 0.010 inch. If measured TIR is
threads at a time) to specified torque.
more t h a n 0.010 in. (as in the example), bore runout
will have to be corrected with offset dowels. Offset
Clutch Housing Misalignment And Runout
dowels are available in 0.007, 0.014 and 0.021 in.
Clutch housing alignment is important to proper sizes for this purpose (Fig. 4). Refer to Correcting
operation. The housing bore maintains alignment be Housing Bore Runout for dowel installation.
tween the crankshaft and transmission input shaft. On diesel engines, the acceptable maximum
Misalignment can cause noise, incomplete clutch TIR for h o u s i n g bore runout is 0.015 inch. How
release and chatter. It can also result in premature ever, unlike g a s engines, offset d o w e l s are not
wear of the pilot bearing, cover release fingers and available to correct runout o n diesel engines. If
clutch disc. In severe cases, misalignment can also bore runout e x c e e d s the stated maximum o n a
cause premature wear of the transmission input diesel engine, it m a y be n e c e s s a r y to replace ei
shaft and bearing. ther the clutch housing, or transmission adapter
Housing face misalignment is generally caused by plate.
incorrect seating on the engine or transmission, loose
housing bolts, missing alignment dowels or housing CORRECTING CLUTCH HOUSING BORE
damage. Infrequently, misalignment may also be RUNOUT (GAS ENGINE ONLY)
caused by housing mounting surfaces t h a t are not On gas engine vehicles, clutch housing bore runout
parallel. is corrected with offset dowels. However, if bore
If housing misalignment is suspected, housing bore runout exceeds 0.015 in. TIR on a diesel equipped
and face runout can be checked with a dial indicator model, the clutch housing, or transmission adapter
as described in the following two procedures: plate may have to be replaced. Offset dowels are not
available for diesel models.
MEASURING CLUTCH HOUSING BORE The dial indicator reads positive when the plunger
RUNOUT moves inward (toward indicator) and negative when
(1) Remove the clutch housing and strut. it moves outward (away from indicator). As a result,
(2) Remove the clutch cover and disc. the lowest or most negative reading determines the
(3) Replace one of the flywheel bolts with a 7/16-20 direction of housing bore offset (runout).
threaded rod that is 10 in. (25.4 cm) long (Fig. 1). In the sample readings shown in Figure 3 and in
The rod will be used to mount t h e dial indicator. step (7) above, the bore is offset toward the 0.010
(4) Remove the release fork from t h e clutch hous inch reading. To correct this, remove the housing and
ing. original dowels. Then install the new offset dowels in
(5) Reinstall the clutch housing. Tighten the hous the direction needed to center the bore with the
ing bolts nearest the alignment dowels first. crankshaft centerline.
(6) Mount the dial indicator on t h e threaded rod In the example, TIR was 0.012 inch. The dowels
and position the indicator plunger on the surface of needed for correction would have an offset of 0.007
the clutch housing bore (Fig. 2). in. (Fig. 4).
Install the dowels with the slotted side facing out
(7) Rotate the crankshaft until the indicator so they can be turned with a screwdriver. Then in
plunger is at the top center of the housing bore. Zero stall the housing, remount the dial indicator and
the indicator at this point. check bore runout again. Rotate the dowels until the
(8) Rotate the crankshaft and record the indicator TIR is less t h a n 0.010 in. if necessary.
readings at eight points (45° apart) around the bore If a TIR of 0.053 in. or greater is encountered, it
(Fig. 3). Repeat the measurement at least twice for may be necessary to replace the clutch housing.
accuracy.
e - 4 CLUTCH •
7/16 - 20 THREAD NUT SLOT SHOWS DIRECTION OFFSET
DOWEL
D O W E L SELECTION
10 INCHES LONG
TIR OFFSET D O W E L
VALUE REQUIRED
J9006-25
0.011 -0.021 inch 0.007 inch
0.022 - 0.035 inch 0.014 inch
0.036 - 0.052 inch 0.021 inch
J9206-7
Fig. 4 Housing Bore Alignment Dowel Selection

(3) Measure and record face runout at four points
90° apart around the housing face (Fig. 6). Perform
the measurement at least twice for accuracy.
(4) Subtract the lowest reading from the highest to
determine total runout. As an example, refer to the
sample readings shown in Figure 6. If the low read
ing was m i n u s 0.004 in. and the highest reading was
p l u s 0.009 in., total runout is actually 0.013 inch.
CLUTCH (5) Total allowable face runout is 0.010 inch. If
HOUSING runout exceeds this figure, runout will have to be
BORE J9006-26
corrected. Refer to Correcting Clutch Housing Face
Fig. 2 Checking Clutch Housing Bore Runout Runout.
CORRECTING CLUTCH HOUSING FACE

.000 RUNOUT
Housing face runout, on gas or diesel engines, can
be corrected by installing shims between the clutch
housing and transmission (Fig. 7). The shims can be
made from shim stock or similar materials of the re
quired thickness.
As an example, assume t h a t face runout is the
same as shown in Figure 6 and in step (4) above. In
this case, three shims will be needed. Shim thick
nesses should be 0.009 in. (at the 0.000 corner), 0.012
CLUTCH
HOUSING in. (at the -0.003 corner) and 0.013 in. (at the -0.004
corner).
qroe {Smm READINGS) J9 006-27
After installing the clutch assembly and housing,
tighten the housing bolts nearest the alignment dow
Fig. 3 Housing Bore Measurement Points And
els first.
Sample Readings
Clutch housing preferred bolt torques are:
MEASURING CLUTCH HOUSING FACE • 4 1 N-m (30 ft. lbs.) for 3/8 in. diameter bolts
RUNOUT (GAS AND DIESEL ENGINES) • 68 Nnn (50 ft. lbs.) for 7/16 in. diameter bolts
(1) Reposition the dial indicator plunger on the • 47 N t h (35 ft. lbs.) for diesel clutch housing bolts
housing face (Fig. 5). Place the indicator plunger at During final transmission installation, install the
the rim of the housing bore as shown. shims between the clutch housing and transmission
(2) Rotate the crankshaft until the indicator at the appropriate bolt locations.
plunger is at the 10 O'clock position on the bore.
Then zero the dial indicator.
• CLUTCH 6 - 5
INDICATOR DIAL INDICATOR CUT/DRILL

CLUTCH BOLT
PLUNGER HOUSING HOLE
FACE TO SIZE
SHIM
STOCK
MAKE SHIM
INDICATOR MOUNTING „ 1-INCH
STUD OR ROD J9006-29 DIAMETER J9006-31
Fig. 5 Measuring Clutch Housing Face Runout Fig. 7 Housing Face Alignment Shims
and rapid wear. Tighten the cover bolts as described
in t h e Clutch Service section.
Improperly seated flywheels and clutch housings
+ .009 are other causes of clutch failure. Improper seating
will produce misalignment and subsequent clutch
problems.
Tighten the clutch housing bolts to proper torque
before installing any struts. Also be sure the align
ment dowels are in place and seated in the block and
housing beforehand.
CLUTCH ,004 The use of non-standard or low quality parts can
HOUSING
FACE (SAMPLE READINGS) also lead to problems and wear. Use the recom
CIRCLE mended factory quality parts to avoid comebacks.
(AT RIM
OF BORE) J9006-30
INSPECTION AND DIAGNOSIS CHARTS
Fig. 6 Housing Face Measurement Points And The clutch inspection chart (Fig. 8) outlines items
Sample Readings to be checked before and during clutch installation.
Use the chart as a check list to help avoid overlook
INSTALLATION METHODS AND PARTS ing potential problem sources during service opera
USAGE tions.
Distortion of clutch components during installation The diagnosis charts describe common clutch prob
and the use of non-standard components are addi lems, causes and correction. Fault conditions are
tional causes of clutch malfunction. listed at the top of each chart. Conditions, causes and
Improper clutch cover bolt tightening can distort corrective action are outlined in the indicated col
the cover. The usual result is clutch grab, chatter umns.
The charts are provided as a convenient reference
when diagnosing faulty clutch operation.
6 - 6 CLUTCH
8 Check input shaft seal if clutch cover and disc were

oil covered. Replace seal if worn, or cut.
9 Do not replace release bearing unless actually faulty.

Replace bearing only if seized, noisy, or damaged.
10 Check clutch cover diaphragm spring and release

fingers. Replace cover if spring or fingers are bent,
warped, broken, cracked. Do not tamper with fac
tory clutch spring setting. Clutch problems will result.
11 Check condition of clutch cover. Replace clutch cover

if plate surface is deeply scored, warped, worn, or
cracked. Be sure cover is correct size and properly
aligned on disc and flywheel.
12 Inspect clutch housing. Be sure alignment dowels are

in position and bolts are tight. Replace housing if
cracked, or damaged. If clutch problems ocurred,
check runout, to be sure housing is square with
flywheel and transmission input shaft.
13 Verify that housing alignment dowels are in position

before installing housing.
14 Clean engine block surface before installing clutch

1 Check clutch housing bolts. Tighten if loose. Be sure housing. Dirt, grime can produce misalignment.
housing is fully seated on engine block.
15 Make sure side of clutch disc marked "flywheel side"
2 Check flywheel condition. Scuff sand flywheel face is toward flywheel.
to remove glaze. Clean surface with a wax and
grease remover afterward. Replace flywheel if 16 Check rear main seal if clutch disc and cover were
severely scored, worn or cracked. Secure flywheel oil covered. Replace seal if necessary.
with new bolts (if removed). Do not reuse old bolts.
Use Lock and Seal on bolts. 17 Check crankshaft flange (if flywheel is removed). Be
sure flange is clean and flywheel bolt threads are
3 Tighten clutch cover bolts 2-3 threads at a time, alter in good condition.
nately and evenly (in a diagonal pattern) to specified
torque. Failure to do so could warp the cover. 18 Check pilot bearing. Replace bearing if dam
aged. Lube with high temp. Grease before in
4 Check release fork. Replace fork if distorted or worn. stallation.
Make sure ball stud and release bearing contact sur
faces are lubricated. 19 Check transmission input shaft. Clutch disc must
slide freely on shaft splines. Lightly grease
5 Check release fork pivot. Be sure pivot is tight and splines before installation. Replace shaft if
ball end is lubricated. splines or pilot bearing hub are damaged.
6 Transmission input shaft bearing will cause noise, 20 Check flywheel bolt torque. If bolts are loose,
chatter, or improper release if damaged. Check con replace them. Use Mopar Lock and Seal to secure
dition before installing transmission. new bolts.
7 Inspect release bearing slide surface of trans, front 21 Check clutch disc facing. Replace disc if facing is
bearing retainer. Surface should be smooth, free of charred, scored, flaking off, or worn. Also
nicks, scores. Replace retainer if necessary. Lubricate check runout of new disc. Runout should not ex
slide surface before installing release bearing. ceed 0.5 mm (0.02 in.).
J9206-9
Fig. 8 Clutch Inspection Points

CLUTCH 6-7
CLUTCH SLIPS
Condition Found Cause Correction
1. Disc facing worn out. a) Normal wear. Replace clutch disc. Also replace
cover if spring is weak or pressure
b) Driver frequently "rides" plate surface is d a m a g e d .
(slips) clutch. Results in rapid
wear overheating.
c) Insufficient clutch cover

diaphragm spring tension.
2. Clutch disc facing a) Leak at rear main seal or at a), b), c), d) Replace leaking
contaminated with oil, grease, transmission input shaft seal. seals. A p p l y less grease to
or clutch fluid. input shaft splines. Replace
b) Excessive amount of grease clutch disc (do not clean and
applied to input shaft splines. reuse). Clean clutch cover and
reuse only if cover is in g o o d
c) Road splash, water entering condition. Replace slave
housing. cylinder if leaking.
d) Slave cylinder leaking.

3. Clutch is running partially Release bearing sticking-binding. Verify that bearing is actually
disengaged. Does not return to normal running binding, then replace bearing and
position. transmission front bearing retainer if
sleeve surface is damaged.
4. Flywheel height incorrect. Flywheel surface improperly Replace flywheel.
machined. Too much stock removed
or surface is tapered.
5. Wrong disc or pressure plate Incorrect parts order or model Replace with correct parts.
installed. number. Compare old and new parts before
installation.
6. Clutch disc, cover and/or a) Rough handling (impact) bent Install new disc or cover as needed.
diaphragm spring, warped, cover, spring, or disc. Follow installation/tightening
distorted. instructions.
b) Incorrect bolt tightening
sequence and method caused
warped cover.
7. Facing on flywheel side of disc Flywheel surface scored and nicked. Reduce scores and nicks by sanding
torn, gouged, worn. or surface grinding. Replace
flywheel if scores-nicks are deeper
than .002-.004 inch.
8. Clutch disc facing burnt a) Frequent operation under high Scuff sand flywheel. Replace clutch
(charred). Flywheel and cover loads or hard acceleration cover and disc. Alert driver to
pressure plate surfaces heavily conditions. problem cause.
glazed.
b) Driver frequently "rides"
(slips) clutch. Results in rapid
wear and overheating of disc
and cover.
J9006-21
6 - 8 CLUTCH
IMPROPER CLUTCH RELEASE

1. Clutch disc warped. New disc not checked for axial Replace disc. Be sure runout of new
runout before installation. disc is less than .5 mm (.020 in.).
2. Clutch disc binds on input a) Clutch disc hub splines Clean, smooth and lubricate disc
shaft splines. damaged during installation. and shaft spines. Replace disc
and/or input shaft if splines are
b) Input shaft splines rough, severely damaged.
damaged.
c) Corrosion, rust formations on

splines of disc and input shaft.
3. Clutch disc rusted to flywheel Occurs in vehicles stored, or not Remove clutch cover and disc. Sand
and/or pressure plate. driven for extended periods rusted surfaces clean with 180 grit
of time. Also occurs after steam paper. Replace disc cover, and
cleaning if vehicle is not used for flywheel if corrosion is severe.
extended period.
4. Clutch disc facing sticks to Vacuum may form in pockets over Drill 1/16 inch diameter hole
flywheel. rivet heads in clutch disc. Occurs as through rivets and scuff sand disc
clutch cools down after use. J r
facing with 180 9 >t paper.
5. Clutch disc too thick. Wrong disc installed. Replace disc.
6. Pilot bushing seized or loose. a) Bushing cocked during a), b), c), d) Lubricate and install
new bushing. Check and
installation. correct any misalignment.
b) Bushing defective.
c) Bushing not lubricated.
d) Clutch misalignment.
7. Clutch will not disengage a) Low clutch fluid level. a) Top off reservoir and check for
properly. leaks.
b) Clutch cover loose.
b) Tighten bolts.
c) Wrong clutch disc.
| c) Install correct disc.
d) Disc bent, distorted during
installation. d) Repalce disc.
e) Clutch cover diaphragm spring

bent or wraped during e) Replace cover.
transmission instalation.
f) Remove and reinstall disc
f) Clutch disc installed
correctly. Be sure disc side
backwards.
marked "to flywheel" is
actually toward flywheel.
g) Replace fork and pivot if worn
g) Release fork bent or fork pivot
or damaged.
is loose or damaged.
h) Replace master and slave
h) Clutch master or slave cylinder
cylinder as assembly.
fault.
J9006-22
• CLUTCH 6 -9
CLUTCH GRAB/CHATTER
T
1. Clutch disc facing covered with a) Oil leak at rear main or input a) Correct leak and replace disc
oil, grease, or clutch fluid. shaft seal. (do not clean and reuse the
disc).
b) Too much grease applied to b) Apply lighter grease coating

splines or disc and input shaft. to splines and replace disc (do
not clean and reuse the disc).
2. Clutch disc and/or cover Incorrect or substandard parts. Replace disc and/or cover with
warped, or disc facings exhibit correct parts.
unusual wear or appear to be
wrong type.
3. Clutch master or slave cylinder a) Master or slave cylinder a) Replace both cylinders as
plunger dragging-binding. components worn or corroded. assembly (and reservoir).
4. N o fault found with clutch a) Problem actually related to a) Further diagnosis required.
components. suspension or driveline Check engine/transmission
component. mounts, propeller shafts and
U-joints, tires, suspension
attaching parts and other
driveline components as
needed.
b) Engine related problem. b) Check EFI and igniton systems.

5. Partial engagement of clutch a) Clutch pressure plate position a) Replace clutch cover and disc.
disc (one side worn-opposite setting incorrect or modified.
side glazed and lightly worn). b) Replace clutch cover and disc.
b) Clutch cover, spring, or release
fingers bent, distorted (rough
handling, improper assembly).
c) Clutch disc damaged or c) Replace disc.

distorted.
d) Clutch misalignment. d) Check alignment and runout of

flywheel, disc, or cover and/or
clutch housing. Correct as
necessary.
J9006-23
6-10 CLUTCH
•
CLUTCH NOISE
1. Clutch components damaged Incorrect or sub-standard clutch Replace with parts of correct type
or worn out prematurely. parts. and quality.
2. Pilot bearing damaged. a) Bearing cocked during a), b), c) Replace bearing.
installation. Be sure it is properly
b) Bearing not lubricated prior seated and lubricated
to installation. before installing clutch.
c) Bearing defect.
d) Clutch misalignment. d) Check and correct

misalignment caused by
excessive runout of flywheel,
disc, cover or clutch housing.
Replace input shaft if bearing
hub is damaged.
3. Loose components. Attaching bolts loose at flywheel, Tighten bolts to specified torque.
cover, or clutch housing. Replace any clutch bolts that are
damaged.
4. Components appear Frequent high load, full throttle Replace parts as needed. Alert
overheated. Hub of disc operation. driver to condition causes.
cracked or torsion damper
springs are distorted or
broken.
5. Contact surface of release a) Clutch cover incorrect, or a) Replace clutch cover and
bearing damaged. release fingers are bent or bearing.
distorted causing damage.
b) Release bearing defect. b) Replace bearing.
c) Release bearing misaligned. c) Check and correct runout of

clutch components. Check front
bearing retainer sleeve surface.
Replace if damaged.
6. Release bearing is noisy. Release bearing defect. Replace bearing.
7. Clutch pedal squeak. a) Pivot pin loose. Tighten pivot pin. Replace bushings
if worn or damaged. Lubricate pin
b) Pedal bushings worn out or and bushings with silicone base
cracked. lubricator chassis grease.
J9206-10
• CLUTCH S - 11
CLUTCH SERVICE
INDEX
page page
Clutch Cover and Disc Installation—All 11 Clutch Pedal Installation 17
Clutch Cover and Disc Removal—All . 11 Clutch Pedal Removal . 15
Clutch Housing Installation 13 Flywheel Service . 17
Clutch Housing Removal 12 Pilot Bearing Replacement 14
Clutch Linkage Service 14 Release Bearing Replacement 13
CLUTCH COVER AND DISC REMOVAL—ALL

(1) Raise vehicle.
(2) Remove transmission and remove transfer case
if equipped. Refer to Group 21 for procedures.
(3) Remove clutch housing from engine.
(4) Support engine with wood block and adjustable
jack stand (Fig. 1). Supporting engine is necessary to
avoid undue strain on engine mounts.
Fig. 2 Marking Clutch Cover Position
Fig. 1 Supporting Engine With Jack Stand And

Wood Block (Diesel Model Shown)
(5) If clutch cover will be reused, m a r k position of
cover on flywheel with paint or scriber (Fig. 2).
(6) Insert clutch alignment tool in clutch disc and
into pilot bushing. Tool will hold disc in place when
cover bolts are removed.
(7) If clutch cover will be reused, loosen cover bolts
evenly, only few threads at a time, and in a diagonal
pattern (Fig. 3). This relieves cover spring tension
evenly to avoid warping.
(8) Remove cover bolts completely and remove
cover, disc and alignment tool.
J9106-17
CLUTCH COVER AND DISC INSTALLATION - ALL Fig. 3 Clutch Cover Bolt Loosening/Tightening
(1) Check runout and free operation of new clutch Pattern
disc:
(a) Install disc on transmission input shaft (b) Leave disc on shaft and check disc runout
splines and check fit. Disc should slide freely on with dial indicator.
splines.
6-12 CLUTCH
(c) Position indicator plunger about 1/4 inch from (9) Remove release lever and release bearing from
outer edge of disc facing. clutch housing. Apply Mopar high temperature bear
(d) Runout should not exceed 0.5 mm (0.020 in.). ing grease to bore of release bearing, release lever
Obtain another clutch disc if runout exceeds this contact surfaces and release lever pivot stud (Fig. 6).
limit.
(2) Lubricate crankshaft pilot bearing with Mopar CLUTCH
HOUSING
high temperature bearing grease.
(3) Insert clutch alignment tool in clutch disc hub,
(4) Verify that clutch disc is positioned correctly. COAT
Side of hub marked "Flywheel Side" should face fly RELEASE
FORK PIVOT
wheel (Fig. 4). If disc is not marked, position raised BALL STUD
side of disc hub toward clutch cover and transmis WITH
sion. HIGH TEMP.
GREASE
CLUTCH
LUBE
DISC
POINTS
(HIGH TEMP.
GREASE)
RELEASE
FORK
"FLYWHEEL SIDE" (HIGH TEMP.

STAMPED O N GREASE)
THIS SURFACE LUBE
POINTS
J9006-33
Fig. 4 Clutch Disc Position (Typical)

(5) Insert alignment tool in pilot bearing and posi
tion disc on flywheel surface (Fig. 5).
(6) Position clutch cover over disc and onto fly
wheel (Fig. 5).
APPLY LIGHT COAT
CLUTCH COVER HIGH TEMP. GREASE
AND DISC TO RELEASE BEARING
BORE J9106-19
Fig. 6 Clutch Release Component Lubrication

Points
CLUTCH DISC
ALIGNMENT TOOL (10) Apply light coat of Mopar high temperature
bearing grease to splines of transmission input shaft
and to release bearing slide surface of transmission
front bearing retainer (Fig. 7). D o not overlubri-
cate shaft splines. Grease contamination of disc
will result.
(11) Install release lever and bearing in clutch
housing.
J9106-18 (12) Install clutch housing (Figs. 8 and 9). Be sure
FLYWHEEL. housing is properly seated on alignment dowels be
Fig. 5 Clutch Disc And Cower Alignment/installation fore tightening housing bolts.
(13) Install transmission/transfer case.
(7) Align and hold clutch cover in position and in (14) Check fluid level in clutch master cylinder.
stall cover bolts finger tight.
(8) Tighten cover bolts evenly and a few threads at CLUTCH HOUSING REMOVAL
a time. C o v e r b o l t s m u s t b e t i g h t e n e d e v e n l y a n d (1) Raise vehicle and remove transmission and
t o specified t o r q u e to a v o i d d i s t o r t i n g c o v e r . transfer case if equipped.
• Tighten 5/16 in. diameter bolts to 23 N-m (17 ft. (2) Remove clutch housing bolts and remove hous
lbs.) ing from engine (Figs. 8 and 9).
• Tighten 3/8 in. diameter bolts to 41 N-m (30 ft. (3) Clean housing mounting surface of engine
lbs.). block with wax and grease remover.
• CLUTCH 6 - 13
APPLY LIGHT COAT OF

HI-TEMP GREASE TO THESE
SURFACES BEFORE INSTALLATION J9106-15
Fig. 7 Input Shaft Lubrication Points (Typical)

ENGINE BLOCK CLUTCH DISC AND COVER
Fig. 9 Clutch Housing/Transmission

Installation—Diesel Engine
(2) Align and install clutch housing on transmis
sion. Tighten housing bolts closest to alignment dow
els first and to torque values indicated (Figs. 8 and
9).
(3) Install transmission-to-engine strut after in
stalling clutch housing. Tighten bolt attaching strut
to clutch housing first and engine bolt last.
(4) Install transmission and transfer case if
equipped. Refer to procedure in Group 21.
RELEASE BEARING REPLACEMENT

(1) Remove transmission.
(2) On models with gas engine and new style re
lease fork, remove clutch housing for access to re
lease fork, pivot stud and release bearing retainer
springs.
(3) Disconnect release bearing from release fork
and remove bearing (Fig. 10).
(4) Inspect bearing slide surface on transmission
J9006-32 front bearing retainer. Replace retainer if slide sur
face is scored, worn or cracked.
Fig. 8 Clutch Housing Installation—Gas Engine (5) Inspect release lever and pivot stud. Be sure
(4) Verify t h a t clutch housing alignment dowels stud is secure and in good condition. Be sure lever is
are in good condition and properly seated. not distorted or worn. Replace release lever retainer
(5) Transfer slave cylinder, release fork and boot, spring if bent or damaged.
fork pivot stud and wire/hose brackets to new hous (6) Lubricate crankshaft pilot bearing, input shaft
ing. splines, bearing retainer slide surface, lever pivot
ball stud and release lever pivot surface with Mopar
CLUTCH HOUSING INSTALLATION high temperature bearing grease.
(1) Lubricate release fork and pivot contact sur (7) Install release lever and release bearing. Be
faces with Mopar High Temperature wheel bearing sure lever and bearing are properly secured.
grease before installation. (8) Install clutch housing, if removed.
6 - 14 CLUTCH
(9) Install transmission. Also install transfer case (6) Lubricate bearing with Mopar high tempera
on 4-wheel drive models. ture grease, or an equivalent quality grease.
(7) Install clutch cover and disc.
(8) Install clutch housing, transmission and trans
fer case on 4-wheel drive models.
CLUTCH LINKAGE SERVICE

The clutch master cylinder, remote reservoir,
slave cylinder a n d connecting lines are all ser
viced as a n assembly. These c o m p o n e n t s cannot
b e serviced separately. The linkage cylinders
a n d connecting lines are sealed units. They are
prefilled with fluid during manufacture a n d
m u s t not be disassembled nor disconnected.
LINKAGE REMOVAL
(1) Raise vehicle.
(2) On diesel models, remove slave cylinder shield
Fig. 10 Clutch Release Fork And Bearing from clutch housing (Fig. 12).
PILOT BEARING REPLACEMENT

(1) Remove transmission and clutch housing.
(2) Remove clutch cover and disc.
(3) Remove pilot bearing. Use blind hole puller
tools such as those included in Snap-On set CG40CB
to remove bearing.
(4) Clean bearing bore with solvent and wipe dry
with shop towel.
(5) Install new bearing with clutch alignment tool
(Fig. 11). Keep bearing straight during installation.
Do not allow bearing to become cocked. Tap bearing
into place until flush with edge of bearing bore. Do
not recess bearing.
Fig. 12 Slave Cylinder Shield—Diesel Models

(3) Remove nuts attaching slave cylinder to studs
on clutch housing flange.
(4) Remove slave cylinder from clutch housing
(Fig. 13).
BEARING SEAL (5) Disengage slave cylinder fluid line from under-
MUST FACE vehicle retainer clips.
(6) Lower vehicle.
(7) On diesel models, disconnect clutch pedal inter
lock switch wires.
(8) Carefully remove locating clip from clutch mas
ter cylinder mounting bracket (Fig. 14).
J9206-8
(9) Remove retaining ring, flat washer and wave
Fig. 11 Typical Method Of Installing Pilot Bearing washer t h a t attach clutch master cylinder push rod
to clutch pedal (Fig. 14).
• CLUTCH 6 - 15
(4) Lubricate master cylinder rubber seal with liq

uid dish soap to ease installation. Then seat seal in
dash and around cylinder. Unlock cylinder to install
seal if necessary. Then relock cylinder after seal in
stallation.
(5) Position clutch fluid reservoir on dash panel
and install reservoir screws. Tighten screws to 5 N»m
(40 in. lbs.) torque.
(6) Install reservoir mounting bracket on dash
panel, if removed.
(7) Install replacement bushing on clutch pedal pin
if necessary.
(8) Install clutch master cylinder push rod on
clutch pedal pin. Secure rod with wave washer, flat
washer and retainer ring.
(9) On diesel models, disconnect clutch interlock
Fig. 13 Slave Cylinder Removal/Installation start switch wires.
(10) Install locating clip in clutch master cylinder
(10) Slide clutch master cylinder push rod off pedal mounting bracket.
pin. (11) Raise vehicle.
(11) Inspect condition of bushing on clutch pedal (12) Install slave cylinder. Be sure cap at end of
pin. Remove and replace bushing if worn or dam cylinder rod is seated in release lever. Check this be
aged. fore installing cylinder attaching nuts.
(12) Verify t h a t cap on clutch master cylinder res (13) Install and tighten cylinder attaching nuts to
ervoir is tight. This will avoid spillage during re 23 N*m (200 in. lbs.) torque.
moval. (14) Lower vehicle.
(13) Remove screws that attach clutch fluid reser (15) If new linkage has been installed, remove
plastic shipping stop from master cylinder push rod.
voir to dash panel.
Do this after installing slave cylinder and before op
(14) If necessary, remove reservoir mounting
erating linkage.
bracket screws and remove bracket from dash panel. (16) Operate linkage several times to verify proper
(15) remove clutch master cylinder rubber seal operation.
from dash panel (Fig. 14).
(16) Rotate clutch master cylinder 45° counter CLUTCH PEDAL REMOVAL
clockwise to unlock it. Then remove cylinder from (1) Remove retaining ring, flat washer and wave
dash panel. washer t h a t secure clutch master cylinder push rod
(17) Remove clutch cylinders, reservoir and con to clutch pedal pin (Fig. 14).
necting lines from vehicle. (2) Remove fastener t h a t secure pedal shaft to
pedal support.
LINKAGE INSTALLATION (3) Slide pedal shaft out left side of pedal support
(1) Tighten cap on clutch fluid reservoir to avoid and out of clutch pedal.
spillage during installation. (4) Slide push rod off clutch pedal pin and remove
(2) Position cylinders, connecting lines and reser clutch pedal.
voir in vehicle. (5) Remove and inspect bushings in clutch pedal
(3) Insert clutch master cylinder in dash panel. Ro shaft bore and on bushing on pedal pin. Replace any
tate cylinder 45° clockwise to lock it in place. bushing t h a t is worn or damaged.
en
PEDAL
SUPPORT
O
—
I
e
HI
O
CYLINDER x
FLUID
RESERVOIR
PEDAL
SHIFT
CLUTCH FLUID LINE

(DIESEL ENGINE)
CLUTCH FLUID LINE

(GAS ENGINE)
CLUTCH
HOUSING
SLAVE
CYLINDER
SHIELD
CLUTCH
HOUSING SLAVE WITH
WITH CYLINDER DIESEL
GAS
ENGINE
ENGINE J9206-1
Fig. 14 Clutch Linkage And Pedal Components

• CLUTCH 6-17
CLUTCH PEDAL INSTALLATION m e n d e d and preferred method of repair.

(1) Lubricate pedal shaft, pedal shaft bore and all In cases where a new flywheel is not readily avail
bushings with Mopar Multi Mileage grease. able, a replacement ring gear can be installed. How
(2) Insert pedal pin into cylinder push rod. Then ever, the following precautions must be observed to
position clutch pedal in support. avoid damaging the flywheel and replacement gear.
(3) Slide pedal shaft through clutch pedal bore and (a) Mark position of the old gear for alignment
bushings. reference on the flywheel. Use a scriber for this
(4) Install bolt that retains pedal shaft in support. purpose.
(5) Secure push rod to pedal pin with wave washer, (b) Wear protective goggles or approved safety
flat washer and retaining ring. glasses. Also wear heat resistent gloves when han
dling a heated ring gear.
FLYWHEEL SERVICE (c) Remove the old gear by cutting most of the
Inspect the flywheel whenever the clutch disc, way through it (at one point) with an abrasive cut
cover and housing are removed for service. Check off wheel. Then complete removal with a cold chisel
condition of the flywheel face, hub, ring gear teeth, or punch.
and flywheel bolts. (d) The ring gear is a shrink fit on the flywheel.
Minor scratches, burrs, or glazing on the flywheel
This means the gear must be expanded by heating
face can be scuff sanded with 180 grit emery cloth.
in order to install it. The m e t h o d of heating a n d
However, the flywheel should be replaced if the disc
expanding the gear is extremely important. Ev
contact surface is severely scored, h e a t checked,
ery surface of the gear must be heated at the same
cracked, or obviously worn.
time to produce uniform expansion. An oven or
Cleanup of minor flywheel scoring should be per
similar enclosed heating device must be used. Tem
formed with surface grinding equipment. Remove
perature required for uniform expansion is
only enough material to reduce scoring (approximate
325-350° F.
ly 0.001 - 0.003 in.). Heavy stock removal is not rec
ommended. Replace the flywheel if scoring is severe C A U T I O N : Never use an oxy/acetylene torch to re
and deeper than 0.076 mm (0.003 in.). Excessive move the old gear, or to heat and expand a new
stock removal can result in flywheel cracking or gear. The high temperature of the torch flame will
warpage after installation; it can also weaken the cause localized heating and damage the flywheel. In
flywheel and interfere with proper clutch release. addition, using the torch to heat a replacement gear
Check flywheel runout if misalignment is sus will cause uneven heating and expansion. The torch
pected. Runout should not exceed 0.08 mm (0.003 flame will also anneal the gear teeth resulting in
in.). Measure runout at the outer edge of the fly rapid wear and damage after installation.
wheel face with a dial indicator. Mount the dial in
dicator on a stud installed in place of one of the (e) The heated gear must be installed evenly to
flywheel attaching bolts. avoid misalignment or distortion. A shop press and
Clean the crankshaft flange before mounting the suitable press plates should be used to install the
flywheel. Dirt and grease on the flange surface may gear if at all possible.
cock the flywheel causing excessive runout. (f) Be sure to wear eye and hand protection.
Check condition of the flywheel hub and attaching Heat resistent gloves and safety goggles are needed
bolts. Replace the flywheel if the hub exhibits cracks for personal safety. Also use metal tongs, vise
in the area of the attaching bolt holes. grips, or similar tools to position the gear as neces
Install new attaching bolts whenever the flywheel sary for installation.
is replaced and use Mopar Lock N' Seal, or Loctite (g) Allow the flywheel and ring gear to cool
242 on replacement bolt threads. down before installation. Set the assembly on a
Recommended flywheel bolt torques are: workbench and let it cool in normal shop air.
• 75 N»m (55 ft. lbs.) for gas engine flywheels
• 137 N*m (101 ft. lbs.) for diesel flywheels C A U T I O N : D o not use water, or compressed air to
Inspect the teeth on the starter ring gear. If the cool the flywheel. The rapid cooling produced by
teeth are w o r n or damaged, the flywheel should water or compressed air can distort, or crack the
be replaced as a n assembly. This is the recom gear and flywheel.
COOLING SYSTEM
CONTENTS
page page
DIAGNOSIS ... 4 SERVICE PROCEDURES 15

ENGINE ACCESSORY DRIVE BELTS 40 SPECIFICATIONS ; 49
ENGINE BLOCK HEATERS 48
GENERAL INFORMATION ating temperature as quickly as possible. It also

Throughout this group, references are made to partic maintains normal operating temperature and pre
ular vehicle models by alphabetical designation or by vents overheating.
the particular vehicle nameplate. A chart showing a The cooling system also provides a means of heat
breakdown of alphabetical designations is included in ing the passenger compartment and cooling the auto
the Introduction section at the beginning of this man matic transmission fluid (if equipped). The cooling
ual. system is pressurized and uses a centrifugal water
5.9L gas powered engines will be' referred to as ei pump to circulate coolant throughout the system.
ther: LDC (Light Duty Cycle) or HDC (Heavy Duty An optional factory installed maximum duty cool
Cycle). ing package is available on most models. This pack
age will provide additional cooling capacity for
COOLING SYSTEM vehicles used under extreme conditions such as
The cooling system regulates engine operating tem trailer towing in high ambient temperatures.
perature. It allows the engine to reach normal oper-
SHUT OFF VALVE

N O T E : HEATER A / C ONLY C O O L A N T FLOW - PUMP TO
C O O L A N T FLOW CYLINDER BLOCK, UP THROUGH
CIRCUIT IS A L W A Y S CYLINDER H E A D S TO INTAKE
O P E N EXCEPT MANIFOLD WATER BOX TO
WHEN IN M A X . A / C R A D I A T O R - T O PUMP
OR OFF M O D E S
HEATER
INTAKE MANIFOLD
C O O L A N T FLOW "METERED"
FROM REAR TO
FRONT A N D BELOW
EXHAUST HEAT
CROSSOVER
•BYPASS
THERMOSTAT C L O S E D - H I G H FLOW
THERMOSTAT O P E N - L O W FLOW
J9207-18
Fig. 1 Cooling System Routing—3.9U5.2L Engine—Typical

7 - 2 COOLING SYSTEM •
SHUT OFF VALVE
NOTE: HEATER A / C ONLY COOLANT FLOW - PUMP TO
COOLANT FLOW CYLINDER BLOCK, UP THROUGH
CIRCUIT IS ALWAYS CYLINDER HEADS TO INTAKE
OPEN EXCEPT MANIFOLD WATER BOX TO
WHEN IN M A X . A / C RADIATOR — TO PUMP
OR OFF MODES
HEATER
INTAKE MANIFOLD
COOLANT FLOW "METERED"
FROM REAR TO
FRONT AND BELOW
EXHAUST HEAT
CROSSOVER
•BYPASS
THERMOSTAT C L O S E D - H I G H FLOW
THERMOSTAT OPEN - LOW FLOW
CYLINDER HEAD
RR07B52
Fig. 2 Cooling System Routing—5.9L (V-8 Gas)—Typical

All vehicles are equipped with either a 3.9L (V-6), COOLING SYSTEM COMPONENTS-DIESEL
a 5.2L (V-8), a 5.9L (LDC-gas V-8), a 5.9L (HDC-gas ENGINE
V-8) or a 5.9L (in-line 6 cylinder diesel) engine. Coolant flow circuits for 5.9L (diesel) engines with
As coolant temperature reaches approximately water cooled intake manifolds are shown in figure 3.
220°F, the engine idle speed is increased by the pow- The cooling system (Fig. 3) consists of: a cross-flow
ertrain control module (PCM) to provide increased radiator, engine driven cooling fan, thermal viscous
cooling system performance. The PCM was formerly fan drive, fan shroud, radiator pressure cap, thermo
referred to as the engine controller or SBEC. stat, coolant reserve/overflow system, transmission
oil cooler (if equipped with an automatic transmis
COOLING SYSTEM COMPONENTS—EXCEPT sion), coolant, water pump, hoses and hose clamps.
DIESEL ENGINE
The cooling system consists of: SYSTEM COOLANT ROUTING-DIESEL ENGINE
• A down-flow radiator Coolant is drawn from radiator into the water
• Thermal viscous fan drive pump. Water pump output is directed to the engine
• F a n shroud oil cooler cavity of the cylinder block (Fig. 4).
• Radiator pressure cap From the oil cooler cavity, the coolant circulates
• Thermostat around each cylinder. It then crosses to the lift pump
• Coolant reserve/overflow system side of engine where it flows up into cylinder head
• Transmission oil cooler (automatic transmission) through openings in top of cylinder block (Fig. 4).
• Coolant Coolant flows past the valve bridges (Fig. 5), to ex
• Water pump (to circulate coolant) haust manifold side of engine, to thermostat. As cool
• Hoses and hose clamps ant flows toward the thermostat, it provides cooling
Coolant flow circuits for 3.9L (V-6) and 5.2L (V-8) for the injector nozzle.
engines with water cooled intake manifolds are When thermostat is closed (engine is below operating
shown in figure 1. temperature), coolant flows through bypass passage to
Coolant flow circuits for 5.9L (V-8 Gas) engines water pump inlet (Fig. 6). Once operating temperature
with water cooled intake manifolds are shown in fig is reached, the thermostat opens and blocks the bypass
ure 2. passage. Coolant then flows to the radiator inlet.
COOLING SYSTEM 7 - 3
•
Fig. 3 Diesel Engine Cooling System-Typical
1. Coolant Flow from Cylinder Block

2. Coolant to Thermostat H o u s i n g
Fig. 4 Cylinder Block Coolant Routing-Diesel Engine F i g 6 coolant Flow at Thermostat-Diesel Engine
DIAGNOSIS
PRELIMINARY CHECKS installed. If not, maximum cooling system compo
nents should be installed for model involved per
ENGINE COOLING SYSTEM OVERHEATING manufacturer's specifications.
Establish what driving conditions caused the com 4. R E C E N T S E R V I C E O R A C C I D E N T R E
plaint. Abnormal loads on the cooling system such as PAIR:
the following may be the cause: Determine if any recent service has been performed
1. P R O L O N G E D I D L E , V E R Y H I G H AMBI
on vehicle t h a t may effect cooling system. This may
E N T T E M P E R A T U R E , S L I G H T T A I L WIND A T
be:
I D L E , SLOW T R A F F I C , T R A F F I C J A M S , H I G H
• Engine adjustments (incorrect timing)
SPEED OR S T E E P GRADES.
• Slipping engine accessory drive belt(s)
Driving techniques t h a t avoid overheating are:
• Idle with A/C off when temperature gauge is at • Brakes (possibly dragging)
end of normal range. • Changed parts. Incorrect water pump or pump ro
* Increasing engine speed for more air flow is recom tating in wrong direction due to belt not correctly
mended. routed
2. T R A I L E R TOWING: • Reconditioned radiator or cooling system refilling
Consult Trailer Towing section of owners manual. (possibly under filled or air trapped in system).
Do not exceed limits. If investigation reveals none of the above as a
3. A I R C O N D I T I O N I N G ; ADD-ON O R A F T E R cause for an engine overheating complaint, refer to
MARKET: the following Symptom and Action chart:
A maximum cooling package should have been or
dered with vehicle if add-on or after market A/C is
SYMPTOM AND ACTION PRELIMINARY FIRST)
SYMPTOM ACTION
Blinking Engine Temperature Normal during temporary operation with heavy load, towing a trailer, high
Warning Light or High Gauge outdoor temperatures, and/or on a steep Loss grade.
indication - Without Coolant Loss
Coolant Loss Improper refilling procedures can result in trapped air in the system. Subsequent
operation of the pressure cap and coolant reserve system will deaereate the
cooling system. A low coolant level will then result in the Coolant Reserve
Tank. Add coolant. If condition persists, refer to System Diagnosis.
Hot Vehicle (Not Engine) Check heat shielding, exhaust system, engine emission controls, ignition
Heat Damage, timing, engine misfiring.
Hot Carpet, Seat,
Hot Catalytic Converter,
Smoke, Burnt Odor
Hot Engine A moderate amount of sound from heating metal can be expected with any
Crackling Noise vehicle. However, a crackling sound from trie thermostat housing, a hot smell
Hot Smell and/or severe local hot spots on an engine can indicate blocked coolant
Severe Local Hot Spots passages, bad castina, core sand deposits and subsequent blockage,
cracked cylinder block or head, or blown cylinder head gasket. Usually
accompanied with coolant loss.
Coolant Color Coolant color is not necessarily an indication of adequate temperature or

corrosion protection.
Coolant Reserve Bottle Level changes are to be expected as coolant volume fluctuates with engine
Level Changes temperature. If the level in the bottle is between the Maximum and Minimum
marks at normal engine operating temperature, the level should return to
within that range after operation at elevated temperatures.
Coolant Not Returning Coolant will not return to the radiator if the radiator cap vent valve does not
To Radiator function, if an air leak destroys vacuum, or if the overflow passage is
blocked or restricted. Inspect all portions of the overflow passage, pressure
cap, filler neck nipple, hose, and passages within the bottle for vacuum leak
only. Coolant return failure will be evident by a low level in the radiator.
Reserve bottle level should increase during heat-up.
J9207-31
• COOLING SYSTEM 7 - 6
COOLING SYSTEM DIAGNOSIS (EXCEPT DIESEL)
CONDITION A N D CHICK DIAGNOSIS

OPTIONAL M°¥ GAUGE READS LOW
30° TO 40°
GAUGE TRAVEL
IS NORMAL
Normal Gauge Travel

(!) Verify gauge reading. Is a low temperature indicated? (1) Inspect temperature gauge sending unit. Refer to Group 8,
Electrical. Repair or replace sending unit as necessary.
(2) Is code 17 recorded in On Board Diagnostics memory? (2) If code 17 is recorded, replace the thermostat. If not, the
thermostat is not the cause of the low gauge reading.
(3) Is the gauge reading in the cold range? (3) Inspect for disconnected sending unit electrical connector or
incorrect sending unit. Ensure that gauge sending unit is installed
and not an indicator light switch.
(4) Low coolant level during cold ambient temperatures (4) WARNING: DO NOT REMOVE THE RADIATOR CAP OF A
(accompanied with poor heater performance). HOT, PRESSURIZED ENGINE. SERIOUS INJURY C A N
RESULT FROM SCALDING COOLANT.
Inspect coolant level in the coolant reserve tank and radiator.
Inspect system for leaks.
(5) Coolant level is correct. (5) Inspect heater door controls. Refer to Group 24, Heating and
Air Conditioning.
GAUGE HEADING HIGH. N O PRESSURE BLOW OFF FROM
RADIATOR PRESSURE CAP OR STEAM FROM COOLANT
RESERVE TANK.
TO TOP AMBIENT
High Gauge Reading — Hot Weather — Heavy Load
(1) Verify gauge reading. Is a high temperature reading indicated? (1) Compare gauge reading to High Gauge Reading Illustration
above.
(2) Gauge reading at "H" without signs of boiling. (2) Inspect for grounded gauge, sending unit or circuit. Refer to
Group 8, Electrical.
(3) Low coolant level in radiator and coolant reserve tank. (3) a — Pill to full.
b — Inspect for leaks in system and repair as necessary,
c — Ensure radiator pressure cap was shut tight. Verify proper
operation of the radiator cap upper and lower seals.
(4) Coolant level in radiator is low. But not low in coolant reserve (4) a — Fill to full,
tank. b — Inspect for leaks in the system and repair as necessary,
c — Inspect for leaks in the coolant reserve tank to radiator
hose.
d — Verify proper operation of the radiator cap upper and
lower seals.
(5) Test coolant freeze point. (5) a — Adjust coolant solution to 50/50 mixture of anti-freeze and
water. Refer to Coolant in this group,
b — If a reading is not recorded or below — 50, the mixture is
too rich. Clean system and fill with a 50/50 mixture of
anti-freeze and water. Refer to Coolant in this group.
(6) Ensure proper coolant flow. (6) a •— With the thermostat open and a slight amount of coolant
removed, inspect for coolant flow through the radiator at
the filler neck opening,
b — Determine reason for lack of coolant flow and repair as
necessary.
J9007-69
COOLING SYSTEM DIAGNOSIS (EXCEPT DIESEL)—CONTINUED
Condition and Checks Diagnosis

(7) Other possible causes. (7) a — If symptom occurs during high speed operation inspect for
plugged air inlet side of the radiator or condenser,
plugged radiator core tubes, add on A/C package without
proper radiator, engine not operating within specifications,
dragging brakes, trailer towing or hill climbing, or an
insect screen.
b — If symptom occurs during high or low speed operation

inspect for: thermostat being stuck partially open if ambient
temperature is below 70°F and the vehicle has high
mileage, plugged air inlet side of the radiator or
condenser, add on A/C with incorrect radiator.
c — If symptom occurs during low speed operation only, inspect

the radiator fan drive. Repair as necessary.
TEMPERATURE GAUGE READS HOT. PRESSURE CAP VENTS

RESULTING IN STEAM AND COOLANT TRANSFER TO
COOLANT RESERVE TANK.
(1) Coolant level low in radiator and coolant reserve tank. (1) a — Fill cooling system and vent trapped air.
b — Inspect for leaks. Repair as necessary.
c — Ensure that pressure cap is completely shut and seals.
d — If level is low in radiator but normal in the coolant reserve

tank, check the filler cap to coolant reserve bottle
connection and pressure cap seal.
(2) Test coolant freeze point. (2) Adjust coolant to 50/50 mix of anti-freeze and water. Refer to
Coolant section in this group.
(3) Ensure coolant is flowing through system. (3) a — With the coolant level low and the thermostat open, check
for coolant flow through the radiator at the filler neck.
b — If a metal cracking sound is heard, inspect for core sand

restricting coolant flow through the water jacket and/or a
faulty cylinder head casting.
(4) Thermostat stuck in the closed position (prevalent in cold ambient (4) Replace thermostat if found to be stuck in closed position. Refer
temperatures). to the Thermostat Testing section in this group.
(5) Cylinder head gasket leak. (5) Inspect for leaking cylinder head gasket with a commercially
available Block Leak Tester.
J9007-57
COOLING SYSTEM DIAGNOSIS (EXCEPT DIESELJ-GONTINUED
CONDITION AND CHECKS DIAGNOSIS

TEMPERATURE GAUGE IS INCONSISTENT, CYCLES AND/OR IS
ERRATIC.
(1) Is cycle normal.
MID
(a) Normal Gauge Reaction to Thermostat Cycle.
MID
(b) Normal Gauge Reaction at Stop After Heavy Use.
(c) Hot Water Build-Up is Normal at Stop after Heavy Use.
(2) Is coolant in radiator low (air will build up in the cooling system (2) Fill system, vent trapped air and check for leaks,
and cause the thermostat to open late).
(3) Is a cylinder head gasket leak allowing exhaust gas to enter (3) a — Test for leaking cylinder head gasket leak with a
cooling system (exhaust gas building up in the cooling system will commercially available Block Leak Tester,
cause the thermostat to open late).
b — Check for coolant in engine oil.
c — Inspect for white steam from exhaust system.
(4) Water pump impeller loose on shaft. Loose accessory drive belt. (4) Repair or replace as necessary.
(5) Air leak on the suction side of the water pump (allows air to build (5) Find leak and repair,
up in cooling system causing thermostat to open late).
WARNING LIGHT GLOWS ALL THE TIME (VEHICLE NOT

EQUIPPED WITH GAUGE).
(1) Inspect temperature gauge sending unit. The warning light sending (1) Ensure that a warning light sending unit is installed,
unit has a screwdriver slot in the electrode (used for calibration).
Gauge sending units do not have a slot in the electrode.
NO GAUGE READING INITIALLY THEN HOT INDICATION

(VEHICLE EQUIPPED WITH GAUGE).
(1) Gauge stationary until very hot, then moves immediately to "H" (1) Vehicle is equipped with sending unit for light not gauge.
J9007-70
7 - 8 COOLING SYSTEM
Condition and Check Diagnosis

PRESSURE CAP VENTS TO ATMOSPHERE AND COOLANT
RESERVE TANK. TEMPERATURE GAUGE READING ABOVE
NORMAL BUT NOT HIGH.
(1) Test radiator pressure cap relief pressure. Refer to Radiator (1) Replace cap if relief pressure is lower than 14 psi.
Pressure cap section in this group.
COOLANT LOSS VISIBLE ON GROUND BELOW VEHICLE, BUT
NO PRESSURE CAP BLOW OFF.
(1) Inspect system for leaks. (1) Repair as necessary.
COOLANT LOSS PAST PRESSURE CAP TOP SEAL, VISIBLE ON
RADIATOR FILLER NECK.
(1) With normal gauge reading. (1) a — Pressure cap not installed tightly.
b— Pressure cap top seal leaks.
c— Pressure cap diaphragm bowed.
d— Damaged radiator filler neck.
e— Pressure cap top seal out of position.
(2) With high or low gauge reading on new vehicle. (2) a — Kinked coolant reserve system hose.
b — Coolant reserve system tank plastic tube plugged,
c — Pressure cap seal out of position.
DETONATION OR PREIGNITION. NOT CAUSED BY IGNITION
OR ENGINE CONDITIONS.
(1) Check engine coolant freeze point. If the tester does not register (1) a — Adjust coolant solution to 50/50 water ethylene-glycol
a reading or if the reading is below 50°F, inspect ethylene- mixture.
glycol/water ratio. A 100 percent solution of ethylene-glycol in b — If 100 percent ethylene-glycol solution is found in system,
the system causes the engine to run hotter and possibly overheat. clean and flush system before replacing with 50/50 mixture
of ethylene-glycol and water.
COOLING SYSTEM HOSES COLLAPSE ON COOLDOWN.
(1) Inspect pressure cap vent valve. (1) a — Gasket swell can prevent valve from opening,
b — Replace pressure cap.
(2) Coolant reserve tank hose plugged or kinked. (2) Repair as necessary.
(3) Inside of pressure cap plugged. (3) Clean cap or replace if necessary.
COOLING SYSTEM SUSPECTED AS CAUSE OF INADEQUATE
AIR CONDITIONING SYSTEM PERFORMANCE.
(1) Inspect for plugged radiator and/or condenser. (1) Clean with low pressure water from fan side.
(2) Inspect for missing air seals in the recirculating air path. (2) Repair as necessary.
EXCESSIVE FAN NOISE
(1) Inspect for loose or bent fan blades. (1) Replace fan.
(2) Inspect clearance between fan and adjacent part. (2) Repair or replace as necessary.
(3) Inspect radiator and condenser for incoming air obstructions. (3) Clean air path with low pressure water from fan side.
(4) Inspect viscous fan drive. (4) Replace if viscous drive does not operate properly.
HEAT ODOR
(1) Was temperature gauge reading high? (1) If YES, refer to GAUGE READING HIGH. If NO, refer to steps
2, 3, and 4.
(2) Are all heat shields in place? (2) If YES, refer to steps 3 and 4. If NO, repair as required.
(3) If the air side of the heat exchanger plugged? (3) Clean as necessary.
(4) Engine running rich causing catalytic converter to overheat. (4) Repair as necessary.
POOR DRIVEABIUTY. SUSPECT THERMOSTAT FAILED IN OPEN
POSITION.
(1) Check On-Board Diagnostics. Is code 17 set in memory? (1) If YES, replace thermostat. If NO, refer to the appropriate
Driveability Manual.
J9007-59
Condition and Chock Diagnosis
POOR HEATER PERFORMANCE. SUSPECT

THERMOSTAT FAILED I N OPEN POSITION.
(1) Does gauge read low? (1) If YES, replace thermostat. If N O , inspect the auxiliary heater
vacuum water valve. The valve should be open except when the
climate controls are OFF or in the M A X A/C mode.
(2) Is coolant level low? (2) Fill cooling system and inspect for leaks. Repair as necessary.
(3) Check On-Board Diagnostics. Is code 17 set in memory? (3) If YES, replace thermostat. If N O , inspect the auxiliary heater
vacuum water valve. The valve should be open except when the
climate controls are OFF or in the MAX A/C mode.
J9007-61
7-10 COOLING SYSTEM
•
DIESEL COOLING SYSTEM DIAGNOSIS
CONDITION AND C H E C K S DIAGNOSIS

OPTIONAL 60»F G A U G E R E A D S LOW
30° TO 40°
GAUGE TRAVEL
IS N O R M A L
MID
Normal Gauge Travel

(1) Verify gauge reading. Is a low temperature indicated? (1) Inspect temperature gauge sending unit. Refer to Group 8,
Electrical. Repair or replace sending unit as necessary.
(2) Thermostat stuck in open position? (2) If Yes, replace the thermostat. If not, the thermostat is not the
cause of the low gauge reading.
(3) Is the gauge reading in the cold range? (3) Inspect for disconnected sending unit electrical connector or
incorrect sending unit. Ensure that gauge sending unit is in
stalled and not an indicator light switch.
(4) Low coolant level during cold ambient temperatures (accom (4) WARNING: DO NOT REMOVE THE RADIATOR CAP
panied with poor heater performance). OF A HOT, PRESSURIZED ENGINE. S E R I O U S IN
JURY CAN RESULT FROM SCALDING COOLANT.
Inspect coolant level in the coolant reserve tank and radiator.
Inspect system for leaks.
(5) Coolant level is correct. (5) Inspect heater door controls. Refer to Group 24, Heating and
Air Conditioning.
GAUGE READING HIGH. NO P R E S S U R E BLOW OFF

FROM RADIATOR P R E S S U R E C A P OR STEAM FROM X
COOLANT R E S E R V E TANK.
M A X I M U M HOT
WEATHER
HEAVY L O A D
M A X I M U M UP
TO TOP AMBIENT
High Gauge Reading — Hot Weather — Heavy Load

(1) Verify gauge reading. Is a high temperature reading indi (1) Compare gauge reading to High Gauge Reading Illustration
cated?
above.
(2) Gauge reading at " H " without signs of boiling.
(2) Inspect for grounded gauge, sending unit or circuit. Refer to
Group 8, Electrical.
(3) Low coolant level in radiator and coolant reserve tank. (3) a - Fill to full.
b — Inspect for leaks in system and repair
a s necessary.
Ensure radiator pressure cap was shut
tight. Verify proper operation of the radiator
cap upper and lower seals.
(4) Coolant level in radiator is low. But not low in coolant reserve (4) a - Fill to full.
tank. b — Inspect for leaks in the system and repair
a s necessary.
Inspect for leaks in the coolant reserve
tank to radiator hose.
d — Verify proper operation of the radiator cap
upper and lower seals.
(5) Test coolant freeze point. (5) a- Adjust coolant solution to 50/50 mixture of
anti-freeze and water. Refer to Coolant
in this group.
If a reading is not recorded or below - 50.
the mixture is too rich. Clean system and fill
with a 50/50 mixture of anti-freeze and water.
Refer to Coolant in this group.
(6) Ensure proper coolant flow.
(6) a- With the thermostat open and a slight amount
of coolant removed, inspect for coolant flow
through the radiator at the filler neck opening.
b — Determine reason for lack of coolant flow
and repair a s necessary. J9107-22
• COOLING SYSTEM 7-11
DIESEL COOLING SYSTEM DIAGNOSIS-CONTINUED
Condition and Chocks Diagnosis

(7) Other possible causes. (7) a — If symptom occurs during high speed operation inspect for
plugged air inlet side of the radiator or condenser,
plugged radiator core tubes, add on A/C package without
proper radiator, engine not operating within specifications,
dragging brakes, trailer towing or hill climbing, or an
insect screen.
b — If symptom occurs during high or low speed operation

inspect for: thermostat being stuck partially open if ambient
temperature is below 70°F and the vehicle has high
mileage, plugged air inlet side of the radiator or
condenser, add on A/C with incorrect radiator.
c — If symptom occurs during low speed operation only, inspect

the radiator fan drive. Repair as necessary.
TEMPERATURE GAUGE READS HOT. PRESSURE CAP VENTS

RESULTING IN STEAM A N D COOLANT TRANSFER TO
COOLANT RESERVE TANK.
(1) Coolant level low in radiator and coolant reserve tank. (1) a — Fill cooling system and vent trapped air.
b — Inspect for leaks. Repair as necessary.
c — Ensure that pressure cap is completely shut and seals.
d — If level is low in radiator but normal in the coolant reserve

tank, check the filler cap to coolant reserve bottle
connection and pressure cap seal.
(2) Test coolant freeze point. (2) Adjust coolant to 50/50 mix of anti-freeze and water. Refer to
Coolant section in this group.
(3) Ensure coolant is flowing through system. (3) a — With the coolant level low and the thermostat open, check
for coolant flow through the radiator at the filler neck.
b — If a metal cracking sound is heard, inspect for core sand

restricting coolant flow through the water jacket and/or a
faulty cylinder head casting.
(4) Thermostat stuck in the closed position (prevalent in cold ambient (4) Replace thermostat if found to be stuck in closed position. Refer
temperatures). to the Thermostat Testing section in this group.
(5) Cylinder head gasket leak. (5) Inspect for leaking cylinder head gasket with a commercially
available Block Leak Tester.
J9007-57

TEMPERATURE GAUGE IS INCONSISTENT, CYCLES
AND/OR IS ERRATIC. J
(1) Is cycle normal.
(a) Normal Gauge Reaction to Thermostat Cycle.
MID
(b) Normal Gauge Reaction at Stop After Heavy Use.
(c) Hot Water Build-Up Is Normal at Stop after Heavy

Use.
(2) Is coolant in radiator low (air will build up in the cooling (2) Fill system, vent trapped air and check for leaks.
system and cause the thermostat to open late).
(3) Is a cylinder head gasket leak allowing exhaust gas to (3) a — Test for leaking cylinder gasket leak with a
enter cooling system (exhaust gas building up in the commercially available Block Leak Tester,
cooling system will cause the thermostat to open late). b — Check for coolant in enaine oil.
c — Inspect for white steamfromexhaust system.
(4) Water pump impeller loose on shaft. Loose accessory drive (4) Repair or replace as necessary.
belt.
(5) Air leak on the suction side of the water pump (allows air to (5) Find leak and repair.
build up in cooling system causing thermostat to open late).
P R E S S U R E C A P VENTS TO ATMOSPHERE AND COOL

ANT R E S E R V E TANK. TEMPERATURE GAUGE READ
ING ABOVE NORMAL BUT NOT HIGH.
(1) Test radiator pressure cap relief pressure. Refer to Radiator ID Replace cap if relief pressure is lower than 14 psi.
Pressure cap section in this group.
COOLANT L O S S VISIBLE ON GROUND BELOW VEHI
CLE, BUT NO P R E S S U R E C A P BLOW OFF.
(1) Inspect system for leaks. (1) Repair as necessary. J9107-23

COOLANT LOSS PAST PRESSURE CAP TOP S E A L ,

VISIBLE ON RADIATOR FILLER NECK.
(1) With normal gauge reading. (1) a — Pressure cap not installed tightly.
b— Pressure cap top seal leaks.
c — Pressure cap diaphragm bowed.
d— Damaged radiator filler neck.
e— Pressure cap top seal out of position.
(2) With high or low gauge reading on new vehicle. (2) a— Kinked coolant reserve system hose.
b— Coolant reserve system tank plastic tube plugged.
c — Pressure cap seal out of position.
DETONATION OR PREIGNITION. NOT CAUSED BY IGNI

TION OR ENGINE CONDITIONS.
(1) Check engine coolant freeze point. If the tester does not regis (1) a — Adjust coolant solution to 50/50 water
ter a reading or if the reading is below 50°F, inspect ethyl ethylene-glycol mixture.
ene-glycol/ water ratio. A 100 percent solution of ethylene- b — If 100 percent ethylene-glycol solution is found
glycol in the system causes the engine to run hotter and possi in system, clean and flush system before
bly overheat. replacing with 50/50 mixture of
ethylene-glycol and water.
COOLING SYSTEM HOSES COLLAPSE ON COOLDOWN.
(1) Inspect pressure cap vent valve. (1) a — Gasket swell can prevent valve from opening.
b — Replace pressure cap.
(2) Coolant reserve tank hose plugged or kinked. (2) Repair as necessary.
(3) Inside of pressure cap plugged. (3) Clean cap or replace if necessary.
COOLING SYSTEM SUSPECTED A S CAUSE OF INADE

QUATE AIR CONDITIONING SYSTEM PERFORMANCE.
(1) Inspect for plugged radiator and/or condenser. (D Clean with low pressure water from fan side.
(2) Inspect for missing air seals in the recirculating air path. (2) Repair as necessary.
EXCESSIVE FAN NOISE
(1) Inspect for loose or bent fan blades. (1) Replace fan.
(2) Inspect clearance between fan and adjacent part. (2) Repair or replace as necessary.
(3) Inspect radiator and condenser for incoming air obstructions. (3) Clean air path with low pressure water from fan side.
(4) Inspect viscous fan drive. (4) Replace if viscous drive does not operate properly.
HEAT ODOR
(1) Was temperature gauge reading high? (1) If YES, refer to GAUGE READING HIGH. If NO, refer to steps
2, 3, and 4.
(2) Are all heat shields in place? (2) If YES, refer to steps 3 and 4. If N O , repair as required.
(3) Is the air side of the heat exchanger plugged? (3) Clean as necessary.
(4) Engine running rich causing catalytic converter to overheat. (4) Repair as necessary.
POOR DRIVEABILITY. SUSPECT THERMOSTAT FAILED

IN OPEN POSITION.
(1) Thermostat stuck in open position? 01 Replace thermostat. ._ _ 0 .
Jy 1 0 7 - 2 4
•
CONDITION AND C H E C K S DIAGNOSIS
POOR HEATER PERFORMANCE. SUSPECT

THERMOSTAT FAILED IN OPEN POSITION.
(1) Does gauge read low? (1) If YES, replace thermostat. If N O , inspect the auxiliary
heater vacuum water valve. The valve should be open
except when the climate controls are OFF or in the MAX
A / C mode.
(2) Is coolant level low? (2) Fill cooling system and inspect for leaks. Repair as neces
sary.
(3) Thermostat failed in open position? (3) If YES, replace thermostat. If N O , inspect the auxiliary
heater vacuum water valve. The valve should be open
except when the climate controls are OFF or in the MAX
A / C mode. J9107-25
SERVICE PROCEDURES
INDEX
page page
Coolant 26 Testing Cooling System for Leaks . 29
Coolant Reserve/Overflow System 30 Thermostat 22
Cooling System Cleaning/Reverse Flushing 28 Transmission Oil Cooler—Diesel 35
Cooling System Fan—Diesel Engine . 37 Transmission Oil Cooler—Except Diesel 35
Cooling System F a n — G a s Engines 36 Transmission Oil-To-Air Cooler 36
Cooling System Hoses 34 Viscous Fan Drive 38
Draining Cooling System 27
Pressure Testing Radiator Caps ............. 32 Water Pump Bypass Hose—All G a s Powered
Radiator Pressure C a p 31 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Radiators 32 Water Pumps—5.9L Diesel 18
Refilling the Cooling System 28 Water Pumps—Except Diesel 15
WATER PUMPS—EXCEPT DIESEL (4) Unsnap coolant reserve/overflow t a n k (up and

A centrifugal water pump circulates coolant out) from the T-slots on side of fan shroud (Fig. 1)
through the water jackets, passages, intake manifold, and lay aside. Do not disconnect hose or drain cool
radiator core, cooling system hoses and heater core. ant from tank.
The pump is driven from the engine crankshaft by a (5) Remove the fan shroud from the radiator. Do
drive belt. not remove shroud from vehicle at this time.
The water pump impeller is pressed onto the rear
of a shaft t h a t rotates in a bearing pressed into the
water pump body. The body has a small hole for ven
tilation. The water pump seals are lubricated by an
tifreeze in the coolant mixture. Additional
lubrication is not necessary.
A quick test to determine if pump is working is to
check if heater warms properly. A defective water
pump will not be able to circulate heated coolant
through the long heater hose to the heater core. FAN
The water pump on all models can be removed SHROUD
without discharging the air conditioning system (if
equipped).
REMOVAL J9107-67
The water pump on all gas powered engines is
bolted directly to the engine timing chain case/cover. Fig. 1 Fan Shroud—Except Diesel
A gasket is used as a seal between the water pump (6) Remove upper radiator hose at radiator. Special
and timing chain case/cover. Clamp Tool number 6094 (Fig. 2) may be used to re
If water pump is replaced because of bearing/shaft move the constant tension clamps.
damage or leaking shaft seal, the mechanical cooling (7) The thermal viscous fan drive is attached
fan assembly should also be inspected. Inspect for fa (threaded) to the water pump hub shaft (Fig. 3). Re
tigue cracks, loose blades or loose rivets that could move the fan/fan drive assembly from water pump by
have resulted from excessive vibration. Replace fan if turning the mounting nut counterclockwise (as
any of these conditions are found. Also check condi viewed from front). Threads on the fan drive are
tion of the thermal viscous fan drive. Refer to Vis R I G H T H A N D . A Snap-On 36 MM F a n Wrench
cous Fan Drive in this group. (number SP346 from Snap-On Cummins Diesel Tool
(1) Disconnect negative battery cable from battery.
Set number 2017DSP) can be used. Place a bar or
(2) Drain cooling system. Refer to Draining Cool
screwdriver between the water pump pulley bolts
ing System in this group.
(Fig. 3) to prevent the pulley from rotating.
Do not waste reusable coolant. If solution is clean,
If water pump is being replaced, do not unbolt fan
drain coolant into a clean container for reuse.
blade assembly (Fig. 3) from the thermal control fan
(3) Disconnect throttle cable from clip at top of fan
drive.
shroud.
HOSE CLAMP HOSE belt by rotating the tensioner counterclockwise (as
viewed from front) (Fig. 5). When all belt tension has
been relaxed, remove accessory drive belt.
J9207-36
Fig. 2 Hose Clamp Tool

(8) Remove fan blade/fan drive and fan shroud as
an assembly from vehicle.
After removing fan blade/fan drive assembly, do
not place the thermal viscous fan drive in the hori
zontal position. If stored horizontally, the silicone
fluid in the viscous drive could drain into its bearing
assembly and contaminate the bearing lubricant.
D o not remove the water pump pulley bolts at this
time. Fig. 4 Belt Tensioner—3.9L/5.2L/5.9L LDC-Gas
FAN BLADE WATER WATER PUMP Engine
VISCOUS FAN DRIVE

J9307-32
Fig. 3 Fan Blade and Viscous Fan Drive—Typical

(9) Remove accessory drive belt as follows: The Fig. 5 Belt Tensioner—5.9L HDC-Gas Engine
drive belt is equipped with a spring loaded automatic (10) Remove the four water pump pulley-to-water
tensioner (Figs. 4 or 5). pump hub bolts (Fig. 3) and remove pulley from ve
3.9L/5.2L/5.9L LDC-Gas Engines: Relax the tension hicle.
from the belt by rotating the tensioner clockwise (as (11) Remove the lower radiator hose and heater
viewed from front) (Fig. 4). When all belt tension has hose from water pump.
been relaxed, remove accessory drive belt.
5.9L HDC-Gas Engines: Relax the tension from the
(12) Loosen heater hose coolant return tube

mounting bolt (Figs. 6 or 7) and remove tube from
water pump. Discard the old tube O-ring.
Fig. 8 Water Pump Bolts—Typical

(15) Discard old gasket.
C A U T I O N : D o not pry the water pump at timing

chain case/cover. The machined surfaces may be
d a m a g e d resulting in leaks.
INSPECTION
Replace water pump assembly if it has any of t h e
Fig. 6 Coolant Return Tube—3.9L/5.2L/5.9L LDC-Gas
following conditions:
Engine
• The body is cracked or damaged
• Water leaks from the shaft seal. This is evident by
traces of coolant below the vent hole
• Loose or rough turning bearing. Also inspect ther
mal fan drive
• Impeller rubs either the pump body or timing
chain case/cover
INSTALLATION
(1) Clean gasket mating surfaces.
(2) Using a new gasket, install water pump to en
gine as follows: Guide water pump nipple into bypass
hose as pump is being installed. Install water pump
bolts (Fig. 8). Tighten water pump mounting bolts to
40 N-m (30 ft. lbs.) torque.
(3) Spin water pump to be sure t h a t pump impeller
does not rub against timing chain case/cover.
(4) Install a new O-ring to the heater hose coolant
return tube (Figs. 6 or 7). Coat the new O-ring with
antifreeze before installation.
(5) Install coolant return tube and its mounting
bolt to engine (Figs. 6 or 7). Be sure the slot in tube
bracket is bottomed to mounting bolt. This will prop
Fig. 7 Coolant Return Tube—5.9L HDC-Gas Engine erly position return tube.
(13) Remove the seven water pump mounting bolts (6) Connect radiator lower hose to water pump.
(7) Connect heater hose and hose clamp to coolant
(Fig. 8).
return tube.
(14) Loosen the clamp at the water pump end of
(8) Install water pump pulley. Tighten bolts to 27
bypass hose (Fig. 3). Slip the bypass hose from the
N*m (20 ft. lbs.) torque. Place a bar or screwdriver
water pump while removing pump from vehicle. Do between water pump pulley bolts (Fig. 3) to prevent
not remove the clamp from the bypass hose. pulley from rotating.
(9) Relax tension from automatic belt tensioner AUTOMATIC
(Figs. 4 or 5). Install drive belt. TENSIONER
C A U T I O N : W h e n installing the serpentine a c c e s s o r y

drive belt, belt must be routed correctly. If not, e n
gine may overheat due to water pump rotating in
wrong direction. Refer to (Figs, i, 10 or 11) for cor
rect belt routing. The correct belt with correct
length must be u s e d .
J9307-56
Fig. 11 Belt Routing—5.9L HDC-Gas

Engine—Without A/C
(10) Position fan shroud and fan blade/viscous fan
drive assembly to vehicle as a complete unit.
(11) Install fan shroud.
(12) Install fan blade/viscous fan drive assembly to
water pump shaft.
*IF VEHICLE IS NOT EQUIPPED WITH POWER
STEERING, THIS WILL BE AN IDLER PULLEY. J9307-26 (13) Fill cooling system. Refer to Refilling Cooling
System in this group.
Fig. 9 Belt Routing—3.9U5.2L/5.9L LDC-Gas Engine (14) Connect negative battery cable.
(15) Start and warm the engine. Check for leaks.
AUTOMATIC
TENSIONER
WATER PUMPS—5.9L DIESEL
The diesel engine water pump draws coolant from
radiator outlet and circulates it through engine,
heater core and back to radiator inlet. The crank
shaft pulley drives the water pump via a serpentine
drive belt (Fig. 12). An automatic belt tensioner (Fig.
12) is used to prevent the belt from slipping.
REMOVAL
(1) Disconnect the negative battery cable at bat
tery.
(2) Drain cooling system. Refer to Draining Cool
ing System in this section.
(3) Remove the accessory drive belt. Refer to the
Engine Accessory Drive Belt section of this group.
(4) Remove water pump mounting bolts (Fig. 13).
(5) Clean water pump sealing surface on cylinder
block.
J9307-55 INSTALLATION
(1) Install new O-ring seal in groove on water
Fig. 10 Belt Routing—5.9L HDC-Gas Engine-With
pump (Fig. 14).
A/C
(2) Install water pump. Tighten mounting bolts to
WATER PUMP BYPASS HOSE-ALL GAS

POWERED ENGINES
MOUNT. A water pump bypass hose (Fig. 15) is used be
BOLT
tween the intake manifold and water pump on all
gas engines. To test for leaks, refer to Testing Cool
ACCESSORY ing System for Leaks in this group.
DRIVE BELT
FAN BLADE WATER WATER PUMP
3/8 ASSEMBLY PUMP
SQUARE
PULLEY PULLEY
BOLTS
HOLE THREADED
NUT
AUTOMATIC
BELT
TENSIONER J9307-59
Fig. 12 Water Pump—5.91 Diesel
o~ "
THREADED SHAFT CRANKSHAFT

(WATER PUMP HUB) PULLEY
VISCOUS FAN DRIVE

J9307-32
Fig. 15 Water Pump Bypass Hose—Typical

v o v X N n N
rSCREW (2) '^ J9107-5 WITHOUT AIR CONDITIONING (A/C)
Fig. 13 Pump Removal/Installation—5.9L Diesel RE10WAL
(1) Partially drain cooling system. Refer to Drain
ing Cooling System in this group.
O-RING Do not waste reusable coolant. If the solution is
SEAL clean, drain the coolant into a clean container for re
use.
(2) Loosen both bypass hose clamps and position to
the center of hose. Special Clamp Tool number 6094
GROOVE
(Fig. 16) may be used to remove the constant tension
clamps.
(3) Remove hose from vehicle.
INSTALLATION
WATER (1) Position bypass hose clamps to the center of
PUMP hose.
J9107-6
(2) Install bypass hose to engine.
Fig. 14 Pump O-ring Seal—5.9L Diesel (3) Secure both hose clamps.
(4) Fill cooling system. Refer to Refilling Cooling
(3) Install accessory drive belt. Refer to the Engine
System in this group.
Accessory Drive Belt section of this group.
(4) Fill cooling system. Refer to Refilling Cooling
System in this section.
(5) Connect battery cable.
HOSE CLAMP HOSE (2) Partially drain cooling system. Refer to Drain
Do not waste reusable coolant. If the solution is
clean, drain t h e coolant into a clean container for re
use.
(3) Remove upper radiator hose clamp at radiator.
Special Clamp Tool number 6094 (Fig. 16) may be
used to remove the constant tension clamps. Remove
hose at radiator.
(4) Disconnect throttle cable from clip at radiator
fan shroud.
(5) Unplug wiring harness from A/C compressor.
(6) Remove the air cleaner assembly.
J9207-36
(7) Remove accessory drive belt. Refer to Belt Re
moval/Installation in the Engine Accessory Drive
Fig. 16 Hose Clamp Tool Belt section of this group.
(8) 3.9L/5.2L/5.9L LDC-Gas: The drive belt idler
WITH AIR CONDITIONING (A/C)
pulley must be removed to gain access to one of the
REMOVAL A/C compressor/generator bracket mounting bolts.
If equipped with A/C, the generator and A/C com Remove the idler pulley bolt and remove idler pulley
pressor along with their common mounting bracket (Fig. 18).
(Fig. 17) must be partially removed. Removing the GENERATOR/COMPRESSOR
generator or A/C compressor from their mounting AND BRACKET
bracket is not necessary. Also, discharging the A/C
SUPPORT BRACKET
system is not necessary. D o not remove any refrig
erant lines from A/C compressor.
SUPPORT BRACKET (ROD)
IGNITION
COIL BRACKET
Fig. 18 Idler Pulley-3.9U5.2U5.9L LDC-Gas Engine
GENERATOR/COMPRESSOR 5.9L HDC-Gas: The automatic belt tensioner/pul-

MOUNTING BRACKET ley assembly must be removed to gain access to one
J9307-66 of the A/C compressor/generator bracket mounting
bolts. Remove the tensioner mounting bolt (Fig. 19)
Fig. 17 Generator—A/C Compressor Mounting
and remove tensioner.
Bracket— Typical
(9) Remove the engine oil dipstick tube mounting
WARNING; THE A / C SYSTEM IS UNDER P R E S S U R E bolt at the side of the A/C-generator mounting
E V E N WITH T H E E N G I N E OFF. R E F E R T O R E F R I G bracket.
E R A N T WARNINGS IN G R O U P 24, HEATING A N D (10) Disconnect throttle body control cables. Refer
AIR CONDITIONING. to Accelerator Pedal and Throttle Cable in Group 14,
Fuel System.
Fig. 19 Belt Tensioner—5.9L HDC-Gas Engine Fig. 21 Coolant Return Tube—5.9L HDC-Gas Engine
(11) Remove heater hose coolant return tube
mounting bolt (Figs. 20 or 21) and remove tube from
engine. Discard the old tube O-ring,
Fig. 22 Bracket Bolts-3.9U5.2U5.9L LDC-Gas

Engine
Fig. 20 Coolant Return Tube-3.9U5.2U5.9L LDC- used to hold assembly in position.
Gas Engine (15) Loosen and position both hose clamps to the
center of bypass hose. Special Clamp Tool number
(12) Remove bracket-to-intake manifold bolts
6094 (Fig. 16) may be used to remove the constant
(number 1 and 2 Fig. 17).
tension clamps. Remove hose from vehicle.
(13) Remove remaining bracket-to-engine bolts
(Figs. 22 or 23). INSTALLATION
(14) Lift and position generator and A/C compres
(1) Position bypass hose clamps to the center of
sor (along with their common mounting bracket) to
hose.
gain access to bypass hose. A block of wood may be
BELT TENSIONER
DOWEL PIN J9307-63
Fig. 24 Tensioner Dowel Pin—5.9L HDC-Gas Engine
Fig. 23 Bracket Bolts—5.9L HDC-Gas Engine

(2) Install bypass hose to engine.
(3) Secure both hose clamps.
(4) Install generator-A/C mounting bracket assem
bly to engine. Tighten bolts (number 1 and 2 Fig. 17)
to 54 Nnn (40 ft. lbs.) torque. Tighten bracket mount
ing bolts (Figs. 22 or 23) to 40 N-m (30 ft. lbs.)
torque.
(5) Install a new O-ring to the heater hose coolant
return tube (Figs. 20 or 21). Coat the new O-ring
with antifreeze before installation.
(6) Install coolant return tube and its mounting Fig. 25 Tensioner Mounting Bracket Dowel
bolt to engine (Figs. 20 or 21). Hote—5.9L HDC-Gas Engine
(7) Connect throttle body control cables. (12) Install upper radiator hose to radiator.
(8) Install oil dipstick mounting bolt. (13) Connect throttle cable to clip at radiator fan
(9) 3.9L/5.2L/5.9L LDC-Gas: Install idler pulley. shroud.
Tighten bolt to 54 Nnn (40 ft. lbs.) torque. (14) Connect wiring harness to A/C compressor.
5.9L H D C - G a s : Install automatic belt tensioner (15) Fill cooling system. Refer to Refilling Cooling
assembly to mounting bracket. A dowel pin is located System in this group.
on back of tensioner (Fig. 24). Align this to dowel (16) Start and warm the engine. Check for leaks.
hole (Fig. 25) in tensioner mounting bracket. Tighten
bolt to 41 N-m (30 ft. lbs.). THERMOSTAT
(10) Install drive belt. Refer to Belt Removal/In
stallation in the Engine Accessory Drive Belt section GENERAL INFORMATION
of this group. The thermostat on all gas powered engines is lo
cated beneath the thermostat housing at the front of
C A U T I O N : When installing the serpentine accessory the intake manifold (Fig. 26). The thermostat has an
drive belt, the belt must be routed correctly. If not, air bleed notch.
the engine may overheat due to the water pump ro The thermostat of the 5.9L diesel engine is located
tating in the wrong direction. Refer to Belt Schemat in the thermostat housing at front of cylinder head.
ics in the Engine Accessory Drive Belt section of This is on exhaust manifold side of engine (Fig. 27).
this group for correct belt routing. The correct belt The thermostat is a wax pellet driven, reverse pop
with the correct length must be used. pet choke type. The wax pellet is located in a sealed
container at the spring end of the thermostat. When
(11) Install air cleaner assembly. heated, the pellet expands, overcoming closing spring
THERMOSTAT OPERATION-EXCEPT DIESEL

The thermostat controls the operating temperature
of the engine by controlling the amount of coolant
flow to the radiator. The thermostat is closed below
88°C (192°F). When the coolant reaches this temper
ature, the thermostat begins to open, allowing cool
ant flow to the radiator. This provides quick engine
warm-up and overall temperature control. The ther
mostat is designed to provide a minimum engine op
erating temperature of 88 to 93°C (192 to 199°F). It
should be fully open for maximum coolant flow dur
ing operation in hot ambient temperatures of approx
imately 104°C (220°F). Above 104°C (220°F), coolant
temperature is controlled by the radiator, fan and
ambient temperature.
•THERMOSTAT
An arrow plus the word U P is stamped on the
front flange next to the air bleed. The words T O
R A D are stamped on one arm of the thermostat.
MACHINED GROOVE
They indicate the proper installed position.
J9207-14 TESTING-ALL ENGINES

The computer On-Board Diagnostics include a
Fig. 26 Thermostat— Gas Engines mode for a thermostat open-too-soon failure condi
tion. The Malfunction Indicator Light (formerly
called the Check Engine Light) will not be lit by an
open-too-soon condition. But, if it has failed open, a
Diagnostic Trouble Code (DTC) number 17 will be
set. Do not change a thermostat for lack of heat as
indicated by the instrument panel gauge or heater
performance unless a DTC number 17 is present. Re
fer to the Diagnosis section of this group for other
probable causes.
The more common type of thermostat failure, usu
ally found on high milage vehicles, is a thermostat
failed in the shut position. The temperature gauge (if
equipped) will give an indication of this condition.
Depending upon length of time t h a t vehicle is oper
ated, pressure cap may vent. This will expel steam
and coolant to coolant reserve/overflow tank and to
surface below vehicle. Refer to the Diagnosis section
Fig. 27 Thermostat—5.9L Diesel—Typical
of this group. Also refer to the DRB II diagnostic
tension and water pump pressure to force the valve scan tool.
to open. Coolant leakage into the pellet container On-Board Diagnostics for the 5.9L diesel engine
will cause the thermostat to fail in the open position. can be obtained through the DRB II scan tool.
Thermostats very rarely stick. Do not attempt to free Vehicles equipped with a 5.9L diesel engine do not
a thermostat with a prying device. have the DTC number 17 malfunction indicator lamp
The same thermostat is used for winter and sum (check engine lamp) feature.
mer seasons. An engine should not be operated with
out a thermostat, except for servicing or testing. REMOVAL-ALL GAS POWERED ENGINES
Operating without a thermostat causes longer engine
WARNING: DO NOT LOOSEN THE RADIATOR
warmup time, unreliable warmup performance, in
D R A I N C O C K WITH T H E S Y S T E M HOT A N D P R E S
creased exhaust emissions and crankcase condensa
SURIZED. S E R I O U S B U R N S FROM THE COOLANT
tion t h a t can result in sludge formation.
CAN OCCUR.
C A U T I O N : D o not operate an engine without a ther
Do not waste reusable coolant. If the solution is
mostat, except for servicing or testing. clean, drain the coolant into a clean container for re
use.
If the thermostat is being replaced, be sure t h a t HOSE CLAMP HOSE
the replacement is the specified thermostat for the
vehicle model and engine type.
Factory installed thermostat housings on 3.9L/5.2L/
5.9L engines are installed on a gasket with an anti-
stick coating. This will aid in gasket removal and
clean-up.
(1) Disconnect negative battery cable at battery.
(2) Drain cooling system until coolant level is be
low thermostat. Refer to Draining Cooling System in
this group. If not equipped with air conditioning, pro
ceed to step number 4.
(3) If equipped with air conditioning:
(a) Remove the support bracket (rod) located
J9207-36
near the rear of generator (Fig. 28).
Fig. 29 Hose Clamp Tool
Fig. 28 Support Bracket—Generator Mounting •THERMOSTAT

Bracket-to-intake Manifold— Typical
(b) The drive belt must be removed. Refer to Belt
Removal/Installation in the Engine Accessory MACHINED GROOVE
Drive Belt section of this group.
(c) The generator must be partially removed. Re J9207-14
move the two generator mounting bolts. Do not re
move any wiring at generator. If equipped with Fig. 30 Thermostat—Gas Engines
4WD, unplug the 4WD indicator lamp wiring har INSTALLATION-ALL GAS POWERED
ness (located near rear of generator). ENGINES
(d) Remove generator. Position generator to gain (1) Clean mating areas of intake manifold and
access for thermostat gasket removal. thermostat housing.
(4) Remove upper radiator hose clamp. Special (2) Install thermostat (spring side down) into re
Clamp Tool number 6094 (Fig. 29) may be used to re cessed machined groove on intake manifold (Fig. 30).
move the constant tension clamps. Remove upper ra (3) Install gasket on intake manifold and over
diator hose at thermostat housing. thermostat (Fig. 30).
(5) Position the wiring harness (behind the ther (4) Position the thermostat housing to the intake
mostat housing) to gain access to thermostat hous manifold. Note the word FRONT stamped on the
ing. housing (Fig. 31). For adequate clearance, this m u s t
(6) Remove thermostat housing mounting bolts, be placed towards the front of vehicle. The housing
thermostat housing, gasket and thermostat (Fig. 30). should be slightly angled forward after installation
Discard old gasket. to intake manifold.
(5) Install two housing-to-intake manifold bolts.
Tighten bolts to 23 N-m (200 in. lbs.) torque.
low 83°C (181°F), the thermostat is closed. Coolant is

routed back to the water pump inlet through the by
pass (Fig. 32).
Fig. 32 Thermostat Operation—5.9L Diesel

When coolant temperature reaches 83°C (181°F),
the thermostat begins to open allowing coolant flow
Fig. 31 Thermostat Position
to the radiator. This provides quick engine warm-up
CAUTION; Housing must be tightened evenly and and overall temperature control. The thermostat is
thermostat must be centered into recessed groove designed to provide a minimum engine operating
in intake manifold. If not, it may result in a cracked temperature of 83°C (181°F) and to be fully open for
housing, damaged intake manifold threads or cool maximum coolant flow at approximately 95°C
ant leak. (203°F). Above 95°C (203°F), coolant temperature is
controlled by the radiator, fan and ambient tempera
(6) Install upper radiator hose to thermostat hous
ture.
ing.
The thermostat is equipped with three air bleeds
(7) Air conditioned vehicles:
on the flange. The air bleeds will vent air when the
(a) Install generator. Tighten bolts to 41 N-m (30
system is filled. It also acts as a check valve to block
ft. lbs.).
the flow of coolant during engine operation.
(b) Install support bracket (generator mounting
bracket-to-intake manifold) (Fig. 28). Tighten bolts REMOVAL-DIESEL
WARNING: DO NOT LOOSEN THE RADIATOR
C A U T I O N : When installing the serpentine accessory D R A I N C O C K WITH T H E S Y S T E M HOT A N D P R E S
drive belt, the belt must be routed correctly. If not, SURIZED. SERIOUS BURNS FROM THE COOLANT
the engine may overheat due to the water pump ro CAN OCCUR.
tating in the wrong direction. Refer to Belt Schemat
ics in the Engine Accessory Drive Belt section of Do not waste reusable coolant. If the solution is
this group for correct engine belt routing. The cor clean, drain the coolant into a clean container for re
rect belt with the correct length must be used. use.
(8) Fill cooling system. Refer to Refilling Cooling (2) Remove accessory drive belt. Refer to Belt Re
System in this Group. moval/Installation in the Engine Accessory Drive
(9) Connect negative battery cable to battery. Belt section in this group.
(10) Start and warm engine. Check for leaks. (3) Drain cooling system until coolant level is be
low thermostat. Refer to Draining Cooling System in
THERMOSTAT r
OPERATION -5.9L DIESEL this section.
ENGINE (4) Remove radiator hose clamp and hose from
The thermostat controls the operating temperature thermostat housing. Special Clamp Tool number
of the engine by controlling the amount of coolant 6094 (Fig. 29) may be used to remove the constant
flow to the radiator. When coolant temperature is be tension clamps.
(5) Loosen generator pivot bolt.
7 - 26 COOLING SYSTEM — — — — •
(6) Remove generator mounting bolt (Fig. 33).
Fig. 35 Thermostat Seai—5.9L Diesel—Typical

Fig. 33 Generator Mounting Bolts—5.9L Diesel (7) Fill cooling system. Refer to Refilling Cooling
(7) Remove thermostat housing mounting bolts. System in this group.
(8) Remove thermostat housing, lifting bracket and
thermostat (Fig. 34).
COOLANT
The cooling system is designed around the coolant.
Coolant flows through the engine water jacket ab
sorbing heat produced during engine operation. The
coolant carries the heat to radiator and heater core.
Here it is transferred to the ambient air passing
through the radiator and heater core fins. The cool
ant also removes heat from t h e automatic transmis
sion fluid in vehicles equipped with an automatic
transmission.
COOLANT PERFORMANCE
The required ethylene-glycol (antifreeze) and water
mixture depends upon climate and vehicle operating
conditions. The coolant performance of various mix
tures follows:
Pure Water-Water can absorb more heat than a
mixture of water and ethylene-glycol. This is for pur
Fig. 34 Thermostat Removal—5.9L Diesel pose of heat transfer only. Water also freezes at a
(9) Clean the mating surfaces of the thermostat higher temperature and allows corrosion.
housing and the cylinder head. 100% Ethylene-Glycol-The corrosion inhibiting
additives in ethylene-glycol need the presence of wa
INSTALLA TION—DIESEL ter to dissolve. Without water, additives form depos
(1) Install the thermostat in the housing. its in system. These act as insulation causing
(2) Position the thermostat seal with the shoulder temperature to rise to as high as 149°C (300°F). This
towards the housing (Fig. 35). temperature is hot enough to melt plastic and soften
(3) Install thermostat, lifting bracket, seal and solder. The increased temperature can result in en
housing. Tighten the mounting bolts to 24 N°m (18 gine detonation. In addition, 100 percent ethylene-
ft. lbs.) torque. glycol freezes at -22°C (-8°F).
(4) Position generator in place. Tighten mounting 50/50 Ethylene-Glycol and Water-Is the recom
bolt to 24 N*m torque. Tighten pivot bolt to 43 N*m mended mixture, it provides protection against freez
(32 ft. lbs.) torque. ing to -37°C (-35°F). The antifreeze concentration
(5) Install accessory drive belt. Refer to Belt Re must a l w a y s be a minimum of 44 percent, year-
moval/Installation in the Engine Accessory Drive round in all climates. If percentage is lower, engine
Belt section of this group. parts may be eroded by cavitation. Maximum protec
(6) Connect battery cable to battery. tion against freezing is provided with a 68 percent
antifreeze concentration, which prevents freezing
down to -67.7°C (-90°F). A higher percentage will move the radiator cap only for testing or when
freeze at a warmer temperature. Also, a higher per refilling the system after service. Removing cap un
centage of antifreeze can cause the engine to over necessarily can cause loss of coolant and allow air to
heat because specific heat of antifreeze is lower t h a n enter system. This produces corrosion.
t h a t of water.
COOLANT LEVEL CHECK-SERVICE
C A U T I O N : Richer antifreeze mixtures cannot be The cooling system is closed and designed to main
measured with normal field equipment a n d c a n tain coolant level to the top of the radiator.
c a u s e problems associated with 100 percent ethyl
ene-glycol. W A R N I N G : D O NOT O P E N RADIATOR D R A I N C O C K
WITH E N G I N E R U N N I N G O R W H I L E E N G I N E I S H O T
AND COOLING SYSTEM IS UNDER PRESSURE.
COOLANT SELECTION-ADDITIVES
The presence of aluminum components in the cool When vehicle servicing requires a coolant level
ing system requires strict corrosion protection. Main check in the radiator, drain several ounces of coolant
tain coolant at specified level with a mixture of from the radiator drain cock. Do this while observing
ethylene-glycol based antifreeze and water. Only use the coolant reserve/overflow system tank. The cool
an antifreeze containing ALUGARD 340-2 ™ such as ant level in the reserve/overflow t a n k should drop
Mopar Antifreeze. If coolant becomes contaminated slightly. If not, inspect for a leak between radiator
or looses color, drain and flush cooling system and and coolant reserve/overflow system connection. Re
fill with correctly mixed solution. move radiator cap. The coolant level should be to the
A 0.25 percent emulsifiable oil is added to the ra top of the radiator. If not and if coolant level in re
diator at the factory to prevent solder corrosion. serve/overflow tank is at the ADD (gas engines) or
MIN (5.9L diesel engine) mark, check for:
C A U T I O N : D o not u s e coolant additives that are
claimed to improve engine cooling. • An air leak in the coolant reserve/overflow t a n k
• An air leak in the radiator filler neck
• Leak in the pressure cap seal to the radiator filler
COOLANT SERVICE-EXCEPT DIESEL neck
It is recommended t h a t the cooling system be
drained and flushed at 84,000 kilometers (52,500 LOW COOLANT LEVEL-AERATION
miles) or 3 years, whichever occurs first. Then every If the coolant level in the radiator drops below the
two years or 48,000 kilometers (30,000 miles), which top of the radiator core tubes, air will enter the sys
ever occurs first. tem.
Low coolant level can cause the thermostat pellet
COOLANT SERVICE-DIESEL ENGINE to be suspended in air instead of coolant. This will
It is recommended t h a t the cooling system be cause the thermostat to open later, which in t u r n
drained and flushed every 24 months or 38,600 kilo causes higher coolant temperature. Air trapped in
meters (24,000 miles), whichever occurs first. cooling system also reduces the amount of coolant
circulating in the heater core. This may result in low
COOLANT LEVEL CHECK-ROUTINE heat output.
D o not remove radiator c a p for routine coolant
level inspections. The coolant level c a n b e DEAERATION
c h e c k e d at the coolant reserve/overflow tank. As the engine operates, air trapped in the cooling
The coolant reserve/overflow system provides a system gathers under the radiator cap. The next time
quick visual method for determining the coolant engine is operated, thermal expansion of coolant will
level without removing the radiator pressure cap. push trapped air past radiator cap into coolant re
With engine idling and at normal operating temper serve/overflow tank. Here it escapes to atmosphere in
ature, observe coolant level in coolant reserve/over the tank. When engine cools down the coolant, it will
flow tank. The coolant level should be between t h e be drawn from reserve/overflow t a n k into radiator to
MIN and MAX (diesel engine) or ADD and FULL replace removed air.
(gas engines) marks.
DRAINING COOLING SYSTEM
ADDING ADDITIONAL COOLANT-ROUTINE
D o not remove the radiator c a p to a d d coolant WARNING: DO NOT R E M O V E THE CYLINDER
to the system. When adding coolant to maintain the B L O C K DRAIN P L U G S O R L O O S E N THE RADIATOR
correct level, do so at the coolant reserve/overflow D R A I N PLUG WITH S Y S T E M HOT A N D U N D E R
t a n k with a 50/50 mixture of ethylene-glycol anti P R E S S U R E . S E R I O U S B U R N S FROM COOLANT
freeze (containing Alugard 340-2 ™) and water. Re CAN OCCUR.
DO NOT WASTE reusable coolant. If the solution overflow tank may drop below the MIN (or ADD)
is clean, drain the coolant into a clean container for m a r k after three or four warm-up and cool-down cy
reuse. cles.
(1) Start the engine and place the heater control
temperature selector in the Full On position. Engine COOLING SYSTEM CLEANING/REVERSE FLUSHING
vacuum is needed to actuate the heater controls.
(2) Turn the ignition off. CLEMMING
(3) Do not remove radiator cap when draining cool Drain cooling system and refill with water. Run
ant from reserve/overflow tank. Open radiator drain engine with radiator cap installed until upper radia
plug and when t a n k is empty, remove radiator cap. If tor hose is hot. Stop engine and drain water from
the coolant reserve/overflow tank does not drain, re system. If water is dirty, fill system with water, r u n
fer to the Testing Cooling System for Leaks section engine and drain system. Repeat until water drains
in this group. The coolant need not be removed from clean.
tank unless the system is being refilled with fresh
REVERSE FLUSHING
mixture.
Reverse flushing of cooling system is the forcing of
(4) On vehicles equipped with gas powered en water through t h e cooling system. This is done using
gines, remove t h e cylinder block drain plugs. These air pressure in t h e opposite direction of normal cool
are located on the sides of the block towards the a n t flow. It is usually only necessary with very dirty
front of engine, just above the oil pan (Fig. 36). systems with evidence of partial plugging.
REVERSE FLUSHING RADIATOR

Disconnect radiator hoses from radiator inlet and
outlet. Attach a section of radiator hose to radiator
bottom outlet fitting and insert flushing gun. Con
nect a water supply hose and air supply hose to
flushing gun.
C A U T I O N : Internal radiator p r e s s u r e m u s t n o t ' e x

ceed 138 kPa (20 psi) a s d a m a g e to radiator m a y re
sult
Allow radiator to fill with water. When radiator is

filled, apply air in short blasts. Allow radiator to re
fill between blasts. Continue this reverse flushing
until clean water flows out through rear of radiator
Fig. 36 Drain Plugs—Gas Powered cooling tube passages. Have radiator cleaned more
Engines—Typical extensively by a radiator repair shop.
(5) Remove radiator pressure cap.
REVERSE FLUSHING ENGINE-EXCEPT
REFILLING THE COOLING SYSTEM DIESEL
Clean cooling system prior to refilling. Refer to Drain cooling system. Remove thermostat housing
and thermostat. Install thermostat housing. Discon
Cooling System Cleaning section of this group.
nect radiator upper hose from radiator and attach
(1) Install the cylinder block drain plugs (Fig. 36).
flushing gun to hose. Disconnect radiator lower hose
(2) Close radiator drain plug.
from water pump and attach a lead-away hose to wa
(3) Fill the cooling system with a 50/50 mixture of
ter pump inlet fitting.
water and antifreeze.
(4) Fill coolant reserve/overflow tank to the MAX C A U T I O N ; O n vehicles equipped with a heater water
(5.9L diesel engine) or FULL (gas engines) mark. control valve, be s u r e heater control valve is c l o s e d
(5) Start and operate engine until thermostat (heat off). T h i s will prevent coolant flow with s c a l e
opens. Upper radiator hose should be warm to touch. a n d other d e p o s i t s from entering heater core.
(6) If necessary, add 50/50 water and antifreeze
mixture to the coolant reserve/overflow tank to main Connect water supply hose and air supply hose to
tain coolant level. This level should be between the flushing gun. Allow engine to fill with water. When
MAX and MIN (5.9L diesel engine) or ADD and engine is filled, apply air in short blasts, allowing
FULL (gas engines) marks. The level in the reserve/ system to fill between air blasts. Continue until
clean water flows through the lead away hose.
+ COOLING SYSTEM 7 - 29
Remove lead away hose, flushing gun, water sup light (black light). Pour one ounce of additive into
ply hose and air supply hose. Remove thermostat cooling system. Place heater control unit in HEAT
housing and install thermostat. Install thermostat position. S t a r t and operate engine until radiator up
housing with a replacement gasket. Refer to Thermo per hose is warm to touch. Aim black light (tool
stat Replacement. Connect radiator hoses. Refill cool C-4555 or an equivalent) at components to be
ing system with correct antifreeze/water mixture. checked. If leaks are present, black light will cause
Refer to Refilling the Cooling System. additive to glow a bright green color.
The black light can be used in conjunction with a
REVERSE FLUSHING ENGINE-DIESEL pressure tester to determine if any external leaks ex
(1) Drain the cooling system. ist (Fig. 38).
(2) Disconnect the upper hose from the radiator.
(3) Disconnect the radiator lower hose from the
water pump.
CAUTION; Be sure the heater control valve is

closed (heat off). This will prevent coolant flow with
scale and other deposits from entering the heater
core.
(4) Remove the heater core inlet hose from tube

(Fig. 37).
Fig. 38 Leak Detection Using Black Light—Typical

PRESSURE TESTER METHOD
The engine should be at normal operating temper
ature. Recheck the system cold if cause of coolant
Fig. 37 Reverse-flushing—5.9L Diesel loss is not located during the warm engine examina
tion.
(5) Attach water supply hose to heater tube.
(6) Back-flush the engine until clean water exits WARNING: H O T , P R E S S U R I Z E D C O O L A N T CAN
the water pump inlet. C A U S E INJURY B Y S C A L D I N G .
CHEMICAL CLEANING Carefully remove radiator pressure cap from filler
In some instances, use a radiator cleaner (Mopar neck and check coolant level. Push down on cap to
Radiator Kleen or equivalent) before flushing. This disengage it from stop tabs. Wipe inside of filler neck
will soften scale and other deposits and aid flushing and examine lower inside sealing seat for nicks,
operation. cracks, paint, dirt and solder residue. Inspect radia
tor-to-reserve/overflow t a n k hose for internal obstruc
CAUTION; Follow manufacturers instructions when
tions. Insert a wire through the hose to be sure it is
using these products.
not obstructed.
Inspect cams on outside of filler neck. If cams are
TESTING COOLING SYSTEM FOR LEAKS bent, seating of pressure cap valve and tester seal
will be affected. Bent cams can be reformed if done
ULTRAVIOLET LIGHT METHOD carefully. Attach pressure tester (7700 or an equiva
A leak detection additive i s available through the lent) to radiator filler neck (Fig. 39).
parts department t h a t can be Sidfled to cooling sys Operate tester pump to apply 103.4 kPa (15 psi)
tem. The additive is highly visible under ultraviolet pressure to system. If hoses enlarge excessively or
COOLING SYSTEM Operate engine without pressure cap on radiator
until thermostat opens. Attach a Pressure Tester to
filler neck. If pressure builds up quickly it indicates
a combustion leak exists. This is usually the result of
a cylinder head gasket leak or crack in engine. Re
pair as necessary.
If there is not an immediate pressure increase,
pump the Pressure Tester. Do this until indicated
pressure is within system range of 110 kPa (16 psi).
Fluctuation of gauge pointer indicates compression or
combustion leakage into cooling system.
Because the vehicle is equipped with a catalytic
converter, d o not remove spark plug cables or short
out cylinders (non-diesel engines) to isolate compres
sion leak.
Fig. 39 Pressure Testing Cooling System—Typical If the needle on dial of pressure tester does not
fluctuate, race engine a few times to check for an ab
bulges while testing, replace as necessary. Observe
normal amount of coolant or steam. This would be
gauge pointer and determine condition of cooling sys
tem according to following criteria: emitting from exhaust pipe. Coolant or steam from
Holds Steady: If pointer remains steady for two exhaust pipe may indicate a faulty cylinder head
minutes, serious coolant leaks are not present in sys gasket, cracked engine cylinder block or cylinder
tem. However, there could be an internal leak t h a t head.
does not appear with normal system test pressure. If A convenient check for exhaust gas leakage into
it is certain t h a t coolant is being lost and leaks can cooling system is provided by a commercially avail
not be detected, inspect for interior leakage or per able Block Leak Check tool. Follow manufacturers
form Internal Leakage Test. instructions when using this product.
Drops Slowly: Indicates a small leak or seepage is
COMBUSTION LEAKAGE TEST-WITHOUT
occurring. Examine all connections for seepage or
PRESSURE TESTER
slight leakage with a flashlight. Inspect radiator,
DO NOT WASTE reusable coolant. If solution is
hoses, gasket edges and heater. Seal small leak holes
clean, drain coolant into a clean container for reuse.
with a Sealer Lubricant (or equivalent). Repair leak
holes and inspect system again with pressure ap WARNING: D O NOT REMOVE CYLINDER BLOCK
plied. DRAIN PLUGS O R LOOSEN RADIATOR DRAIN-
Drops Quickly: Indicates t h a t serious leakage is C O C K WITH S Y S T E M HOT A N D U N D E R P R E S
occurring. Examine system for external leakage. If SURE. SERIOUS BURNS FROM COOLANT CAN
leaks are not visible, inspect for internal leakage. OCCUR.
Large radiator leak holes should be repaired by a
reputable radiator repair shop. Drain sufficient coolant to allow thermostat re
moval. Refer to Thermostat Replacement. Disconnect
INTERNAL LEAKAGE INSPECTION water pump drive belt.
Remove engine oil pan drain plug and drain a Add coolant to radiator to bring level to within 6.3
small amount of engine oil. If coolant is present in mm (1/4 in) of top of thermostat housing.
the pan, it will drain first because it is heavier t h a n
oil. An alternative method is to operate engine for a C A U T I O N : Avoid overheating. D o not operate en
short period to churn the oil. After this is done, re gine for an excessive period of time. Open drain-
move engine dipstick and inspect for water globules. cock immediately after test to eliminate boil over.
Also inspect transmission dipstick for water globules
and transmission fluid cooler for leakage. Start engine and accelerate rapidly three times, to
approximately 3000 rpm while observing coolant. If
W A R N I N G : W I T H P R E S S U R E T E S T E R T O O L 7700 %
internal engine combustion gases are leaking into
I N S T A L L E D O N RADIATOR, D O NOT A L L O W P R E S cooling system, bubbles will appear in coolant. If
S U R E T O E X C E E D 110 K P A (20 P S I ) . P R E S S U R E bubbles do not appear, internal combustion gas leak
W I L L B U I L D U P Q U I C K L Y IF A C O M B U S T I O N L E A K age is not present.
IS P R E S E N T . T O R E L E A S E P R E S S U R E , R O C K
TESTER FROM SIDE TO SIDE. WHEN REMOVING COOLANT RESERVE/0WERFL0W SYSTEM
T E S T E R , D O N O T T U R N T E S T E R M O R E T H A N 1/2 The coolant reserve/overflow system (Fig. 40 or 41)
T U R N IF S Y S T E M I S U N D E R P R E S S U R E . works in conjunction with the radiator pressure cap.
It utilizes thermal expansion and contraction of cool Should the reserve/overflow t a n k become coated
ant to keep coolant free of trapped air. It provides a with corrosion or emulsifiable oil, it can be cleaned
volume for expansion and contraction of coolant. It with detergent and water. Rinse t a n k thoroughly be
also provides a convenient and safe method for fore refilling cooling system as described in the Cool
checking coolant level and adjusting level at atmo ant section of this group.
spheric pressure. This is done without removing ra
diator pressure cap. It also provides some reserve TANK REMOVAL
coolant to cover minor leaks and evaporation or boil (1) Remove overflow hose at reserve/overflow tank.
ing losses. (2) Unsnap the coolant reserve/overflow t a n k from
fan shroud. Lift straight up. The fan shroud is
equipped with T-shaped slots to attach the tank.
TANK INSTALLATION
(1) Snap tank into fan shroud.
(2) Install overflow hose to tank.
RADIATOR PRESSURE CAP

Radiators are equipped with a pressure cap, which
releases pressure at some point within a range of 97-
FAN
SHROUD
124 k P a (14-18 psi). The pressure relief point (in
pounds) is engraved on top of cap.
The cooling system will operate at pressures
slightly above atmospheric pressure. This results in a
higher coolant boiling point allowing increased radi
J9107-67
ator cooling capacity. The cap (Fig. 42) contains a
Fig. 40 Coolant Reserve/Overflow Tank—Gas spring-loaded pressure relief valve t h a t opens when
Engines system pressure reaches release range of 97-124 k P a
(14-18 psi).
Fig. 42 Radiator Pressure Cap and Filler

Neck—Typical
A vent valve in the center of cap allows a small
coolant flow through cap when coolant is below boil
ing temperature. The valve is completely closed
when boiling point is reached. As the coolant cools, it
contracts and creates a vacuum in the cooling sys
tem. This causes the vacuum valve to open and cool
Fig. 41 Coolant Reserve/Overflow Tank—Diesel ant in the reserve/overflow tank to be drawn through
Engines its connecting hose into radiator. If the vacuum valve
Refer to Coolant Level Check—Service, Deaeration is stuck shut, the radiator hoses will collapse on cool-
and Radiator Pressure Cap sections in this group for down. Clean the vent valve (Fig. 42).
coolant reserve/overflow system operation and ser A rubber gasket seals radiator filler neck to pre
vice. vent leakage. This is done to keep system under
pressure. It also maintains vacuum during coolant
cool-down allowing coolant to return from reserve/
overflow tank.
RADIATOR CAP-TO-FILLER NECK

SEAL-PRESSURE RELIEF CHECK
The pressure cap upper gasket (seal) pressure relief
can be tested by removing overflow hose from radia
tor filler neck nipple. Attach hose of pressure tester
tool 7700 or equivalent to nipple. It will be necessary
to disconnect hose from its adapter for filler neck.
Pump air into radiator. The pressure cap upper gas
ket should relieve at 69-124 kPa (10-18 psi) and hold
pressure at a minimum of 55 kPa (8 psi).
WARNING; THE WARNING W O R D S - D O NOT

O P E N HOT— O N R A D I A T O R P R E S S U R E C A P , A R E
A SAFETY PRECAUTION. WHEN HOT, P R E S S U R E
B U I L D S U P IN C O O L I N G S Y S T E M . T O P R E V E N T
S C A L D I N G O R INJURY, RADIATOR C A P S H O U L D
NOT B E R E M O V E D WHILE S Y S T E M IS HOT
AND/OR UNDER PRESSURE.
Fig. 43 Pressure Testing Radiator Cap
Do not remove radiator cap at any time e x c e p t for inspect radiator filler neck and cap's top gasket for
the following purposes: damage. Also inspect for dirt or distortion t h a t may
• Check and adjust antifreeze freeze point prevent cap from sealing properly.
• Refill system with new antifreeze
• Conducting service procedures C A U T I O N : Tool 7700 is very sensitive to small air
• Checking for vacuum leaks leaks, which will not cause cooling system prob
lems. A pressure cap that does not have a history
W A R N I N G ; IF V E H I C L E H A S B E E N R U N R E C E N T L Y ,
of coolant loss should not be replaced just because
W A I T A T L E A S T 15 M I N U T E S B E F O R E R E M O V I N G it leaks slowly when tested with this tool. Add water
R A D I A T O R C A P . WITH A R A G , S Q U E E Z E RADIA to tool. Turn tool upside down and recheck pres
T O R U P P E R H O S E T O C H E C K IF S Y S T E M I S U N sure cap to confirm that cap needs replacement.
DER PRESSURE. PLACE A R A GOVER C A P A N D
W I T H O U T P U S H I N G C A P D O W N , R O T A T E IT
COUNTER-CLOCKWISE TO FIRST STOP. ALLOW INSPECTION
FLUID T O E S C A P E THROUGH T H E C O O L A N T R E Hold cap at eye level, right side up. The vent valve
S E R V E / O V E R F L O W H O S E INTO R E S E R V E / O V E R (Fig. 42) at bottom of cap should open. If rubber gas
FLOW TANK. S Q U E E Z E RADIATOR UPPER H O S E ket has swollen and prevents vent valve from open
TO DETERMINE WHEN P R E S S U R E H A S B E E N R E ing, replace cap.
LEASED. WHEN COOLANT AND STEAM STOP BE Hold cap at eye level, upside down. If any light can
I N G P U S H E D INTO T A N K A N D S Y S T E M P R E S S U R E be seen between vent valve and rubber gasket, re
DROPS, REMOVE RADIATOR CAP COMPLETELY. place cap. Do not use a replacement cap that h a s
a spring to hold vent shut. A replacement cap
PRESSURE TESTING RADIATOR CAPS must be the type designed for a coolant reserve/over
Remove cap from radiator. Be sure t h a t sealing flow system with a completely sealed diaphragm
surfaces are clean. Moisten rubber gasket with water spring and a rubber gasket. This gasket is used to
and install cap on pressure tester 7700 or an equiv seal to radiator filler neck top surface. Use of proper
alent (Fig. 43). cap will allow coolant return to radiator.
Operate tester pump to bring pressure to 104 k P a
(15 psi) on gauge. If pressure cap fails to hold pres RADIATORS
sure of at least 97 kPa (14 psi) replace cap. Refer to 3.9L, 5.2L and 5.9L Gas Engines: The radiator is a
C A U T I O N below. down-flow type (vertical tubes).
The pressure cap may test properly while posi 5.9L Diesel Engines: The radiator is a cross-flow
tioned on tool 7700 (or equivalent). It may not hold type (horizontal tubes).
pressure or vacuum when installed on radiator. If so,
The radiator supplies sufficient heat transfer to HOSE CLAMP HOSE

cool the engine and automatic transmission (if TOOL 6094 CLAMP
equipped).
RADIATOR COOLANT FLOW CHECK

Use the following procedure to determine if coolant
is flowing through the cooling system.
(1) Idle engine until operating temperature is
reached. If the upper radiator hose is warm to the
touch, the thermostat is opening and coolant is flow
ing to the radiator.
WARNING: HOT, P R E S S U R I Z E D COOLANT C A N

C A U S E INJURY B Y SCALDING. USING A R A G T O
COVER THE RADIATOR P R E S S U R E C A P , OPEN J9207-36
RADIATOR C A P S L O W L Y TO T H E FIRST S T O P .
THIS WILL A L L O W A N Y BUILT-UP P R E S S U R E T O Fig. 44 Hose Clamp Tool
V E N T TO T H E R E S E R V E / O V E R F L O W T A N K . A F T E R
RADIATOR SHROUD
P R E S S U R E BUILD-UP H A S B E E N R E L E A S E D , R E MOUNTING MOUNTING
M O V E C A P FROM FILLER NECK. BOLTS CUPS
(2) Drain a small amount of coolant from the radi

ator until the ends of the radiator tubes are visible
through the filler neck. Idle the engine at normal op
erating temperature. If coolant is flowing past the
exposed tubes, the coolant is circulating.
RADIATOR REMOVAL-EXCEPT DIESEL

W A R N I N G ; D O NOT R E M O V E THE C Y L I N D E R
B L O C K D R A I N P L U G S O R L O O S E N THE R A D I A T O R 1
D R A I N C O C K WITH T H E S Y S T E M HOT A N D U N D E R RADIATOR V
FAN S H R O U D ^
J9207-44
PRESSURE. SERIOUS BURNS FROM COOLANT
CAN OCCUR. Fig. 45 Radiator and Fan Shroud—Gas Engines
ing on loosened bottom mounting bolts. Install upper
(2) Drain the cooling system. Refer to Draining
mounting bolts. Tighten all mounting bolts to 11
Cooling System.
N*m (95 in. lbs.) torque.
(3) Disconnect throttle cable from clip at radiator
fan shroud. (3) Connect radiator hoses.
(4) Remove hose clamps and hoses from radiator. (4) Connect transmission oil cooler lines to bottom
#
Special Clamp Tool number 6094 (Fig. 44) may be tank. Tighten hose clamps to 4 N m (35 in. lbs.)
used to remove the constant tension clamps. torque.
(5) Remove coolant reserve/overflow tank hose (5) Position fan shroud on radiator flange. Install
from radiator filler neck nipple. mounting clips (Fig. 45).
(6) If equipped with an automatic transmission (6) Connect throttle cable to fan shroud.
(except diesel), disconnect oil cooler hoses at radiator (7) Position heater controls to full h e a t position.
lower tank. (8) Fill cooling system with coolant. Refer to Refill
(7) Remove fan shroud mounting bolts/clips and ing Cooling System in this group.
position shroud rearward on engine (Fig. 45). (9) Operate engine until it reaches normal temper
(8) Loosen radiator lower mounting bolts. Remove ature. Check cooling system and automatic transmis
the upper mounting bolts. Lift radiator straight up sion (if equipped) fluid levels.
and out of engine compartment. Take care not to
damage radiator cooling fins or tubes. RADIATOR REMOVAL-DIESEL
INSTALLATION
(1) Position shroud rearward on engine.
(2) Slide radiator into position. Place behind radi
ator support with lower mounting holes (slots) rest-
WARNING; DO NOT REMOVE THE CYLINDER RADIATOR DRAINCOCK SERVICE
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR The radiator draincock is replaceable. Unscrew the
D R A I N C O C K WITH T H E S Y S T E M HOT A N D U N D E R draincock in a clockwise direction and remove from
PRESSURE. SERIOUS BURNS FROM COOLANT radiator. Install replacement draincock.
CAN OCCUR.
COOLING SYSTEM HOSES
(2) Drain the cooling system. Refer to Draining Rubber hoses route coolant to and from the radia
Cooling System in this group. tor, intake manifold and heater core. Radiator lower
(3) Remove hose clamps and hoses from radiator. hoses are spring-reinforced to prevent collapse from
Remove coolant reserve/overflow t a n k hose from ra water pump suction at moderate and high engine
diator filler neck nipple. speeds.
(4) Remove fan shroud retaining clips. The shroud Inspect the hoses at regular intervals. Replace
has two tabs t h a t fit into clips in the bottom of the hoses t h a t are cracked, feel brittle when squeezed or
radiator. Lift the shroud up and position it back onto swell excessively when system is pressurized. The
the engine (Fig. 46). use of molded replacement hoses is recommended.
When performing a hose inspection, inspect radiator
lower hose for proper position and condition of
spring.
RADIATOR
Fig. 46 Radiator and Fan Shroud—5.9L Diesel

Engine
(5) Remove radiator top mounting brackets. The
brackets fit over support dowels on the radiator inlet
t a n k (Fig. 46).
(6) The bottom of the radiator has two dowels t h a t
fit into holes in the lower support panel. Taking care J9207-35
not to damage radiator cooling fins or tubes, lift ra
diator straight up out of engine compartment Fig. 47 Radiator Hoses—Typical
HOSE CLAMPS
INSTALLATION
Constant tension hose clamps are used on some
(1) Position shroud rearward on engine.
cooling system hoses. The clamp size is identified by
(2) Lower radiator into position. The dowels on the
a letter stamped on the tongue. Special Clamp Tool
bottom of the radiator fit into alignment holes in the
number 6094 (Fig. 48) may be used to remove the
lower support panel.
constant tension clamps.
(3) Install top mounting brackets. Tighten mount
Ordinary worm gear type hose clamps (when
ing bolts to 23 N*m (17 in. lbs.) torque.
equipped) can be removed with a straight screw
(4) Connect radiator hoses. Install hose clamps.
driver or a hex socket. T o p r e v e n t d a m a g e t o
(5) Position fan shroud on radiator flange. Install
hoses or clamps, the hose clamps should be
retaining clips.
t i g h t e n e d to 4 N«m (34 in. lbs.) torque. D o n o t
(6) Place heater controls in full h e a t position.
over tighten hose clamps.
(7) Fill cooling system with coolant. Refer to Refill
(8) Operate engine until it reaches normal temper
ature. Check cooling system.
HOSE CLAMP HOSE REPLACING OIL COOLER IN BOTTOM TANK

TOOL 6094 CLAMP Remove radiator. Refer to Radiator removal in this
group. The servicing should be performed by a qual
ified repair facility.
Once the repaired or replacement radiator has been
installed, fill the cooling system and inspect for
leaks. Refer to Refilling Cooling System and Testing
Cooling System For Leaks sections in this group. If
the transmission operates properly after repairing
the leak, drain the transmission and remove the
transmission oil pan. Inspect for sludge and/or rust.
Inspect for a dirty or plugged inlet filter. If none of
these conditions are found, the transmission and
torque convertor may not require reconditioning. Re
J9207-36 fer to Group 21 for automatic transmission servicing.
Fig. 48 Hose damp Tool
1RANSMISSI0N OIL COOLER-DIESEL
TRANSMISSION OIL COOLER—EXCEPT DIESEL The transmission oil cooler is mounted to a bracket
The automatic transmission oil is cooled when it on the turbocharger side of the engine (Fig. 51).
passes through a cooler in the radiator lower tank TRANSMISSION
(Fig. 49 and 50). OIL
AUTOMATIC
COOLER
h*-TRANSMISSION TRANSMISSION
- OIL COOLER
FRONT OF VEHICLE
PRESSURE LINE
6 AND 8 CYLINDER ENGINE RETURN LINE RY402
Fig. 49 Top View of Transmission Oil Cooling

Circuit—Except Diesel—Typical
COOLING TUBE
(CUT-A-WAY)
Fig. 51 Automatic Transmission Oil Cooler—5.9L

Diesel
REMOVAL
In case of a leak in the transmission oil cooler, en
gine coolant may become mixed with transmission
fluid or transmission fluid may enter engine cooling
HOSE TO system. Both cooling system and transmission should
DRAIN COCK COOLER LINE be drained and inspected in the event cooler is leak
HOSE TO ing.
HOSE
CLAMP COOLER LINE (1) Disconnect negative battery cable at battery.
RY401 (2) Drain cooling system. Refer to Draining Cool
ing System.
Fig. 50 Automatic Transmission Oil Cooler—Except (3) Disconnect coolant lines from cooler.
Diesel— Typical (4) Disconnect transmission oil lines from cooler.
Plug cooler lines to prevent oil leakage.
In case of a leak in the transmission oil cooler, en
(5) Remove oil cooler mounting straps.
gine coolant may become mixed with transmission
(6) Lift oil cooler off of mounting bracket.
fluid or transmission fluid may enter engine cooling
system. Both cooling system and transmission should INSTALLATION
be drained and inspected in the event cooler is leak (1) Position oil cooler on bracket.
ing. (2) Install mounting straps.
(3) Connect transmission oil lines to cooler.
(4) Connect coolant hoses to cooler. COOLING SYSTEM FAN—GAS ENGINES
(5) Connect battery cable to battery. Also refer to Viscous Fan Drive in this group for
(6) Fill cooling system. Refer to Refilling Cooling additional information.
System in this section.
(7) Check transmission oil level and fill as neces REMOVAL
sary. (1) Disconnect negative battery cable from battery.
(2) Remove throttle cable at top of fan shroud.
TRANSMISSION OIL/TO-AIR COOLER (3) Unsnap coolant reserve/overflow t a n k from fan
Oil to air transmission coolers are mounted ahead shroud and lay aside. The tank is held to shroud
of the radiator and operate in conjunction with the with T-shaped slots. Do not disconnect hose or drain
main cooler (Figs, 52 or 53). The transmission oil is coolant from tank.
routed through the main cooler first, then the auxil (4) The thermal Viscous F a n Drive/Fan Blade As
iary cooler, before returning to the transmission. sembly is attached (threaded) to water pump hub
shaft (Fig. 54). Remove fan blade/viscous fan drive
assembly from water pump by turning mounting nut
FRONT counterclockwise as viewed from front. Threads on
viscous fan drive are R I G H T H A N D . A Snap-On 36
OIL-TO-AIR MM F a n Wrench (number SP346 from Snap-On
COOLER Cummins Diesel Tool Set number 2017DSP) can be
RETURN used. Place a bar or screwdriver between water pump
pulley bolts (Fig. 54) to prevent pulley from rotating.
RADIATOR Do not attempt to remove fan/viscous fan drive as
sembly from vehicle at this time.
RADIATOR GRILL
SUPPORT FAN BLADE WATER WATER PUMP
ASSEMBLY PUMP
PULLEY PULLEY
THREADED BOLTS
NUT
JO
_ TRANSMISSION
* PRESSURE
(FROM BOTTOM COOLER)
VIEW IN CIRCLE J9007-75
Fig. 52 Transmission Oil-to-Air Cooler—Except

Diesel— Typical
THREADED SHAFT CRANKSHAFT
(WATER PUMP HUB) PULLEY
VISCOUS FAN DRIVE
J9307-32
Fig. 54 Fan Blade/Viscous Fan Drive—Gas Engines

Do not unbolt fan blade assembly (Fig. 54) from
viscous fan drive at this time.
(5) Remove fan shroud attaching hardware (two
bolts at bottom-two clips at top).
(6) Remove fan shroud and fan blade/viscous fan
AUXILIARY
OIL TO AIR drive assembly as a complete unit from vehicle.
COOLER J9107-73 After removing fan blade/viscous fan drive assem
bly, d o n o t place viscous fan drive in horizontal po
sition. If stored horizontally, silicone fluid in the
Fig. 53 Transmission Oil-to-Air Cooler—Diesel
viscous fan drive could drain into its bearing assem
Engine—Typical
bly and contaminate lubricant.
C A U T I O N : D o not remove water p u m p pulley-to-wa (3) The thermal viscous fan drive/fan blade assem
ter p u m p bolts (Fig. 54), T h i s pulley is under spring bly is attached (threaded) to the fan hub shaft (Fig.
tension. 55). Remove t h e fan blade/fan drive assembly from
fan pulley by turning the mounting n u t clockwise (as
(7) Remove four bolts securing fan blade assembly viewed from front). Threads on the viscous fan drive
to viscous fan drive (Fig. 54). are L E F T H A N D . A Snap-On 36 MM Fan Wrench
(number SP346 from Snap-On Cummins Diesel Tool
INSPECTION Set number 2017DSP) can be used. Place a bar or
The fan cannot be repaired. If fan is damaged, it screwdriver between the fan pulley bolts to prevent
must be replaced. Inspect fan as follows: pulley from rotating.
(1) Remove fan blade and viscous fan drive as an
assembly from the engine. Refer to preceding Re THREADED
moval procedure.
(2) Remove fan blade assembly from viscous fan
drive unit (four bolts).
(3) Lay fan on a flat surface with leading edge fac
ing down. With tip of blade touching flat surface, re
place fan if clearance between opposite blade and
surface is greater t h a n 2.0 mm (.090 inch). Rocking
motion of opposite blades should not exceed 2.0 mm
(.090 inch). Test all blades in this manner.
W A R N I N G : D O N O T A T T E M P T TO B E N D O R
S T R A I G H T E N F A N B L A D E S IF N O T WITHIN S P E C I
FICATIONS.
(4) Inspect fan assembly for cracks, bends, loose

rivets or broken welds. Replace fan if any damage is
found,
C A U T I O N : If fan blade assembly is replaced be

cause of mechanical damage, water pump and vis
cous fan drive should also be inspected. These
components could have been damaged due to ex Fig. 55 Fan Blades/Viscous Fan Drive-5.9L Diesel
cessive vibration.
(4) Remove the fan shroud and the fan blade/vis
cous drive as an assembly from vehicle.
INSTALLATION (5) Remove fan blade-to-viscous fan drive mount
(1) Install fan blade assembly to viscous fan drive. ing bolts.
Tighten bolts (Fig. 48) to 23 N*m (17 ft. lbs.) torque. Inspect the fan for cracks, loose rivets, loose or
(2) Position fan shroud and fan blade/viscous fan bent fan blades.
drive assembly to vehicle as a complete unit.
(3) Install fan shroud. INSPECTION
(4) Install fan blade/viscous fan drive assembly to The fan cannot be repaired. If the fan is damaged,
water pump shaft (Fig. 54). it must be replaced. Inspect the fan as follows:
(5) Install coolant reserve/overflow tank to fan (1) Remove fan blade and thermal viscous fan
shroud. Snaps into position. drive assembly from engine. Refer to the preceding
(6) Install throttle cable to fan shroud. Removal procedure.
(7) Connect negative battery cable. (2) Remove fan blade assembly from thermal vis
cous fan drive unit (four bolts).
COOLING SYSTEM F A N - D I E S E L ENGINE (3) Lay fan on a flat surface with leading edge fac
ing down. With tip of blade touching flat surface, re
REMOVAL
(1) Disconnect negative battery cable from battery. place fan if clearance between opposite blade and
(2) Remove the fan shroud mounting bolts. Posi surface is greater t h a n 2.0 mm (.090 inch). Rocking
tion fan shroud towards engine. motion of opposite blades should not exceed 2.0 mm
(.090 inch). Test all blades in this manner.
C A U T I O N : Do not remove the fan puHey bolts. This
pulley is under spring tension.
W A R N I N G : DO N O T A T T E M P T T O B E N D O R MOUNTING NUT
S T R A I G H T E N F A N B L A D E S IF N O T WITHIN S P E C I TO WATER PUMP
FICATIONS.
(4) Inspect fan assembly for cracks, bends, loose

rivets or broken welds. Replace fan if any damage is
found.
CAUTION; If the fan blade a s s e m b l y is replaced be

c a u s e of mechanical d a m a g e , the fan pulley a n d
v i s c o u s fan drive s h o u l d also be inspected. T h e s e
c o m p o n e n t s could have been d a m a g e d d u e to ex
c e s s i v e vibration.
INSTALLATION
(1) Install fan blade assembly to viscous fan drive. Fig. 56 Viscous Fan Drive
Tighten mounting bolts. CAUTION; If v i s c o u s fan drive is replaced b e c a u s e
(2) Position the fan shroud and fan blade/viscous of mechanical d a m a g e , cooling fan blades s h o u l d
fan drive to the vehicle as an assembly. also be inspected. Inspect for fatigue c r a c k s , loose
(3) Install viscous fan drive assembly on fan hub blades or l o o s e rivets that could have resulted from
shaft. Tighten mounting n u t to 57 N*m (42 ft. lbs.) e x c e s s i v e vibration. Replace fan blade a s s e m b l y if
any of these conditions are found. A l s o inspect wa
torque.
ter p u m p bearing a n d shaft a s s e m b l y for a n y re
(4) Install fan shroud bolts. lated d a m a g e d u e to a v i s c o u s drive malfunction.
(5) Install battery cable to battery.
Regardless of increased engine speed, once the fan
VISCOUS FAN DRIVE has reached its maximum operating speed, it will not
The thermal viscous fan drive (Figs. 54 or 55) con rotate any faster. When the necessary engine cooling
sists of the viscous fan drive clutch and a thermo has been accomplished causing a reduction in tem
static spring coil mounted on its front face (Fig. 56). perature of radiator discharge air, the spring coil
The viscous fan drive clutch is a silicone-fluid-filled again reacts. This will cause fan speed to be reduced
coupling connecting fan blade assembly to water to its previous disengaged speed.
pump shaft. The coupling allows fan to be driven in a
normal manner at low engine speeds. It will limit top TESTING VISCOUS FAN DRIVE
speed of fan to a predetermined maximum level at In case of engine overheating, inspect thermal vis
higher engine speeds. cous fan drive for proper operation. Observe move
The thermostatic spring coil (Fig. 56) reacts to the ment of thermostatic spring coil and shaft. Lift end
of thermostatic spring up and out of retaining slot in
temperature of radiator discharge air. It engages
fan drive (Fig. 57). Rotate spring counterclockwise
drive clutch for higher fan speed if air temperature
until a stop is felt. The gap between end of coil and
from radiator rises above a certain point. Until addi
retaining clip should be approximately 12 mm (0.5
tional engine cooling is necessary, fan will remain at
inch) (Fig. 58). Replace unit if shaft does not rotate
a reduced rpm regardless of engine speed. Only when with coil. After testing, install end of coil in slot of
sufficient heat is present in the air, will the viscous retaining clip.
fan drive clutch engage. This air flowing through ra
diator core will cause a reaction to thermostatic REMOVAUINSTALLA TION
spring coil. F a n speed will then increase to provide For removal and installation procedures, refer to
necessary additional engine cooling. Cooling System Fans in this group.
Fig.
Fig. 57 Disconnecting End of Thermostatic 58 Testing Spring and Shaft Rotation-Typical
Spring—Typical
ENGINE ACCESSORY DRIVE BELTS
INDEX
page page
Automatic Belt Tensioner 45 Belt Schematics 40
Belt Diagnosis 40 Belt Tension 40
Belt Removal/Installation . 40 General Information 40
GENERAL INFORMATION
All vehicles are available with either a 3.9L (V-6),
a 5.2L (V-8), a 5.9L (gas V-8) or a 5.9L (in-line 6 cyl
inder diesel) engine.
The accessory drive components are operated by a
single, crankshaft driven, serpentine drive belt on all
engines. An automatic belt tensioner is used to main
NORMAL CRACKS
tain correct belt tension at all times. Refer to Auto BELT OK
matic Belt Tensioner proceeding in this group.
BELT DIAGNOSIS
SERPENTINE DRIVE BELT DIAGNOSIS-ALL
ENGINES
When diagnosing serpentine drive belts, small
cracks that run across ribbed surface of belt from rib
to rib (Fig. 1), are considered normal. These are not a
reason to replace belt. However, cracks running
along a rib (not across) are n o t normal. Any belt
with cracks running along a rib must be replaced NOT NORMAL CRACKS
REPLACE BELT J9007-44
(Fig. 1). Also replace belt if it has excessive wear,
frayed cords or severe glazing. Fig. 1 Serpentine Accessory Drive Belt Wear
Refer to the Serpentine Drive Belt Diagnosis charts Patterns
for further belt diagnosis. Also refer to Automatic
and removal/installation procedures, refer to Auto
Belt Tensioner proceeding in this group.
matic Belt Tensioner proceeding in this group. Due
BELT SCHEMATICS to use of this belt tensioner, do not attempt to use a
The following belt routing schematics are pub belt tension gauge on any engine.
lished from the latest information available at the
time of publication. If anything differs b e t w e e n BELT REMOVAL/INSTALLATION
these schematics a n d t h e Belt Routing Label, Caution: D o not attempt to check belt tension with
u s e t h e schematics o n Belt Routing Label. This
a belt tension g a u g e o n vehicles equipped with a n
label is located in the engine compartment.
automatic belt tensioner. Refer to Automatic Belt
BELT TENSION Tensioner in this group.
ALL ENGINES
Correct accessory drive belt tension is required to 3.9L/5,2U5*9L LDC-GAS ENGINES
be sure of optimum performance of belt driven en
gine accessories. If specified tension is not main REMOVAL
tained, belt slippage may cause; engine overheating, Drive belts on these engines are equipped with a
lack of power steering assist, loss of air conditioning spring loaded automatic belt tensioner (Fig. 7). This
capacity, reduced generator output rate and greatly belt tensioner will be used on all belt configurations,
reduced belt life. such as with or without power steering or air condi
It is not necessary to adjust belt tension on any en tioning. For more information, refer to Automatic
gine. All engines are equipped with an automatic Belt Tensioner, proceeding in this group.
belt tensioner. The tensioner maintains correct belt (1) Attach a socket/wrench to pulley mounting bolt
tension at all times. For other tensioner information of automatic tensioner (Fig. 7).
SERPENTINE DRIVE BELT DIAGNOSIS-EXCEPT DIESEL ENGINE
RIB CHUNKING (1) Foreign objects imbedded in (1) Remove foreign objects from
(ONE OR MORE RIBS pulley grooves. pulley grooves. Replace belt.
HAS SEPARATED
FROM BELT BODY) (2) Installation damage. (2) Replace belt.
RIB OR BELT WEAR (1) Put ley (s) misaligned. (1) Align pulley(s).
(2) Abrasive environment. (2) Clean pulley(s). Replace

belt if necessary.
(3) Rusted pulley(s). (3) Clean rust from pulley(s).
(4) Sharp or jagged pulley groove tips. (4) Replace pulley.
(5) Rubber deteriorated. (5) Replace belt.
LONGITUDINAL (1) Belt has mistracked from pulley (1) Replace belt.
BELT CRACKING groove.
(CRACKS BETWEEN
TWO RIBS) (2) Pulley groove tip has worn away (2) Replace belt.
rubber to tensile member.
BELT SLIPS (1) Belt slipping because of (1) Adjust tension.
insufficient tension.
(2) Belt or pulley subjected to (2) Replace belt and clean pulleys.
substance (belt dressing, oil,
ethylene glycol) that has reduced
friction.
(3) Driven component bearing failure. (3) Replace faulty component bearing.
(4) Belt glazed and hardened from (4) Replace belt.

heat and excessive slippage.
"GROOVE JUMPING" (1) Belt tension either too (1) Adjust belt tension.
(BELT DOES NOT high or too low.
MAINTAIN CORRECT
POSITION ON (2) Pulley(s) not within design (2) Replace pulley(s).
PULLEY) tolerance.
(3) Foreign object(s) in grooves. (3) Remove foreign objects from

grooves.
(4) Pulley misalignment. (4) Align pulley(s).
(5) Belt cordline is broken. (5) Replace belt.
BELT BROKEN (1) Excessive tension. (1) Replace belt and adjust tension
(NOTE: IDENTIFY to specification.
AND CORRECT
PROBLEM BEFORE (2) Tensile members damaged during (2) Replace belt.
NEW BELT IS belt installation.
INSTALLED)
(3) Severe misalignment. (3) Align pulley(s).
(4) Bracket, pulley, or bearing (4) Replace defective component and

failure. belt.
NOISE (1) Belt slippage. (1) Adjust belt.

(OBJECTIONAL
SQUEAL, SQUEAK, (2) Bearing noise. (2) Locate and repair.
bR RUMBLE IS
HEARD OR FELT (3) Belt misalignment. (3) Align belt/pulley(s).
WHILE DRIVE BELT
IS IN OPERATION) (4) Beit-to-pulley mismatch. (4) Install correct belt.
E8907-143
SERPENTINE DRIVE BELT DIAGNOSIS-DIESEL ENGINE
RIB C H U N K I N G (1) Foreign objects imbedded in (1) Remove foreign objects from
(ONE O R M O R E RIBS pulley grooves. pulley grooves. Replace belt.
HAS SEPARATED
FROM BELT BODY) (2) Installation damage. (2) Replace belt.
RIB OR BELT WEAR (1) Pulley(s) misaligned. (1) Align pulley(s).
(2) Abrasive environment. (2) Clean pulley(s). Replace

belt if necessary.
(3) Rusted pulley(s). (3) Clean rust from pulley(s).
(4) Sharp or jagged pulley groove tips. (4) Replace pulley.
(5) Rubber deteriorated. (5) Replace belt.
LONGITUDINAL (1) Belt has mistracked from (1) Replace belt.

BELT CRACKING pulley groove.
(CRACKS BETWEEN
TWO RIBS) (2) Pulley groove tip has worn away (2) Replace belt.
rubber to tensile member.
BELT SLIPS (1) Belt slipping because of 0) Replace tensioner.
insufficient tension.
(2) Incorrect belt. (2) Replace belt.
(3) Belt or pulley subjected to (3) Replace belt and clean pulleys.
substance (belt dressing, oil,
ethylene glycol) that has
reciuced friction.
(4) Driven component bearing failure. (4) Replace faulty component bearing.
(5) Belt glazed and hardened from (5) Replace belt.

heat and excessive slippage.
" G R O O V E JUMPING" (1) Belt tension either too (1) Replace tensioner.
5
(BELT DOES NOT high or too low.
MAINTAIN CORRECT
POSITION O N PULLEY) (2) Incorrect belt. (2) Replace belt.
(3) Pulley(s) not within design (3) Replace pulley(s).

tolerance.
(4) Foreign object(s) in grooves. (4) Remove foreign objects

from grooves.
(5) Pulley misalignment. (5) Check and Replace.
(6) Belt cordline is broken. (6) Replace belt.
BELT BROKEN 0) Excessive tension. 0) Replace belt and

(NOTE: IDENTIFY tensioner.
A N D CORRECT
PROBLEM BEFORE (2) Incorrect belt. (2) Replace belt.
NEW BELT IS
INSTALLED) (3) Tensile members damaged during (3) Replace belt.
belt installation.
(4) Severe misalignment. (4) Check and replace.
(5) Bracket, pulley, or bearing (5) Replace defective component

failure. ana belt.
NOISE 0) Belt slippage. (1) Replace belt or belt tensioner.
(OBJECTIONAL
SQUEAL, SQUEAK, (2) Bearing noise. (2) Locate and repair.
OR RUMBLE IS
HEARD OR FELT (3) Belt misalignment. (3) Replace belt.
WHILE DRIVE BELT
IS IN OPERATION) (4) Belt-to-pulley mismatch. (4) Install correct belt.
J9107-74
AUTOMATIC
TENSIONER
*IF VEHICLE IS NOT EQUIPPED WITH POWER

STEERING, THIS WILL BE A N IDLER PULLEY. J9307-26 J9307-56
Fig. 2 Beit Routing - 3.9U5.2L/5.9L LDC-Gas Engine Fig. 4 Belt Routing—5.9L HDC-Gas Engine—Without
A/C
AUTOMATIC
TENSIONER 'POWER STEERING PUMP IS NOT BELT DRIVEN
J9307-55
Fig. 3 Beit Routing—5.9L HDC-Gas Engine—With

A/C
Fig. 5 Belt Routing-5.9L Diesel-With A/C
(2) Rotate tensioner assembly clockwise (as viewed
wrong direction. Refer to (Fig. 2) for correct engine
from front) until tension has been relieved from belt.
belt routing. The correct belt with correct length
(3) Remove belt from idler pulley first.
must be used.
(4) Remove belt from vehicle.
(1) Position drive belt over all pulleys except idler
INSTALLATION
pulley. This pulley is located between generator and
A/C compressor.
C A U T I O N : W h e n installing serpentine a c c e s s o r y
(2) Attach a socket/wrench to pulley mounting bolt
drive belt, belt must be routed correctly. If not, e n
of automatic tensioner (Fig. 7).
gine may overheat d u e to water pump rotating in
5.9L HDC-GAS ENGINE
REMOVAL
Drive belts are equipped with a spring loaded au
tomatic belt tensioner (Fig. 8). This belt tensioner
will be used on all belt configurations, such as with
or without power steering or air conditioning. For
more information, refer to Automatic Belt Tensioner,
proceeding in this group.
Fig. 6 Belt Routing-5.9L Diesel-Without A/C
Fig. 8 Belt Tensioner—5.9L HDC-Gas Engine

of automatic tensioner (Fig. 8). (The threads on this
bolt are left hand).
(2) Relax the tension from the belt by rotating the
tensioner counterclockwise (as viewed from front)
(Fig. 8). When all belt tension has been relaxed, re
move belt from tensioner pulley first and other pul
leys last.
INSTALLATION
C A U T I O N : When installing serpentine accessory

drive belt, belt must be routed correctly. If not, en
Fig. 7 Belt Tensioner-3.9L/5.2U5.9L LDC-Gas gine may overheat due to water pump rotating in
Engine wrong direction. Refer to (Figs. 3 or 4) for correct
engine belt routing. The correct belt with correct
(3) Rotate socket/wrench clockwise. Place belt over
length must tê used.
idler pulley. Let tensioner rotate back into place. Re
move wrench. Be sure belt is properly seated on all
pulleys. C A U T I O N : if the pulley is to be removed from the
(4) Check belt indexing marks. Refer to the pro tensioner, its mounting bolt h a s left hand threads.
ceeding Automatic Belt Tensioner for more belt in
formation. (1) Position drive belt over all pulleys except ten
sioner pulley.
of automatic tensioner (Fig. 8).
(3) Rotate socket/wrench counterclockwise. Install sioner rotate back into place. Remove ratchet. Be
belt over tensioner pulley. Let tensioner rotate back sure belt is properly seated on all pulleys.
into place. Remove wrench. Be sure belt is properly
seated on all pulleys. AUTOMATIC BELT TENSIONER
Drive belts on all engines are equipped with a
5«9L DIESEL ENGINE spring loaded automatic belt tensioner (Figs. 10, 11
or 12). This belt tensioner will be used with all belt
REMOVAL configurations, such as with or without power steer
Drive belts on diesel engines are equipped with a ing or air conditioning.
spring loaded automatic belt tensioner (Fig. 9). Fig
ure 9 displays the tensioner for vehicles without Caution: D o not attempt to check belt tension with
air conditioning. a belt tension g a u g e o n vehicles equipped with an
This belt tensioner will be used on all belt config automatic belt tensioner.
urations, such as with or without air conditioning.
For more information, refer to Automatic Belt Ten
sioner, proceeding in this group.
Fig. 9 Belt Tensioner—5.9L Diesel Engine—Typical

(1) A 3/8 inch square hole is provided in the auto
matic belt tensioner (Fig. 9). Attach a 3/8 inch drive- Fig. 10 Belt Tensioner—3.9U5.2U5.9L LDC-Gas
long handle ratchet to this hole. Engine
(2) Rotate ratchet and tensioner assembly counter On 3.9L/5.2L and 5.9L LDC-gas engines, the ten
clockwise (as viewed from front) until tension has sioner is equipped with an indexing arrow (Fig. 13)
been relieved from belt. on back of tensioner and an indexing mark on ten
(3) Remove belt from water pump pulley first. sioner housing. If a new belt is being installed, arrow
(4) Remove belt from vehicle. must be within approximately 3 mm (1/8 in.) of in
dexing mark (Point B—Fig. 13). Belt is considered
INSTALLATION new if it has been used 15 minutes or less. If this
specification cannot be met, check for:
C A U T I O N : When installing serpentine accessory • The wrong belt being installed (incorrect length/
drive belt, belt must be routed correctly. If not, en width)
gine may overheat due to water pump rotating in
• Worn bearings on an engine accessory (A/C com
wrong direction. Refer to (Figs. 5 or 6) for correct
pressor, power steering pump, water pump, idler pul
engine belt routing. The correct belt with correct
ley or generator)
length must be used.
• A pulley on an engine accessory being loose
(1) Position drive belt over all pulleys e x c e p t wa • Misalignment of an engine accessory
ter pump pulley. • Belt incorrectly routed. Refer to (Figs. 2, 3 or 4)
(2) Attach a 3/8 inch ratchet to tensioner. On 3.9L/5.2L and 5.9L LDC-gas engines, a used
(3) Rotate ratchet and belt tensioner counterclock belt should be replaced if tensioner indexing arrow
wise. Place belt over water pump pulley. Let ten has moved beyond point A (Fig. 13).
7 - 4S COOLING SYSTEM •
IDLER TENSIONER
PULLEY ASSEMBLY
BOLT iUlLTPULLEY-
TENSIONER
MOUNTING NUT
TENSIONER
MOUNTING
BOLT
INDEXING
ARROW
INDEXING
MARK
ULLC
TENSIONER \ r ,\ , / ^ J9307-64 ,
Fig. 11 Beit Tensioner—5.9L HDC-Gas Engine
J9207-17
MOUNT.
BOLT Fig. 13 indexing Marks-3.9L/5.2L/5.9L LDC-Gas
Engine
ACCESSORY (5) Remove pulley bolt. Remove pulley from ten
DRIVE BELT
sioner.
3/8
SQUARE INSTALLATION
HOLE (1) Install pulley and pulley bolt to tensioner.
AUTOMATIC Tighten bolt to 61 Nnn (45 ft. lbs.).
BELT (2) Install tensioner assembly to mounting bracket.
TENSIONER J9307-59 An indexing tab is located on back of tensioner.
Align this tab to slot in mounting bracket. Tighten
Fig. 12 Belt Tensioner—5.9L Diesel Engine—Typical nut to 67 Nnn (50 ft. lbs.) torque.
3MLm.2Lm.9L LDG°GA8 ENGINES (3) Connect all wiring to ignition coil.
(4) Install coil to coil bracket. If nuts and bolts are
REMOVAL used to secure coil to coil bracket, tighten to 11 Nnn
(1) Remove accessory drive belt. Refer to Belt Re (100 in. lbs.) torque. If coil mounting bracket has
moval/Installation in this group. been tapped for coil mounting bolts, tighten bolts to
(2) Disconnect wiring and secondary cable from ig 5 Nnn (50 in. lbs.) torque.
nition coil.
(3) Remove ignition coil from coil mounting C A U T I O N : To prevent damage to coil case, coil
bracket (two bolts). Do not remove coil mounting mounting bolts must be torqued.
bracket from cylinder head.
(4) Remove tensioner assembly from mounting (5) Install drive belt. Refer to Belt Removal/Instal
bracket (one nut) (Fig. 13). lation in this group.
(6) Check belt indexing marks (Fig. 13).
W A R N I N G : B E C A U S E O F HIGH S P R I N G P R E S
S U R E , D O NOT A T T E M P T T O D I S A S S E M B L E A U T O
M A T I C T E N S I O N E R . UNIT I S S E R V I C E D A S A N
A S S E M B L Y (EXCEPT FOR PULLEY).
5.9L HDC'GAS ENGINE

BELT TENSIONER
REMOVAL
(1) Remove accessory drive belt. Refer to Belt Re
moval/Installation in this group.
(2) Remove tensioner mounting bolt (Fig. 11) and
remove tensioner.
C A U T I O N : If the pulley is to be removed from the

tensioner, its mounting bolt h a s left hand threads.
W A R N I N G : B E C A U S E O F HIGH S P R I N G P R E S
S U R E , D O NOT ATTEMPT TO D I S A S S E M B L E AUTO
M A T I C T E N S I O N E R . UNIT I S S E R V I C E D A S A N DOWEL PIN J9307-63
A S S E M B L Y (EXCEPT FOR PULLEY).
Fig. 14 Tensioner Dowel Pin—5.9L HDC-Gas Engine
INSTALLATION
(1) Install pulley and pulley bolt to tensioner (ob
serve the previous CAUTION). Tighten bolt to 88
N*m (65 ft. lbs.) torque.
(2) Install tensioner assembly to mounting bracket.
A dowel pin is located on back of tensioner (Fig. 14).
Align this to dowel hole (Fig. 15) in tensioner mount
ing bracket. Tighten bolt to 41 N-m (30 ft. lbs.)
torque.
(3) Install drive belt. Refer to Belt Removal/Instal
lation in this group.
5.9L DIESEL ENGINE
REMOVAL
(1) Remove accessory drive belt. Refer to Belt Re Fig. 15 Tensioner Mounting Bracket Dowel
moval/Installation in this group. Hole—5.9L HDC-Gas Engine
(2) Remove tensioner mounting bolt (Fig. 12) and INSTALLATION
remove tensioner. (1) Install pulley to tensioner.
(2) Install tensioner assembly to mounting bracket.
W A R N I N G : B E C A U S E O F HIGH S P R I N G P R E S A dowel is located on back of tensioner. Align this
S U R E , D O NOT A T T E M P T T O D I S A S S E M B L E AUTO dowel to hole in tensioner mounting bracket. Tighten
M A T I C T E N S I O N E R . UNIT I S S E R V I C E D A S A N bolt to 41 N*m (30 ft. lbs.) torque.
A S S E M B L Y (EXCEPT FOR PULLEY). (3) Install drive belt. Refer to Belt Removal/Instal
lation in this group.
ENGINE BLOCK HEATERS
GENERAL INFORMATION
DESCRIPTION AND OPERATION

An optional engine block heater is available with
for all models. The heater is equipped with a power
cord t h a t is located behind the grille. The cord is at
tached to a n engine compartment component with
tie-straps. The heater warms t h e engine providing
easier engine starting and faster warm-up in low
temperatures. The heater is mounted in a core hole
of the engine cylinder block (in place of a freeze plug)
with t h e heating element immersed in engine cool
ant. The power cord is located behind t h e radiator
grille. Connect the power cord to a grounded 110-120
volt AC electrical outlet with a grounded, three wire
extension cord.
WARNING: DO NOT OPERATE ENGINE UNLESS

BLOCK HEATER CORD HAS BEEN DISCONNECTED
FROM POWER SOURCE AND SECURED IN PLACE.
THE POWER CORD MUST B E SECURED IN ITS RE
TAINING CLIPS AND ROUTED AWAY FROM EX
HAUST MANIFOLDS AND MOVING PARTS. Fig. 1 Engine Block Heater—Except Diesel
REMOVAL
(2) Drain coolant from radiator and cylinder block.
(3) Remove pow^r cord from heater (Fig. 1 or 2).
(4) Loosen bolt a t center of block heater. Remove
block heater.
INSTALLATION
(1) Thoroughly clean cylinder block core hole a n d
block heater seat.
(2) Insert block heater (with element loop pointing
down).
(3) With heater fully seated, tighten center bolt se
curely.
(4) Fill cooling system with recommended coolant.
Refer to Refilling Cooling System section in this Fig. 2 Engine Block Heater—Diesel Engine
group.
SPECIFICATIONS
GENERAL INFORMATION DRIVE BELT TENSION
The following specifications are published from the All engines are equipped with a spring loaded au
latest information available a t t h e time of publica tomatic belt tensioner. Do not a t t e m p t to check belt
tion. If a n y t h i n g differs b e t w e e n the specifica tension with a belt tension gauge on vehicles
tions found o n the Vehicle Emission Control equipped with an automatic belt tensioner. Refer to
I n f o r m a t i o n (VECI) label a n d t h e f o l l o w i n g spec Automatic Belt Tensioner in this group.
ifications, u s e s p e c i f i c a t i o n s o n V E C I label. The
VECI label is located in the engine compartment.
CAPACITIES
CAPACITY
ENGINE MODEL DRIVE QUARTS LITERS
3.9L D150, D250 2WD 15.1 14.0
5.2L D150, D250, D350 2WD 17.0 16.0
5.2L RAMCHARGER 4WD 16.5 15.7
5.2L W150, W250, W350 4WD 17.0 16.0
5.9L D150, D250, D350 A N D RAMCHARGER 2WD 15.5 14.7
5.9L RAMCHARGER 4WD 15.0 14.0
5.9L W150, W250, W350 4WD 15.5 14.7
DIESEL ALL MANUAL 16.0 15.1
DIESEL ALL AUTOMATIC 17.0 16.1
J9207-41
TORQUE
DISCMPflON TORQUE TORQUi
Automatic Belt Tensioner Pulley Radiator Mounting Bobs 11 N-m (95 in. lbs.)
Bolt-3.9l/2.5L/5.9LLDC
Gas Engine 61 N-m (45ft.lbs.) Radiator Top Mounting Brackets-
Diesel Engine...... 23 N-m (17 in. lbs.)
Automatic Belt Tensioner Pulley
Bolt - 5.9L HDC Gas Engine 88 N-m (65ft.lbs.) Thermal Viscous Fan-to-Hub-
Diesel Engine 57 N-m (42ft.lbs.)
Automatic Belt Tensioner-to-
Mounting Bracket - 3.9L/5.2L/ Thermostat Housing Bolts -
5.9L IDC Gas Engine 67 N-m (50ft.lbs.) All Except Diesel 23 N-m (200 in. lbs.)
Automatic Belt Tensioner-to- Thermostat Housing Bolts -

Mounting Bracket - 5.9L Diesel Engine 24 N-m (18ft.lbs.)
HDC Gas Engine 41 N-m (30ft.lbs.) Water Pump Mounting Bolts -
Fan Shroud Mounting Nuts 11 N-m (95 in. lbs.) All Gas Engines 40 N-m (30ft.lbs.)
Hose Clamps 4 N-m (34 in. lbs.) Water Pump Pulley Bolts -
All Gas Engines 27 N-m (20ft.lbs.)
Idler Pulley Mounting Bolt -
Water Pump Mounting Bolts -
All Gas Engines 61 N-m (45ft.lbs.)
Diesel Engine 24 N-m(18ft. lbs.)
J9307-60
• ELECTRICAL 8A - 1
ELECTRICAL
INDEX
Group Group
AUDIO SYSTEMS 8F POWER MIRRORS 8T

BATTERY/STARTER/GENERATOR SERVICE . . 8B POWER WINDOWS 8S
BATTERY/STARTING/CHARGING SYSTEMS REAR WINDOW DEFOGGER 8N
DIAGNOSTICS 8A TURN SIGNALS AND HAZARD WARNING
HORNS 8G FLASHERS 8J
IGNITION SYSTEMS 8D VEHICLE SPEED CONTROL SYSTEM 8H
INSTRUMENT PANEL AND GAUGES 8E WARNING BUZZER SYSTEM 8U
LAMPS 8L WINDSHIELD WIPERS AND WASHERS 8K
POWER LOCKS 8P WIRING DIAGRAMS 8W
BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS
CONTENTS
page page
BATTERY TEST PROCEDURES 2 GENERATOR TEST PROCEDURES ON VEHICLE . 13

ENGINE STARTER MOTOR TEST PROCEDURES ..9 SPECIFICATIONS 18
GENERAL INFORMATION
The Battery, Starting, and Charging Systems oper
ate with one another, and therefore, must be thor
oughly tested as a complete system. In order for the
vehicle to start and charge properly, it must have a
battery that will perform to specifications. The starter
motor, generator, wiring, and electronics also must NEGATIVE
BATTERY
7
POSITIVE
perform within specifications. Group 8A covers Start BATTERY
A
CABLE CABLE
ing (Fig. 1) and Charging (Fig. 2) System diagnostic
procedures. These procedures include the most basic
conventional methods to On-Board Diagnostics (OBD)
built into the Powertrain Control Module (PCM).
Use of an ammeter, volt/ohmmeter, battery
charger, carbon pile rheostat (load tester), and 12 BATTERY
volt test light will be required.
All OBD sensing systems are monitored by the J918A-11
PCM. The PCM will store in memory any detectable
failure in the monitored circuits. Refer to Using On- Fig. 1 Starting System Components—Typical
Board Diagnostic System in this group for more in
formation.
8A - 2 ELECTRICAL •
MALFUNCTION
INDICATOR
LAMP
DIAGNOSTIC SCAN
TOOL
POWERTRAIN CONTROL
MODULE
BATTERY
GENERATOR J938A-23
Fig. 2 Charging System Components—Typical
BATTERY TEST PROCEDURES
INDEX
page page
Battery Charging 6 General Information 2
Battery Load Test 5 Ignition Off Draw (IOD) 4
Battery Open Circuit Voltage Test ............. 4 State of Charge Test Using Test Indicator ....... 3
Causes of Battery Discharging 3 Test Indicator 3
GENERAL INFORMATION ated when t h e battery is being charged. The battery

The battery stores, stabilizes, and produces electri top, posts, and terminals should be cleaned when
cal current. A battery must be able to accept a other underhood maintenance is performed (Fig. 3).
charge and produce high-amperage current over a n
extended period. A chemical reaction takes place be W A R N I N G : DO NOT A T T E M P T TO ASSIST BOOST,
tween sulfuric acid solution (electrolyte) and lead + /- CHARGE, OR TEST BATTERY WHEN ELECTRO
plates in each cell of t h e battery. As t h e battery LYTE LEVEL I S BELOW THE TOP OF THE PLATES
(YELLOW OR BRIGHT COLOR IS VISIBLE). PER
discharges, t h e plates collect acid from t h e electro
S O N A L INJURY M A Y OCCUR.
lyte. When t h e charging system charges t h e battery,
water is converted to sulfuric acid in t h e battery. The When t h e electrolyte level is below t h e top of t h e
amount of acid (specific gravity) in t h e electrolyte plates (yellow or bright indicator), t h e battery must
can be measured with a hydrometer. A factory in be replaced. The battery must be completely charged
stalled battery h a s a built-in test indicator to help (green indicator) and t h e top, posts, and terminals
determine state-of-charge. The factory installed bat should be properly cleaned before diagnostic proce
tery is also nonrefillable, water can not be added. dures are performed. Refer to Group 8B - Battery/
The battery is vented to release gases t h a t are cre- Starter Service, for additional information.
The battery is inadequately charged and must be

charged until green dot is visible (12.4 volts or
greater) before t h e battery is tested or returned to
use. Refer to Causes of Battery Discharging for more
information.
YELLOW OR BRIGHT COLOR
WARNING: D O NOT ATTEMPT TO CHARGE, TEST,

OR ASSIST BOOST BATTERY WHEN YELLOW O R
BRIGHT C O L O R I S VISIBLE. P E R S O N A L INJURY
MAY OCCUR.
A yellow or bright color indicates water (electro

lyte) level in battery is below the test indicator (Fig.
5). Water can not be added to a maintenance free
Fig. 3 Battery Construction and Test Indicator battery. The battery must be replaced. A low electro
TEST INDICATOR lyte level m a y be caused by a n over charging condi
A test indicator (hydrometer) built into the top of tion. Refer to Generator Test Procedures On Vehicle
the battery case, provides visual information for bat in this group.
tery testing (Fig. 4). The test indicator is to be used
with diagnostic procedures described in this group. It TEST INDICATOR/STATE OF CHARGE
is important when using t h e test indicator t h a t the IfVW, "TCfV
REPLACE BATTERY
battery is relatively level and h a s a clean top to see lUUTu /Otu L
f
correct indications. A light may be required to view
indicator.
WARNING: D O NOT U S E O P E N FLAME. EXPLOSIVE
G A S E S FORM ABOVE BATTERY. SBl
ill, iMMiMMMMSMM^MM
GREEN BLACK YELLOW 898A-3
Fig. 5 Test Indicator Sight Glass

CAUSES OF BATTERY DISCHARGING
It is normal to have a small (5 to 20 milliamperes)
draw from t h e battery with t h e ignition in t h e O F F
position, and ALL lamps OFF. The constant draw is
due to various electronic features or accessories t h a t
require electrical current with the ignition OFF to
function properly. If a vehicle is not used for a period
Fig. 4 Built in Test Indicator of 20 days or more, t h e black battery disconnect
should be disconnected. The disconnect is located be
STATE OF CHARGE TEST USING TEST INDICATOR hind t h e battery on t h e engine wiring harness. This
The built-in test indicator (hydrometer) measures will prevent battery discharging.
the specific gravity of the electrolyte. Specific gravity
(SG) of the electrolyte will indicate state-of-charge ABNORMAL BATTERY DISCHARGING
(voltage); although, t h e test indicator will not indi (1) Corroded battery posts and terminals.
cate cranking capacity of the battery. Refer to Bat (2) Loose or worn generator drive belt.
tery Load Test for more information. Look into t h e (3) Electrical loads t h a t exceed the output of t h e
sight glass and note t h e color of t h e indicator (Fig. charging system due to equipment or accessories in
5), refer to the following description as color indi stalled after delivery.
cates: (4) Slow driving speeds (heavy traffic conditions)
G R E E N - 7 5 to 100% state-of-charge or prolonged idling with high-amperage electrical
The battery is adequately charged for more testing systems in use.
or return to use. If t h e vehicle will not crank for a (5) Defective electrical circuit or component caus
maximum 15 seconds, refer to Battery Load Test for ing excess Ignition Off Draw (IOD).
more information. (6) Defective charging system.
BLACK OR DARK—0 to 75% state-of-charge (7) Defective battery.
IGNITION OFF DRAW (IOD) After higher amperage IOD has been corrected, low
Ignition off draw refers to power being drained amperage IOD may be checked.
from the battery with the ignition turned off. A nor It is now safe to install milliamp meter to check for
mal vehicle electrical system will draw from 5 to 20 low amperage IOD.
milliamps. A vehicle that has not been operated for (5) With test light still connected, securely clamp
an extended period of time (approximately 20 days) an ammeter between battery negative terminal and
may discharge the battery to an inadequate level. negative battery cable.
Battery drain should not exceed approximately 20 If the test light or the milliamp meter circuit is
MA (20 milliamps = 0.020 amps). broken the various timer circuits will start. D o
The 20 MA are needed to supply PCM memory, not o p e n any doors or turn o n any electrical ac
digital clock memory, and ETR (electronically tuned cessories with the test light disconnected or the
radio) memory. meter m a y be damaged.
Excessive battery drain is caused by items left
(6) Disconnect test light. The current draw should
turned on, internally shorted generator, or intermit
not exceed 0.020 amp. If it exceeds 20 milliamps iso
tent short in wiring.
late each circuit by removing circuit breakers and
If the IOD is excessive (over 20 milliamperes), the
fuses. The meter reading drops once the high current
defect must be found and corrected before replacing a
battery. In most cases the battery can be charged problem is found. Repair this section of the circuit,
and returned to service. whether it is a wiring short or component failure.
TEST PROCEDURE BATTERY OPEN CIRCUIT VOLTAGE TEST

T e s t i n g for h i g h e r a m p e r a g e I O D m u s t b e p e r A battery voltage (no load) test will indicate the
f o r m e d first t o p r e v e n t d a m a g e t o m o s t milliamp state of charge of a battery t h a t will pass the Battery
meters. Load Test described in this section. Before proceed
Verify t h a t all electrical accessories are OFF. Turn ing with this test or the Battery Load Test the
off all lights, remove ignition key, and close all battery must b e completely charged as de
doors. If the vehicle is equipped with electronic acces scribed in Battery Charging in this section.
sories (illuminated entry, high line radio), allow the If a battery has a no load voltage reading of 12.4
systems to automatically shut off (time out), up to 3 volts or greater but will not endure a load test, it is
minutes. defective and should be replaced. Refer to Group 8B,
(1) After determining t h a t the underhood lamp is Battery/Starter Service for instructions. To test bat
operating properly then disconnect bulb. tery no load voltage, perform the following operation:
(2) Disconnect negative cable from battery. (1) Before measuring open circuit voltage, the sur
(3) Connect a typical 12 volt test light (low watt face charge must be removed from plates. Turn head
age bulb) between the negative cable clamp and the lights on for 15 seconds then allow up to 5 minutes
battery negative terminal. for voltage to stabilize.
The test light may light brightly for up to 3 min
(2) Remove both battery cables, negative first.
utes or may not light at all (depending on the elec
(3) Using a voltmeter connected to the battery
trical equipment). The term brightly being used
posts, see instructions provided with voltmeter, mea
throughout the following tests, implies the bright
sure open circuit voltage (Fig. 6).
ness of the test light will be the same as if it were
connected across the battery. This voltage reading will indicate state of charge,
The test light must be securely clamped to the neg but will not reveal cranking capacity. Refer to Bat
ative cable and battery terminal. If the test light be tery Open Circuit Voltage chart.
comes disconnected during any of the IOD test, the BATTERY OPEN CIRCUIT VOLTAGE
electronic timer function will be activated and all
tests must be repeated.
(4) After 3 minutes, the test light should t u r n OFF
Open Circuit Volts Percent Chang©
or be DIMLY lit (depending on the electrical equip
ment). If the test light remains brightly lit do not
disconnect it. Remove each fuse or circuit breaker 11.7 volts or less 0%
(refer to Group 8 - Wiring Diagrams) until test light 12.0 25%
is either OFF or DIMLY lit. This will eliminate the 12.2 50%
higher amperage draw.
12.4 75%
If test light is still bright after disconnecting each
fuse and circuit breaker, disconnect the wiring har 12.6 or more 100%
ness from the generator. Refer to Generator Testing 918A-3
in this group. Do not disconnect the test light.
• ELECTRICAL 8A - i
INDUCTION NEGATIVE
AMPMETER CLAMP
CLAMP
POSITIVE
CLAMP
898A-7 J908A-12
Fig. 6 Testing Open Circuit Voltage Fig. 8 Volt-Ammeter-Load Tester Connections

(3) Rotate the load control knob (Carbon pile rheo
BATTERY LOAD TEST
stat) to apply a 300 amp load for 15 seconds then
W A R N I N G : IF B A T T E R Y S H O W S S I G N S O F F R E E Z control knob to off (Fig. 9). This will remove the sur
ING, L E A K I N G , L O O S E P O S T S , O R E X C E S S I V E L Y face charge from the battery.
LOW ELECTROLYTE LEVEL, D O NOT TEST. ACID
BURNS O R EXPLOSIVE CONDITION M A Y RESULT.
A battery load test will verify the actual cranking

performance based on the cold crank rating of the
battery.
Before performing the battery load test, the
battery must b e F U L L Y C H A R G E D .
(1) Remove both battery cables, negative first. Bat
tery top and posts should be clean. If green color is
not visible in indicator, charge the battery, see Bat
tery Charging Procedures in this section.
(2) Connect a suitable Volt-Ammeter-Load tester
(Fig. 7) to the battery posts (Fig. 8). Refer to operat
898A-10
ing instructions provided with the.tester being used.
Check the open circuit voltage (no load) of the bat
Fig. 9 Remove Surface Charge from Battery
tery. Voltage should be equal to or greater t h a n 12.4
volts (Fig. 7) with green color visible in test indica (4) Allow the battery to stabilize to open circuit
tor. voltage (may take up to 5 minutes).
(5) Rotate the load control knob to maintain a load
(50% of cold crank rating—see specifications) for a
minimum 15 seconds (Fig. 10). After 15 seconds,
record the (loaded) voltage reading and return t h e
load control to off.
(6) Voltage drop will vary according to battery
temperature at the time of t h e load test. Battery
temperature can be estimated by t h e temperature of
exposure over the preceding several hours. If t h e bat
tery has been charged, boosted, or loaded a few min
utes prior to test, the battery would be somewhat
warmer. Refer to Load Test Temperature chart for
proper loaded voltage reading.
898A-8 (7) If battery passes load test, it is in good condi
tion. No further tests are necessary. If it fails load
Fig. 7 Volt-Amps-Load Tester— Typical test, it should be replaced.
WARNING: POISON, C A U S E S S E V E R E BURNS.
BATTERY CONTAINS SULFURIC ACID, AVOID CON
TACT WITH S K I N , E Y E S , O R C L O T H I N G . IN E V E N T
O F C O N T A C T , F L U S H WITH W A T E R A N D C A L L
PHYSICIAN IMMEDIATELY. K E E P OUT OF R E A C H
OF CHILDREN.
C A U T I O N : Disconnect the vehicle's battery negative

cable before charging battery to avoid d a m a g e to
electrical s y s t e m s . D o not exceed 16.0 volts while
charging battery.
Battery electrolyte will bubble inside of case while

being charged properly. If the electrolyte boils vio
Fig. 10 Load 50% Cold Crank Rating Note Voltage lently or is discharged from the vent holes while
charging, immediately reduce charging rate or t u r n
LOAD TEST TEMPERATURE off charger and evaluate battery condition.
Minimum Voltage Temperature Some battery chargers are equipped with polarity
P c° (+ to +/- to -) sensing devices to protect the charger
9.6 70 and above 21 and above or battery from being damaged if improperly con
nected. If the battery state of charge is too low for
9.5 60 16
the polarity sensor to detect, the sensor must be by
9.4 50 10 passed for charger to operate. Refer to operating in
9.3 40 4 structions provided with battery charger being used.
9.1 30 -1
8.9 20 -7 C A U T I O N : C h a r g e battery until test indicator a p
pears green. D o not overcharge.
8.7 10 -12
8.5 0 • 18 It may be necessary to jostle the battery or vehicle
J908A-4 to bring the green ball into view in the test indicator
BATTERY CHARGING when the state-of-charge has reached 75%.
A battery is completely charged when it has: BATTERY CHARGING TIME TABLE
• an open circuit voltage of 12.4 volts or more.
• has enough cranking capacity (minimum 9.6 volts 5 Amps 10 Amps 20 Amps
Charging Amperage
when loaded for 15 seconds to 50% of cold cranking
Open Circuit Voltage Hours Charging at21°C (70°F)
amperage rating at 21°C/70°F).
12.25 to 12.39 6Hrs. 3Hrs. 1.5 Hr.
A green color, in the test indicator on the top of the
battery, indicates the battery is charged enough for 12.00 to 12.24 8Hrs. 4Hrs. 2Hrs
further testing. A black color indicates the battery 11.95 to 12.09 12Hrs. 6Hrs. 3Hrs.
voltage state of charge is below 75%. A yellow or 10.00to11.95 14Hrs. 7Hrs. 3.5 Hrs.
bright color indicates the battery has excessively low 10.00 to 0 See Charging Completely
electrolyte level. The battery cannot be refilled or Discharged Battery
charged, it must be replaced.
928A-19
WARNING: D O NOT C H A R G E A BATTERY THAT After the battery has been charged, green indica
HAS EXCESSIVELY LOW ELECTROLYTE LEVEL. tor, perform a load test to determine cranking capac
BATTERY MAY A R C INTERNALLY AND EXPLODE. ity. If the battery will endure a load test, return the
battery to use. If battery will not endure a load test,
it must be replaced. Clean and inspect battery hold
WARNING: EXPLOSIVE G A S E S FORM OVER BAT downs, tray, terminals, posts, and top before complet
TERY, D O NOT S M O K E , USE FLAME, O R CREATE ing service, see Group 8B - Battery/Starter/Generator
S P A R K S NEAR BATTERY. Service.
CHARGING TIME REQUIRED

W A R N I N G : D O NOT A S S I S T B O O S T O R C H A R G E A
The time required to charge a battery will vary de
FROZEN BATTERY, CASING MAY FRACTURE.
pending upon the following factors:
(1) Size of Battery— A completely discharged

large heavy-duty battery requires more t h a n twice
the recharging time as a completely discharged small
capacity battery.
W A R N I N G : N E V E R E X C E E D 20 A M P S WHEN
C H A R G I N G A COLD (-1°C/30°F) BATTERY, P E R
S O N A L I N J U R Y M A Y RESULT.
(2) T e m p e r a t u r e — A longer time will be needed

to charge a battery at -18°C (0°F) t h a n a t 27°C
(80°F). When a fast charger is connected to a cold
battery, current accepted by battery will be very low VOLT SELECTOR FIELD SELECTOR TEST SELECTOR
at first. Then, in time, the battery will accept a 898A-12

higher rate as battery warms.
(3) Charger Capacity— A charger t h a t supplies Fig. 11 Voltmeter Accurate to 1/10 Volt Connected
only 5 amperes requires a much longer charging (3) Battery chargers vary in the amount of voltage
time t h a n a charger t h a t supplies 20 amperes. and current they provide. For time required for bat
(4) State Of Charge— A completely discharged tery to accept measurable charger current a t various
battery requires more charging time t h a n a partially voltages, refer to Charge Rate chart. If charge, cur
charged battery. Electrolyte is nearly pure water in a rent is still not measurable a t end of charging times,
completely discharged battery. At first t h e charging the battery should be replaced. If charge current is
current amperage will be low. As acid is forced from
measurable during charging time, t h e battery may
the plates, inside t h e battery, the current amperate
be good and charging should be completed in the nor
will rise. Also, the specific gravity of t h e electrolyte
mal manner.
will rise, bringing the green dot into view.
CHARGING COMPLETELY DISCHARGED

BATTERY Voltage Hours
The following procedure should be used to recharge
a completely discharged battery. Unless procedure is
16.0 volts maximum up to 4 hrs.
properly followed, a good battery may be needlessly
replaced. 14.0 to 15.9 volts up to 8 hrs
(1) Measure voltage at battery posts with a volt
meter, accurate to 1/10 volt (Fig, 11). If below 10 13.9 volts or less up to 16 hrs.
volts, then charge current will be low and it could
take some time before it accepts a current in excess J928A-6
of a few milliamperes. Such low current may not be
detectable on ammeters built into many chargers.
(2) Connect charger leads. Some chargers feature
polarity protection circuitry which prevents operation
unless charger is connected to battery posts correctly.
A completely discharged battery may not have
enough voltage to activate the protection circuitry,
even though leads are connected properly. This
makes it appear t h a t battery will not accept charging
current. Refer to instructions provided with battery
charger being used.
8A - 8 ELECTRICAL
BATTERY D I A G N O S T I C S CHART
STARTER W O N T C R A N K VISUAL INSPECTION

CHECK FOR OBVIOUS DAMAGE SUCH AS CRACKED OR
BROKEN CASE THAT SHOWS LOSS OF ELECTROLYTE,
BROKEN/CRACKED TERMINAL DAMAGE, LOOSE OR CORRODED
F. C. = 1 CONNECTIONS, CLEAN A N D TIGHTEN CONNECTORS
REPLACE BATTERY*
STARTER STILL W O N T C R A N K
PROCEED TO STARTER TEST N O OBVIOUS DAMAGE
PROCEDURES O N VEHICLE IN THIS GROUP
CHECK TEST INDICATOR/OPEN CIRCUIT VOLTAGE TEST INDICATOR/OPEN CIRCUIT VOLTAGE TEST
1. TURN HEADLAMPS O N FOR 15 SECONDS
2. TURN HEADLAMPS OFF FOR 5 MINUTES TO ALLOW
BATTERY VOLTAGE TO STABILIZE
3. REMOVE NEGATIVE, THEN POSITIVE CABLE.
POSSIBLE CAUSE—I0D-REFER
TO IGNITION OFF DRAW SECTION
YELLOW OR BRIGHT INDICATOR
F. C. = 2
ELIMINATE EXCESS IOD N O EXCESS IOD FOUND DO NOT CHARGE, BOOST, OR
F. C. = 3 TEST, ELECTROLYTE BELOW
INDICATOR. REPLACE BATTERY,
GREEN BALL SHOWING A N D CHECK CHARGING SYSTEM
•CHARGE BATTERY-REFER CHARGE OPEN CIRCUIT VOLTAGE
TO CHARGING BATTERY ACCEPTED ABOVE 12.40 VOLTS** T
STARTER STILL W O N T C R A N K
PROCEED TO STARTER TEST
W O N T ACCEPT CHARGE PROCEDURES O N VEHICLE IN
F. C = 4 THIS GROUP
1. N O GREEN BALL S H O W I N G
2. OPEN CIRCUIT VOLTAGE BELOW 12.40
VOLTS. SEE CHARGING COMPLETELY
DISCHARGED BATTERY LOAD TEST VOLTAGE CHARGE
MINIMUM
ESTIMATED REQUIRED
LOAD TEST ELECTROLYTE VOLTAGE
TEMPERATURE UNDER
DISCHARGE BATTERY AT 300 AMPERES FOR 15 SECONDS. ALLOW BATTERY
TO RECOVER FOR 15 SECONDS. CONNECT VOLTMETER A N D AMPERE LOAD 15 SEC. LOAD
EQUAL TO 1/2 THE COLD CRANKING AMPERE RATING OF THE BATTERY FOR
70° (21° C)& ABOVE 9.6
15 SECONDS. OBSERVE VOLTAGE AT 15 SECONDS WITH LOAD O N .
60° (16° C 9.5
NOTE: ESTIMATE TEMPERATURE OF BATTERY. 50° (16° C 9.4
REFER TO LOAD TEST VOLTAGE CHART. 40° (4° C 9.3
30° H°C 9.1
20° 1-7° C 8.9
VOLTAGE AT OR ABOVE VOLTAGE BELOW 10° (-12°C 8.7
9.6 VOLTS AT ROOM 9.6 VOLTS AT ROOM 0° (-18°C 8.5
(70 DEG. F) TEMP. (70 DEG. F) TEMP.
VOLTMETER MUST BE ACCURATE
TO 1/10 VOLT
PASSED LOAD TEST FAILED LOAD TEST

RETURN BATTERY TO USE F. C. = 5
* REPLACE BATTERY FAILURE C O D E (F.C) CHART
FAILURE CODE (R C )
NUMBER CONDITION
STARTER ST8LL W O N T C R A N K BROKEN/CRACKED
1
PROCEED TO STARTER TEST YELLOW/BRIGHT INDICATOR
2
PROCEDURES O N VEHICLE IN IGNITION OFF DRAW
3
THIS GROUP BATTERY WON'T ACCEPT CHARGE
4
5 BATTERY FAILED LOAD TEST
NOTES: * AFTER C H A R G I N G O R REPLACING A BATTERY,
CHECK THE VEHICLE'S C H A R G I N G SYSTEM, A N D
CLEAN A N D TIGHTEN BATTERY C O N N E C T O R S ** CHECKING O P E N CIRCUIT VOLTAGE WILL
(REFER TO APPLICABLE SECTIONS OF THIS M O N I T O R ' ' G R E E N BALL" I N D I C A T I O N
SERVICE M A N U A L ) . FOR ALL 6 CELLS. J938A-22
ENGINE STARTER MOTOR TEST PROCEDURES

GENERAL INFORMATION wiring
The starting system consists of an: switch
• ignition switch solenoid
• starter relay relay
• park/neutral position switch (automatic transmis park/neutral position switch
sion)
• clutch switch (diesel engine-manual transmission) COLD CRANKING TEST
• wiring harness (1) Battery must first pass load and voltage drop
• battery tests and be fully charged before proceeding. Refer to
• starter motor with an integral solenoid. Battery Test Procedures.
These components form 2 separate circuits. A high (2) Connect a suitable volt-ampere tester to the
amperage circuit t h a t feeds the starter motor up to battery terminals (Fig. 2). Refer to the operating in
300+ amps-gas engine; 500+ amps-diesel engine, structions provided with the tester being used.
and a control circuit that operates on less t h a n 20
amps (Fig. 1). POSITIVE NEGATIVE
CLAMP CLAMP
IGNITION SWITCH
a. + 1 1 AUTOMATIC TRANSMISSION •
BATTERY
J NEUTRAL SAFETY SWITCH I
"JL"
STARTER RELAY INDUCTION

AMPMETER
1" CLAMP
MOTOR m, ... 898A-15
4- S T A
3- T E R
SOLENO,Dn l h
Fig. 2 Volt-Amps Tester Connections (Typical)

898A-14
Fig. 1 Starting System Components (3) Fully engage parking brake, place manual
transmission in NEUTRAL, automatic transmission
STARTER SYSTEM DIAGNOSTIC INSPECTIONS
in PARK.
Before removing any unit from the starter motor
system for repair, perform t h e following inspections: (4) Verify t h a t all lights and accessories are OFF.
(5) Remove coil secondary cable from distributor
BATTERY INSPECTION and connect to ground.
To determine condition of the battery, perform the (6) Rotate and hold the ignition switch (key) in the
testing procedure outlined in the Battery Section. START position. Note cranking voltage and amper
age.
WIRING INSPECTION
(a) If voltage reads above 9.6 volts and amperage
Inspect wiring for damage. Inspect all connections
at the starter motor solenoid, park/neutral position draw reads above (220 amps gas engine) (550 amps
switch (if equipped), back-up lamp switch connector, diesel) go to Starter Feed Circuit Tests.
ignition/start switch, and battery (including all (b) If voltage reads 12.5 volts or greater and am-
ground connections). Clean and tighten all connec perate reads 0 to 10 amps, go to Starter Control
tions as required. Circuit Tests.
A cold engine will increase starter motor cur
SOLENOID, RELAY AND IGNITION/START rent.
SWITCH INSPECTION
Inspect the solenoid, relay and switch to determine STARTER FEED CIRCUIT TESTS - (W0LTAGE DROP
their condition. Also, if equipped with automatic METHOD)
transmission, inspect condition of the park/neutral The voltage drop tests will determine if there is ex
position switch. Testing information can be found in cessive resistance in the high current circuit. When
the following pages. performing these tests, it is important t h a t the volt
If the following components are working properly meter be connected to the terminals t h a t the cables
remove the starter motor and follow procedures in are connected to instead of to the cables themselves.
the Testing Section. For example, when testing between the battery and
• battery solenoid, touch the voltmeter test probes to the bat-
STARTING SYSTEM DIAGNOSIS
TEST C O N D I T I O N S
• PLACE GEAR SELECTOR IN PARK OR NEUTRAL A N D SET PARK BRAKE OR EQUIVALENT.
• VERIFY BATTERY STATE-OF-CHARGE A N D C R A N K I N G CAPACITY, SEE BATTERY SECTION.
• CLEAN BATTERY TOP, POSTS, A N D TERMINALS.
• VERIFY ALTERNATOR DRIVE BELT T E N S I O N .
• DISCONNECT A N D G R O U N D COIL CABLE.
SYMPTOM SYMPTOM SYMPTOM SYMPTOM SYMPTOM
STARTER FAILS TO STARTER FAILS TO STARTER ENGAGES, STARTER ENGAGES STARTER DOES NOT
ENGAGE. NO SOUNDS ENGAGE SOLENOID FAILS TO TURN DRIVE CLUTCH DISENGAGE AFTER
OR RELAY CLICKS ENGINE. DOME LIGHT SPINS OUT ENGINE STARTS
DIMS
POSSIBLE CAUSE POSSIBLE CAUSE POSSIBLE CAUSE POSSIBLE CAUSE POSSIBLE CAUSE
STARTER CONTROL RESISTANCE TOO RESISTANCE TOO DRIVE CLUTCH FAULTY IGNITION SWITCH
CIRCUIT FAULTY HIGH IN STARTER HIGH IN STARTER FAULTY
FEED CIRCUIT FEED CIRCUIT
BROKEN TEETH
IGNITION SWITCH ON RING GEAR STARTER RELAY
FAULTY STARTER CONTROL STARTER ASSEMBLY FAULTY
CIRCUIT FAULTY FAULTY
STARTER ASSEMBLY
PARK/NEUTRAL FAULTY STARTER ASSEMBLY
POSITION STARTER SOLENOID ENGINE FAULTY
SWITCH FAULTY SEIZED
(AUTO TRANS.)
FAULTY OR STARTER
MISADJUSTED STARTER ASSEMBLY IMPROPERLY
FAULTY MOUNTED
STARTER RELAY REFER TO

FAULTY APPROPRIATE GROUP
AND SECTION OF THIS
MANUAL FOR PROPER
STARTER ASSEMBLY SERVICE AND TEST
FAULTY PROCEDURES FOR THE
COMPONENTS
INVOLVED
J938A-9
tery post and the solenoid threaded stud. The follow
ing operation will require a voltmeter, accurate to
1/10 of a volt.
Before performing t h e tests, assure t h e following
procedures are accomplished:
• Disconnect the distributor connector (gas engine).
• Disconnect both wires on the fuel solenoid (diesel
engine) (Fig. 3).
Verify that:
• all lights and accessories are OFF
• transmission shift selector is in PARK (automatic)
or NEUTRAL (manual)
• parking brake is applied
• battery is fully charged (refer to Battery Test Pro
cedures).
(1) Connect positive lead of voltmeter to battery
negative post. Connect negative lead of voltmeter to
Fig. 3 Diesel Engine Fuel Solenoid
battery negative cable clamp (Fig. 4). Rotate and
hold the ignition switch (key) in the START position. VOLTMETER

Observe the voltmeter. If voltage is detected, correct
poor contact between the cable clamp and post.
VOLTMETER
BATTERY ENGINE , ^ J ^ P
GROUND \ BATTERY 898A-18
Fig. 6 Test Ground Circuit Resistance
(7) Connect positive voltmeter lead to starter mo
898A-17 tor housing. Connect negative lead of voltmeter to
battery negative terminal (Fig. 7).
Fig. 4 Test Battery Connection Resistance
(2) Connect positive lead of voltmeter to battery STARTER BATTERY
positive post. Connect negative lead of voltmeter to MOTOR
battery cable positive clamp (Fig. 4). Rotate and hold
the ignition switch (key) in the START position. Ob
serve the voltmeter. If voltage is detected, correct
poor contact between the cable clamp and post.
(3) Connect a voltmeter to measure between the
battery positive post and the center of the B + VOLTMETER
starter solenoid stud (Fig. 5).
BATTERY
898A-26
Fig. 7 Test Starter Motor Ground (Typical)

(8) Rotate and hold the ignition switch (key) in the
START position. If voltage reads above 0.2 volt, cor
rect poor starter to engine ground.
If resistance tests detect no feed circuit failures, re
move the starter motor and go to Bench Testing
Starter Solenoid.
STARTER
MOTOR VOLTMETER 898A-20 STARTER CONTROL CIRCUIT TESTS
The starter control circuit consists of a:
Fig. 5 Test Positive Battery Cable Resistance • starter solenoid
(Typical) • starter relay
(4) Rotate and hold the ighition with (key) in the • ignition switch
START position. If voltage reads above 0.2 volt, cor • park/neutral position switch (automatic transmis
rect poor contact at battery cable to solenoid connec sion)
tion. If reading is still above 0.2 volt, replace positive • clutch switch (diesel engine-manual transmission)
battery cable. • all their wiring and connections.
(5) Connect the voltmeter to measure between the Testing procedures for these components are as fol
battery negative post and the engine block (Fig. 6). lows and should be followed in order as described.
(6) Rotate and hold the ignition with (key) in the
START position. If voltage reads above 0.2 volt, cor C A U T I O N : Before performing any test, disconnect
rect poor contact at ground cable attaching point. distributor connector to prevent engine from start
Voltage reading still above 0.2 volt, replace ground ing.
cable. Disconnect both wires on fuel solenoid (diesel en
gine).
ENGINE STARTER RELAY IGNITION SWITCH TEST
After testing starter solenoid and relay and they
STARTER RELAY CONNECTIONS check out okay, trouble is probably with ignition
switch or its wiring.
Check all wiring for opens and shorts and connec
tions for being loose or corroded.
BENCH TESTING STARTER SOLENOID

Refer to Group 8B - Battery Starter Service for
starter removal procedures.
(1) Disconnect field coil wire from field coil termi
nal (Fig. 9).
GROUND SOLENOID
(85) TERMINAL
(87)
J928B-1
RELAY OPERATION/TESTING
OPERATION Fig. 9 Field Coil Wire Terminal

• The Battery terminal is connected to battery volt (2) Check for continuity between solenoid terminal
age (B + ) at all times. and field coil terminal with a continuity tester.
• The Solenoid terminal is connected to the battery There should be continuity (Fig. 10).
terminal in the energized position which supplies
battery voltage to the operated device.
• The Ignition terminal is connected to the electromag
net and usually connected to a switched power source.
• The Ground terminal is connected to the electro
magnet and is usually grounded by a switch or PCM.
TESTING
• Resistance value between the ground and ignition
terminals (electromagnet) is 75 ± 5 ohms for resistor
relays and 8 6 ± 5 ohms for diode relays. Fig. 10 Continuity Test Between Solenoid Terminal
• Connect a battery to the ignition terminal and and Field Coil Terminal
connect ground to the ground terminal. There should
(3) Check for continuity between solenoid terminal
be continuity between the battery and solenoid ter
and solenoid housing. There should be continuity
minals (contact closed).
(Fig. 11).
ENGINE STARTER RELAY REPLACEMENT SOLENOID
The starter relay is located on the driver's side in
ner fender (Fig. 8).
PART THROTTLE A / C CLUTCH STARTER A U T O SHUT
U N L O C K RELAY RELAY RELAY D O W N RELAY
RR8BD33
Fig. 11 Continuity Test Between Solenoid Terminal

and Solenoid Case
(4) If there is continuity solenoid is good. If there
is no continuity in either test solenoid has an open
circuit and is defective. Replace the starter motor.
(5) Install starter as described in Group 8B - Bat
Fig. 8 Starter Relay tery Starter Service.
(1) Replace the relay as required. (6) Connect field coil wire to field coil terminal
(Fig. 9).
(2) Test relay operation.
GENERATOR T E S T P R O C E D U R E S ON V E H I C L E
INDEX
page page
Current Output Test ...................... 14 How to U s e Malfunction Indicator (Check Engine)
Diagnostic Procedures 13 Lamp for Fault Codes 17
General Information 13 Operational Check with Voltmeter . . . . . . . . . . . . 13
Generator Output Wire Resistance Test ....... 13 Using On-Board Diagnostic System 15
GENERAL INFORMATION • Inspect connection a t generator B + output. It

The generator is belt-driven by the engine. All en should be clean and tight. Repair as required.
gines use serpentine drive.
The amount of DC current produced by the gener GENERATOR OUTPUT WIRE RESISTANCE TEST
ator is controlled by the Powertrain Control Module (FIG. 1)
(PCM). Generator output wire resistance test will show
All vehicles are equipped with On Board Diagnos amount of voltage drop across generator output wire
tics (OBD). All OBD sensing systems are monitored between generator BAT terminal and battery posi
by the PCM. The PCM will store in electronic mem tive post.
ory any detectable failure within the monitored cir
cuits. Refer to USING ON-BOARD DIAGNOSTIC PREPARATION
SYSTEM in this group for more information. (1) Before starting test make sure vehicle has a
fully charged battery. Test and procedures on how to
OPERATIONAL CHECK WITH VOLTMETER check for a fully charged battery a r e shown in Bat
When the ignition switch is turned to t h e RUN po tery section of this Group.
sition, battery potential will register on the voltme (2) Turn OFF ignition switch.
ter. During engine cranking a lower voltage will (3) Disconnect negative cable from battery.
appear on t h e meter. With the engine running, a (4) Disconnect generator output wire from genera
voltage reading higher t h a n the first reading (igni tor output Battery terminal.
tion in RUN) should register. (5) Connect a 0-150 ampere scale D.C. ammeter in
series between generator BAT terminal and discon
DIAGNOSTIC PROCEDURES nected generator output wire. Connect Positive lead
If the indicator does not operate properly, or if an to generator BAT terminal and Negative lead to dis
undercharged or overcharged battery condition oc connected generator output wire.
curs, the following procedures may be used to diag (6) Connect Positive lead of a test voltmeter
nose the charging system. (Range 0-18 volts minimum) to disconnected genera
Remember t h a t an undercharged battery is often tor output wire. Connect negative lead of test voltme
caused by: ter to battery positive cable a t positive post.
• accessories being left on overnight (7) Connect one end of a Jumper Wire to ground
• or by a defective switch and with other end probe green K20 lead wire a t
which allows a bulb, such as a trunk or glove box back of generator (Fig. 1). (This will generate a fault
light, to stay on (refer to Ignition Off Draw). code).
WISUAL INSPECTION C A U T I O N : D o not connect blue A142 lead of wiring
• Inspect condition of battery cable terminals, bat to ground. Refer to Group 8W - Wiring Diagrams for
tery posts, connections at engine block, starter motor more information.
solenoid and relay. They should be clean and tight.
Repair as required. (8) Connect an engine tachometer and connect neg
• Inspect all fuses in the fuse block for tightness in ative cable to battery.
receptacles. They should be properly installed and (9) Connect a variable carbon pile rheostat be
tight. Repair or replace as required. tween battery terminals. Be sure carbon pile is in
• Inspect generator mounting bolts for tightness. Re "Open" or "Off position before connecting leads. See
place or torque bolt as required (refer to Torque Battery Section, Load Testing for instructions.
Specifications).
• Inspect generator drive belt condition and tension. TEST
Tension or replace belt as required. Refer to Belt (1) Start engine. Immediately after starting, re
Tension Specifications. duce engine speed to idle.
8A - 14 ELECTRICAL
CASE GROUND FIELD BATTERY m^mm i A21 DB-

TERMINALS VOLTAGE IGNITION SWITCH
20 AMP FUSE
ACC
142-DG/OR \ OFF
TO ENGINE AUTO A14 RD \

CONTROLLER SHUTDOWN POWER
TERMINAL RELAY DISTRIBUTION
51 CENTER
LESS THAN JUMPER WIRE
"BATTERY VOLTAGE TO GROUND
TEST TEST
ALTERNATOR CASE ALTERNATOR AMMETER VOLTMETER
GROUND BATTERY
TERMINAL 2
i
DISCONNEaED
GROUND ALTERNATOR
OUTPUT
ENGINE WIRE
CONTROLLER
CARBON PILE
RHEOSTAT
J938A-17
Fig. 1 Generator Output Wire Resistance Test (Typical)

(2) Adjust engine speed and carbon pile to main PREPARATION
tain 20 amperes flowing in circuit. Observe voltmeter (1) Before starting any tests make sure vehicle has
reading. Voltmeter reading should not exceed 0.5 a fully charged battery. Test and procedures on how
volts. to check for a fully charged battery are shown in
Battery section of this Group,
RESULTS (2) Disconnect negative cable from battery.
If a higher voltage drop is indicated, inspect, clean (3) Disconnect generator output wire at the gener
and tighten all connections between generator BAT ator battery terminal.
terminal and battery Positive post. A voltage drop (4) Connect a 0-150 ampere scale D.C. ammeter in
test may be performed at each connection to locate series between generator BAT terminal and discon
connection with excessive resistance. If resistance nected generator output wire (Fig. 2). Connect posi
tested satisfactorily, reduce engine speed, turn off tive lead to generator BAT terminal and negative
carbon pile and turn off ignition switch. lead to disconnected generator output wire.
(1) Disconnect negative cable from battery. (5) Connect positive lead of a test voltmeter (range
(2) Remove test ammeter, voltmeter, carbon pile, 0-18 volts minimum) to generator BAT terminal.
and tachometer. (6) Connect negative lead of test voltmeter to a
(3) Remove "Jumper Wire". good ground.
(4) Connect generator output wire to generator (7) Connect an engine tachometer and connect neg
BAT terminal post. Tighten to 5 to 6 Nnn (45 to 75 ative cable to battery.
in. lbs.). (8) Connect a variable carbon pile rheostat be
(5) Connect negative cable to battery. tween battery terminals. Be sure carbon pile is in
(6) Use DRB II Scan Tool to erase diagnostic trou Open or Off position before connecting leads. See
ble code.
Battery section, Load Testing for instructions.
CURRENT OUTPUT TEST (9) Connect one end of a Jumper Wire to ground
Current output test determines whether or not gen and with other and probe green K20 lead wire at
erator is capable of delivering its rated current out back of generator (Fig. 2). (This will generate a fault
put. code).
FIELD BATTERY A21 DB-

a CASE G R O U N D
TERMINALS VOLTAGE ..... IGNITION SWITCH
20 AMP FUSE ACC
A 142-DG/OR OFF
K20-DG —! TO ENGINE AUTO A H ^ RUN
CONTROLLER SHUTDOWN POWER
GROUND TERMINAL RELAY DISTRIBUTION
51 \ CENTER OFF
LESS THAN JUMPER WIRE Bl
~L
BATTERY VOLTAGE TO GROUND
CAPACITOR
ALTERNATOR CASE
til
ALTERNATOR
TEST TEST
AMMETER VOLTMETER
START*T
|ACC
GROUND BATTERY
TERMINAL GO
5 — n
DISCONNECTED
ALTERNATOR
OUTPUT GROUND
ENGINE WIRE
CONTROLLER
CARBON PILE
RHEOSTAT
J938A-18
Fig. 2 Generator Current Output Test—Typical

C A U T I O N : D o not connect blue A142 lead of wiring (4) Remove test ammeter, voltmeter, tachometer
to ground. Refer to Group 8W - Wiring Diagrams for and carbon pile.
more information. (5) Remove Jumper Wire (Fig. 2).
(6) Connect generator output wire to generator
BAT terminal post. Tighten nut to 5-6 Nnn (45-75 in.
TEST lbs.).
(1) Start engine. Immediately after starting reduce (7) Connect negative cable to battery.
engine speed to idle. (8) Use DRB II Scan Tool to erase diagnostic trou
(2) Adjust carbon pile and engine speed in incre ble code.
ments until a speed of 1250 rpm and voltmeter read
ing of 15 volts is obtained. USING ON-BOARD DIAGNOSTIC SYSTEM
C A U T I O N : Do not allow voltage meter to read above OPERATION OF ON-BOARD DIAGNOSTIC
16 volts. SYSTEM
The Powertrain Control Module monitors critical
(3) The ammeter reading must be within limits input and output circuits of the charging system
shown in generator specifications in back of this making sure they are okay. Some are checked contin
group for that size of generator being tested. uously and some are only checked under certain con
ditions.
RESULTS If the OBD system senses that one of the critical
(1) If reading is less than specified and generator circuits is bad, it will consider this a real problem
output wire resistance is not excessive, the generator and put a DTC into memory. Each input and output
should be replaced. Refer to Group 8B - Generator circuit monitored by the OBD system has its own
Service for information. DTC. The DTC will stay in memory as long as the
(2) After current output test is completed reduce circuit continues to be bad. If the problem does not
engine speed, turn off carbon pile and turn off igni occur again after the code is put into memory, the
tion switch. Powertrain Control Module will clear the memory af
(3) Disconnect negative cable from battery. ter 50 to 100 engine starts.
8A - 16 ELECTRICAL
CHARGING SYSTEM DIAGNOSTICS

IMPROPER
CHARGING
UNS' rEADY
OR LOW o\ /ER 1 N OISY
CHAF K3ING CHAR .GING 1 ALTERfMATOR
CHECK BATTERY
CONDITION TEST GROUNDED W O R N OR
SEE BATTERY GENERATOR GENERATOR FIELD FRAYED
SECTION FOR OUTPUT WIRE WIRE, FIELD DRIVE BELT
DETAILS RESISTANCE TERMINAL, OR
CONNECTIONS
CORRODED CHARGING GENERATOR

BATTERY CABLES RESISTANCE REFER TO MOUNTING
OR TERMINALS TOO HIGH USING ON-BOARD LOOSE
DIAGNOSTIC
SYSTEM
DRIVE BELTS CORRODED OR

LOOSE SHORTED CABLES
OR HIGH FAULTY FAULTY
RESISTANCE GENERATOR GENERATOR
ACROSS FUSIBLE
LOOSE OR LINK
CORRODED
WIRING
C O N N E C T I O N S AT
GENERATOR
RESISTANCE •FOR MORE INFORMATION REFER TO
O.K. THE POWERTRAIN DIAGNOSTIC PROCEDURES
M A N U A L COVERING THE VEHICLE INVOLVED
LOOSE OR
CORRODED
WIRING *SEE GROUP 8W, W I R I N G DIAGRAMS FOR
C O N N E C T I O N S AT TEST CIRCUIT A N D C O M P O N E N T INFORMATION
TERMINAL BLOCK GENERATOR
CURRENT
OUTPUT
LOOSE
CHASSIS TO
BATTERY G R O U N D
CABLE CURRENT
OUTPUT
O.K.
LOOSE
GENERATOR
G R O U N D WIRE
REFER TO
USING ON-BOARD
DIAGNOSTIC
LOOSE OR SYSTEM
CORRODED
WIRING
C O N N E C T I O N S AT
BULKHEAD FAULTY
DISCONNECT GENERATOR
CHECK FOR
APPROXIMATELY
12 VOLTS AT FIELD
INPUT BRUSH
TERMINAL WIHT
IGNITION SWITCH
"ON" J938A-V0
DIAGNOSTIC TROUBLE CODES ing on and off. There is a short pause between
Diagnostic trouble codes are 2 digit numbers flashes and a longer pause between digits. All codes
flashed on Malfunction Indicator lamp (Check En displayed are two digit numbers with a four second
gine) t h a t identify which circuit is bad. In most cases pause between codes.
they do not identify which component in a circuit is An example of a code is as follows:
bad. A DTC description can be read using the DRB II (1) Lamp on for 2 seconds, then t u r n s off.
scan tool. Refer to Group 14 - Fuel Systems for more (2) Lamp flashes 4 times pauses and then flashes
information. Therefore, a DTC is only a result, not 1.
necessarily the reason for the problem. However, in (3) Lamp pauses for 4 seconds, flashes 4 times,
some cases, as a result of the design of the driveabil- pauses and then flashes 7 times.
ity test procedure, a DTC can be the reason for the The two codes are 41 and 47. Any number of codes
problem. It is important t h a t the test procedure be can be displayed (maximum of 8 faults can be stored)
followed in order to understand what the DTC of the as long as they are in memory. The lamp will flash
on-board diagnostic system are trying to tell. until all of them (including 55) are displayed (55 =
End of test).
HOW TO USE MALFUNCTION INDICATOR (CHECK
ENGINE) LAMP FOR FAULT CODES CHARGING SYSTEM FAULT CODES
To activate this function cycle the ignition switch See Generator Fault Code Chart for fault codes
on-off-on-off-on within 5 seconds and any DTC stored which apply to the charging system. Refer to the
in the Powertrain Control Module will be displayed. Powertrain Diagnostic Procedures Manual to diag
The Check Engine lamp will display a DTC by flash nose an On-Board Diagnostic System, Fault Code.
GENERATOR DIAGNOSTIC TROUBLE CODE (DTC)
Malfunction When Monitored Sensor

Indicator By the Logic Actuator Read
DTC Type Lamp Circuit Module When Put Into Memory Test Test
Generator Field All the time when An open or shorted condition in

41 Fault Yes Control the ignition switch the generator field Yes None
(Charging System) is on. control circuit.
If the battery sense voltage is

Charging System All the time when the more than 1 volt above the
46 Fault Yes None Yes
Voltage engine is running. desired control voltage for
more than 20 seconds.
Battery voltage 1 volt less

than set point during engine
Charging System Engine rpm above operation and no change in
47 Fault Yes voltage during internal PCM None Yes
Voltage 1,500 rpm
test performed on generator
field.
J938A-20
SPECIFICATIONS
BATTERY SPECIFICATIONS
Load Cold
Test Cranking Reserve
(Amps) Rating @ 0°F Capacity
300 Amp 600 Amp 120 Minutes
C R A N K I N G RATING is the current a battery can deliver for 30 seconds and maintain a terminal voltage of 7.2 volts or greater at
specified temperature.
RESERVE CAPACITY RATING is the length of time a battery can deliver 25 amps and maintain a minimum terminal voltage of
10.5 volts at27°C (80 °F).
J938A-25
GAS ENGINE STARTER DIESEL ENGINE STARTER
Manufacturer Nippondenso R E D U C T I O N G E A R STARTER

Engine Application 5.9L, 5.21 e\ 3.9L Manufacturer Nippondenso
Part Number and 53005984 Engine Application 5.9L
Power Rating 1.4 Kw 4428221
Part Number and
Voltage 12 Power Rating . . . . . . . . . . . . . . 3 kw
No. of Fields 4 Voltage 12
No. of Poles. 4 No. of Fields 4
Brushes 4 No. of Poles 4
Drive Reduction Brushes . . . . . . . . . . . . . . . . . . . . 4
Gear Train Conventional
Drive
Free Running Test Gear Train
Voltage 11
Free Running Test
Amperage Draw . . . . . . . . . . . . 73 Amps 11
Voltage .
Minimum Speed rpm 3601 rpm
Amperage Draw 220 Amps Max.
Solenoid Closing Voltage 7.5 Volts Minimum Speed rpm 4200 rpm Min.
Cranking Amperage Draw Test . . . 125-200 Amps* Solenoid Closing Voltage. 8 Volts
* Engine should be up to operating temperature. Extremely heavy Cranking Amperage Draw Test . . 450-550 Amps*
oil or tight engine will increase starter amperage draw.
* Engine should be up to operating temperature. Extremely
heavy oil or tight engine will increase starter amperage draw.
J938B-14 J918B-21
GENERATOR SPECIFICATIONS
TYPE PART N U M B E R PULLEY G R O O V E S ENGINE RATING
NIPPONDENSO 53008646 7 ALL GASOLINE 75 AMPS
NIPPONDENSO 5234374 8 DIESEL 120 AMPS
J938B-28
• BATTERY/STARTER/GENERATOR SERVICE 8B - 1
BATTERY/STARTER/GENERATOR SERVICE
CONTENTS
page page
BATTERY SERVICE PROCEDURES 1 SPECIFICATIONS 9
GENERATOR SERVICE 6 STARTER SERVICE PROCEDURES 4
BATTERY SERVICE PROCEDURES

GENERAL INFORMATION W A R N I N G : W E A R A SUITABLE PAIR O F R U B B E R
This section will cover the Battery service, re G L O V E S (NOT T H E H O U S E H O L D T Y P E ) W H E N R E
moval, and installation procedures only. For diagnos MOVING A BATTERY B Y HAND. SAFETY G L A S S E S
tic procedures, see Group 8 A - Battery/Starting/ S H O U L D A L S O B E W O R N . IF T H E B A T T E R Y I S
Charging Systems Diagnostics. CRACKED OR LEAKING THE ELECTROLYTE C A N
The Maintenance Free Battery (Fig. 1) does not BURN THE SKIN AND EYES.
have removable battery cell caps. Water can not be
added to this battery. The battery is sealed, except (3) Remove battery hold down (Fig. 2) and remove
for small vent holes in the top. The chemical compo battery from vehicle.
sition inside of the battery produces an extremely
small amount of gases at normal charging voltages.
The battery is equipped with a test indicator (Fig. 1)
t h a t display colored balls to indicate battery state-of-
charge.
Green Indicator = Full charge
Black Indicator = Discharged
Yellow Indicator = Battery replacement required
Fig. 2 Battery Holddown

Fig. 1 Maintenance Free Battery
BATTERY VISUAL INSPECTION AND SERVICE
(1) Make sure ignition switch is on OFF position
and all battery feed accessories are OFF.
(2) Disconnect and remove battery cables at bat
tery. Remove NEGATIVE cable first.
8B - 2 BATTERY/STARTER/GENERATOR SERVICE •
(4) Clean top of battery with a solution of clean be necessary to clean area with same solution de
warm water and baking soda. Scrub area with a stiff scribed in Step (4) (Fig. 4).
bristle brush and wipe off with a cloth moistened (7) Clean battery post with a suitable battery post
with ammonia or baking soda in water (Fig. 3). cleaning tool (Fig. 5).
TERMINAL
BRUSH
TEST
INDICATOR
BATTERY
J928B-30
Fig. 3 Cleaning Battery
C A U T I O N : Care should be taken to ensure that Fig. 5 Cleaning Battery Post
solution d o e s not enter vent holes.
(8) Clean inside surfaces of terminal clamps with a
(5) Inspect battery case and cover for cracks or suitable battery terminal cleaning tool (Fig. 6). Re
leakage. If cracks or leakage is present, battery must place damaged or frayed cables and broken terminal
be replaced. clamps.
(6) Inspect battery tray for damage caused by loss
BATTERY
of acid from battery. If acid damage is present it will CABLE
WASHER NUT
BATTERY HOLD
DOWN
HOLD DOWN
STUD
HOLD
DOWN
STUD
BATTERY
TRAY
J928B-3f
J908B-13 Fig. 6 Cleaning Battery Cable Terminal

A
Fig. 4 Battery Tray
(9) Inspect battery for proper or damaged hold

down ledge.
(10) Install battery in vehicle making sure t h a t
battery is properly positioned on battery tray (Fig.
2).
(11) Install battery hold down clamp, making sure
t h a t it is properly positioned on battery. Tighten bolt
to 12 N-m (100 in. lbs.).
(12) Place felt oil washer onto Positive ( + ) battery
post.
(13) Connect cable clamps to battery post making
sure top of clamp is flush with top of post (Fig. 7).
(14) Tighten clamp nut securely. Fig. 7 Battery Cables Disconnected
STARTER SERVICE PROCEDURES
GENERAL INFORMATION
This section will cover the Starter removal and in
stallation. For diagnostic procedures, see Group 8A -
Battery/Starting/Charging Systems Diagnostics.
STARTING SYSTEM DESCRIPTION

The starter system circuits consist of:
• a battery
• engine starter motor and solenoid
• starter relay
• ignition switch
© park/neutral position switch (automatic transmis
sion)
• clutch interlock switch (manual transmission-die-
sel)
• connecting wires and battery cables.
Turning the ignition switch to the start position,
causes the starter relay points to close allowing cur
rent to energize solenoid windings. This causes sole
noid plunger and clutch shift lever to move engaging
clutch pinion gear into ring gear. At the same time
the solenoid contacts close causing starter motor to
crank. As soon as engine starts running clutch pin
ion gear overruns to protect starter armature from
damage due to excessive speed. Once the engine
starts running, the ignition key switch should be im
mediately returned to the run position to prevent ex
cessive starter motor damage.
WARNING: A L W A Y S DISCONNECT NEGATIVE CA

BLE FROM BATTERY B E F O R E S E R V I C I N G T H E
STARTER.
STARTER MOTOR REMOVAL AND INSTALLATION

EXCEPT DIESEL
(1) Disconnect negative cable from battery.
(2) Remove wire terminal connector from starter
motor (Fig. 1).
(3) Remove mounting bolt and n u t securing starter
to bellhousing (Fig. 2).
(.4) Move starter forward to clear lower mounting
stud and starter gear housing nose. This allows
starter to come down past the exhaust pipe (Fig. 3).
To install, reverse removal procedures.
Fig. 2 Remove or Install Starter Mounting Bolt and
Nut
Fig. 3 Remove or Install Starter Motor

STARTER MOTOR REMOVAL AND INSTALLATION
DIESEL
(2) Remove battery cable by pulling rubber boot up
and removing nut (Fig. 1).
(3) Remove solenoid wire from solenoid.
(4) Remove starter motor mounting bolts (Figs. 1
and 2).
INSTALLATION
(1) Install starter motor. Tighten bolts to 68 N»m
(50 ft. lbs.).
(2) Attach solenoid wire. Tighten solenoid n u t to 6
N»m (55 in. lbs.).
(3) Attach battery cable to starter motor. Tighten
cable nut to 10 N*m (90 in. lbs.).
(4) Connect negative cable to battery.
Fig. 2 Remove Or Install Starter Motor Mounting

Bolt
GENERATOR SERVICE
CONTENTS
page page
GENERATOR REPLACEMENT- GENERATOR REPLACEMENT—3.9L/5.2L/

DIESEL ENGINE 8 5.9L-LDC GAS ENGINE 6
GENERAL INFORMATION 6 GENERATOR REPLACEMENT—5.9L HDC-GAS
ENGINE 7
GENERAL INFORMATION
This section will cover generator removal and in
stallation. The generator is not serviceable. Informa
tion covering on-vehicle testing can be found in
Group 8A - Battery/Starting/Charging/System Diag
nostics.
The standard equipment generator on the D and W
bodies is the 75 amp generator. The Ramcharger is
equipped with the 90 amp generator. When a vehicle
is equipped with a heavy duty package or diesel en
gine, a 120 amp generator is used.
GENERATOR REPLACEMENT -3.9L/5.2L/5.9L-LDC

GAS ENGINE
Drive belts on these engines are equipped with a
spring loaded automatic belt tensioner (Fig. 1). This
belt tensioner is used on all belt configurations. For
more information, refer to Group 7 - Cooling, Belt
Removal/Installation.
REMOVAL
(2) Attach a socket/wrench to pulley mounting bolt Fig. 1 Automatic Belt Tensioner—Belt Removal/
of automatic tensioner (Fig. 1). Installation
(3) Rotate tensioner assembly clockwise (as viewed
from front) until tension h a s been relieved from belt.
(4) Remove belt from idler pulley first.
(5) Remove belt from vehicle.
(6) Remove lower generator mounting bolt and n u t
(Fig. 2).
(7) Remove upper generator mounting bolt and re
move generator.
(8) Remove B + terminal nut, 2 field terminal
nuts, ground, and harness hold down nuts (Fig. 3).
Remove wire connectors.
INSTALLATION
(1) Install harness to generator. Tighten nuts as
follows:
• Ground terminal, B + terminal and Wire Harness
Hold Down 7-10 N*m (60-90 in. lbs.).
• Field terminals 2.5-3 N-m (20-30 in. lbs.). Fig. 2 Generator Mounting Bolts
(2) Install generator. Tighten both bolts to 41 N»m
(30 ft. lbs.).
Fig. 3 Remove or install Wire Connector Assembly Fig. 4 Automatic Belt Tensioner—5.9L HDC-Gas
Engine
CAUTION: When installing serpentine accessory
drive belt, the belt MUST be routed correctly. If not, (3) Rotate tensioner assembly counterclockwise (as
the engine may overheat due to the water pump ro viewed from front) until tension h a s been relieved
tating in the wrong direction. Refer to Group 7 - from belt.
Cooling System for correct engine belt routing. The (4) Remove belt from idler pulley first.
correct belt with the correct length must be used (5) Remove belt from vehicle.
(6) Remove lower generator mounting bolt and n u t
(3) Position drive belt over all pulleys e x c e p t the (Fig. 5).
idler pulley. This pulley is located between the gen
erator and A/C compressor.
of the automatic tensioner (Fig. 1).
(5) Rotate socket/wrench clockwise. Place belt over
idler pulley. Let tensioner rotate back into place. Re
move wrench. Be sure belt is properly seated on all
pulleys.
(6) Check belt indexing marks. Refer to Group 7 -
Cooling, Automatic Belt Tensioner.
GENERATOR REPLACEMENT—5.9L HDC-GAS

ENGINE
Drive belts on these engines are equipped with a
spring loaded automatic belt tensioner (Fig. 4). This
belt tensioner is used on all belt configurations. For Fig. 5 Generator Mounting Bolts
more information, refer to Group 7 - Cooling, Belt (7) Remove upper generator mounting bolt and re
Removal/Installation. move generator.
REMOVAL (8) Remove B + terminal nut, 2 field terminal
(1) Disconnect negative cable from battery. nuts, ground, and harness hold down nuts (Fig. 6).
of automatic tensioner (Fig. 4). T h e t h r e a d s o n t h i s
b o l t a r e left h a n d .
GENERATOR REPLACEMENT—DIESEL ENGINE
(1) Remove negative cable from battery.
(2) Remove generator drive belt. See Group 7 -
Cooling System, for instructions.
(3) Remove B + terminal nut, 2 field terminal
nuts, ground, and harness hold down nuts (Fig. 6).
(4) Remove upper mounting bolt and nut (Fig. 7).
(5) Remove lower mounting bolt.
(6) Remove generator from the vehicle.
(7) To install generator, first tighten lower mount
ing bolt to 43 Nun (32 ft. lbs.). Tighten upper bolt to
24 Nun (18 ft. lbs.).
Fig. 6 Remove or Install Wire Connector Assembly

INSTALLATION
(1) Install harness to generator. Tighten nuts as
follows:
• Ground terminal, B + terminal and Wire Harness
Hold Down 7-10 Nun (60-90 in. lbs.).
• Field terminals 2.5-3 Nun (20-30 in. lbs.).
(2) Install generator. Tighten both bolts to 41 Nun
Fig. 7 Remove or Install Generator Mounting Bolts
(30 ft. lbs.).
C A U T I O N : When installing the serpentine accessory

drive belt, the belt M U S T be routed correctly. If not,
the engine may overheat due to the water pump ro
tating in the wrong direction. Refer to Group 7 -
Cooling System for correct engine belt routing. The
correct belt with the correct length must be used
(3) Position drive belt over all pulleys e x c e p t wa

ter p u m p pulley.
(4) Attach a 3/8 inch rachet to tensioner.
(5) Rotate ratchet and belt tensioner counterclock
wise. Place belt over water pump pulley. Let ten
sioner rotate back into place. Remove ratchet. Be
sure belt is properly seated on all pulleys.
SPECIFICATIONS
BATTERY SPECIFICATIONS
Load cold
Test Cranking Reserve
(Amps) Rating @ 0°F Capacity
C R A N K I N G RATING is the current a battery can deliver for 30 seconds anej maintain a terminal voltage of 7.2 volts or greater at
specified temperature.
RESERVE CAPACITY RATING is the length of time a battery can deliver 25 amps and maintain a minimum terminal voltage of
10.5 volts at 27 °C (80 °F).
J938A-25
GAS ENGINE DIESEL ENGINE
Manufacturer Nippondenso R E D U C T I O N G E A R STARTER

Engine Application 5.9L, 5.2L & 3.9L Manufacturer Nippondenso
Part Number and 53005984 Engine Application 5.9L
Power Rating 1.4 Kw Part Number and 4428221
Voltage 12 Power Rating 3 kw
No. of Fields 4 Voltage 12
No. of Poles. 4 No. of Fields 4
Brushes 4 No. of Poles 4
Drive Reduction Brushes 4
Gear Train
Drive Conventional
Free Running Test Gear Train
Voltage 11 Free Running Test
Amperage Draw 73 Amps Voltage 11
Minimum Speed rpm 3601 rpm
Amperage Draw 220 Amps Max.
Solenoid Closing Voltage 7.5 Volts Minimum Speed rpm 4200 rpm Min.
Cranking Amperage Draw Test . . . 125-200 Amps* Solenoid Closing Voltage 8 Volts
* Engine should be up to operating temperature. Extremely heavy Cranking Amperage Draw Test . . 450-550 Amps*
oil or tight engine will increase starter amperage draw.
* Engine should be up to operating temperature. Extremely
heavy oil or tight engine will increase starter amperage draw.
J938B-14 J918B-21
GENERATOR SPECIFICATIONS
TYPE PHUT H U M S I R PULLEY G R O O V E S ENGINE RATING
NIPPONDENSO 5234374 8 DIESEL 120 AMPS
J938B-28
• IGNITION SYSTEMS 8D - 1
IGNITION SYSTEMS
CONTENTS
page page
COMPONENT IDENTIFICATION/SYSTEM DIAGNOSTICS/SERVICE PROCEDURES 7

OPERATION 1 IGNITION SWITCH 25
COMPONENT REMOVAL/INSTALLATION . . . . . 18 SPECIFICATIONS 28
COMPONENT IDENTIFICATION/SYSTEM OPERATION
INDEX
page page
Automatic Shut Down ( A S D ) Relay 1 Ignition Coil 3
Camshaft Position Sensor 2 Intake Manifold Charge Air Temperature Sensor .. 4
Crankshaft Position Sensor 2 Manifold Absolute Pressure (MAP) Sensor 4
Distributors 3 Powertrain Control Module ( P C M ) .5
Engine Coolant Temperature S e n s o r ........... 4 Throttle Position Sensor 5
General Information 1
GENERAL INFORMATION found in Group 0, Lubrication and Maintenance. This

Throughout this group, references are made to par schedule can also be found in the Owners Manual.
ticular vehicle models by alphabetical designation or
by the particular vehicle nameplate. A chart showing IGNITION SYSTEMS
a breakdown of alphabetical designations is included The ignition systems used on all engines are basi
in the Introduction group at the beginning of this cally identical. Similarities and differences between
manual. the systems will be discussed.
5.9L gas powered engines will be referred to as ei A sequential multi-port fuel injection system is
ther: LDC (Light Duty Cycle), or HDC (Heavy Duty used on all gas powered engines.
Cycle). The ignition system is controlled by the powertrain
This section of the group, Component Identifica control module (PCM) on all engines. The PCM was
tion/System Operation, will discuss ignition system formerly referred to as the SBEC or engine control
operation and will identify ignition system compo ler.
nents. The ignition system consists of:
For diagnostic procedures and adjustments, refer to • Spark Plugs
the Diagnostics/Service Procedures section of this • Ignition Coil
group. • Secondary Ignition Cables
For removal and installation of ignition system • Ignition distributor. Contains rotor and camshaft
components, refer to the Component Removal/Instal position sensor
lation section of this group. • Powertrain Control Module (PCM)
For other useful information, refer to On-Board Di • Crankshaft Position Sensor
agnostics in the General Diagnosis sections of Group
14, Fuel System in this manual. AUTOMATIC SHUT DOWN (ASD) RELAY
For operation of the DRB II Diagnostic Scan Tool, The automatic shut down (ASD) relay is located in
refer to the appropriate Powertrain Diagnostic Proce the engine compartment (Fig. 1). As one of its func
dures service manual. tions, the ASD relay will supply battery voltage to
An Ignition specifications section is included at the the ignition coil. The ground circuit for the ASD re
end of this group. A general Maintenance Schedule lay is controlled by the powertrain control module
(mileage intervals) for ignition related items can be (PCM). The PCM regulates ASD relay operation by
switching the ground circuit on-and-off.
8D - 2 IGNITION SYSTEMS •
A / C CLUTCH RELAY STARTER RELAY For component testing, refer to the Diagnostics/Ser
vice Procedures section o f this group.
For removal and installation of this component, re
fer to the Component Removal/Installation section of
this group.
CRANKSHAFT POSITION SENSOR

The sensor is bolted to the top of cylinder block
near the rear of the right cylinder head (Fig. 3).
DATA LINK CONTROL

CONNECTOR MODULE J9314-164
Fig. 1 Auto Shut Down Relay

CAMSHAFT POSITION SENSOR
The camshaft position sensor is located in the igni
tion distributor (Fig. 2) on all engines.
Fig. 3 Crankshaft Position Sensor—Typical

* Engine speed and crankshaft position are provided
through the crankshaft position sensor. The sensor
generates pulses t h a t are the input sent to the pow
ertrain control module (PCM). The PCM interprets
Fig. 2 Camshaft Position Sensor— Typical the sensor input to determine the crankshaft posi
tion. The PCM then uses this position, along with
The camshaft position sensor contains a hall effect other inputs, to determine injector sequence and ig
device called a sync signal generator to generate a nition timing.
fuel sync signal. This sync signal generator detects a
The sensor is a hall effect device combined with an
rotating pulse ring (shutter) on the distributor shaft.
internal magnet. It is also sensitive to steel within a
The pulse ring rotates 180 degrees through the sync
certain distance from it.
signal generator. Its signal is used in conjunction
with the crankshaft position sensor to differentiate
SENSOR OPERATION-3.9L ENGINE
between fuel injection and spark events. It is also
The flywheel/drive plate has groups of notches at
used to synchronize the fuel injectors with their re
its outer edge. On 3.9L V-6 engines, there are three
spective cylinders.
sets of double notches and three sets of single
When the leading edge of the pulse ring (shutter)
notches (Fig. 4 ) .
enters the sync signal generator, the following oc
The notches cause a pulse to be generated when
curs: The interruption of magnetic field causes the
voltage to switch high resulting in a sync signal of they pass under the sensor. The pulses are the input
approximately 5 volts. to the PCM.
When the trailing edge of the pulse ring (shutter) The engine will not operate if the PCM does not re
leaves the sync signal generator, the following oc ceive a crankshaft position sensor input.
curs: The change of the magnetic field causes the For component testing, refer to the Diagnostics/Ser
sync signal voltage to switch low to 0 volts. vice Procedures section of this group.
For removal and installation of this sensor, refer to

CRANKSHAFT
the Component Removal/Installation section of this POSITION-
group. SENSOR
CRANKSHAFT
.FLYWHEEL
POSITION
NOTCHES*
SENSOR
FLYWHEEL
NOTCHES-
J9314-88
Fig. 5 Sensor Opera tion—5.2L/5.9L Engine

—^^j^jV^ J9314-89 trolled by the PCM, base ignition timing i s not
adjustable o n a n y of these engines.
Fig. 4 Sensor Operation—3.9L Engine The distributor is held to the engine in the conven
SENSOR OPERATION'-5.2U5.9L ENGINES tional method using a holddown clamp and bolt. Al
On 5.2L and 5.9L engines, the flywheel/drive plate t h o u g h the distributor can b e rotated, it will
has 8 single notches, spaced every 45 degrees, at its h a v e n o effect o n ignition timing.
outer edge (Fig. 5). All distributors contain an internal oil seal t h a t
The notches cause a pulse to be generated when prevents oil from entering the distributor housing.
they pass under the sensor. The pulses are the input The seal is not serviceable.
to the PCM. For each engine revolution, there are 8 For removal and installation of this component, re
pulses generated on V-8 engines. fer to the Component Removal/Installation section of
The engine will not operate if the PCM does not re this group.
ceive a crankshaft position sensor input.
For component testing, refer to the Diagnostics/Ser IGNITION COIL
vice Procedures section of this group. Battery voltage is supplied to the ignition coil pos
For removal and installation of this component, re itive terminal from the ASD relay.
fer to the Component Removal/Installation section of The powertrain control module (PCM) opens and
this group. closes the ignition coil ground circuit for ignition coil
operation.
DISTRIBUTORS B a s e ignition timing is not adjustable o n any
For component testing, refer to the Diagnostics/Ser
engine. By controlling the coil ground circuit, the
vice Procedures section of this group.
PCM is able to set the base timing and adjust the ig
ALL ENGINES nition timing advance. This is done to meet changing
All engines are equipped with a camshaft driven engine operating conditions.
mechanical distributor, containing a shaft driven dis The ignition coil is not oil filled. The windings are
tributor rotor. They are equipped with an internal embedded in an epoxy compound. This provides heat
camshaft position (fuel sync) sensor. This sensor pro and vibration resistance that allows the ignition coil
vides fuel injection synchronization and cylinder to be mounted on the engine.
identification. • 3.9L/5.2L/5.9L LDC-Gas Engines: The coil is
Distributors do not have built in centrifugal or vac mounted to a bracket that is bolted to the front of
uum assisted advance. Base ignition timing and all the right engine cylinder head (Fig. 6). This bracket
timing advance is controlled by the powertrain con is also used to mount the automatic belt tensioner.
trol module (PCM). Because ignition timing is con-
mal operating temperatures are reached. Refer to
Modes Of Operation in Group 14, Fuel System for a
description of Open and Closed Loop operation.
The sensor is installed in the intake manifold near
the thermostat housing (Fig. 8).
Fig. 6 ignition Coil—3.9L/5.2L/5.9L LDC-Gas

Engines
Fig. 8 Coolant Temperature Sensor—Typical

this group.
INTAKE MANIFOLD CHARGE AIR TEMPERATURE

SENSOR
The sensor element extends into the intake mani
fold air stream. It provides an input voltage to the
powertrain control module (PCM) indicating intake
manifold air temperature. The input from this sensor
Fig. 7 Ignition Coil—5.9L HDC-Gas Engine is used along with inputs from other sensors to de
• 5.9L HDC-Gas Engines: The coil is mounted to a termine injector pulse width. As the temperature of
bracket t h a t is bolted to the automatic belt tensioner the air-fuel stream in the manifold varies, the sensor
mounting bracket (Fig. 7). resistance will change. This will result in a different
For component testing, refer to the Diagnostics/Ser input voltage to the PCM. For more information, re
vice Procedures section of this group. fer to Group 14, Fuel System.
For removal and installation of this component, re This sensor is installed in the intake manifold
fer to the Component Removal/Installation section of (Figs. 9 or 10).
this group. For component testing, refer to the Diagnostics/Ser
ENGINE COOLANT TEMPERATURE SENSOR For removal and installation of this component, re
The sensor provides an input voltage to the power- fer to the Component Removal/Installation section of
train control module (PCM) relating coolant temper this group.
ature. The PCM uses this input, along with inputs
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
from other sensors, to determine injector pulse width
The MAP sensor reacts to absolute pressure in the
and ignition timing. As coolant temperature varies, intake manifold and provides an input voltage to the
the coolant temperature sensor resistance will powertrain control module (PCM). As engine load
change, resulting in a different input voltage to the changes, manifold pressure varies, causing the MAP
PCM. sensor voltage to change. This change results in a
When the engine is cold, the PCM will operate in different input voltage to the PCM. The input volt
the Open Loop Cycle. It will demand slightly richer age level supplies the PCM with information. This
air-fuel mixtures and higher idle speeds, until nor relates to ambient barometric pressure during engine
THROTTLE ^ y ^SUPPORT B R A C K E T / | THROTTLE

u
BODY CHARGE AIR BODY
BRACKET
ijmmmmk TEMPERATURE S E N S O R
MANIFOLD
ABSOLUTE
PRESSURE ELECTRICAL J l p ^
SENSOR CONNECTOR ^ g i s ! —
Fig. 9 Sensor Location—3.9L Engine—Typical Fig. 11 MAP Sensor—Typical

INTAKE MANIFOLD A / C CLUTCH RELAY STARTER RELAY
'b AIR TEMPERATURE
SENSOR
TORQUE CONVERTER AUTO SHUTDOWN RELAY
CLUTCH RELAY
FUEL PUMP RELAY
POWERTRAIN
DATA LINK CONTROL
J9314-162 CONNECTOR MODULE J9314-164
Fig. 10 Sensor Location—5.2L/5.9L Fig. 12 PCM Location—Typical

Engines—Typical
The PCM opens and closes the ignition coil ground
start-up (cranking) and to engine load while the en circuit to operate the ignition coil. This is done to ad
gine is running. The PCM uses this input, along with just ignition timing, both initial (base) and advance,
inputs from other sensors, to adjust air-fuel mixture. for changing engine operating conditions.
For more information, refer to Group 14, Fuel Sys The amount of electronic spark advance provided
tem. by the PCM is determined by five input factors: Cool
The MAP sensor is mounted to the throttle body ant temperature, engine rpm, intake manifold tem
(Fig. 11). It is connected to the throttle body with an perature, manifold absolute pressure and throttle
L-shaped rubber fitting and to the PCM electrically. position.
For component testing, refer to the Diagnostics/Ser For removal and installation of this component, re
vice Procedures section of this group. fer to the Component Removal/Installation section of
For removal and installation of this component, re this group.
fer to the Component Removal/Installation section of For diagnostics, refer to the appropriate Powertrain
this group.
Diagnostic Procedures service manual for operation
POWERTRAIN CONTROL MODULE (PCM) of the DRB II scan tool.
The powertrain control module (PCM) is located in
the engine compartment behind the battery (Fig. 12). THROTTLE POSITION SENSOR
The PCM was formerly referred to as the SBEC or The sensor is mounted on the throttle body (Fig.
engine controller. 13). It is connected to the throttle blade shaft. The
The ignition system is controlled by the PCM. sensor is a variable resistor. It provides the power-
Base ignition timing by rotation of distributor train control module (PCM) with an input signal
is not adjustable. (voltage) t h a t represents throttle blade position. As
the position of the throttle blade changes, the resis MANIFOLD ABSOLUTE
tance of the sensor changes.
The PCM supplies approximately 5 volts to the
sensor. The sensor output voltage (input signal to the
PCM) represents the throttle blade position. The
PCM receives an input signal voltage from the sen
sor. This will vary in an approximate range of from 1
volt at minimum throttle opening (idle), to 4 volts at
wide open throttle. Along with inputs from other sen
sors, the PCM uses the sensor input to determine
current engine operating conditions. It also will ad
just fuel injector pulse width and ignition timing.
this group.
Fig. 13 Throttle Position Sensor—Typical

• IGNITION SYSTEMS 80 - 7
DIAGNOSTICS/SERW1CE P R O C E D U R E S
INDEX
page page
Automatic Shut Down ( A S D ) Relay 7 Ignition Timing 12
Camshaft Position Sensor Test . . . . . . . . . . . . . . . 7 Intake Manifold Charge Air Temperature Sensor
Crankshaft Position Sensor Test 8 Test 12
Distributor C a p 8 Manifold Absolute Pressure (MAP) Sensor Test . 12
Distributor Rotor 8 Oxygen Sensor Tests 17
Engine Coolant Temperature Sensor Test 10 Powertrain Control Module (PCM) . . . . . . . . . . . . 14
General Information 7 Spark Plug Secondary Cables 16
Ignition Coil 8 Spark Plugs ............................ 14
Ignition Secondary Circuit Diagnosis 10 Throttle Position Sensor Test 17
GENERAL INFORMATION (2) Connect the negative (-) voltmeter lead into t h e
This section of the group, Diagnostics/Service Pro ground wire. For wire identification, refer to Group
cedures, will discuss basic ignition system diagnos 8W, Wiring Diagrams.
tics and service adjustments. (3) Set t h e voltmeter to the 15 Volt DC scale.
For system operation and component identification, (4) Remove distributor cap from distributor (two
refer to t h e Component Identification/System Opera screws). Rotate (crank) t h e engine until t h e distribu
tion section of this group. tor rotor is pointed towards the rear of vehicle. The
For removal or installation of ignition system com movable pulse ring should now be within the sensor
ponents, refer to the Component Removal/Installa pickup.
tion section of this group. (5) Turn ignition key to ON position. Voltmeter
For other useful information, refer to On-Board Di should read approximately 5.0 volts.
agnostics in t h e General Diagnosis sections of Group (6) If voltage is not present, check t h e voltmeter
14, Fuel System in this manual. leads for a good connection.
For operation of the DRB II Diagnostic Scan Tool, (7) If voltage is still not present, check for voltage
refer to t h e appropriate Powertrain Diagnostic Proce at t h e supply wire. For wire identification, refer to
dures service manual. Group 8W, Wiring Diagrams.
(8) If voltage is not present at supply wire, check
AUTOMATIC SHUT DOWN (ASD) RELAY for voltage at pin-7 of powertrain control module
Refer to Relays—Operation/Testing in t h e Group (PCM) 60-way connector. Leave t h e PCM connector
14, Fuel System section of this service manual. connected for this test.
(9) If voltage is still not present, perform vehicle
CAMSHAFT POSITION SENSOR TEST test using t h e DRB II diagnostic scan tool.
The camshaft position sensor is located in the dis (10) If voltage is present at pin-7, but not at t h e
tributor on all engines. supply wire:
To perform a complete test of this sensor and its (a) Check continuity between the supply wire.
circuitry, refer to t h e DRB II diagnostic scan tool. This is checked between the distributor connector
Also refer to t h e appropriate Powertrain Diagnostics and pin-7 at the PCM. If continuity is not present,
Procedures manual. To test the sensor only, refer to repair the harness as necessary.
the following: (b) Check for continuity between t h e camshaft
For this test, a n a n a l o g (non-digital) voltmeter position sensor output wire and pin-44 at the PCM.
is needed. Do not remove t h e distributor connector If continuity is not present, repair the harness as
from the distributor. Using small paper clips, insert necessary.
them into t h e backside of t h e distributor wire har (c) Check for continuity between the ground cir
ness connector to make contact with t h e terminals. cuit wire a t the distributor connector and ground.
Be sure t h a t t h e connector is not damaged when in If continuity is not present, repair the harness as
serting t h e paper clips. Attach voltmeter leads to necessary.
these paper clips. (11) While observing t h e voltmeter, crank t h e en
(1) Connect t h e positive ( + ) voltmeter lead into gine with ignition switch. The voltmeter needle
should fluctuate between 0 and 5 volts while the en
the sensor output wire. This is at done t h e distribu
gine is cranking. This verifies t h a t the camshaft po
tor wire harness connector. For wire identification,
sition sensor in t h e distributor is operating properly
refer to Group 8W, Wiring Diagrams.
and a sync pulse signal is being generated.
If sync pulse signal is not present, replacement of
the camshaft position sensor is necessary.
For removal or installation of ignition system com
ponents, refer to the Component Removal/Installa
tion section of this group.
For system operation and component identification,
refer to the Component Identification/System Opera
CRANKSHAFT POSITION SENSOR TEST

To perform a complete test of this sensor and its
circuitry, refer to the DRB II diagnostic scan tool.
Also refer to the appropriate Powertrain Diagnostics
VIEW LOOKING INTO
Procedures manual. To test the sensor only, refer to
CPS CONNECTOR J938D-7
the following:
The sensor is located on the top of cylinder block
Fig. 2 Sensor Connector
near the rear of right cylinder head (Fig. 1).
(1) Near the rear of intake manifold, disconnect the cap through cracks). Replace any cap t h a t dis
sensor pigtail harness connector from main wiring plays charred or eroded terminals. The machined
harness. surface of a terminal end (faces toward rotor) will in
dicate some evidence of erosion from normal opera
tion. Examine the terminal ends for evidence of
mechanical interference with the rotor tip.
Fig. 3 Cap Inspection—External—Typical

DISTRIBUTOR ROTOR
Fig. 1 Crankshaft Position Sensor—Typical Visually inspect the rotor (Fig. 5) for cracks, evi
(2) Place an ohmmeter across terminals B and C dence of corrosion, or the effects of arcing on the
(Fig. 2). Ohmmeter should be set to lK-to-lOK scale metal tip. Also check for evidence of mechanical in
for this test. The meter reading should be open (no terference with the cap. Some charring is normal on
resistance). Replace sensor if a low resistance is indi the end of the metal tip. The silicone-dielectric-var
cated. nish-compound applied to the rotor tip for radio in
terference noise suppression, will appear charred.
DISTRIBUTOR CAP This is normal. Do not remove the charred com
pound. Test the spring for insufficient tension. Re
INSPECTION place a rotor t h a t displays any of these adverse
Remove the distributor cap and wipe it clean with conditions.
a dry lint free cloth. Visually inspect the cap for
cracks, carbon paths, broken towers, or damaged ro IGNITION COIL
tor button (Figs. 3 and 4). Also check for white de To perform a complete test of the ignition coil and
posits on t h e inside (caused by condensation entering its circuitry, refer to the DRB II diagnostic scan tool.
Fig. 4 Cap Inspection—internal—Typical Fig. 6 Ignition Coil-3.9U5.2U5.9L LDC-Gas Engine

INSUFFICIENT
SPRING
TENSION
CORRODED EVIDENCE OF
PHYSICAL Fig. 7 Ignition Coil—5.9L HDC-Gas Engine
CONTACT
WITH CAP J908D-48 Inspect the ignition coil for arcing. Test the coil ac
cording to coil tester manufacturer's instructions.
Fig. 5 Rotor Inspection—Typical Test the coil primary and secondary resistance. Re
Also refer to the appropriate Powertrain Diagnostics place any coil t h a t does not meet specifications. Refer
Procedures manual. To test the coil only, refer to the to the Ignition Coil Resistance chart.
following: If the ignition coil is being replaced, the secondary
The ignition coil (Figs. 6 or 7) is designed to oper spark plug cable must also be checked. Replace cable
ate without an external ballast resistor. if it has been burned or damaged.
IGNITION COIL RESISTANCE
PRIMARY RESISTANCE SECONDARY RESISTANCE

COIL (MANUFACTURER) 2!-27°C (70-80°F) 21-27°C (70-80°F)
Diamond 0.97 - 1.18 Ohms 11,300- 15,300 Ohms
Toyodenso 0.95- 1.20 Ohms 11,300- 13,300 Ohms

J918D-2
Arcing at the tower will carbonize the cable boot, SENSOR RESISTANCE (OHMSJ
which if it is connected to a new ignition coil, will
cause the coil to fail.
If the secondary coil cable shows any signs of dam TEMPERATURE RESISTANCE ( O H M S )
age, it should be replaced with a new cable and new
terminal. Carbon tracking on the old cable can cause C F MIN MAX
arcing and the failure of a new ignition coil.
-40 -40 291,490 381,710
ENGINE COOLANT TEMPERATURE SENSOR TEST -20 -4 85,850 108,390
To perform a complete test of this sensor and its -10 14 49,250 61,430
0 32 29,330 35,990
circuitry, refer to the DRB II diagnostic scan tool. 10 50 17,990 21,810
Also refer to the appropriate Powertrain Diagnostics 20 68 11,370 13,610
Procedures manual. To test the sensor only, refer to 25 77 9,120 10,880
the following: 30 86 7,370 8,750
40 104 4,900 5,750
The sensor is located in a water passage of the in 50 122 3,330 3,880
take manifold next to the thermostat housing (Fig. 60 140 2,310 2,670
8). 70 158 1,630 1,870
(1) Disconnect wire harness connector from sensor 80 176 1,170 1,340
90 194 860 970
(Fig. 8). On engines with air conditioning, do not pull 100 212 640 720
directly on wiring harness. Fabricate an L-shaped 110 230 480 540
hook tool from a coat hanger (approximately eight 120 248 370 410
inches long). Place the hook part of tool under the
connector for removal. The connector is snapped onto J928D-4
the sensor. It is not equipped with a lock type tab. IGNITION SECONDARY CIRCUIT DIAGNOSIS
COOLANT
TEMPERATURE
CHECKING FOR SPARK
SENSOR
C A U T I O N : When disconnecting a high voltage cable
from a spark plug or from the distributor cap, twist
the rubber boot slightly (1/2 turn) to break it loose.
G r a s p the boot (not the cable) and pull it off with a
steady, even force.
(1) Disconnect the ignition coil secondary cable

from center tower of the distributor cap. Hold the ca
ble terminal approximately 12 mm (1/2 in.) from a
good engine ground (Fig. 9).
V
J9314-78
Fig. 8 Coolant Temperature Sensor—Typical
(2) Test the resistance of the sensor with a high in
put impedance (digital) volt-ohmmeter. The resis
tance should be less t h a n 1340 ohms at normal
engine operating idle temperature. For resistance
values, refer to the Sensor Resistance chart. Replace
the sensor if it is not within the range of resistance
specified in the chart.
(3) Test continuity of the wire harness. This is CHECK HERE IGNITION
done between powertrain control module (PCM) wire FOR SPARK COIL 918D-18
harness connector terminal-2 and the sensor connec

tor terminal. Also check continuity between wire Fig. 9 Checking for Spark—Typical
harness terminal-4 to the sensor connector terminal.
Repair the wire harness if an open circuit is indi
cated.
* IGNITION SYSTEMS 80 - 11
WARNING: BE VERY CAREFUL WHEN THE ENGINE

IS C R A N K I N G . D O N O T P U T Y O U R H A N D S N E A R
THE PULLEYS, BELTS O R T H E F A N . D O NOT
W E A R L O O S E FITTING C L O T H I N G .
(2) Rotate (crank) the engine with the starter mo

tor and observe the cable terminal for a steady arc. If
steady arcing does not occur, inspect the secondary
coil cable. Refer to Spark Plug Cables in this group.
Also inspect the distributor cap and rotor for cracks
or burn marks. Repair as necessary. If steady arcing
occurs, connect ignition coil cable to the distributor
cap.
(3) Remove a cable from one spark plug.
(4) Using insulated pliers, hold the cable terminal
approximately 12 mm (1/2 in.) from the engine cylin
der head or block while rotating the engine with the Fig. 11 Coil Harness Connector—5.9L HDC-Gas
starter motor. Observe the spark plug cable terminal Engine
for an arc. If steady arcing occurs, it can be expected IGNITION COIL COIL CONNECTOR
t h a t the ignition secondary system is" operating cor
rectly. If steady arcing occurs at the spark plug ca
bles, but the engine will not start, connect t h e DRB
II diagnostic scan tool. Refer to the Powertrain Diag
nostic Procedures service manual.
FAILURE TO START TEST

To prevent unnecessary diagnostic time and wrong
test results, the previous Checking For Spark test
should be performed prior to this test.
WARNING: SET PARKING B R A K E OR BLOCK THE

DRIVE W H E E L S B E F O R E P R O C E E D I N G WITH THIS J928D-13
TEST.
Fig. 12 Coil Terminals—Typical
(1) Unplug the ignition coil harness connector at (3) Determine t h a t sufficient battery voltage (12.4
the coil (Figs. 10 or 11). volts) is present for the starting and ignition sys
tems.
(4) Crank the engine for 5 seconds while monitor
ing the voltage at the coil positive terminal (Fig. 12):
• If the voltage remains near zero during the entire
period of cranking, refer to On-Board Diagnostics in
Group 14, Fuel Systems. Check the powertrain con
trol module and auto shut down relay.
• If voltage is at near battery voltage and drops to
zero after 1-2 seconds of cranking, check the power-
t r a i n control module circuit. Refer to On-Board Diag
nostics in Group 14, Fuel Systems.
• If voltage remains at near battery voltage during
the entire 5 seconds, turn the key off. Remove the
60-way connector (Fig. 13) from the powertrain con
trol module (PCM). Check 60-way connector for any
spread terminals.
Fig. 10 Coil Harness Connector—3.9/5.2L/5.9L
(5) Remove test lead from the coil positive termi
LDC-Gas Engine
nal. Connect an 18 gauge jumper wire between the
(2) Connect a set of small jumper wires (18 gauge battery positive terminal and the coil positive termi
or smaller) between the ignition coil and coil electri nal.
cal connector (Fig. 12).
THROTTLE ^ SUPPORT BRACKET /
BODY ^ CHARGE AIR
X X BRACKET TEMPERATURE S E N S O R
oooooooooo OOOOOOOOOO
si 20
,0000000000 fcjiÔQOOOOOOJ
\21 4 1 3 %« r • o o~ o o•o•o o- o• o- o- . #
lOOOOOOOOOO
CONNECTOR
TERMINAL SIDE
SHOWN J908D-42
Fig. 13 PCM 60-Way Connector

(6) Make the special jumper shown in Figure 14.
Using the jumper, m o m e n t a r i l y ground terminal-19
of the 60-way connector. A spark should be generated
at the coil cable when the ground is removed.
CAPACITOR CONNECT THIS- Fig. 15 Sensor Location--3.9L Engine—Typical
ALLIGATOR INTAKE M A N I F O L D
A I R TEMPERATURE
GROUND CLIP W
SENSOR
THIS MOMENTARILY
CLIP G R O U N D THIS
CLIP T O COIL^
NEGATIVE
ALLIGATOR CLIP
PR1003
Fig. 14 Special Jumper Ground-to-Coil Negative

Terminal
(7) If spark is generated, replace the powertrain
control module (PCM).
(8) If spark is not seen, use the special jumper to
ground the coil negative terminal directly. J9314-162
(9) If spark is produced, repair wiring harness for
an open condition. Fig. 16 Sensor Location—5.2U5.9L
(10) If spark is not produced, replace the ignition Engines—Typical
coil.
(2) Test the resistance of the sensor with a input
IGNITION TIMING impedance (digital) volt-ohmmeter. Do not remove
B a s e (Initial) i g n i t i o n t i m i n g Is N O T a d j u s t a b l e the sensor from the engine for testing. For resistance
o n a n y e n g i n e . D o n o t a t t e m p t to a d j u s t Ignition values, refer to the Sensor Resistance chart. Replace
timing by rotating the distributor. the sensor if it is not within the range of resistance
All ignition timing functions are controlled by the specified in the chart.
powertrain control module (PCM). Refer to On-Board (3) Test the resistance of the wire harness. This is
Diagnostics in the Multi-Port Fuel Injection—Gen done between the powertrain control module (PCM)
eral Diagnosis section of Group 14, Fuel Systems for wire harness connector terminal-2 and the sensor
more information. Also refer to the appropriate Pow connector terminal. Also check continuity between
ertrain Diagnostics Procedures service manual for terminal-4 to the sensor connector terminal. Repair
operation of the DRB II Scan Tool. the wire harness as necessary if the resistance is
greater t h a n 1 ohm.
INTAKE MANIFOLD CHARGE AIR TEMPERATURE For removal and installation of this component, re
SENSOR TEST fer to the Component Removal/Installation section of
To perform a complete test of this sensor and its this group.
circuitry, refer to the DRB II diagnostic scan tool.
Also refer to the appropriate Powertrain Diagnostics MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
Procedures manual. To test the sensor only, refer to TEST
the following:
To perform a complete test of MAP sensor (Fig. 17)
(1) Disconnect the wire harness connector from t h e
and its circuitry, refer to DRB II tester and appropri-
sensor (Figs. 15 or 16).
IGNITION SYSTEMS 8D - 13
SENSOR RESISTANCE (OHMS)

MOUNTING SCREWS
AAAP SENSOR
TEMPERATURE RESISTANCE ( O H M S )
C F MIN MAX RUBBER FITTING
-40 -40 291,490 381,710

-20 -4 85,850 108,390
-10 14 49,250 61,430
0 32 29,330 35,990
10 50 17,990 21,810
20 68 11,370 13,610
25 77 9,120 10,880
30 86 7,370 8,750
40 104 4,900 5,750
50 122 3,330 3,880 J9314-87
60 140 2,310 2,670
70 158 1,630 1,870 Fig. 18 Rubber Fitting—MAP Sensor-to-Throttle
80 176 1,170 1,340
90 194 860 970 Body
100 212 640 720 (2) Test the MAP sensor output voltage at the
110 230 480 540 MAP sensor connector between terminals A and B
120 248 370 410
(Fig. 19). With the ignition switch ON and the en
J928D-4 gine OFF, output voltage should be 4-to-5 volts. The
voltage should drop to 1.5-to-2.1 volts with a hot,
ate Powertrain Diagnostics Procedures manual. To
neutral idle speed condition.
test the MAP sensor only, refer to the following:
(1) Inspect the rubber fitting from t h e MAP sensor
to the throttle body (Fig. 18). Repair as necessary.
MANIFOLD ABSOLUTE
PRESSURE SENSOR
A. Ground
B. Output Voltage
C. 5 Volts
J8914-91
Fig. 19 MAP Sensor Connector Terminals

(3) Test powertrain control module (PCM) termi
J9314-86 nal-1 for the same voltage described above to verify
the wire harness condition. Repair as necessary.
Fig. 17 Manifold Absolute Pressure (MAP) (4) Test MAP sensor supply voltage at sensor con
Sensor— Typical nector between terminals A and C (Fig. 19) with the
ignition ON. The voltage should be approximately 5
C A U T I O N : When testing the M A P sensor, be sure
volts (±0.5V). Five volts (±0.5V) should also be at
that the harness wires are not damaged by the test
terminal-6 of the PCM wire harness connector. Re
meter probes.
pair or replace the wire harness as necessary.
(5) Test the MAP sensor ground circuit at sensor
connector terminal-A (Fig. 19) and PCM connector
terminal-4. Repair the wire harness if necessary.
(6) Test the MAP sensor ground circuit at the
PCM connector between terminal-4 and terminal-11
with an ohmmeter. If the ohmmeter indicates an
open circuit, inspect for a defective sensor ground
connection. Refer to Group 8W, Wiring for location of
this connection. If the ground connection is good, re
place the PCM. If terminal-4 has a short circuit to 12
volts + , correct this condition before replacing the
PCM.
POWERTRAIN CONTROL MODULE {PCM)

The PCM (formerly called the SBEC or engine -con
troller) is located in the engine compartment (Fig.
20). Fig. 21 Heat Shields
number of ways: poor fuel economy, power loss, de
crease in engine speed, hard starting and, in general,
poor engine performance.
Remove the spark plugs and examine them for
burned electrodes and fouled, cracked or broken por
celain insulators. Keep plugs arranged in the order
in which they were removed from the engine. An iso
lated plug displaying an abnormal condition indi
cates t h a t a problem exists in the corresponding
cylinder. Replace spark plugs at the intervals recom
mended in the maintenance chart in Group 0, Lubri
cation and Maintenance.
Spark plugs t h a t have low mileage may be cleaned
DATA UNK CONTROL and reused if not otherwise defective. Refer to the
CONNECTOR MODULE J9314-164 following Spark Plug Condition section of this group.
Fig. 20 PCM Location CONDITION

The ignition system is controlled by the PCM.
For removal and installation of this component, re NORMAL OPERATING
fer to the Component Removal/Installation section of The few deposits present on the spark plug will
this group. probably be light t a n or slightly gray in color. This is
For diagnostics, refer to the appropriate Powertrain evident with most grades of commercial gasoline
Diagnostic Procedures service manual for operation (Fig. 22). There will not be evidence of electrode
of the DRB II scan tool. burning. Gap growth will not average more t h a n ap
proximately 0.025 mm (.001 in) per 1600 km (1000
SPARK PLUGS miles) of operation. Spark plugs t h a t have normal
For spark plug removal, cleaning, gap adjustment wear can usually be cleaned, have the electrodes
and installation, refer to the Component Removal/In filed, have the gap set and then be installed.
stallation section of this group. Some fuel refiners in several areas of the United
Spark plug cable boot heat shields are pressed into States have introduced a manganese additive (MMT)
the cylinder head to surround each cable boot and for unleaded fuel. During combustion, fuel with
spark plug (Fig. 21). These shields protect the spark MMT causes the entire tip of the spark plug to be
plug boots from damage (due to intense engine heat coated with a rust colored deposit. This rust color can
generated by the exhaust manifolds) and should not be misdiagnosed as being caused by coolant in the
be removed. After the spark plug cable has been in combustion chamber. Spark plug performance is not
stalled, the lip of the cable boot should have a small affected by MMT deposits.
air gap to the top of the heat shield (Fig. 21).
Faulty carbon and/or gas fouled plugs generally COLD FOULING/CARBON FOULING
cause hard starting, but they will clean up at higher Cold fouling is sometimes referred to as carbon
engine speeds. Faulty plugs can be identified in a fouling. The deposits t h a t cause cold fouling are ba-
change the chemical n a t u r e of deposits and decrease

spark plug misfire tendencies. Notice t h a t accumula
tion on the ground electrode and shell area may be
heavy, but the deposits are easily removed. Spark
plugs with scavenger deposits can be considered nor
mal in condition and can be cleaned using standard
procedures.
GROUND
ELECTRODE
COVERED
J908D-15
Fig. 22 Normal Operation and Cold (Carbon) Fouling

sically carbon (Fig. 22). A dry, black deposit on one
or two plugs in a set may be caused by sticking
valves or defective spark plug cables. Cold (carbon)
fouling of the entire set of spark plugs may be caused
by a clogged air filter or .repeated short operating J908D-12
times (short trips).
Fig. 24 Scavenger Deposits
ELECTRODE GAP BRIDGIMG CHIPPED ELECTRODE INSULATOR
Electrode gap bridging may be traced to loose de A chipped electrode insulator usually results from
posits in the combustion chamber. These deposits ac bending the center electrode while adjusting the
cumulate on the spark plugs during continuous stop- spark plug electrode gap. Under certain conditions,
and-go driving. When the engine is suddenly severe detonation can also separate the insulator
subjected to a high torque load, deposits partially liq from the center electrode (Fig. 25). Spark plugs with
uefy and bridge the gap between electrodes (Fig. 28). this condition must be replaced.
This short circuits the electrodes. Spark plugs with
GROUND
electrode gap bridging can be cleaned using standard
procedures.
GROUND
ELECTRODE
J908D-13
Fig. 25 Chipped Electrode Insulator

J908D-11 PREIGNITION DAMAGE
Preignition damage is usually caused by excessive
Fig. 23 Electrode Gap Bridging
combustion chamber temperature. The center elec
SCAVENGER DEPOSITS trode dissolves first and the ground electrode dis
Fuel scavenger deposits may be either white or yel solves somewhat latter (Fig. 26). Insulators appear
low (Fig. 24). They may appear to be harmful, but relatively deposit free. Determine if the spark plug
this is a normal condition caused by chemical addi has the correct heat range rating for t h e engine. De
tives in certain fuels. These additives are designed to termine if ignition timing is over advanced, or if
other operating conditions are causing engine over be removed. After the spark plug cable has been in
heating. (The heat range rating refers to the operat stalled, the lip of the cable boot should have a small
ing temperature of a particular type spark plug. air gap to the top of the heat shield (Fig. 28).
Spark plugs are designed to operate within specific
temperature ranges. This depends upon the thickness
and length of the center electrodes porcelain insula
tor.)
GROUND
ELECTRODE
CENTER
ELECTRODE
DISSOLVED
Fig. 28 Heat Shields

TESTING
J908D-14 Spark plug cables are sometimes referred to as sec
ondary ignition cables or secondary wires. The cables
Fig. 26 Preignition Damage transfer electrical current from the distributor to in
SPARK PLUG OVERHEATING dividual spark plugs at each cylinder. The spark plug
Overheating is indicated by a white or gray center cables are of nonmetallic construction and have a
electrode insulator t h a t also appears blistered (Fig. built in resistance. The cables provide suppression of
27). The increase in electrode gap will be consider radio frequency emissions from the ignition system.
ably in excess of 0.001 inch per 1000 miles of opera Check the high-tension cable connections for good
tion. This suggests t h a t a plug with a cooler heat contact at the ignition coil, distributor cap towers
range rating should be used. Over advanced ignition and spark plugs. Terminals should be fully seated.
timing, detonation and cooling system malfunctions The terminals and spark plug covers should be in
can also cause spark plug overheating. good condition. Terminals should fit tightly to the ig
BLISTERED
nition coil, distributor cap and spark plugs. The
WHITE OR spark plug cover (boot) of the cable should fit tight
around the spark plug insulator. Loose cable connec
tions can cause corrosion and increase resistance, re
sulting in shorter cable service life.
Clean the high tension cables with a cloth moist
ened with a nonflammable solvent and wipe dry.
Check for brittle or cracked insulation.
When testing secondary cables for damage with an
oscilloscope, follow the instructions of the equipment
manufacturer.
If a n oscilloscope is not available, spark plug cables
may be tested as follows:
C A U T I O N : D o not leave any one spark plug cable

J908D-16 disconnected for longer than necessary during test
ing. This may c a u s e possible heat damage to the
Fig. 27 Spark Plug Overheating
catalytic converter. Total test time must not exceed
SPARK PLUG SECONDARY CABLES ten minutes.
Spark plug heat shields are pressed into the cylin
der head to surround each spark plug cable boot and With the engine not running, connect one end of a
spark plug (Fig. 28). These shields protect the spark test probe to a good ground. Start the engine and r u n
plug boots from damage (due to intense engine h e a t the other end of the test probe along the entire
generated by the exhaust manifolds) and should not length of all spark plug cables. If cables are cracked
• IGNITION SYSTEMS 80-17
or punctured, there will be a noticeable spark jump THROTTLE POSITION SENSOR TEST
from the damaged area to t h e test probe. The cable To perform a complete test of this sensor and its
running from the ignition coil to the distributor cap circuitry, refer to the DRB II diagnostic scan tool.
can be checked in the same manner. Cracked, dam Also refer to the appropriate Powertrain Diagnostics
aged or faulty cables should be replaced with resis Procedures manual. To test t h e sensor only, refer to
tance type cable. This can be identified by the words the following:
ELECTRONIC SUPPRESSION printed on the cable The throttle position sensor can be tested with a
digital voltmeter. The center terminal of the sensor
jacket.
connector is the output terminal (Fig. 29).
Use an ohmmeter to test for open circuits, exces
sive resistance or loose terminals. Remove the dis MANIFOLD ABSOLUTE
tributor cap from the distributor. D o n o t r e m o v e
c a b l e s from c a p . Remove cable from spark plug.
Connect ohmmeter to spark plug terminal end of ca
ble and to corresponding electrode in distributor cap.
Resistance should be 250 to 1000 Ohms per inch of
cable. If not, remove cable from distributor cap tower
and connect ohmmeter to the terminal ends of cable.
If resistance is not within specifications as found in
the Spark Plug Cable Resistance chart, replace the
cable. Test all spark plug cables in this manner.
SPARK PLUG CABLE RESISTANCE
MINIMUM MAXIMUM
250 Ohms Per Inch 1000 Ohms Per Inch
3000 Ohms Per Foot 12,000 Ohms Per Foot
J908D-43
To test ignition coil-to-distributor cap cable, do not

remove the cable from the cap. Connect ohmmeter to Fig. 29 Sensor Testing—Typical
rotor button (center contact) of distributor cap and With the ignition key in the ON position and en
terminal at ignition coil end of cable. If resistance is gine not running, check the sensor output voltage at
not within specifications as found in the Spark Plug the center terminal wire of the connector. Check this
Cable Resistance chart, remove the cable from the at idle (throttle plate closed) and at wide open throt
distributor cap. Connect the ohmmeter to the termi tle (WOT). At idle, sensor output voltage should be
nal ends of the cable. If resistance is not within spec greater t h a n 200 millivolts. At wide open throttle,
ifications as found in the Spark Plug Cable sensor output voltage must be less than 4,8 volts.
The output voltage should increase gradually as the
Resistance chart, replace the cable. Inspect the igni
throttle plate is slowly opened from idle to WOT.
tion coil tower for cracks, burns or corrosion.
For removal and installation of spark plug cables, OXYGEN SENSOR TESTS
refer to Spark Plug Secondary Cables in the Compo For diagnosis, removal or installation, refer to
nent Removal/Installation section. Group 14, Fuel Systems in this manual.
C O M P O N E N T REMGWAL/INSTALLATION
INDEX
page page
Automatic Shut Down ( A S D ) Relay 18 Intake Manifold Charge Air Temperature Sensor . 22
Camshaft Position Sensor , 18 Manifold Absolute Pressure (MAP) Sensor ..... 22
Crankshaft Position Sensor 18 Oxygen ( 0 ) Sensor
2 22
Distributor Service 20 Powertrain Control Module ( P C M ) 22
Engine Coolant Temperature Sensor 20 Spark Plug Secondary Cables 24
General Information 18 Spark Plugs 23
Ignition Coil 21 Throttle Position Sensor (TPS) 24
GENERAL INFORMATION REMOVAL

This section of the group, Component Removal/In Distributor removal is not necessary to remove
stallation, will discuss the removal and installation camshaft position sensor.
of ignition system components.
CAMSHAFT
For basic ignition system diagnostics and service POSITION
adjustments, refer to the Diagnostics/Service Proce SENSOR
dures section of this group.
For system operation and component identification, SYNC
refer to the Component Identification/System Opera SIGNAL
GENERATOR
AUTOMATIC SHUT DOWN (ASb) RELAY

The automatic shut down (ASD) relay is located in
the engine compartment (Fig. 1).
A / C CLUTCH RELAY STARTER RELAY
CLUTCH RELAY DISTRIBUTOR
FUEL PUMP RELAY ASSEMBLY J9314-82
Fig. 2 Camshaft Position Sensor—Typical

(2) Remove distributor cap from distributor (two
screws).
(3) Disconnect camshaft position sensor wiring
harness from main engine wiring harness.
(4) Remove distributor rotor from distributor shaft.
POWERTRAIN
DATA UNK CONTROL (5) Lift the camshaft position sensor assembly from
CONNECTOR MODULE J9314-164 the distributor housing (Fig. 2).
Fig. 1 Auto Shut Down Relay INSTALLATION

REMOVAL (1) Install camshaft position sensor to distributor.
(1) Disconnect negative battery cable a t battery. Align sensor into notch on distributor housing.
(2) Remove the relay by pulling from connector. (2) Connect wiring harness.
(3) Install rotor.
INSTALLATION (4) Install distributor cap. Tighten mounting
(1) Check the terminals in the relay connector for screws.
corrosion or damage before installation.
(2) Push the relay into the connector. CRANKSHAFT POSITION SENSOR
CAMSHAFT POSITION SENSOR REMOVAL
The camshaft position sensor is located in t h e dis The sensor is bolted to the top of the cylinder block
tributor (Fig. 2). near the rear of right cylinder head (Fig. 3).
• IGNITION SYSTEMS 80-19
Fig. 3 Crankshaft Position Sensor—Typical Fig. 4 Oil Pressure Sending

(1) Remove the spark plug cable loom and spark Unit—Removal/Installation
plug cables from valve cover mounting stud at rear (3) Clean the EGR tube and exhaust manifold (at
of right valve cover (Fig. 3). Position spark plug ca EGR tube mounting point) of any old gasket mate
bles to top of valve cover. rial.
(2) Disconnect 2 hoses at Exhaust Gas Recircula (4) Install a new gasket to exhaust manifold end of
tion (EGR) valve. Note position of hoses at EGR EGR tube and install EGR tube to both manifolds.
valve before removal. Tighten mounting nut at intake manifold. Tighten 2
#
(3) Disconnect electrical connector and hoses at mounting bolts at exhaust manifold to 23 N m (204
electric EGR transducer (EET). Note position of in. lbs.) torque.
hoses at EET before removal. (5) Coat the threads of the oil pressure sending
(4) Remove 2 EGR valve mounting bolts and re unit with thread sealant. Do not allow any of the
move EGR valve. Discard old EGR gasket. thread sealant to get into the sending unit opening,
(5) Disconnect electrical connector at engine oil or the opening at the engine. Install sending unit to
pressure sending unit. engine and tighten to 14 N»m (130 in. lbs.) torque.
(6) To prevent damage to oil pressure sending unit, Install electrical connector to sending unit.
a special tool, such as number C-4597 must be used (6) Clean the intake manifold and EGR valve of
(Fig. 4). Remove sending unit from engine. any old gasket material.
(7) Loosen EGR tube mounting n u t at intake man (7) Install a new EGR valve gasket at intake man
ifold. ifold.
(8) Remove 2 EGR tube mounting bolts at exhaust (8) Install EGR valve to intake manifold. Tighten
manifold (Fig. 3) and remove EGR tube. Discard old 2 bolts to 23 N«m (200 in. lbs.) torque.
gasket at exhaust manifold. (9) Position EET and install its electrical connec
(9) Disconnect crankshaft position sensor pigtail tor. Connect hoses between EGR valve and EET.
harness from main wiring harness. Connect hose between main vacuum harness and
(10) Remove 2 sensor (recessed hex head) mount EET.
ing bolts (Fig. 3) and remove sensor. (10) Install spark plug cable loom and spark plug
cables to valve cover mounting stud.
INSTALLATION
(1) Position crankshaft position sensor to engine
#
and install mounting bolts. Tighten bolts to 8 N m
(2) Connect main harness electrical connector to
sensor.
ENGINE COOLANT TEMPERATURE SENSOR ventional timing light can not be used to adjust dis
tributor position after installation, note position of
WARNING: HOT, PRESSURIZED COOLANT C A N distributor before removal.
CAUSE INJURY B Y SCALDING. COOLING SYSTEM
MUST BE PARTIALLY DRAINED BEFORE REMOV (1) Disconnect negative battery cable at battery.
ING THE COOLANT TEMPERATURE SENSOR. RE (2) Remove distributor cap from distributor (two
FER TO GROUP 7, COOLING. screws).
(3) Mark the position of distributor housing in
relationship to engine or dash panel. This is done
REMOVAL to aid in installation.
(1) Partially drain cooling system. Refer to Group Before distributor is removed, the number one cyl
7, Cooling. inder must be brought to the top dead center (TDC)
(2) Disconnect electrical connector from sensor firing position.
(Fig. 5). (4) Attach a socket to the Crankshaft Vibration
E n g i n e s w i t h air conditioning: When removing Damper mounting bolt.
the connector from sensor, do not pull directly on (5) Slowly rotate engine clockwise, as viewed from
wiring harness. Fabricate an L-shaped hook tool front, until indicating mark on crankshaft vibration
from a coat hanger (approximately eight inches damper is aligned to 0 degree (TDC) mark on timing
long). Place the hook part of tool under the connector chain cover (Fig. 6).
for removal. The connector is snapped onto the sen
sor. It is not equipped with a lock type tab.
(3) Remove sensor from intake manifold.
Fig. 6 Damper-To-Cover Alignment Marks—Typical

(6) The distributor rotor should now be aligned to
the CYL. NO. 1 alignment mark (stamped) into the
Fig. 5 Coolant Temperature Sensor— Typical
camshaft position sensor (Fig. 7). If not, rotate the
INSTALLATION crankshaft through another complete 360 degree
(1) Install sensor. turn. Note the position of the number one cylinder
(2) Tighten to 7 Nnn (5.5 ft. lbs.) torque. spark plug cable (on the cap) in relation to rotor. Ro
(3) Connect electrical connector to sensor. tor should now be aligned to this position.
The sensor connector is symmetrical (not indexed). (7) Disconnect camshaft position sensor wiring
It can be installed to the sensor in either direction. harness from main engine wiring harness.
(4) Replace any lost engine coolant. Refer to Group (8) Remove distributor rotor from distributor shaft.
7, Cooling System. (9) Remove distributor holddown clamp bolt and
clamp (Fig. 8). Remove distributor from vehicle.
DISTRIBUTOR SERVICE
REMOVAL CAUTION: D o not crank engine with distributor re
moved. Distributor/crankshaft relationship will be
C A U T I O N : B a s e ignition timing is not adjustable on lost.
any engine. Distributors d o not have built in centrif
ugal or v a c u u m assisted advance. B a s e ignition
timing and timing advance are controlled by the
powertrain control module (PCM). Because a con
IGNITION SYSTEMS 80 - 21
(6) Rotate the distributor housing until rotor is

aligned to CYL. NO. 1 alignment mark on the cam
shaft position sensor (Fig. 7).
(7) Tighten clamp holddown bolt (Fig. 8) to 22.5
(8) Connect camshaft position sensor wiring har
ness to main engine harness.
(9) Install distributor cap. Tighten mounting
screws.
IGNITION COIL
The ignition coil is a n epoxy filled type. If the coil
is replaced, it must be replaced with the same type.
REMOVAL
DISTRIBUTOR J9314-81
3.9L/5.2L/5.9L LDC-Gas Engines: The coil is
Fig. 7 Rotor Alignment Mark mounted to a bracket t h a t is bolted to the front of
the right engine cylinder head (Fig. 9). This bracket
is also used to mount the automatic belt tensioner.
5.9L HDC-Gas Engines: The coil is mounted to a
bracket t h a t is bolted to the automatic belt tensioner
mounting bracket (Fig. 10).
Fig. 8 Distributor Holddown Clamp

INSTALLATION
If engine has been cranked while distributor is re
moved, establish the relationship between distributor
shaft and number one piston position as follows:
Fig. 9 Ignition Coil-3.9U5.2U5.9L LDC-Gas
Rotate crankshaft in a clockwise direction, as
Engines
viewed from front, until number one cylinder piston
is at top of compression stroke (compression should
be felt on finger with number one spark plug re
moved). Then continue to slowly rotate engine clock
wise until indicating mark (Fig. 6) is aligned to 0
degree (TDC) mark on timing chain cover.
(1) Clean top of cylinder block for a good seal be
tween distributor base and block.
(2) Lightly oil the rubber O-ring seal on the dis
tributor housing.
(3) Install rotor to distributor shaft.
(4) Position distributor into engine to its original
position. Engage tongue of distributor shaft with slot
in distributor oil pump drive gear. Position rotor to
the number one spark plug cable position.
(5) Install distributor holddown clamp and clamp
bolt. Do not tighten bolt at this time. Fig. 10 Ignition Coil—5.9L HDC-Gas Engine
(1) Disconnect the wiring and secondary cable from
the ignition coil (Figs. 9 or 10).
W A R N I N G : (3.9L/5.2L/5.9L L D C - G A S E N G I N E S ) D O
NOT R E M O V E T H E C O I L M O U N T I N G B R A C K E T - T O -
CYLINDER H E A D MOUNTING B O L T S . T H E COIL
MOUNTING B R A C K E T IS UNDER A C C E S S O R Y
D R I V E B E L T T E N S I O N . IF T H I S B R A C K E T I S T O B E
REMOVED FOR ANY R E A S O N , A L L BELT TENSION
MUST FIRST B E RELIEVED. REFER TO THE BELT
S E C T I O N O F G R O U P 7, C O O L I N G S Y S T E M .
(2) Remove ignition coil from coil mounting

bracket (two bolts).
INSTALLATION
(1) Install the ignition coil to coil bracket. If nuts Fig. 12 Sensor Location—5.2L/5.9L
and bolts are used to secure coil to coil bracket, Engines—Typical
tighten to 11 N«m (100 in. lbs.) torque. If the coil MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
mounting bracket has been tapped for coil mounting For removal and installation, refer to Manifold Ab
bolts, tighten bolts to 5 N«m (50 in. lbs.) torque. solute Pressure Sensor in group 14, Fuel Systems.
(2) Connect all wiring to ignition coil.
OXYGEN (0 ) SENSOR
2
INTAKE MANIFOLD CHARGE AIR TEMPERATURE For diagnostics and removal/installation proce
SENSOR dures, refer to Group 14, Fuel Systems, in this man
REMOVAL ual.
The charge air temperature sensor is located in POWERTRAIN CONTROL MODULE (PCM)
right-front side of intake manifold (Figs. 11 or 12).
REMOVAL
The PCM is located in the engine compartment be
hind the battery and under the left front fender (Fig.
13).
Fig. 11 Sensor Location—3.9L Engine—Typical

(1) Disconnect electrical connector at sensor (Figs. DATA UNK CONTROL
11 or 12).
(2) Remove sensor from intake manifold. Fig. 13 PCM Location—Typical
INSTALLATION (1) Disconnect negative battery cable at battery.
(1) Install sensor to intake manifold. (2) Disconnect positive battery cable at battery.
(2) Tighten the sensor to 13 N-m (10 ft. lbs.) (3) Remove battery holddown clamps and remove
torque. battery.
(3) Install electrical connector. (4) Remove 60-way electrical connector from PCM.
(5) Remove the three PCM mounting bolts (Fig.
14).
PCM
MOUNTING
Fig. 15 Heat Shields

(2) Prior to removing the spark plug, spray com
PCM CONNECTOR pressed air around the spark plug hole and the area
CONNECTOR M O U N T I N G
BOLT J9314-165 around the spark plug. This will help prevent foreign
material from entering the combustion chamber.
Fig. 14 PCM Removal/Installation (3) Remove the spark plug using a quality socket
(6) Remove PCM from vehicle. with a rubber or foam insert.
(4) Inspect the spark plug condition. Refer to
INSTALLATION Spark Plugs in the Diagnostics/Service Procedures
(1) Check pins in PCM 60-way connector for dam section of this group.
age. Repair as necessary.
(2) Position PCM and install mounting bolts. PLUG CLEANING
Tighten bolts to 4 N»m (35 in. lbs.) torque. The plugs may be cleaned using commercially
(3) Connect 60-way electrical connector to the available spark plug cleaning equipment. After
PCM. cleaning, file the center electrode flat with a small
(4) Install battery. point file or jewelers file before adjusting gap.
(5) Connect battery cables to battery (positive ca
PLUG GAP ADJUSTMENT
ble first).
Check the spark plug gap with a gap gauge tool. If
the gap is not correct, adjust it by bending the
SPARK PLUGS
Spark plug cable heat shields are pressed into the ground electrode (Fig. 16). Never attempt to adjust
cylinder head to surround each cable boot and spark the g a p b y bending the center electrode.
plug (Fig. 15). These shields protect the spark plug
SPARK PLUG GAP
boots from damage (due to intense engine heat gen
erated by the exhaust manifolds) and should not be All Engines: .89 mm (.035 in).
removed. After the spark plug cable has been in
PLUG INSTALLATION
stalled, the lip of the cable boot should have a small
Always tighten spark plugs to the specified torque.
air gap to the top of the heat shield (Fig. 15).
Over tightening can cause distortion resulting in a
If removal of the heat shield(s) is necessary, re
change in the spark plug gap.
move the spark plug cable and compress the sides of
shield for removal. Each shield is slotted to allow for When replacing the spark plug and ignition coil ca
compression and removal. To install the shields, bles, route the cables correctly and secure them in
align shield to machined opening in cylinder head the appropriate retainers. Failure to route the cables
and tap into place with a block of wood. properly can cause the radio to reproduce ignition
noise. It could cause cross ignition of the spark plugs,
PLUG REMOVAL or short circuit the cables to ground.
(1) Always remove spark plug or ignition coil ca (1) Start the spark plug into the cylinder head by
bles by grasping at the cable boot. Turn the cable hand to avoid cross threading.
boot 1/2 t u r n and pull straight back in a steady mo (2) Tighten spark plugs to 35-41 N-m (26-30 ft.
tion. Never pull directly on the cable. Internal dam lbs.) torque.
age to cable will result. (3) Install spark plug cables over spark plugs.
.040
GAUGE
a
FRONT
C L O C K W I S E ROTATION
1-8-4-3-6-5-7-2
OF
ENGINE
SPARK
"PLUG
J9314-79
Fig. 18 Engine Firing Order—5.2U5.9L V-8 Engines

retainers. Failure to route the cables properly can
cause the radio to reproduce ignition noise. It could
also cause cross ignition of the plugs, or short circuit
J908D-10 the cables to ground.
When installing new cables, make sure a positive
Fig. 16 Setting Spark Plug Gap—Typical
connection is made. A snap should be felt when a
SPARK PLUG SECONDARY CABLES good connection is made between the plug cable and
the distributor cap tower.
C A U T I O N : When disconnecting a high voltage cable Spark plug cable boot heat shields are pressed into
from a spark plug or from the distributor cap, twist the cylinder head to surround each cable boot and
the rubber boot slightly (1/2 turn) to break it loose. spark plug (Fig. 19). These shields protect the spark
G r a s p the boot (not the cable) and pull it off with a plug boots from damage (due to intense engine heat
steady, even force. generated by the exhaust manifolds) and should not
be removed. After the spark plug cable has been in
Install cables into the proper engine cylinder firing stalled, t h e lip of the cable boot should have a small
order (Figs. 17 or 18). air gap to the top of the heat shield (Fig. 19).
CLOCKWISE ROTATION
FRONT 1-6-5-4-3-2
OF
ENGINE
SPARK PLUG B O O T
J9314-80 - HEAT SHIELD J9314-94
Fig. 17 Engine Firing Order—3.9L V-6 Engine Fig. 19 Heat Shields

When replacing t h e spark plug and coil cables, THROTTLE POSITION SENSOR (TPS)
route the cables correctly and secure in the proper For removal and installation, refer to Throttle Po
sition Sensor in Group 14, Fuel Systems.
IGNITION SYSTEMS 80 - 25
IGNITION SWITCH
INDEX
page page
General Information . . 25 Ignition Switch and Key Cylinder Service . . 25
GENERAL INFORMATION
The ignition switch is located in the steering col
umn. The Key-In-Switch and Halo Light are integral
with the ignition switch. Refer to Group 8M for Key-
In-Switch and Halo Light diagnosis.
IGNITION SWITCH AND KEY CYLINDER SERVICE

REMOVAL
(1) Disconnect negative battery cable.
(2) Tilt column: Remove tilt lever (counterclock
wise).
(3) Remove upper and lower shrouds (Fig. 1).
STEERING
COLUMN IGNITION
STEERING TILT UPPER PANEL SWITCH 908D-14
WHEEL LEVER SHROUD BRACKET
Fig. 2 Ignition Switch Screw Removal
KEY-IN SWITCH & MULTIFUNCTION

NUT SWITCH
HALO LIGHT
SPACER
TURN SIGNAL
SWITCH & LEVER
CLOCK SPRING
IGNITION SPEED
SWITCH CONTROL J918J-2
LOWER
SHROUD NUT J928J-2 Fig. 3 Key in Switch and Halo Lamp Connector
Fig. 1 Shroud Removal/Installation—Typical (a) With the key inserted and the ignition switch
in the lock position, proceed as follows: Use a small
(4) Remove ignition switch mounting screws screwdriver to depress the key cylinder retaining
(Snap-on torx bit tool TTXR20B0 or equivalent re pin flush with the key cylinder surface (Fig. 4).
quired—Fig. 2). (b) Rotate the key clockwise to the OFF position.
(5) Gently pull switch away from the column. Re The key cylinder should now be unseated from the
lease two connector locks on the 7-terminal wiring ignition switch assembly (Fig. 5).
connector. Remove t h e connector from the ignition
switch (Fig. 3). C A U T I O N : Do not remove key cylinder at this time.
(6) Release connector lock on the Key-In-Switch
and Halo Light 4-terminal connector (Fig. 3). (c) With key cylinder in unseated position (key
(7) Remove the key cylinder from the ignition cylinder bezel about 1/8 inch above ignition switch
switch as follows:
8D - 28 IGNITION SYSTEMS
SMALL KEY CYLINDER

SCREWDRIVER RETAINING PIN
HALO LIGHT
RING
KEY CYLINDER
RETAINING PIN
i-i-ii \IGNITION
SWITCH 908D-17
Fig. 6 Key Cylinder Removal

Park-lock dowel pin on ignition switch assembly
must engage with column park-lock slider linkage
IGNITION (Fig. 8). Verify ignition switch is in lock position
SWITCH 908D-15 (flag is parallel with the ignition switch terminals)
(Fig. 6). Apply a dab of grease to flag and pin. Posi
Fig. 4 Key Cylinder Retaining Pin tion park-lock link and slider to mid-travel. Position
KEY CYLINDER ignition switch against lock housing face. Be sure pin
BEZEL is inserted into park-lock link contour slot. Tighten
#
retaining screws to 2 N m (17 in. lbs.) torque.
FASTENER LOCATING
LOCATIONS PIN
PARK LOCK
'DOWEL PIN
COLUMN
LOCK
FLAG
IGNITION
SWITCH
ELECTRICAL
CONNECTION
908D-18
Fig. 7 Ignition Switch View From Column

j HALO LIGHT (3) Assemble cover to the column (3 screws).
^ RING 908D-16
Tighten retaining screws to 2 N»m (17 in. lbs.)
Fig. 5 Unseated Key Cylinder torque.
(4) Tilt column: Install tilt lever (clockwise).
halo light ring), proceed as follows: Rotate the key (5) Install negative battery cable.
counterclockwise to the Lock position and remove (6) Install key cylinder.
the key. (a) With key cylinder and ignition in lock posi
(d) Remove key cylinder (Fig. 6). tion, gently insert key cylinder into ignition switch
assembly until it bottoms.
INSTALLATION (b) Insert key. While gently pushing on the key
(1) Install electrical connectors to switch. Make cylinder (inward) toward the ignition switch, rotate
sure t h a t the switch locking tabs are fully seated in key clockwise to end of travel.
the wiring connectors.
(2) Mount ignition switch to the column (Fig. 7).
IGNITION SWITCH CIRCUITS
.__|.
1 2 3 4 5 6 7
I G N I T I O N SWITCH CONNECTOR
L O O K I N G INTO SWITCH
WIRE WIRE
APPLICATION
CAVITY COLOR
1 YELLOW STARTER RELAY
2 DARK BLUE IGNITION RUN/START
BRAKE W A R N I N G
Fig. 8 Ignition Switch Mounting Pad 3 WHITE / BLACK
LAMP
(7) Check for proper operation of push-to-lock, halo
IGNITION SWITCH
lighting, Accessory, Lock, Off, Run, Start, column 4 PINK/BLACK
BATTERY FEED
lock and shift lock (if applicable).
BLACK/ORANGE
5 RUN ACCESSORY
OR BLACK/TAN
6 BLACK / WHITE ACCESSORY
IGNITION SWITCH
7 RED
BATTERY FEED
J938D-18
SPECIFICATIONS
GENERAL INFORMATION VECI label is located in t h e engine compartment.
The following specifications are published from the
latest information available at the time of publica IGNITION TIMING
tion. If anything differs b e t w e e n the specifica Ignition timing is not adjustable on any engine.
tions found o n the Vehicle Emission Control Refer to Ignition Timing in the Diagnostics/Service
Information (VECI) label a n d the following spec Procedures section of this group for more informa
ifications, u s e specifications o n VECI label. The tion.
IGNITION COIL
COii TOYODSNSO
Primary Resistance .95- 1.20 Ohms .96- 1.18 Ohms
Secondary Resistance at 70° - 80 °F 11,300- 13,300 Ohms 11,300 - 15,300 Ohms

J918D-25
SPARK PLUGS
S p a r k Plug
Engine Original Application Tightening Size
Replacement Gap Torque
Equipment
3.9L/5.2L/5.9L RC12YC RC12YC All .035° 41 N m 14mm

(0.9mm) (30 ft. lbs.) %" Reach
J928D-23
SPARK PLUG CABLE RESISTANCE ENGINE FIRING ORDER-3.9L V-6 ENGINE
MINIMUM MAXIMUM
250 Ohms Per Inch 1000 Ohms Per Inch
3000 Ohms Per Foot 12,000 Ohms Per Foot
J908D-43
©
a FRONT
CLOCKWISE ROTATION
1 -6-5-4-3-2
,
OF V© ^ ©y
ENGINE
©
J9314-80
IGNITION SYSTEMS 8D - 29
ENGINE FIRING ORDER—5.2L/5.9L V-8 EN TORQUE

GINES
Description Torque
Crankshaft Position Sensor.. 8 N*m (70 in. lbs.)

Distributor Hold Down Bolt.. 23 N«m(17ft.ibs.)
Powertrain Control Module
Mounting Screws............ 1 N«m (9 in. lbs.)
Powertrain Control Module
(PCM) Elect. Connector... 4 N*m (35 in. lbs.)
CLOCKWISE ROTATION Spark Plugs
1-8-4-3-6-5-7-2 All Engines 41 N<>m (30ft.lbs.)
FRONT
J9314-166
OF
ENGINE
J9314-79
1
• • ^ ^ ^ INSTRUMENT PANEL AND GAUGES 8E - 1
INSTRUMENT PANEL AND GAUGES
CONTENTS
page page
CLUSTER AND GAUGE SERVICE PROCEDURES . 12 MESSAGE CENTER-DIESEL ENGINE . . . . . . . . 4
CLUSTER AND GAUGE TEST PROCEDURES .. i MESSAGE CENTER-GAS ENGINE . . . . . . . . . . 3
GENERAL INFORMATION . 1 SWITCH AND PANEL COMPONENT SERVICE . 16
GENERAL I N F O R M A T I O N
INDEX
page page
Generator Indicating System 2 Malfunction Indicator (Check Engine) 3
Distance Sensor 2 Oil Pressure Warning Lamp ................. 2
Electronic Digital Clock 3 Speedometer/Odometer System 2
Fuel Level Indicating System 1 Temperature and Oil Indicating System . . . . . . . . . 2
D-body trucks have an instrument cluster which Resistance is greatest when the fuel level in the
includes gauges for fuel level, coolant temperature, tank is low and t h e float arm drops. With high resis
oil pressure, and charging system voltage (Fig. 1). tance current flow is low and consequently positions
When the ignition switch is in t h e OFF position all the instrument panel gauge pointer to low.
the gauges will show a reading except the voltage Resistance in the circuit is at a minimum when the
gauge. However, the readings are only accurate t a n k is full and the float arm is raised. With resis
when the ignition switch is in the O N position. tance at a minimum, current flow is high registering
The cluster also includes warning lamps for: full on the instrument panel gauge.
• seat belt warning 12 VOLTS
• low oil pressure TO
• high beam GAUGE
• left and right t u r n signals
FUEL
• check engine.
IP GAUGE
FUEL TANK
SENDING UNIT
J908E-66 j ^ fCONNECTOR
Fig. 11nstrument Cluster

!g|yj-»—
1:
1
FUEL LEVEL INDICATING SYSTEM (FIG. 2)
A hinged float arm in the fuel tank raises or lowers FUEL
FLOAT TANK
depending on the fuel level. The float arm contacts a SENDING
variable resistor in the gauge sending unit. This pro UNIT J098E-47
vides a change of resistance in the fuel gauge circuit
with any up or down movement of the float. This sender Fig. 2 Fuel Level Indicating System
resistance is shown as fuel level on the gauge.
8E - 2 INSTRUMENT PANEL AND GAUGES •
TEMPERATURE AND OIL INDICATING SYSTEM
(FIG. 3)
The operation of the temperature and oil pressure
indicating systems are identical. In the temperature
system the sending unit resistance varies in direct
relationship to the temperature of the coolant.
When the engine is cold, the resistance of the tem
perature sending unit is high and a cold temperature
will be indicated on the gauge.
When the engine is hot, the resistance of the tem
perature sending unit is low and a hot temperature
will be indicated on the gauge.
In the oil pressure indicating system the sending
unit resistance is actuated by a diaphragm as the oil
VOLTAGE / * \
pressure increases or decreases. Low oil pressure GAUGE P/
causes high resistance. High pressure causes low re
sistance.
12 VOLTS
TO J908E-49
GAUGE
TEMPERATURE/
OIL GAUGE
Fig. 4 Generator Indicating System
SPEEDOMETER/ODOMETER SYSTEM
The speedometer/odometer system consists of an
electric speedometer and pushbutton reset odometer
mounted in the cluster. The system also includes the
wire harness from the cluster to the distance sensor
at the transmission, and the adapter and pinion in
the transmission. The speedometer/odometer has the
TEMPERATURE/OIL same appearance as a conventional version but it
SENDING UNIT
eliminates the cable-driven mechanical system. A
signal is sent from a transmission mounted distance
sensor to the speedometer/odometer circuitry through
the wiring harness. By eliminating the speedometer
cable, instrument cluster service and removal is im
proved. Refer to Group 21 - Transmission for select
ing the proper pinion, and selecting and indexing the
J908E-48 proper adapter.
Fig. 3 Temperature/Oil indicating System DISTANCE SENSOR
OIL PRESSURE WARNING LAMP DISTANCE SENSOR TEST
The oil pressure warning switch, mounted on the For testing of the distance sensor and related com
engine, is controlled by engine oil pressure.
ponents refer to the Vehicle Diagnostics Test Proce
When engine oil pressure is normal, the switch is
dure Manual.
held in the OFF or OPEN position. This stops cur
rent from flowing to the oil pressure warning lamp DISTANCE SENSOR REMOVAL AND
on instrument panel. INSTALLATION
When the engine oil pressure is low, the switch is (1) Remove harness connector from sensor. Be sure
in the ON or CLOSED position. This allows current weather seal stays on harness connector.
to flow to the oil pressure warning lamp in the in (2) Remove sensor by loosening sensor coupling
strument cluster causing the warning lamp to illumi nut from the pinion gear adapter until sensor is free
nate. (Fig. 5).
GENERATOR INDICATING SYSTEM (FIG. 4) (3) To install the sensor, reverse the removal pro
The voltmeter gauge senses the voltage of the elec cedures. Tighten coupling nut to 17 N»m (150 in. lbs.)
trical system.
• INSTRUMENT PANEL AND GAUGES 8E - 3
MALFUNCTION INDICATOR (CHECK ENGINE) The PCM t h e n substitutes a modified signal in place
of t h e one t h a t failed until a repair is made:
• Manifold Absolute Pressure (MAP) Sensor
• Throttle Position Sensor
• Coolant Temperature Sensor
• Battery Voltage Sense
• Battery Voltage Too High
Refer to t h e appropriate Powertrain Diagnostic
Test Procedures manual for further information.
ELECTRONIC DIGITAL CLOCK

The electronic digital clock is in t h e radio. The
clock and radio each use t h e display panel built into
the radio. A digital readout indicates t h e time in
hours and minutes whenever the ignition switch is in
the ON or ACC position.
When the ignition switch is in t h e OFF position or
when t h e radio frequency is being displayed, time
Fig. 5 Distance Sensor keeping is accurately maintained.
If t h e input from one of t h e following sensors fails The procedure for setting the clock varies slightly
an internal Powertrain Control Module (PCM) self with each radio. The correct procedure is described
under t h e individual radio operating instructions re
check, the PCM t u r n s on t h e Check Engine Lamp.
ferred to in t h e Owner Manual supplied with t h e ve
hicle.
MESSAGE CENTER—GAS ENGINE

The message center (Fig. 6), located above the m u s t b e c o r r e c t e d t o i n s u r e safe vehicle o p e r a
Heater-A/C controls, includes warning lamps for the: tion. The components covered by t h e system include
• brake systems (parking and service) the EGR system, PCV valve, and oxygen sensor.
• ABS brakes Refer to Group 25 - Emissions, for further informa
• liftgate open (Ramcharger only) tion.
• maintenance required.
ABS WARNING LIGHT
This light monitors the ABS Brake System. This
BRAKE (P)(7 light will come on when the ignition key is turned to
O/D the ON position and may stay on for as long as
GATE OPEN thirty seconds. If t h e ABS light remains on or comes
on during driving, it indicates t h a t the ABS portion
MAINT REQD. of t h e brake system is not functioning. Refer to
Group 5 - Brakes for further information.
BRAKE SYSTEM WARNING LIGHT

The dual brake system provides a reserve braking
J938E-54 capability in t h e event of a failure to a portion of t h e
hydraulic system. Failure of either of t h e dual sys
Fig. 6 Message Center—Gas Engine
tem is indicated by the brake warning light which
EMISSIONS MAINTENANCE REMINDER will glow when t h e service brake pedal is depressed.
This system is designed to act as a reminder t h a t The light will remain on until t h e cause is corrected.
scheduled vehicle emissions maintenance should be The light will also come on when t h e parking
performed. It is n o t i n t e n d e d to indicate a warn brake is applied with t h e ignition in the ON position.
ing or that a state of e m e r g e n c y exists w h i c h Refer to Group 5 - Brakes for further information.
MESSAGE CENTER—DIESEL ENGINE
The message center (Fig. 7), which is located above BRAKE SYSTEM WARNING LIGHT
the Heater-A/C controls, includes warning lamps for The Brake light is connected to a sensor t h a t mon
the: itors vacuum in the brake booster system. The Brake
• brake systems (parking and service brakes) light when lit indicates LOW VACUUM.
• ABS brakes The dual brake system provides a reserve braking
• water in fuel capability in the event of a failure to a portion of the
• wait to start (controlled by Air Heater Control hydraulic system. Failure of either of t h e dual sys
tem is indicated by t h e brake warning light which
Module)
will glow when t h e service brake pedal is depressed.
• Low Fuel.
The light will remain on until t h e cause is corrected.
The light will also come on when t h e parking
brake is applied with the ignition in the ON position.
BRAKE
Refer to Group 5 - Brakes for further information.
C U M M I N S W A T E R IN F U E L WATER IN FUEL
T U R B O DIESEL, The Water In Fuel light is connected to a sensor lo
WAIT TO S T A R T cated in t h e fuel filter. If water collects in t h e fuel/
LOW water separator filter, t h e Water In Fuel indicator
FUEL will light.
DIESEL FUEL ONLY
WAIT TO START
The Wait To Start light is connected to a sensor
J938E-55 t h a t monitors intake air temperature in t h e intake
manifold. If intake air temperature is low and igni
Fig. 7 Message Center—Diesel Engine tion switch is in ON position, t h e PCM sends current
to t h e intake manifold air heaters and t h e Wait To
ABS WARNING LIGHT
Start light. This intake manifold preheat cycle is
This light monitors t h e ABS Brake System. This controlled by a n electronic Air Heater Control Mod
light will come on when the ignition key is turned to ule.
the ON position and m a y stay on for as long as
thirty seconds. If the ABS light remains on or comes LOW FUEL
on during driving, it indicates t h a t t h e ABS portion The Low Fuel light is connected to a sensor in t h e
of t h e brake system is not functioning. Refer to fuel tank. When the fuel level reaches approximately
Group 5 - Brakes for further information. 1/6 of a tank, t h e words LOW FUEL will illuminate
and remain on until fuel is added.
C L U S T E R A N D GAUGE TEST P R O C E D U R E S
INDEX
page page
Fuel Gauge Circuit Test 9 Speedometer 10
Fuel Tank Sending Unit Test 5 Temperature Gauge Circuit Test 8
Oil Pressure Gauge Circuit Test .............. 9 Voltage Gauge Circuit Test 10
Sending Unit (Sensor) Test 5 Warning Lamp System Tests 6
C A U T I O N : Disconnect battery negative cable, in en FUEL TANK SENDING UNIT TEST
gine compartment, before servicing instrument (1) Disconnect wire from terminal on fuel tank
panel. When power is required for test purposes, sending unit (Fig. 1).
connect battery cable (for test only).
FUEL PUMP SUPPLY
Disconnect battery negative cable after test
and before continuing service procedures.
INPUT TO G A U G E
SENDING UNIT (SENSOR) TEST
When a problem occurs with a cluster gauge, be SENDING UNIT GROUND
fore disassembling the cluster to check the gauge,
check for a defective sending unit (sensor) or wiring. FUEL PUMP GROUND
(1) Sending units and wiring can be checked by J928E-49
grounding the connector leads, a t the sending unit,
in t h e vehicle. Fig. 1 Fuel Tank Sending Connector Terminals
C A U T I O N : When connecting an input terminal to (2) Connect wire to a known good sending unit.
ground, D o Not leave the connection grounded for (3) Connect a jumper wire between sending unit
more than a few seconds. fuel pick up tube and a good ground.
(4) Check fuel gauge as described in following
(2) With the ignition in the O N position; a steps. Allow a t least three minutes at each test point
grounded input will cause t h e oil, fuel or tempera for gauge to settle. Lightly tapping instrument clus
ture gauge to read a t or above maximum. ter may help position pointer.
FUEL GAUGE SYSTEM DIAGNOSIS
FUEL G A U G E S Y S T E M D I A G N O S I S
FUEL G A U G E FUEL G A U G E 1 FUEL CpAUGE I

FUEL G A U G E
DOES NOT INOPERATIVE 1 DOES> N 0 ? 1
INACCURATE
I
R E A D FULL OR ERRATIC 1 R E A D 1EMPTY 1
1 r
CHECK FAULTY WIRING OR TANK DEFORMED TANK N O T EMPTY

TANK NOT FULL COMPONENTS CHECK CHECK
E i
PROPER ALIGNMENT
CHECK ALL WIRING OF PICKUP A N D
INCLUDING SENDER ASSEMBLY.
GROUND REFER TO GROUP 14
i
FAULTY PRINTED FAULTY FUEL GAUGE FAULTY FUEL
CIRCUIT BOARD SENDING UNIT GAUGE
J908E-74
(5) Clip float arm of sending unit to its empty stop (c) Sending unit improperly installed. Install
(Fig. 2) and t u r n ignition key to ON position. The properly.
gauge should read Empty, plus one pointer width, or (d) Mounting flange on fuel t a n k for sending
minus two pointer widths. unit deformed. Feel for interference fit of sending
(6) Move and clip sending unit float arm to full unit to bottom of tank. It is permissible to bend
stop. The gauge should read Full, or above. pick up tube down a little near mounting flange to
gain interference fit.
(e) Fuel tank bottom deformed causing improper
positioning of sending unit pick up tube. Replace or
repair t a n k and recheck sending unit. Refer to Fuel
Tank Section of Group 14 - Fuel System.
WARNING LAMP SYSTEM TESTS

LOW OH. PRESSURE WARNING LAMP
CIRCUIT TEST
The low oil pressure warning lamp will illuminate
when the ignition key is turned to the ON position.
The lamp also illuminates if the engine oil pressure
drops below a safe oil pressure level.
To test the system t u r n ignition key to the ON po
sition.
If the lamp fails to light, inspect for a broken or
disconnected wire at the oil pressure combination
unit. The combination unit is located at the rear of
the engine (Fig. 3). If the wire at the connector
checks good, pull connector loose from the switch and
with a jumper wire ground connector to the engine
Fig. 2 Fuel Tank Sending Unit Test (Fig. 4). With the ignition key turned to the ON po
RESULTS sition check the warning lamp. If lamp still fails to
(1) If fuel gauge does not meet specifications, check light, inspect for a burned out bulb or disconnected
following items as possible causes; socket in the cluster.
(a) Wiring and connections between the gauge If light c o m e s on, proceed and start engine. If the
sending unit and multiple connector. lamp remains on, immediately t u r n engine off and
(b) Wiring and connections between multiple check engine oil pressure according to procedures as
connector and printed circuit board terminals. outlined in Group 9 - Engine of this manual. If the
(c) Circuit continuity between printed circuit oil pressure meets specifications, check for a
board terminals and gauge terminals. grounded wire and/or replace the oil pressure send
If these items check okay, fuel gauge is defective ing unit (refer to combination oil unit test).
and must be replaced.
(2) If the fuel gauge meets specifications check fuel
t a n k and original installed fuel t a n k sending unit as
follows:
(a) Carefully remove fuel t a n k sending unit from
tank.
(b) Connect sending unit wire and jumper wire
as described in the procedure.
(3) If fuel gauge now checks within specifications,
originally installed sending unit is electrically okay,
check following as possible cause:
(a) Ground strap from sending unit to fuel line
for continuity.
(b) Sending unit deformed. Make sure sending
unit float arm moves freely and pick up tube is not
bent so t h a t it contacts bottom of tank. Inspect
float for any signs of damage or leaks. Fig. 3 Oil Pressure Sending Unit—Gas Engine
ENGINE WARNING LAMP DIAGNOSIS

OIL PRESSURE FUNCTION
TURN
IGNITION
SWITCH "OH"
(DO NOT
ISTART ENGINE)!
LAMP "OFF' LAMP "ON" LAMP STAYS

"ON"
DEFECTIVE START AND IDLE TURN OFF

BULB ENGINE ENGINE
STEERING
PUMP ENGINE BLOCK J9U9-74
BULB SOCKET CHECK FOR
OR WIRING LAMP GOES GROUNDED
Fig. 4 Oil Pressure Sending Unit—Diesel Engine OPEN "OFF" WIRING
COMBINATION OIL UNIT TEST (FIG. 5)
The combination oil unit has 2 functions:
(1) The normal closed circuit keeps t h e oil pressure
DEFECTIVE WARNING CHECK FOR
warning lamp on until there is oil pressure. LOW OIL
SWITCH LIGHT OK
(2) The sending provides a resistance t h a t varies LEVEL
with oil pressure.
To test the normally closed oil lamp switch, discon
nect the locking connector and measure the resis
tance between the switch terminal and the metal ENGINE OIL ENGIM IE OIL 1 TEST ENGINE
PRISSURi PRESSURE 1 OIL PRESSURE
housing. The ohmmeter should read 0 ohms. Start LOW 0, K
the engine. I
If there is oil pressure, the ohmmeter should read
an open circuit.
To test the sending unit, measure the resistance REFER TO DEFECTIVE
between the sending unit terminal and the metal ENGINE SERVICE SWITCH
housing. The ohmmeter should read open, Start the DIAGNOSIS
PR1448C
engine.
The ohmmeter should read between 30 to 55 ohms, SENDING UNIT
depending on engine speed, oil temperature, and oil (GAUGE)
viscosity.
If the previous results are not obtained, replace the
switch.
SEAT BELT WARNING SYSTEM

For testing of this system refer to Section 8M -
Seat Belt Warning Systems. SWITCH
(LIGHT)
BRAKE SYSTEM WARNING LAMP (FIG. 6)
The brake warning lamp illuminates when the 898E-2
parking brake is applied with the ignition key
turned ON. The same lamp will also illuminate Fig. 5 Combination Oil Unit Terminals
should one of the two service brake systems fail nected wire at the switch. The lamp also lights when
when the brake pedal is applied. To test the system the ignition switch is turned to the START position.
turn the ignition key ON, and apply the parking To test the service brake warning system,
brake. If the lamp fails to light, inspect for a burned (1) Raise the vehicle on a hoist.
out bulb, disconnected socket, a broken or discon- (2) Open a wheel cylinder bleeder while a helper
(TURN IGNITION KEY "ON"

TO BRAKE (DO NOT START ENGINE
BRAKE WARNING I RELEASE PARKING BRAKE) I
WARNING LAMP
LAMP I
SWITCH X
[ WARNING LIGHT GOES I APPLY PARKING BRAKE
"ON" I (WARNING LIGHT
1 (LIGHT SHOULD BE "OFF")! SHOULD G O "ON")
X
BRAKE SYSTEM WARNING LIGHT
LEAKING FLUID FAILS TO GO "ON"
GROUNDED WIRING BULB BURNED OUT

PR! 451
Fig. 6 Brake Warning Lamp Switch

SHORTED PARKING BRAKE DISCONNECTED OR FAULTY
depresses the brake pedal and observes the warning OR BRAKE WARNING SWITCH BULB SOCKET
lamp.
If the lamp fails to light, inspect for: X
FAULTY BRAKE SYSTEM BROKEN WIRE OR WIRE
• a burned out bulb PROPORTIONING DISCONNECTED AT PARKING
• disconnected socket VALVE UNIT* BRAKE SWITCH
• a broken or disconnected wire a t t h e switch. X
If t h e bulb is not burned out and the wire continu
FAULTY PARKING
ity is proven, replace the brake warning switch. The BRAKE SWITCH
switch is in t h e brake line Tee fitting mounted on
the frame rail in the engine compartment below the X
master cylinder. APPLY SERVICE BRAKES
(WARNING LIGHT
SHOULD NOT G O "ON")
C A U T I O N : If wheel cylinder bleeder w a s opened
check master cylinder fluid level. JZ X
TEST SERVICE BRAKE WARNING LIGHT GOES
WARNING
O n Diesel Models The Brake light is also con SYSTEM FUNCTION*
"ON"
nected to a sensor t h a t monitors vacuum in the
brake booster system. The Brake light when lit indi X
cates LOW VACUUM. Refer to Group 5 - Brakes for WARNING LIGHT BRAKE SYSTEM
more information. DOES NOT GO "ON" LEAKING FLUID
X
TEMPERATURE GAUGE CIRCUIT TEST GROUNDED WIRING OR
(1) Remove temperature gauge. Refer to Gauge Re OPEN CIRCUIT IN WIRING SHORTED BRAKE WARNING
TO SERVICE BRAKE SWITCH SWITCH
placement.
(2) Check continuity in the wire between the tem X
perature sensor and the temperature gauge (sensor FAULTY BRAKE SYSTEM
LOOSE BULKHEAD PROPORTIONING
input pin) (Figs. 7, 8 and 9). CONNECTOR VALVE UNIT*
(3) With the ignition switch in the ON position,
check for battery voltage across the B + pin and the
•TESTS ARE DESCRIBED
Ground pin. FAULTY SERVICE BRAKE IN APPROPRIATE
SWITCH SECTION OF SERVICE
MANUAL
X
FAULTY SERVICE BRAKE
SYSTEM PROPORTIONING
VALVE UNIT* PR1449A
INSTRUMENT PANEL AND GAUGES 8E - S
J908E-6i_
Fig. 9 Temperature Gauge Pins

TEMPERATURE/OIL/FUEL GAUGE DIAGNOSIS
GAUGE INDICATES HIGHER

OR LOWER T H A N ACTUAL
I
FAULTY WIRING
'TEST
J938E-34 PROCEDURES
FAULTY SENDING UNIT* DESCRIBED
Fig. 7 Coolant Temperature Sensor—Gas Engine ARE
IN
AIR APPROPRIATE
FAULTY INSTRUMENT PANEL SECTION
TEMPERATURE GAUGE*
SWITCH OF
SERVICE
MANUAL
ERRATIC GAUGE OPERATION
LOOSE OR DIRTY ELECTRICAL CONNECTIONS
FAULTY INSTRUMENT PANEL

GAUGE* J908E-52
FUEL GAUGE CIRCUIT TEST
- COOLANT (1) Remove fuel gauge assembly. Refer to Gauge
TEMPERATURE
SWITCH Replacement.
(2) Check for continuity in the wire between the
Fig. 8 Coolant Temperature Sensor—Diesel Engine fuel t a n k sending unit and the gauge (fuel level in
put pin) (Figs. 14 and 15).
OIL PRESSURE GAUGE CIRCUIT TEST
(1) Remove oil pressure gauge. Refer to Gauge Re
placement. Ground pin.
(2) Check for continuity in the wire between t h e
oil pressure sensor and the oil pressure gauge (sensor
input pin) (Figs. 10, 11, 12 and 13).
check for battery voltage across the B + pin and t h e
Ground pin.
8E - 10 INSTRUMENT PANEL AND GAUGES
GROUND OIL PRESSURE

SENSOR INPUT
J908E-70
Fig. 10 Oil Pressure Sending Unit—Gas Engine Fig. 13 Oil Pressure Gauge Pins
r— FUEL PUMP SUPPLY
0 INPUT TO G A U G E
- S E N D I N G UNIT G R O U N D
-FUEL PUMP G R O U N D
J928E-49
Fig. 14 Fuel Tank Sending Connector Terminals

FUEL GAUGE
INPUT
STEERING
PUMP ENGINE BLOCK J9119-74
Fig. 11 Oil Pressure Sending Unit—Diesel Engine

S E N D I N G UNIT
(GAUGE)
^ GROUND y J908E-71
Fig. 15 Fuel Gauge Pins
SWITCH
(LIGHT) check for battery voltage across the B + pin and the
Ground pin (Fig. 16).
898E-2 The instrument p a n e l v o l t m e t e r i n d i c a t e s elec
t r i c a l system battery voltage.
Fig. 12 Combination Oil Unit Terminals
VOLTAGE GAUGE CIRCUIT TEST SPEEDOMETER
(1) Remove voltage gauge. Refer to Gauge Replace (1) Remove speedometer assembly. Refer to Gauge
ment. Replacement.
• — INSTRUMENT PANEL AND GAUGES 8E - 11
(4) Perform distance sensor test. Refer to General

Information - Distance Sensor in this section.
(5) If all previous tests prove good, replace speed
ometer.
Fig. 16 Voltmeter Pins

(2) Check for continuity in the wire between the
distance sensor connector and the speedometer (dis
tance sensor input pin) (Fig. 17).
(3) With the ignition switch in the ON position, Fig. 17 Speedometer Pins
Ground pin.
CLUSTER AND GAUGE SERVICE PROCEDURES
INDEX
page page
Cluster Bezel 12 Lamp Bulbs .. 15
Cluster Mask and Lens 12 Printed Circuit Board 13
Fuel Gauge 13 P R N D 2 1 Indicator . 15
Instrument Cluster Assembly 12 Specifications 15
Lamp Bulb Replacement—Message Center . . . . . 15 Speedometer/Odometer 14
CLUSTER BEZEL (5) Install map lamp.

(6) Remove tape from steering column.
REMOVAL (7) Connect negative cable to battery.
(2) Tape or cover steering column to prevent dam CLUSTER MASK AND LENS
age to paint.
(3) Remove 2 screws and remove map lamp. REMOVAL
C A U T I O N : M a p lamp must be removed to prevent (2) Remove cluster bezel.
damage to instrument panel. (3) Remove 8 screws holding mask and lens.
(4) Remove mask and lens.
(4) Remove 6 screws which attach cluster bezel to
base panel (Fig. 1). Make sure t h e screw below t h e INSTALLATION
Heater-A/C control is removed. (1) Position mask and lens.
(5) Place column shift lever in Position " 1 " . (2) Install 8 screws.
(6) Remove bezel by pulling top edge rearward to (3) Install cluster bezel.
clear brow. Disengage attaching clips around bottom (4) Connect negative cable to battery.
of bezel and complete removal of bezel.
(7) If bezel is equipped with a four wheel drive in INSTRUMENT CLUSTER ASSEMBLY (Fig. 2)
dicator, remove bulb socket as bezel is removed.
REMOVAL
(8) Disconnect message center wires.
INSTRUMENT (2) Tape or cover steering column to prevent dam
age to paint.
(3) Remove bezel.
(4) Remove lower steering column cover 4 screws.
(5) Spread upper steering column cover out of the
locking tangs and slide downward.
(6) Disconnect PRND21 actuator cable from steer
ing column if equipped.
(7) Loosen heater and A/C control. Pull rearward
to clear forward mount on cluster housing.
(8) Remove 6 screws t h a t retain cluster. Pull clus
ter rearward and disconnect 2 large connectors.
CLUSTER BEZEL J938E-51 (9) Remove cluster.
Fig. 1 instrument Cluster Bezel INSTALLATION
INSTALLATION (1) Connect 2 large connectors to cluster.
(1) Connect bulb socket for four wheel drive indi (2) Position cluster to instrument panel and install
cator if equipped. 6 retaining screws.
(2) Connect message center wires. (3) Install heater A/C control.
(3) Engage attaching clips around bottom of bezel, (4) Connect PRND21 actuator to steering column if
roll bezel into position. equipped.
(4) Install 6 mounting screws. (5) Position upper steering column cover and slide
upward until tangs snap into place.
INSTRUMENT PANEL AND GAUGES 8E - 13
INSTRUMENT M A P LAMP
PANEL BRACKET
HEADLAMP
SWITCH
CLUSTER
ASSEMBLY
C A R G O LAMP S W I T C H
HEADLAMP BEZEL A N D APPLIQUE
SWITCH MOUNTING
NUT
HEADLAMP
SWITCH BEZEL
HEADLAMP
KNOB A N D STEM
BRACKET-AAAP LAMP M O U N T I N G CLUSTER MASK

A N D LENS J928E-46
Fig. 2 Instrument Panel Cluster and Switches

(6) Position lower steering cover and install 4 INSTALLATION
screws.
(7) Install bezel. C A U T I O N : D o not overtighten mounting screws or
(8) Remove protective cover from steering column. damage to circuit board and/or cluster housing will
(9) Connect negative cable to battery. occur.
(10) Check to see t h a t all instruments are func
(1) Position printed circuit board on cluster hous
tioning properly.
ing, install mounting screws and tighten.
PRINTED CIRCUIT BOARD (2) Install gauges.
A visual inspection of the conductors should be (3) Install lamp socket assemblies. Be sure illumi
made for cracks or damaged circuits. If no visual nation lamp diffusers are installed.
damage is evident, each circuit should be tested for (4) Install instrument cluster.
continuity with an ohmmeter or a test light. Should
an open circuit be detected, the printed circuit board FUEL GAUGE
should be replaced. TEMPERATURE GAUGE
VOLTAGE GAUGE
REMOVAL (FIG. 3J OIL PRESSURE GAUGE
(1) Remove instrument cluster. See cluster re It is not necessary to remove instrument clus
moval. ter from vehicle for g a u g e replacement.
(2) Remove lamp socket assemblies. When removing gauge assemblies (Fig. 4) from
(3) Remove gauge mounting screws and remove cluster, gauge must be pulled straight out, not
gauges. twisted, or damage to gauge pin and/or printed cir
(4) Remove printed circuit board mounting screws. cuit board may result.
(5) Remove printed circuit board from cluster hous (1) Disconnect negative cable from battery.
ing. (2) Remove bezel. Refer to Cluster Bezel Removal.
(3) Remove cluster mask and lens. Refer to Cluster
Mask and Lens Removal.
Fig. 3 instrument Cluster Printed Circuit Board

VOLTAGE SPEEDOMETER OIL PRESSURE
GAUGE GAUGE
TEMPERATURE
GAUGE FUEL GAUGE J908E-69
Fig. 4 Cluster With Mask Removed

(4) Remove gauge mounting screws. (1) Disconnect negative cable from battery.
(5) Pull gauge rearward to remove. (2) Remove bezel. Refer to Cluster Bezel Removal.
For Installation, reverse Removal procedures. (3) Remove cluster mask and lens. Refer to Cluster
Mask and Lens Removal.
SPEEDOMETER/ODOMETER (4) Remove mounting screws retaining speedome
It is n o t n e c e s s a r y to r e m o v e instrument clus ter/odometer to housing.
t e r from vehicle for s p e e d o m e t e r replacement. (5) Pull speedometer/odometer rearward to remove.
When removing speedometer (Fig. 4) from cluster, For Installation, reverse Removal procedures.
gauge must be pulled straight out, not twisted, or
damage to gauge pin and/or printed circuit board
may result.
PRND21 INDICATOR (2) Install lamp socket assembly into printed cir
cuit board.
REMOVAL (3) Install Instrument Cluster bezel assembly to
(1) Remove bezel. Refer to Cluster Bezel Removal. instrument panel. Refer to Instrument Cluster instal
(2) Remove cluster mask and lens. Refer to Cluster lation.
Mask and Lens Removal. (4) Connect negative cable from battery.
(3) Remove cluster assembly. Refer to Instrument
Cluster Removal. FOUR WHEEL DRIVE INDICATOR LAMP
(4) Remove screws attaching PRND21 mechanism (1) Pull bulb and socket assembly from rear of
to cluster housing. housing.
(5) Remove PRND21 mechanism. (2) Remove bulb from socket.
INSTALLATION (3) Reverse removal procedures to install.
(1) Position PRND21 mechanism to cluster hous
SPECIFICATIONS
ing.
(2) Install mounting screws. Fuel Gauge Calibration
(3) Install cluster assembly. Mntar Position Resistance
(4) Install mask-lens. Empty Graduation 90 ohms ± 3 ohms
(5) Install bezel. Empty Stop Greater than 96.5 ohms
Full Graduation 12 ohm ± 3 ohms
LAMP BULBS
Full Stop Less than 8 ohms
CLUSTER ILLUMINATION LAMPS 1/2 45.3 ohms ± 3 ohms
TURN SIGNAL INDICATOR LAMPS
LOW OIL PRESSURE INDICATOR LAMP Temperature Gauge Calibration
HIGH BEAM INDICATOR LAMP Pointer Position Resistance
CHECK ENGINE LAMP Cold Graduation 655 ohms
SEAT BELT WARNING LAMP Hot Graduation 64 ohms
REMOVAL
(1) Disconnect negative cable from battery. Oil Pressure Gauge Calibration
(2) Remove instrument cluster. See cluster re Pointer Position Resistance
moval. Low Graduation 100 ohms
(3) Twist lamp socket assembly and remove from High Graduation 12 ohms
printed circuit board. J908E-58
(4) Remove bulb from socket.
INSTALLATION
(1) Install bulb into socket.
(2) Install socket assembly into printed circuit
board.
(3) Position cluster into place in panel. See cluster
installation.
(4) Connect battery negative cable.
LAMP BULB REPLACEMENT—MESSAGE CENTER

REMOVAL
(1) Disconnect battery negative cable.
(2) Remove instrument cluster bezel assembly. Re
fer to Instrument Cluster removal.
(3) Twist lamp socket assembly and remove from
printed circuit board.
(4) Remove bulb from socket.
INSTALLATION
(1) Install bulb into socket assembly.
SWITCH AND PANEL COMPONENT S E R V I C E
INDEX
page page
A s h Tray 20 Heater Control 16
Cigar Lighter . . . . . . . . . . . . . . . . . . . . . . . . 20 Hood Release 19
Four Wheel Drive Indicator 19 Illumination Bulb Replacement 22
Fuse Block and Flashers . . . . . . . . . . . . . . . . . . . 19 M e s s a g e Center Module . . . . . . . . . . . . . . . . . . . 18
Glove Box 21 Steering Column Lowering and Raising 16
Heater A / C Control 17 Switches 17
DISCONNECT NEGATIVE CABLE FEOM RAISING STEERING COLUMN

B A T T E R Y IN E N G I N E C O M P A E T M E N T B E (1) Raise steering column assembly against the in
FORE SERVICING INSTRUMENT PANEL. strument panel support bracket.
(2) Install 2 steering column bracket washers and
STEERING COLUMN LOWERING AND RAISING nuts (Finger Tighten Only).
When servicing the instrument panel and the Low
ering and Raising of the steering column is required, C A U T I O N : Check that all wiring is clear and not
the following is the procedure for doing so: pinched.
This procedure is not for removing and replac
ing the steering column. Refer to Group - 19 (3) Tighten the 2 bracket nuts to 12 Nnn-(110 in.
Steering of this manual for the removal and re lbs.) torque.
placement procedures. (4) Slide toe plate into position, install attaching
screw, tighten to 4 N®m (35 in. lbs.).
LOWERING STEERING COLUMN (5) Install toe plate nuts and washers and tighten
(1) Disconnect negative cable from battery. to 23 N*m (200 in. lbs.).
(2) Remove 3 toe plate nuts and washers (Fig. 1).
(6) Connect cable to shift indicator bracket.
(3) Remove 1 toe plate screw.
(7) Position upper steering column cover and slide
(4) Remove 4 screws attaching lower steering col
upward until tangs snap into place.
umn cover and remove cover. The fuse block is at
tached to this cover and should be supported when (8) Install fuse block to cover.
cover is removed. (9) Position lower steering column cover and in
(5) Spread upper steering column cover out of lock stall 4 attaching screws.
ing tangs and slide downward.
(6) Disconnect cable from shift indicator bracket. HEATER CONTROL
(7) Remove 2 nuts and washers attaching steering
REMOVAL
column bracket to instrument panel steering column
(1) Remove map lamp.
support bracket.
(2) Remove cluster bezel (refer to Cluster Bezel Re
(8) Allow column to lower and rest on seat.
moval).
STEERING (3) Remove 2 control attaching screws.
COLUMN SUPPORT (4) Pull control rearward.
(5) Disconnect illumination lamp, and wire connec
tions.
(6) Disconnect control cables.
(7) Remove control.
INSTALLATION
(1) Position control near panel.
(2) Connect control cables to control (see Heater
A/C Section).
(3) Connect illumination lamp, and wire connec
tors.
(4) Push control into panel.
WASHER A N D NUT (5) Install 2 control mounting screws.
(6) Install bezel.
Fig. 1 Steering Column Mounting (7) Install map lamp.
INSTRUMENT PANEL AND GAUGES 8E - 17
HEATER A/C CONTROL SWITCHES

REMOVAL HEADLAMP SWITCH (FIG. 2)
(2) Remove cluster bezel (refer to Cluster Bezel Re REMOVAL
moval). (1) Remove cluster bezel (refer to Cluster Bezel Re
(3) Remove 2 control attaching screws. moval).
(4) Pull control rearward. (2) Reaching under instrument panel, depress knob
(5) Disconnect blower switch wiring. and stem release button located on bottom of switch
(6) Disconnect wires to pushbutton switch (three housing. At the same time pull knob a n d stem as
connectors). sembly out of switch housing located on front of
(7) Disconnect illumination lamp. panel.
(8) Disconnect vacuum harness. (3) Remove power mirror switch knob by pulling
(9) Disconnect temperature cable. straight off.
(10) Remove control. (4) Remove bezel.
(5) From front of panel remove spanner nut,
INSTALLATION mounting switch to panel.
(1) Position control near panel. (6) Reaching under instrument panel, lower switch
(2) Connect temperature cable (see Group 24 - down far enough to disconnect electrical leads.
Heating and Air Conditioning). (7) Remove switch.
(3) Connect vacuum harness.
(4) Connect illumination lamp. INSTALLATION
(5) Attach 3 wire connectors to pushbutton switch. (1) Connect all electrical leads to switch.
(6) Connect wires to blower motor switch. (2) Guide switch into position in panel, install
(7) Push control into panel. spanner nut and tighten securely.
(8) Install 2 control mounting screws. (3) Install bezel.
(9) Install cluster bezel. (4) Install power mirror switch knob.
(10) Install map lamp. (5) Insert knob and stem assembly into switch.
INSTRUMENT AAAP LAMP

PANEL BRACKET
HEADLAMP
SWITCH
CLUSTER
ASSEMBLY
CARGO LAMP SWITCH
HEADLAMP BEZEL AND APPLIQUE
SWITCH MOUNTING
NUT
HEADLAMP
SWITCH BEZEL
HEADLAMP
KNOB AND STEM
BRACKET-MAP LAMP MOUNTING CLUSTER AAASK

AND LENS J928E-46
Fig. 2 Instrument Panel Switches

8E - 18 INSTRUMENT PANEL AND GAUGES — •
(6) Install cluster bezel.
(7) Check operation of switch.
POWER MIRROR SWITCH

Refer to Group 8T - Power Mirrors
CARGO LAMP SWITCH
REMOVAL
(1) Locate chime module. Grasp chime module and
twist it to remove it from the bracket.
(2) Remove wiring connector from cargo lamp
switch.
(3) Depress lock tabs on switch and push it out of
the instrument panel.
INSTALLATION
(1) Hold wiring connector in switch opening.
(2) Push switch on to wiring connector.
(3) Continue to push until switch snaps into place.
(4) Install chime module on to bracket.
MAP LAMP SWITCH

Fig. 3 Overdrive Lockout Switch and Message
REMOVAL Center Module
(1) Remove 2 attaching screws.
(2) Drop assembly down and remove wiring con
nector, then remove map lamp assembly.
INSTALLATION
(1) Connect wiring connector to lamp assembly.
(2) Position map lamp assembly to panel and in
stall 2 mounting screws.
GLOVE BOX LAMP SWITCH
REMOVAL
(1) Open glove box until stops in bin rest against
instrument panel.
J918E-32
(2) Depress stops to clear instrument panel and
continue pivoting glove box assembly downward. Fig. 4 Message Center Printed Circuit
(3) Disconnect wire to switch. Board—Automatic Transmission
(4) Snap switch out of panel.
INSTALLATION
INSTALLATION (1) Position lockout switch into module and push
(1) Snap switch into panel. until retaining tabs lock into place.
(2) Connect wire to switch. (2) Connect switch connector.
(3) Depress stops and close glove box door. (3) Install instrument cluster bezel to panel.
OVERDRIVE LOCKOUT SWITCH (FIG. 3) MESSAGE CENTER MODULE (Fig. 3)

REMOVAL REMOVAL
(1) Remove map lamp. (1) Remove map lamp.
(2) Remove cluster bezel (refer to Cluster Bezel Re (2) Remove cluster bezel (refer to Cluster Bezel Re
moval). moval).
(3) Reach behind bezel and disconnect lockout (3) Reach behind bezel and disconnect lockout
switch connector. switch (if equipped) and message center connectors.
(4) Depress retaining tabs on top and bottom of (4) Remove 3 module retaining screws and one clip
switch and pull switch out of module. and pull module from bezel.
MESSAGE CENTER • Horn relay.

• Hazard Warning Flasher.
INSTALLATION
(1) Position fuse block to steering column cover.
(2) Push locking tab to lock fuse block in position.
HOOD RELEASE
REMOVAL
(1) Disengage cable from hood latch in engine com
partment.
(2) Remove 4 screws holding handle assembly to
PRINTED CIRCUIT BOARD instrument panel.
J918E-33
(3) Remove assembly by pulling cable rearward
Fig. 5 Message Center Printed Circuit through dash panel grommet.
Board—Manual Transmission
INSTALLATION
LOW FUEL MODULE > (1) Feed cable assembly forward through dash
panel grommet.
(2) Mount handle assembly to instrument panel
with four screws.
(3) Connect cable to hood latch.
FOUR WHEEL DRIVE INDICATOR

REMOVAL
moval).
PRINTED CIRCUIT BOARD (3) Remove 2 screws and remove indicator from be
J918E-34
zel (Fig. 7).
Fig. 6 Message Center Printed Circuit Board—Diesel
(5) Remove overdrive lockout switch from module.
INSTALLATION
(1) Install overdrive lockout switch into module.
(2) Position module on bezel and install screws and
clip.
(3) Connect lockout switch and message center
connectors.
(4) Install instrument cluster bezel to panel.
(5) Install map lamp.
FUSE BLOCK AND FLASHERS

FUSE BLOCK
The fuse block is located directly below the steer
ing column, on the lower steering column cover.
REMOVAL
Push fuse block locking tab on column cover down
o J928E-48
ward and lower fuse block. The following components
plug into the fuse block. Fig. 7 Four Wheel Drive Indicator Bezel
• Fuses.
• 30 amp circuit breakers.
• Turn signal flasher.
INSTALLATION ASH TRAY (Fig. 8)
(1) Position indicator to bezel and attach with two
screws. TRAY
REMOVAL
(3) Install map lamp.
(1) Open ash tray.
CIGAR LIGHTER (Fig. 8) (2) Remove ash tray bin.
REMOVAL INSTALLATION
(1) Open ash receiver. (1) Install ash tray bin.
(2) Remove lighter element from shell.
(3) Disconnect wiring. (2) Push ash tray inward to closed position.
(4) Turn clamp counterclockwise and remove.
HOUSING
(5) Remove shell through front of housing.
REMOVAL
INSTALLATION
(1) Remove ash tray bin.
(1) Insert shell through front of housing.
(2) Disconnect electrical leads from cigar lighter.
(2) Install clamp on shell, t u r n clockwise and
(3) Remove 6 screws retaining housing to panel.
tighten securely.
(4) Remove cigar lighter from housing.
(3) Connect wiring to shell.
(4) Install lighter element. INSTALLATION
(5) Install wires and close ash receiver. (1) Install cigar lighter in housing.
(2) Connect electrical leads to cigar lighter.
(3) Position housing to panel and install six
mounting screws.
(4) Install ash tray bin.
Fig. 8 Cigar Lighter and Ash Tray

GLOVE BOX (Fig. 9) INSTALLATION

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

ILLUMINATION BULB REPLACEMENT (3) Remove bulb and socket.
ASH TRAY ILLUMINATION LAMP INSTALLATION

(1) Snap in bulb and socket.
REMOVAL (2) Replace cluster bezel.
(1) Open ash receiver and remove bin. (3) Install map lamp.
(2) Disconnect wires from cigar lighter.
(3) Remove 6 screws t h a t retain assembly to panel. HEATER OR HEATER A/C ILLUMINATION
(4) While dropping ash receiver, remove lamp as LAMP
sembly from top of the housing.
REMOVAL
INSTALLATION
(1) Install lamp assembly into top of housing. (2) Remove cluster bezel (refer to Cluster Bezel Re
(2) Position housing and install 6 mounting moval).
screws.
(3) Remove two control attaching screws.
(3) Connect wires to cigar lighter.
(4) Pull control rearward.
(4) Install bin and close ash receiver.
(5) Snap out illumination lamp.
MAP LAMP BULB
INSTALLATION
To replace bulb, snap lens out, replace bulb. (1) Install bulb into socket.
(2) Snap socket into control.
FOUR WHEEL DRIVE INDICATOR (3) Push control forward and install two attaching
screws.
REMOVAL
(1) Remove map lamp. (5) Install map lamp.
moval).
AUDIO SYSTEMS
CONTENTS
page page
SERVICE PROCEDURES .. 7 TEST PROCEDURES .. 2
GENERAL INFORMATION
For operation of the factory installed radios, refer RADIO NOISE DIAGNOSIS
to the Owner Manual supplied with the vehicle.
When connecting or disconnecting the Ignition Off Noise, Static
Draw (IOD) connector, it is important t h a t the igni Hash, Etc.
tion switch be in the OFF position.
Failure to place the ignition switch in the OFF po Check For Noise in the
Following Positions:
sition can cause the radio display to become scram 1. Accessory (All Electrical
bled when the IOD is disconnected. Connecting the Accessories Off)
IOD will correct the scrambled display. 2. Engine Running
INTERFERENCE ELIMINATION
Is
Many components are used on vehicles equipped 'Static/NoiseS
with a radio to suppress radio frequency interference Present No
(static). 'With Ign. Key in Acc.
A capacitor is mounted inside the generator and Y e s \ ^ | j Accessories/
ground straps are utilized from cab to box and from Off
Is
the engine to cowl. Static/Noise
No Yes
The previously mentioned Capacitor and Ground Present
Straps should be securely mounted to a clean ground With Engine
Running?.
surface to work effectively. Refer to
Radio resistance spark plug wires complete the in Antenna
Diagnosis
terference suppression system. Faulty or deteriorated
Check Following:
spark plug wires should be replaced. \ f A. Electric Fuel Pump
B. Ignition System Faults
Stop C. Faulty Ground Connections
D. Faulty Electronic Voltage Reg.
J928F-3 E. Tighten Antenna Mounting Nut
8F - 2 AUDIO SYSTEMS
•
RADIO CONNECTOR PINS
CHRYSLER A M / F M STEREO
A M / F M STEREO RADIOS
RADIOS 2 SPEAKERS
4 SPEAKERS
BLACK GRAY BLACK GRAY
4
BLACK GRAY BLACK GRAY
XL
0@[3]S[3]@[D [ZlSmEIULIlLT]
VIEWED VIEWED
FROM FROM
X52 X54 X58 WIRE X56 E2 Ml X54 X54 X56 WIRE X56 E2 Ml
END END
X51 X53 X57 X55 L7 XI2 X53 X53 X55 X55 L7 X12
LEGEND: E2- ILLUMINATION X51-LEFT REAR FEED X55-LEFT DR RETURN

L7- PARK LAMPS X52-RIGHT REAR FEED X56-RIGHT DR RETURN
M l - BATTERY X53-LEFT DR FEED X57-LEFT REAR RETURN
X12-ACC/RUN X54-RIGHT DR FEED X58-RIGHT REAR RETURN
NOTE: FOR WIRE COLORS REFER TO

SECTION 8W-WIRING DIAGRAMS J938F-8
TEST PROCEDURES
RADIO DIAGNOSIS
Turn Ign. Key
to ACC.
T
Check A M , FM and
Tape Player Operation
SPEAKER DIAGNOSIS
Turn Ign. Key

to ACC.
X
Select Known Station
Volume at Listening Level
Adjust Speaker Control (Fader &

Balance) to Check if All Spkrs.
Am Distorted or Inoperative
All
Speakers Yes
Without
yr yr Sound?,
Any One Channel Only One Check Ign. Feed
Right or Left Speaker at Radio
1 r
Replace Check Defective Spkr.
Connection, Wiring at Repair as
Radio Required
Sack of Radio or Amp
Yes
Yes
Check for Short

Repair as Check for No. Replace To Ground on Any/
Yes
Required Short Circuit Speaker All Speaker Leaas
To Ground
Yes Replace
Stop Radio
No Send Original
Radio
for Service
J928F-10
ANTENNA (2) No continuity or a very high resistance of sev

eral megohms should be observed between the
TESTING ground shell of the connector and radio end pin.
Antenna performance may be tested by substitut (3) Continuity should be observed between the
ing a known good antenna. Check short or open cir ground shell of the connector and the mounting hard
cuits with an ohmmeter or continuity light once the ware on the fender.
antenna cable is disconnected from the radio as fol
lows: BENCH TEST FOR ANTENNA MALFUNCTION
(1) Continuity should be observed between the tip (1) With test lamp and battery in circuit;
of the mast and radio end pin (Fig. 1). (a) attach one test lead to concentric pin on
lead-in connector
8F - 4 AUDIO SYSTEMS •
ANTENNA DIAGNOSIS
-TIP OF MAST
Turn Ign. Key to • RADIO LEAD IN
ACC
Tune to Known
Strong A M Station PR519
f Fig. 2 Antenna Bench Test Points
Check Antenna
Connections NOT light. If it does, look for a short circuit in the
body or in the cable probably at the connector.
(3) Remove clip lead from connector pin and clip
on outer shell of connector. Connect other clip lead to
11 antenna body assembly. The lamp should LIGHT
again. If it does not Light, antenna shielding has an
open circuit.
No
Wiggle c a b l e o v e r its e n t i r e l e n g t h t o r e v e a l in
t e r m i t t e n t s h o r t o r o p e n c i r c u i t s d u r i n g s t e p s 1,
Check for Repair as 2 a n d 3.
Reception Using Required*
A Test Antenna REMOVAL
*Be Sure Antenna is (1) Disconnect negative cable from battery.
Properly Grounded to Car. (2) Open glove box door. Depress 2 "stops" on glove
(Poor Grounding of Antenna
May Cause Engine Noise or box at center upper area near latch (Fig. 3).
Yes Static Especially on AM) INSTRUMENT PANEL
Replace or Repair
Remove Radio Defective Antenna
For Service Or Lead in J928F-4
DEPRESS
TIP OF MAST TABS
TEST POINT
GLOVE
BOX
GLOVE
BOX
DOOR
J928E-51
Fig. 3 Glove Box "Stops"

(3) Reach behind instrument panel and unplug an
tenna cable from radio (Fig. 4).
(4) Working through the glove box opening, pull
antenna cable from retainer clip (Fig. 5).
RY684 (5) Open right door and remove cable grommet
from A pillar (Fig. 6).
Fig. 1 Antenna Test Points (6) Pull cable from A pillar.
(b) other test lead to tip of mast (Fig. 2). (7) Loosen antenna mast from antenna body. D o
The lamp should light indicating Continuity. not remove at this time.
(2) Keeping one lead on connector pin, clip other (8) Loosen cap n u t using tool C4816 (Fig. 7).
lead on a n t e n n a body assembly. The lamp should
• AUDIO SYSTEMS 8F - 5
RN1005
Fig. 4 Unplugging Antenna Lead from Radio
ADAPTER PR517 A
Fig. 7 Cap Nut and Adapter
Fig. 5 Removing Antenna Cable
Fig. 8 Removing or Installing Antenna Body

INSTALLATION
(1) Route antenna cable between fender and dash
panel to A pillar area.
(2) Insert antenna mast through hole in fender and
screw into antenna body.
(3) Pull assembly up and position into place and
Fig. 6 Removing Grommet
hold.
(9) While holding antenna mast with one hand, re (4) Install adapter making sure t a b indexes with
move cap n u t with other hand. opening in fender and antenna body.
(10) Lower antenna assembly down far enough to (5) Install cap n u t and tighten securely with tool
gain access to antenna body (Fig. 8). C-4816.
(11) While holding body remove antenna mast. (6) Insert cable through opening in A pillar and
(12) Pull antenna body and cable assembly from from inside glove box opening pull in far enough to
fender area and remove. snap grommet into place.
(13) Remove adapter on fender.
8F - 6 AUDIO SYSTEMS •
(7) Route cable through retainer clip, over to radio,
and plug into back of radio.
(8) Close glove box.
CASSETTE TAPE PLAYER DIAGNOSIS

TAPE PLAYER DIAGNOSIS
Turn Radio On & Insert Tape
Tape Poor
Inoperative Performance
1
Check Player Try A Known
For Obstruction Good Tape
Behind Doors
Yes
Yes
Try A Known Correct As

Good Tape Required Advise Owner
of Worn or
Defective Tape
Yes
NO EJECT
Advise Owner Do Not Force Removal
Remove Unit of Worn or of Jammed Cassette
For Repair Defective Tape J928F-5
• AUDIO SYSTEMS 8F - 7
SERVICE PROCEDURES
RADIO REPLACEMENT (5) Install map lamp, if equipped.
REMOVAL
(1) Disconnect negative cable from battery. DOOR MOUNTED SPEAKER
C A U T I O N : M a p lamp must be r e m o v e d to prevent REMOVAL
damage to instrument panel. (1) Remove remote control handle.
(2) Remove window regulator handle, if equipped.
(2) Remove 2 screws and the map lamp (if (3) Remove pull strap if equipped.
equipped) (Fig. 9). (4) Remove screw at top of armrest.
(3) Remove 6 screws attaching I/P bezel to the in (5) Using a trim stick or other suitable flat tool,
strument panel. Be sure the screw below the Heat- gently pry trim panel away from door.
er/C control is removed. (6) Remove screws holding speaker (Fig. 11).
(7) Disconnect speaker leads.
(8) Remove speaker.
CLUSTER BEZEL J938E-51
Fig. 9 Instrument Cluster Bezel

(4) Remove 2 mounting screws from front of radio
(Fig. 10).
(5) Pull radio out of instrument panel and discon
nect wiring and antenna.
(6) Remove screw from ground strap. Fig. 11 Door Mounted Speaker
INSTALLATION
(1) Connect leads to speaker.
(2) Position speaker into place, install mounting
(3) Install door trim panel.
REAR SPEAKER - STANDARD CAB PICKUP

REMOVAL
(1) Remove grille and speaker assembly to pillar
mounting screws (Fig. 12).
RF431 (2) Pull speaker and grille away from pillar and
disconnect wiring.
Fig. 10 Radio to Instrument Panel Mounting (3) Remove speaker to grille retaining nuts (2).
INSTALLATION
INSTALLATION
(1) Install ground strap.
(1) Position speaker onto studs of speaker grille
(2) Install wiring and antenna.
and install nuts.
(3) Insert radio into panel and install mounting
(2) Install wiring harness connector on speaker.
screws.
(3) Position speaker and grille on pillar and install
(4) Install instrument cluster bezel.
mounting screws.
•
Fig. 13 Club Cap Speaker Installation

REAR SPEAKER - RAMCHARGER
(1) Remove screws holding the speaker and grille
Fig. 12 Rear Speakers assembly to the mounting plate (Fig. 14).
REAR SPEAKER - CLUB CAB PICKUP SPEAKER MOUNTING
REMOVAL
(1) Remove two screws from bottom of speaker
housing (Fig. 13).
(2) Lower speaker housing and pull bottom out, al
lowing retaining tab on top of housing to clear slot.
(3) Disconnect speaker connector and remove
speaker.
INSTALLATION
(1) Install wiring harness connector on speaker. GRILLE ASSEMBLY
(2) Install retaining tab into clip. J908F-12
(3) Install screws on the bottom of the speaker
housing. Fig. 14 Ramcharger Rear Speaker
(2) Disconnect speaker connector and remove
speaker.
(3) Remove screws holding speaker to grille and
remove speaker.
(4) To install the speaker and grille assembly, re
verse the removal procedures.
• HORNS 8G - 1
HORNS
CONTENTS
page page
GENERAL INFORMATION plied from the fuse block and grounded in the horn
The horn system consists of a horn switch, horn re- switch. When the horn switch on the steering column
lay (located on the fuse block), horns, and all their is pressed, the ground circuit is completed, energiz-
wiring and connections. The circuit voltage is sup- ing the relay, and supplying power to the horns.
TEST PROCEDURES
HORNS WILL NOT SOUND TO RELAY AND
HORN TEST LAMP
If the horns do not sound, check for a blown horn HORN BUTTON -
fuse in cavity number 4 of the fuse block. If the fuse
is blown, replace it with the same type fuse. If the HORN,
horns fail to sound and the newly replaced fuse blows TO GOOD BODY GROUND CONNECTOR PR714
the horn switch is depressed, check for one of the fol
lowing: Fig. 1 Testing for Voltage
• a short circuit in the horn
senger compartment (Fig. 2). Plug in a known good
• the horn wiring between the fuse terminal and the
horn is faulty. relay. If the horns stop blowing, relay is defective
If the fuse is intact, unplug wire connector at horn. and must be replaced. Should the horns still sound,
Connect one lead of a test lamp to the wire connector proceed with Horn Diagnosis Chart.
and the other lead to a good body ground (Fig. 1).
Depress the horn switch. Should test lamp illuminate
the horn is ungrounded or faulty. Ground can be
checked by using a jumper wire between horn
bracket (scratch through paint) and the battery neg HORN RELAY
ative terminal. If the horn still fails to sound with
the ground jumper wire still intact and the horn re
connected, replace the horn. FUSE BLOCK
If the lamp fails to illuminate, check for a defective
horn relay by substituting a known good horn relay
in the circuit. If the lamp illuminates when depress
ing the horn switch, the original relay is defective. If
the lamp fails to illuminate with a known good relay,
unplug that relay. Connect a jumper wire from the
battery terminal to the horn terminal on the relay
terminal board. If the lamp, connected in place of the
horns, fails to illuminate, inspect for an open circuit
between the horn fuse and the horn terminal on the
RB1359
relay. Also check between relay terminal board and
the horn terminals. Should the lamp illuminate, a Fig. 2 Horn Relay
defective horn switch or an open circuit in the wiring
between the relay terminal and the horn switch is at Remove steering wheel pad and disconnect wire
fault. from horn switch. Repeat the above test and if the
test lamp still illuminates, wire is shorted and
HORNS SOUND CONTINUOUSLY should be repaired. If test lamp does not illuminate,
Should the horns sound continuously, unplug the horn switch is defective and must be replaced.
horn relay from the relay connector inside the pas-
8G - 2 HORNS •
HORN DOES NOT HORN SOUNDS HORN SOUNDS
SOUND INTERMITTENTLY CONTINUOUSLY
H O R N S W I T C H O R WIRE NOTE: I M M E D I A 1rELY UNPLUG HORN

TEST FUSE TO H O R N S W I T C H RELAY A N D Dl SCONNECT WIRES
G R O U N D I N G OUT FRO/V\ H O R N S
USE TEST LIGHT BETWEEN HORN

RELAY SOCKETS t A N D 3
FUSE BLOWN
(SEE INSET DIAGRAM)
REMOVE H O R N P A D A N D
H O R N CIRCUIT
CHECK C O N T I N U I T Y B E
W I R I N G SHORTED
T W E E N S T E E R I N G SHAFT TEST LIGHT "OFF" TEST LIGHT " O N "
TO G R O U N D
A N D BODY G R O U N D
INTERNAL FAULTY
USE TEST LIGHT AT WIRE T O H O R N
SHORT CIRCUIT H O R N RELAY
H O R N S (DEPRESS H O R N TEST LIGHT' O N BUTTON S W I T C H
IN H O R N
BUTTON) (FIG. 2) G R O U N D E D OR H O R N
BUTTON S W I T C H
GROUNDED
REFER T O TEST
HORN NOT* SHORTED PROCEDURES
TEST UGHT "OFF" GROUNDED H O R N RELAY
REPLACE H O R N WRONG
RELAY WITH A FAULTY H O R N
FUSE SIZE
KNOWN GOOD ONE
(FIG. 3)
TEST LIGHT " O N "
HORN
FAULTY O R I G I N A L RELAY C O N N E C T O R
TEST LIGIHT "OFF"
RELAY ALL M O D E L S
TO H O R N TO FUSE
SWITCH BLOCK
U N P L U G REPLACEMENT
RELAY FROM S O C K E T A N D
C O N N E C T A JUMPER
WIRE B E T W E E N RELAY
SOCKET 1 A N D 2 TO
SEE INSET D I A G R A M HORNS
*IT IS IMPORTANT THAT H O R N S

BE ADEQUATELY G R O U N D E D . G R O U N D I N G
C A N BE VERIFIED BY M A K I N G A
TEMPORARY JUMPER WIRE C O N N E C T I O N
B E T W E E N H O R N BRACKET (SCRATCH
T H R O U G H PAINT) A N D THE BATTERY
N E G A T I V E TERMINAL.
INSPECT FOR O P E N
CIRCUIT I N W I R I N G F R O M FAULTY H O R N S W I T C H
FUSE BLOCK T H R O U G H OR W I R I N G BETWEEN
RELAY B O A R D T O H O R N RELAY TERMINAL A N D
TERMINAL H O R N SWITCH
J918G-5
• HORNS 8G - 3
SERVICE PROCEDURES
HORN SWITCH (HORN PAD ASSEMBLY) HORN
(HI-NOTE)
REPLACEMENT
REMOVAL HORN
(1) From underside of steering wheel, remove horn (LOW-NOTE)
pad mounting screws (Figs. 3 and 4).

(2) Pull pad up from wheel and disconnect electri
cal leads.
(3) Remove pad.
INSTALLATION
(1) Connect electrical leads to switch terminal on
HORN
horn pad.
MOUNTING
(2) Position pad into place on steering wheel, install BOLTS
mounting screws and tighten to 1.5 N*m (15 in. lbs.). J908G-10
NUT & SOURCE STEERING
WASHER FOR HORN WHEEL Fig. 5 Horn Removal and Installation—Gas Engine
RELAY GROUND
HORN REPLACEMENT - DIESEL ENGINE
The horns are located on the inside of the left front
fender behind the battery (Fig. 6).
STEERING (1) Raise the hood.
SHAFT
(2) Remove screw and washer holding the horn
bracket to t h e fender.
(3) Lower t h e horn and bracket toward the rear of
the battery.
(4) Disconnect the horn electrical connector.
COVER
(WITHOUT (5) Remove the horn and bracket assembly by
HORN
SPEED RELAY COVER working it under the battery tray brace (Fig. 6).
CONTROL GROUND RETAINING (6) To install the horns reverse the removal proce
SWITCHES) J9119-9
WIRE SCREW
dures.
Fig. 3 Standard Steering Wheel
HORN PAD
COLUMN LEFT
FENDER
HORN
LEADS STEERING
WHEEL J9219-55
Fig. 4 Optional Steering Wheel

HORN REPLACEMENT - GAS ENGINE
The horns are located on either side of the radiator
support (Fig. 5).
(1) Raise the hood.
(2) Disconnect the horn electrical connector.
(3) Remove bolt holding the horn bracket to the ra HI NOTE LOW NOTE
diator support and remove the horn. HORN & BRACKET HORN & BRACKET
(4) To install the horns reverse the removal proce ASSEMBLY ASSEMBLY J908G-11
dures. Tighten the bolts to 200 in. lbs.
Fig. 6 Horn Removal and Installation—Diesel Engine
• VEHICLE SPEED CONTROL SYSTEM 8H - 1
VEHICLE SPEED CONTROL SYSTEM
CONTENTS
page page
SERVICE PROCEDURES . 11 TEST PROCEDURES .. 7
GENERAL INFORMATION TO ACTIVATE: By pushing the ON/OFF button

The vehicle speed control system (Figs. 1, and 2) is to the depressed latched position, ON, the speed con
electrically actuated and vacuum operated. The elec trol function is now ready for use.
tronic control is integrated into the Powertrain Con TO DEACTIVATE: A soft tap of the brake pedal,
trol Module (PCM). The PCM is located next to the normal brake use or clutch pedal use while the sys
battery. The controls are located on the steering tem is engaged will disengage speed control without
wheel and consist of the ON/OFF, RESUME/ACCEL erasing memory. A sudden increase in engine R.P.M.
and SET/DECEL buttons. The system is designed to may be experienced if the clutch pedal is depressed
operate at speeds between 35 mph (50 km/h) and 85 while the speed control system is engaged. Pushing
mph (142 km/h). the ON/OFF button to the unlatched position or
turning off the ignition erases the memory.
WARNING: THE USE OF VEHICLE SPEED CON TO SET SPEED: When the vehicle has reached
TROL IS NOT RECOMMENDED WHEN DRIVING the desired speed push the SET/DECEL button to en
CONDITIONS DO NOT PERMIT MAINTAINING A gage system which will then automatically maintain
CONSTANT SPEED, SUCH AS IN HEAVY TRAFFIC the desired speed.
OR ON ROADS THAT ARE WINDING, ICY, SNOW TO DECELERATE: When speed control is en
COVERED, OR SLIPPERY. gaged, holding the SET/DECEL button depressed al
lows the vehicle to coast to a lower speed setting.
CABLE BRACKET
SPEED CONTROL
SERVO AND BRACKET
SPEED
CONTROL
CABLE
»CABLE
VIEW IN DIRECTION RRAfKFT
OF ARROW Z B R A C K E T J928H-16
Fig. 1 Speed Control System—3.9L/5.2L/5.9L Gas Engine—Typical

8H - 2 VEHICLE SPEED CONTROL SYSTEM •
T O R E S U M E : After disengaging the speed control
system by tapping the brake or clutch pedal, push
the RESUME/ACCEL button to return vehicle to the
previously set speed.
T O A C C E L E R A T E : While speed control is en
gaged, hold the RESUME/ACCEL button depressed
and release at a new desired speed. This will allow
the vehicle to continuously accelerate and set at a
higher speed setting.
T A P - U P : When the speed control system is en
gaged, tapping the RESUME/ACCEL button will in
crease the speed setting by 2 mph (3 km/h). The
system will respond to multiple tap-ups.
T O A C C E L E R A T E for P A S S I N G : Depress the
accelerator as you would normally. When the pedal
is released the vehicle will return to the speed set
ting in memory.
SERVO CONNECTOR J918H-20
Fig. 2 Speed Control System —Diesel Engine

VEHICLE SPEED CONTROL SYSTEM 8H - 3
GAS ENGINE
w a r n i n g s t h e u s i of T H E S P E E D c o n t r o l START ENGINE
is NOT r e c o m m e n d e d w h e n DRIVING
C O N D I T I O N S D O n o t PERMIT m a i n t a i n i n g
A c o n s t a n t SPEED, S U C H A S H E A V Y
TRAFFIC © r o n R O A D S THAT ARE W I N D I N G , r
I C Y , S N O W C O V E R E D O R SLIPPERY* SPEED C O N T R O L
ACCELERATE VEHICLE
ENGAGES WHEN
T O DESIRED SPEED
mmm is S T A R T E D
E
PUSH ON/OFF BUTTON FAULTY
TO " O N " P O S I T I O N . ELECTRICAL CIRCUIT*
i
DEFECTIVE S E R V O
SPEED C O N T R O L E N G A G E S
PUSH A N D RELEASE
W I T H O U T P U S H I N G THE
"SET/DECEL' ' BUTTON
"SET/DECEL" BUTTON
FAULTY ELECTRICAL CIRCUIT* R E M O V E FOOT F R O M

ACCELERATOR. SPEED
S H O U L D BE CONTROLLED
DEFECTIVE S E R V O
T
1
N O W E E D CONTROL W H E N
i
HUNTING SURGE O R
1
EXCESSIVE S A G
*
SPEED S E T T I N G AFTER
S E T / D E C E L BUTTON IS SPEED V A R I A T I O N S ON H I L L S O R LOCK-IN, T O O H I G H
P R E S S E D A N D RELEASED A T LOW S P E E D S I N TRAILER T O W I N G C3«t LOW
4 *
LOCK-UP
ENGINE
FUSE B L O W N T O R Q U E CONVERTER V A C U U M LEAK
PERFORMANCE
ROUGHNESS
# f
t f
AMPLIFICATION
N O V A C U U M AT OF ENGINE VACUUM DEFECTIVE S E R V O
SERVO SURGE LEAK
1f it
SPEED C O N T R O L
t
EXCESSIVE L O A D MAY
DEFECTIVE
t
THROTTLE CABLE DEFECTIVE S E R V O REQUIRE M A N U A L
CABLE
DISCONNECTED A S S I S T A N C E O N HILLS
i f f • *
IMPROPER STOP L A M P DEFECTIVE V A C U U M
DEFECTIVE DEFECTIVE
A N D SPEED C O N T R O L RESERVOIR
CABLE V A C U U M RESERVOIR
SWITCH A D J U S T M E N T (CHECK VALVE)
1f *
FAULTY ELECTRICAL DEFECTIVE
CIRCUIT* E N G I N E CONTROLLER
* TESTS AND A D J U S T M E N T S ARE DESCRIBED

DEFECTIVE S E R V O I N APPROPRIATE SECTION O F SERVICE
MANUAL.
DEFECTIVE V A C U U M
RESERVOIR
J918H-7
8H - 4 VEHICLE SPEED CONTROL SYSTEM
GAS ENGINE CONTINUED
1
DRIVE VEHICLE OVER
ROUGH ROAD
TAP BRAKE PEDAL

UNIT DISENGAGES LIGHTLY, SPEED
O N ROUGH ROAD CONTROL SHOULD
DISENGAGE
IMPROPER
ADJUSTMENT OF STOP
LAMP AND SPEED SPEED CONTROL N O SYSTEM
CONTROL SWITCH* DISENGAGES DISENGAGEMENT
WHEN M A K E PEDAL
IS DEPRESSED
FAULTY
ELECTRICAL
CIRCUIT
DEFECTIVE OR
IMPROPERLY ADJSUTED
STOP LAMP AND
SPEED CONTROL
PUSH RESUME/ACCEL SWITCH
SWITCH VEHICLE
SHOULD RESUME yf
£ PREVIOUSLY
MEMORIZED SPEED
SPEED CONTROL
ENGINE DOES THROTTLE CABLE
NOT RETURN TO KINKED OR DAAAAGED
NORMAL IDLE
1
VEHICLE RESUMES FAULTY ELECTRICAL

SPEED CONTROL CIRCUIT*
THROTTLE CABLE SPEED
KINKED OR DAMAGED
f
DEPRESS BRAKE DEFECTIVE SERVO

STANDARD THROTTLE PEDAL, SPEED
LINKAGE FAULTS CONTROL
SHOULD DISENGAGE
SPEED CONTROL NO SYSTEM RESUME SPEED

N O RESUME WHEN
BUTTON IS PRESSED DISENGAGES DISENGAGE I S P O SSIBLE
WHEN BRAKE PEDAL IS BELOW 210 M.P.H.
DEPRESSED
yt
1f
DEFECTIVE DISTANCE
DEFECTIVE SWITCH
DEFECTIVE ENGINE SENSOR
CONTROLLER
y
f
1
FAULTY ELECTRICAL SPEED CONTROL DEFECTIVE
CIRCUIT* SYSTEM OK FAULTY ELECTRICAL ENGINE CONTROLLER
CIRCUIT*
STICKY BRAKE SWITCH

J928H-14
• ^ ^ VEHICLE SPEED CONTROL SYSTEM 8H - I
DIESEL ENGINE
WARNING: THE USE OF THE SPEED CONTROL

IS NOT RECOMMENDED WHEN DRIVING START ENGINE
CONDITIONS DO NOT PERMIT MAINTAINING
A CONSTANT SPEED, SUCH A S HEAVY
TRAFFIC OR O N ROADS THAT ARE WINDING,
S P E E D CONTROL
ICY, SNOW COVERED OR SLIPPERY* ACCELERATE VEHICLE
ENGAGES WHEN
TO DESIRED SPEED ENGINE IS STARTED
PUSH ON/OFF BUTTON FAULTY

TO "ON" POSITION. ELECTRICAL CIRCUIT*
T
DEFECTIVE SERVO
SPEED CONTROL ENGAGES
WITHOUT PUSHING THE PUSH AND RELEASE
"SET/DECEL" BUTTON "SET/DECEL" BUTTON
±
FAULTY ELECTRICAL CIRCUIT* REMOVE FOOT FROM
ACCELERATOR. SPEED
±
DEFECTIVE SERVO
SHOULD BE CONTROLLED
N O SPEED CONTROL WHEN HUNTING SURGE OR EXCESSIVE SAG SPEED SETTING AFTER
SET/DECEL BUTTON IS SPEED VARIATIONS O N HILLS OR LOCK-IN, TOO HIGH
PRESSED A N D RELEASED AT LOW SPEEDS IN TRAILER TOWING OR TOO LOW
I T
LOCK-UP
FUSE BLOWN TORQUE CONVERTER ENGINE VACUUM LEAK
ROUGHNESS PERFORAAANCE
AMPLIFICATION
NO VACUUM AT VACUUM
OF ENGINE DEFECTIVE SERVO
SERVO LEAK
SURGE
T
SPEED CONTROL EXCESSIVE LOAD MAY
THROTTLE CABLE DEFECTIVE SERVO DEFECTIVE
REQUIRE M A N U A L
DISCONNECTED CABLE
ASSISTANCE ON HILLS
T
IMPROPER STOP LAMP
AND SPEED CONTROL DEFECTIVE DEFECTIVE DEFECTIVE
CABLE VACUUM PUMP VACUUM PUMP
SWITCH ADJUSTMENT
REFER TO GROUP 5 - BRAKES

FAULTY ELECTRICAL DEFECTIVE FOR VACUUM PUMP DIAGNOSIS.
CIRCUIT* ENGINE CONTROLLER
T "TEST A N D ADJUSTMENTS ARE DESCRIBED

DEFECTIVE SERVO IN APPROPRIATE SECTION OF SERVICE
MANUAL.
DEFECTIVE
VACUUM PUMP
J928H-15
- 6 VEHICLE SPEED CONTROL SYSTEM •
DIESEL ENGINE CONTINUED
DRIVE VEHICLE OVER

ROUGH ROAD
£ ±
TAP BRAKE PEDAL
UNIT DISENGAGES LIGHTLY, SPEED
O N ROUGH ROAD CONTROL SHOULD
DISENGAGE
IMPROPER
ADJUSTMENT OF STOP
LAMP AND SPEED SPEED CONTROL NO SYSTEM
CONTROL SWITCH* DISENGAGES DISENGAGEMENT
WHEN M A K E PEDAL
i IS DEPRESSED
FAULTY
ELECTRICAL
CIRCUIT
DEFECTIVE OR
IMPROPERLY ADJSUTED
STOP LAMP AND
SPEED CONTROL
PUSH RESUME/ACCEL SWITCH
SWITCH VEHICLE
SHOULD RESUME 11
PREVIOUSLY SPEED CONTROL
MEMORIZED SPEED THROTTLE CABLE
ENGINE DOES
NOT RETURN TO KINKED OR DAAAAGED
NORMAL IDLE
1
VEHICLE RESUMES FAULTY ELECTRICAL

SPEED CONTROL CIRCUIT*
THROTTLE CABLE SPEED
KINKED OR DAAAAGED
1
DEPRESS BRAKE DEFECTIVE SERVO
STANDARD THROTTLE PEDAL, SPEED
LINKAGE FAULTS CONTROL
SHOULD DISENGAGE
NO RESUME WHEN SPEED CONTROL

1
NO SYSTEM RESUME SPEED
DISENGAGES DISENGAGE I S P O SSIBLE
BUTTON IS PRESSED
WHEN BRAKE PEDAL IS BELOW* 10 M.P.H.
DEPRESSED
1
1r
DEFECTIVE DISTANCE
DEFECTIVE SWITCH
DEFECTIVE ENGINE SENSOR
CONTROLLER
f
* r
FAULTY ELECTRICAL SPEED CONTROL DEFECTIVE
CIRCUIT* SYSTEM OK FAULTY ELECTRICAL ENGINE CONTROLLER
CIRCUIT*
STICKY BRAKE SWITCH

J928H-14
TEST PROCEDURES
INDEX
page page
Checking for Diagnostic Trouble Code 7 Speed Control Cable Attachment—Servo 10
General Information 7 Stop Lamp Switch Test 9
Inoperative System 7 Vacuum Supply Test . . . . . . . . . . . . . . . . . . . . . . . 9
Road Test 7 Vehicle Speed Control Switch Test . 9
Speed Control Cable Adjustment—Diesel Engine . 9 Vehicle Speed Control System Electrical Tests ... 7
Speed Control Cable Attachment 10 Vehicle Speed Sensor Test 7
GENERAL INFORMATION will be displayed in a series of flashes representing

Before starting diagnosis and repair procedures for digits. Three flashes in rapid succession, a slight
a speed control malfunction, verify t h a t the speed pause, then 4 flashes in rapid succession would in
control wire harness is properly connected to all con dicate DTC 34.
nectors. Refer to Diagnosis Chart. (2) If a DTC 34 is observed, perform the tests in
the sections Electrical Tests at Servo and Electrical
ROAD TEST Tests at Powertrain Control Module.
Road test vehicle to verify reports of speed control If a DTC 15 is observed, perform the test for a
system malfunction. The road test should include at faulty Vehicle Speed Sensor.
tention to the speedometer. Speedometer operation (3) If a fault code 11 is observed (Diesel only), per
should be smooth and without flutter at all speeds. form the test for a faulty engine speed sensor. Refer
Flutter in the speedometer indicates a problem to the Powertrain Diagnostics Procedures Manual.
which might cause surging in the speed control sys (4) Correct any problems found when performing
tem. The cause of any speedometer deficiencies these tests and recheck for DTC if changes were
should be corrected before proceeding. made.
INOPERATIVE SYSTEM VEHICLE SPEED SENSOR TEST

If road test verifies a system problem and the For testing of the Vehicle Speed Sensor and related
speedometer operates properly, check for: components refer to the Powertrain Diagnostic Proce
• loose electrical and vacuum connections at the dures manual.
servo.
• check for correct installation of the vacuum check VEHICLE SPEED CONTROL SYSTEM ELECTRICAL
valve in the hose from servo to vacuum source (Gas TESTS
Engine Only). The word VAC on the valve must Vehicle speed control systems may be tested using
point toward the vacuum source. two different methods. One involves the use of the
• corrosion t h a t should be removed from electrical DRBII Scan Tool. If this test method is desired,
terminals and a light coating of Mopar Multi-Pur please refer to the Powertrain Diagnostic Procedures
pose Grease, or equivalent, applied. manual.
• secure attachment of both ends of speed control ca The other test method uses a voltmeter. The volt
ble. meter method is described in the following tests.
If any information is needed concerning wiring, re
CHECKING FOR DIAGNOSTIC TROUBLE CODE fer to Group 8W - Wiring Diagrams.
(1) When trying to verify a speed control system
electrical problem, use a DRB II Scan Tool to find C A U T I O N : When test probing for voltage or conti
the cause. Refer to Powertrain Diagnostic Procedures nuity at electrical connectors, care must be taken
manual. not to damage connector, terminals, or seals. If
If the DRBII is not available, the Diagnostic Trou these components are damaged, intermittent or
ble Code (DTC) may be determined with the follow complete system failure may occur.
ing method:
(a) With key inserted in ignition switch, cycle
switch to ON position 3 times. On third cycle, leave ELECTRICAL TESTS AT SERVO
switch in ON position. (1) Turn ignition switch to ON position.
(b) After switch h a s been cycled 3 times, observe (2) Push speed control switch to ON position.
Malfunction Indicator Lamp (CHECK ENGINE) on (3) Connect the negative lead of a voltmeter to a
instrument cluster. If a DTC is present, the code good chassis ground near the servo.
(4) Disconnect the 4-way connector going to the
servo (Figs. 1 and 2), The blue wire with the red A VACUUM
y~ HOSE
tracer of the main harness 4-way connector should
read approximately battery voltage. If not, check for
loose connections, brake switch adjustment or, repair
the main harness as necessary.
(5) Connect a jumper wire between the male and
female terminals of the blue wire with red tracer.
The other 3 male terminals from the servo should
show battery voltage. If not, replace the servo.
(6) Turn ignition OFF. Using an ohmmeter, con
nect one lead to a good body ground. Touch the other
lead to the black (BK) wire terminal in the 4-way
connector of the main harness. The meter should
show continuity. If not, repair the ground circuit as
necessary.
J918H-25
Fig. 2 Servo And Harness Connector—Diesel

Engine
PCM
MOUNTING
BOLTS
J918H-24
Fig. 1 Servo And Harness Connector—Gas

Engine—Typical
ELECTRICAL TESTS AT POWERTRAIN
CONTROL MODULE
(1) Unplug 60-way connector from Powertrain Con PCM CONNECTOR
CONNECTOR MOUNTING
trol Module, located on the left fender (Fig. 3). BOLT J9314-165
(2) Connect negative lead of voltmeter to a good
body ground near the module. Fig. 3 Powertrain Control Module and Connector
(3) For the following tests, the ignition switch Location
must be in the ON position. Refer to Fig. 4 for con
voltmeter should read 0 volts with the switch in the
troller terminal locations. Touch the positive lead of
OFF position and battery voltage with the switch in
the voltmeter to the terminal in cavity number 33.
the ON position.
With the speed control switch in the OFF position,
(5) Touch the positive lead of the voltmeter to the
the voltmeter should read 0 volts. With the speed
control switch in the ON position, the voltmeter terminal in cavity number 48. With the speed control
should read battery voltage. If not, repair the main switch in the OFF position, the voltmeter should
harness as necessary. read 0 volts. With the switch in the ON position, the
(4) Touch the positive lead of the voltmeter to the voltmeter should read battery voltage. Pressing the
terminal in cavity number 53. As in step (3), the SET button should cause the voltmeter to change
VEHICLE SPEED CONTROL SYSTEM 8H - 9
SPEED CONTROL SWITCH CONTINUITY

rain CHART
oooooooooo OOOOOOOOOO^
11 20 CONNECTOR TERMINAL E N D
1
.oooooooooo
\21
10,
30 „ . 51
OOOOOOOOOO
3 1 1
JE El
\£]
x
50 6ooooooooo 6 0 y /
OOOOOOOOOO
Tratr TJKT RR8HC7
Fig. 4 Powertrain Control Module 60-Way Connector

Shown from Terminal End
from battery voltage to 0 volts for as long as the
switch is held. If not, perform the speed control
switch test. If the switch is not at fault, then check
the main harness and repair as necessary.
(6) Touch the positive lead of the voltmeter to the
terminal in cavity number 50. The voltmeter should
SWITCH
read 0 volts with the speed control switch in either
the OFF or ON position. With switch in either RE SPEED C O N T R O L S W I T C H
SUME or SET position, the voltmeter should read
CONTINUITY
battery voltage. If not, perform the speed control
SWITCH! rea?!®^ CONTINUITY BETWEEN
switch test. If the switch is not at fault, then check
the main harness and repair as necessary. OFF PIN 1 A N D PIN 4
(7) Touch the positive lead of the voltmeter to the PIN 1 A N D PIN 4
ON PIN 1 A N D PIN 2
terminal in cavity number 49. The voltmeter should PIN 2 A N D PIN 4
read 0 volts with the switch in the OFF position.
O N A N D SET PIN 1 A N D PIN 2
With the switch in the ON position, the voltmeter
should read battery voltage. The voltmeter will con O N A N D RESUME PIN 1 A N D PIN 3
tinue to read battery voltage when either the SET or J928H-4

RESUME switch is pressed. If not, perform the speed
(b) With brake pedal depressed, there should be:
control switch test. If the switch is not at fault, then
• continuity between pink (PK) and white (WT)
check the main harness and repair as necessary .
wires.
(8) Turn key OFF. Using an ohmmeter, connect
• No continuity between black (BK) and white with
one lead to a good body ground and touch the other
lead to the terminal in cavity number 29. With the pink tracer (WT/PK) wires.
brake pedal released, the meter should show continu • No continuity between yellow with red tracer (YL/
ity. When the pedal is depressed, the meter should RD) and dark blue with red tracer (DB/RD) wires.
show open circuit. (2) If the above results are not obtained, the stop
lamp switch is defective or out of adjustment.
VEHICLE SPEED CONTROL SWITCH TEST Stop lamp switch adjustment is detailed in Group 5 -
To check the switch, remove the switch from its Brakes.
mounting position. Use an ohmmeter and refer to the
Switch Continuity Chart to determine if continuity is VACUUM SUPPLY TEST
correct. If there is no continuity at any one of the (1) Disconnect vacuum hose at the servo and in
switch positions, replace the switch. stall a vacuum gauge in the hose (Fig. 6).
(2) Start engine and observe gauge at idle. Vac
STOP LAMP SWITCH TEST uum gauge should read at least ten inches of mer
(1) Disconnect connector at stop lamp switch. Us cury.
ing an ohmmeter, continuity may be checked at (3) If vacuum does not meet this requirement,
switch side of connector as follows (Fig. 5): check for vacuum leaks or poor engine performance.
(a) With brake pedal released, there should be:
• continuity between black (BK) and white with SPEED CONTROL CABLE ADJUSTMENT-DIESEL
pink tracer (WT/PK) wires ENGINE
• continuity between yellow with red tracer (YL/RD) (1) The gap between the end of the slot on the ca
and dark blue with red tracer (DB/RD) wires ble and the bellcrank pin must be as small as possi
• No continuity between pink (PK) and white (WT) ble (0 to 1mm) without moving the throttle. If gap is
wires. not correct, remove adjustment clip. Push protective
ADJUSTMENT CLIP PULLED
OUT OF SLOT
18PK 18WT
-TfiROTTLE/SPEED CONTROL
CABLE BRACKET RR8HC22
Fig. 7 Adjustment Clip Pulled Out of Slot to Move

Sleeve
(2) Visual inspection will verify t h a t the cable is
securely attached. If the cable is not attached, the
STOP LAMP
speed control system will be inoperative. Refer to Ca
SWITCH WITH ble Adjustment.
SPEED CONTROL J938H-9
GAS ENGINE
Fig. 5 Stop Lamp Switch Connector The clevis of the speed control cable is retained to
the throttle body lever by slipping the clevis into the
slot on the lever. Visual inspection will verify t h a t
the cable is securely attached. If the cable is not at
tached, the speed control system will be inoperative.
SPEED CONTROL CABLE ATTACHMENT-SERVO

The speed control cable is attached to the servo
with a wire clip (Fig. 8). A check should be made to
verify t h a t the clip is in place. If the clip is missing
the speed control system will be inoperative.
Fig. 6 Vacuum Gauge Test

sleeve into housing to decrease gap or pull sleeve out
HAIRPIN CLIP
of housing to increase gap (Fig. 7).
(2) Install adjustment clip.
/ J918H-9
SPEED CONTROL CABLE ATTACHMENT
Fig. 8 Speed Control Cable Attachment at Servo
DIESEL ENGINE
(1) The clevis of the speed control cable is retained
to the bellcrank by a washer and hairpin clip.
SERVICE PROCEDURES
INDEX
page page
Servo Throttle Cable Assembly—Diesel Engine . . 12 Speed Control Vacuum Reservoir Replacement—Gas
Servo Throttle Cable Assembly—Gas Engine ... 11 Engine 12
Servo Unit 11 Vacuum Pump—Diesel Engine . 12
Speed Control Switch Replacement 12
SERVO UNIT
REMOVAL
(1) Disconnect vacuum hose at servo.
(2) Disconnect electrical connector at servo.
(3) Remove 2 nuts from servo mounting bracket.
(4) Pull servo away from mounting bracket.
(5) Remove and discard push nuts on servo studs.
(6) Pull speed control cable away from servo to ex
pose cable retaining clip.
(7) Remove clip attaching cable to servo.
INSTALLATION
(1) Block throttle to full open position (gas engine),
pivot bellcrank full rearward (diesel engine), and
align hole in cable sleeve with hole in servo pin. In
stall retaining clip.
(2) Insert servo studs through holes in the cable.
(3) Install new push nuts on the servo studs.
(4) Insert servo studs through holes in servo
mounting bracket. O n e s t u d m o u n t s r e s e r v o i r .
(5) Install the 2 attaching nuts and tighten to 6
N*m (50 in. lbs.).
(6) Connect vacuum hose to servo.
(7) Connect the electrical connector to servo termi
nals.
SERVO THROTTLE CABLE A S S E M B L Y - G A S

ENGINE
Fig. 1 Remove Bell Crank Connector— Typical
REMOVAL (9) Disconnect cable at servo and remove cable as
(1) Remove air cleaner. sembly.
(2) Using finger pressure only, remove speed con
trol cable connector at bell crank by PUSHING con INSTALLATION
nector off the bell crank (Fig. 1). DO NOT try to pull (1) Locate cable through servo mounting bracket.
connector off perpendicular to the bell crank. (2) Connect cable sleeve to servo stud, align holes,
(3) Squeeze tabs on speed control cable and push and install hairpin clip.
out of locking plate. (3) Insert servo studs through holes in cable.
(4) Remove 2 nuts from servo mounting bracket. (4) Install new push nuts on servo studs.
(5) Pull servo away from mounting bracket. (5) Insert servo studs through holes in bracket. In
(6) Remove and discard push nuts on servo studs. stall nut washers and torque to 6 Nnn (50 in. lbs.).
(7) Pull speed control cable away from servo to ex (6) Route cable from servo, through cable support
pose cable retaining clip. bracket, and install cable on nail head stud.
(8) Remove clip attaching cable to servo. (7) Install air cleaner.
SERVO THROTTLE CABLE ASSEMBLY—DIESEL HORN PAD
ENGINE
REMOVAL
(1) Remove hairpin clip and washer retaining ca
bles on bellcrank. Remove servo throttle cable from
bellcrank.
(2) Remove servo throttle cable from cable support
bracket.
(3) Remove 2 nuts from servo mounting bracket.
(4) Pull servo away from mounting bracket.
(5) Remove and discard push nuts on servo studs. Fig. 2 Sport Steering Wheel
(6) Pull speed control cable away from servo to ex
pose cable retaining clip. CLOCKSPRING
(7) Remove clip attaching cable to servo.
(8) Disconnect cable at servo and remove cable as
sembly.
INSTALLATION
(1) Locate cable through servo mounting bracket.
(2) Connect cable sleeve to servo stud, align holes,
and install hairpin clip.
(3) Insert servo studs through holes in cable.
(4) Install new push nuts on servo studs.
(5) Insert servo studs through holes in bracket. In
stall n u t washers and torque to 6 N*m (50 in. lbs.).
(6) Route cable from servo, to cable support
bracket,
(7) Install cable end on bellcrank rod.
(8) Adjust cable as described under speed control Fig. 3 Speed Control Switches
cable adjustment. SPEED CONTROL VACUUM RESERVOIR
(9) Install washer and hairpin clip on end of bell REPLACEMENT-GAS ENGINE
crank rod.
REMOVAL
SPEED CONTROL SWITCH REPLACEMENT (1) Disconnect all hoses.
(1) Disconnect negative cable from battery. (2) Remove nuts and slide vacuum reservoir off
(2) From underside of steering wheel, remove horn studs.
pad mounting screws (Fig. 2).
(3) Pull pad up from wheel and disconnect electri INSTALLATION
cal leads. (1) Install vacuum reservoir onto bracket studs.
(4) Remove pad. (2) Install n u t washers and torque to 6 N r n (50 in.
(5) Unplug 4-way electrical connector from clock- lbs.).
spring. (3) Connect vacuum hoses.
(6) Remove 4 screws holding switches and remove
switches (Fig. 3) VACUUM P U M P - D I E S E L ENGINE
(7) Install new switches with 4 screws. Refer to Group 5 - Brakes for removal and instal
(8) Connect 4-way electrical connector from clock- lation of the vacuum pump.
spring to switches.
(9) Connect electrical leads to horn pad.
(10) Install horn pad with 3 screws.
• TURN SIGNALS AND HAZARD WARNING FLASHER 8J - 1
TURN SIGNALS AND HAZARD WARNING FLASHER
CONTENTS
page page
GENERAL INFORMATION 1 MULTIFUNCTION SWITCH TESTING

MULTIFUNCTION SWITCH SERVICE PROCEDURES 2
PROCEDURES 3
GENERAL INFORMATION
TURN SIGNALS HAZARD WARNING SYSTEM
DESCRIPTION DESCRIPTION
With t h e ignition key ON a n d t h e multi-function With t h e hazard switch OUT, current flows
lever in its U P or DOWN position, current flows through t h e
through the: • hazard flasher canister
• t u r n signal flasher canister • hazard switch
• Turn/Hazard switch • two front t u r n signal bulbs
• t u r n indicator lamp • two rear t u r n signal bulbs
• front and rear bulbs. • both indicator bulbs.
The selected t u r n signal indicator with front and All of t h e t u r n lamps and both indicators will
rear t u r n signal bulbs will flash. flash.
DIAGNOSIS DIAGNOSIS
High generator output voltage can burn out Hazard switch in ON. The park and stop lamps
lamps rapidly. should light. If not replace t h e 20 amp fuse in fuse
(1) Remove and inspect fuse in cavity # 9 of fuse block cavity # 1 3 .
block. Replace if necessary. The fuse block is behind (1) Measure voltage a t the fuse side of t h e flasher
the lower instrument panel cover under steering (side terminal). Meter should read battery voltage. If
wheel. not, repair open circuit in wiring to fuse.
(2) Turn key to ACCY. There should be battery (2) Replace Hazard flasher with known good
voltage a t t h e fuse side of t h e t u r n signal flasher flasher. Lamps should flash. If not, replace with orig
(bottom terminal). If not, repair open circuit in wir inal flasher and go to next step.
ing between fuse and flasher. (3) Measure voltage a t t h e Turn/Hazard switch
(3) Replace Turn Flasher with 2 lamp 12 volt rated connector cavity # 1 3 . Meter should read battery volt
flasher t h a t is know to be good. The lamps should age. If not, repair open circuit in wiring to hazard
flash. If not, replace with original flasher and go to flasher.
next step.
(4) Measure voltage a t t h e Turn/Hazard switch TURN SIGNAL AND HAZARD WARNING FLASHER
connector cavity # 1 7 . Meter should read battery volt LOCATION
age. If OK, replace Turn/Hazard switch assembly. If The t u r n signal and hazard warning flasher a r e
not, repair open circuit in wiring between flasher both located on t h e fuse block (Fig. 1). The fuse block
and Turn/Hazard switch connector. is on t h e lower instrument panel cover under t h e
steering column.
8J - 2 TURN SIGNALS AND HAZARD WARNING FLASHER •
INSTRUMENT
PANEL
REAR VIEW
HAZARD
WARNING
FLASHER
FUSE
BLOCK
VIEW IN DIRECTION
OF ARROW RR8JC10
Fig. 1 Turn Signal and Hazard Warning Flashers
M U L T I F U N C T I O N SWITCH TESTING P R O C E D U R E S
The multifunction switch contains electrical cir This integrated switch assembly is mounted to the
cuitry for: left-hand side of the steering column. Should any
• t u r n signal function of the switch fail, the entire switch assem
• hazard warning bly must be replaced.
• headlamp beam select To test the switch:
• headlamp optical horn (1) Disconnect negative cable from battery.
• windshield wiper (2) Remove upper and lower column covers to gain
• pulse wipe access to the switch connector.
• windshield washer switching. (3) Remove switch connector (Figs. 2 and 3).
Fig. 2 Multifunction Switch Connector Fig. 3 Steering Column Connectors

• TURN SIGNALS AND HAZARD WARNING FLASHER 8J - 3
(4) Using an ohmmeter, test for continuity (no re

sistance) between the terminals of the switdh as
shown in the following continuity chart (Pig. 4).
VIEW FROM TERMINAL CASE
SWITCH P O S I T I O N S
TURN S I G N A L HAZARD WARNING CONTINUITY B E T W E E N
NEUTRAL OFF 12 AND 14 A N D 15
LEFT OFF 15 AND 16 A N D 17

LEFT OFF 12 AND 14
LEFT OFF 22 A N D 2 3 WITH OPTIONAL CORNER LAMPS
RIGHT OFF 11 AND 12 A N D 17

RIGHT OFF 14 AND 15
RIGHT OFF 23 AND 2 4 WITH OPTIONAL CORNER LAMPS
NEUTRAL ON 11 AND 12 A N D 13 AND 15 A N D 16
908J-4
Fig. 4 Turn Signal and Hazard Switch Continuity Chart
MULTIFUNCTION SWITCH SERVICE PROCEDURES

REMOVAL (3) Install steering column covers. Torque retain
(1) Disconnect negative cable from battery. ing screws to 17 in. lbs.
(2) Remove tilt lever (Tilt column only). (4) Install tilt lever (tilt column only).
(3) Remove both upper and lower steering column (5) Install negative cable to battery.
covers. (6) Check all functions of switch for proper opera
(4) Remove multifunction switch tamper proof tion.
mounting screws (tamper proof torx bit Snap On HAZARD WARNING
TTXR20B2 or equivalent required).
(5) Gently pull switch away from column. Loosen
connector screw. The screw will remain in the con
nector.
(6) Remove wiring connector from multifunction
switch (Fig. 5).
INSTALLATION
(1) Install wiring connector to switch and tighten
connector retaining screw to 17 in. lbs.
(2) Mount multifunction switch to column and
torque retaining screws to 17 in. lbs.
908J-9
Fig. 5 Muitifunction Switch

• WINDSHIELD WIPER AND WASHER SYSTEMS 8K - 1
WINDSHIELD WIPER A N DWASHER S Y S T E M S
CONTENTS
page page
INTERMITTENT WINDSHIELD WIPER FUNCTION WINDSHIELD WASHERS . . 10
AND SWITCH TESTING PROCEDURES 6 WINDSHIELD WIPER SYSTEM SERVICE
TWO SPEED WINDSHIELD WIPER MOTOR AND PROCEDURES 7
SWITCH TESTING PROCEDURES 1
GENERAL INFORMATION and high speed, has a delay mode. The delay mode
The windshield wipers can be operated with the has a range of 2 to 15 seconds. This is accomplished
windshield wiper switch only when the ignition by a variable resistor in the wiper switch and is con
switch is in t h e ACCESSORY or RUN position. A trolled electrically by a control module.
fuse located in the fuse block protects the circuitry of The wiper system completes the wipe cycle when
the wiper system and the vehicle. the switch is turned OFF. The blades park in the
The same motor is used for standard and intermit lowest portion of the wipe pattern.
tent wipe systems. Depressing the washer knob while the system is in
The wiper motor has permanent magnet fields. The the OFF position,
speeds are determined by current flow to the appro • turns the wiper motor on
priate set of brushes. • allows the motor to operate through 3-4 wipe cy
The intermittent wipe system in addition to low cles and then t u r n OFF.
TWO SPEED WINDSHIELD WIPER MOTOR A N D SWITCH TESTING PROCEDURES
INDEX
page page
Multifunction (Two Speed Wiper) Switch Testing Two Speed Wiper Motor Testing Procedures 1
Procedures 4
TWO SPEED WIPER MOTOR TESTING (d) If replacement fuse blows, proceed to step No.
PROCEDURES 5.
The following is a list of general wiper motor sys (2) Place switch in low speed position.
tem problems. It contains the tests t h a t are to be per (3) Listen to motor. If you cannot hear it running,
formed to locate the faulty part, and the corrective proceed to step No. 4. If you hear it running, check
action to be taken. The same motor is used for stan motor output shaft. If output shaft is not turning, re
dard and optional systems. If the malfunction in place motor assembly. If it is turning, crank arm or
volves only the Delay mode, switch, or wiring, refer drive link is not properly connected. Replace worn
to the Intermittent Windshield Wiper Motor and parts and/or properly connect drive link to t h e motor
Switch Service Procedures. output shaft.
(4) Connect a voltmeter between motor terminal
CONDITION "L" and ground strap (Fig. 1). If there is no voltage
Motor will not run in a n y switch position. or very little voltage (less t h a n one volt) present,
PROCEDURE move negative test lead from t h e ground strap to bat
(1) Check for a blown fuse in the fuse block. tery negative terminal.
(a) If fuse is good, proceed to step No. 2. (a) If an increase in voltage is noticed, t h e prob
(b) If fuse is defective, replace and check motor lem is a bad ground circuit. Make sure t h e motor
operation in all switch positions. mounting is free of paint and t h a t nuts or bolts are
(c) If motor is still inoperative and the fuse does tight.
not blow, proceed to step No. 2.
8K - 2 WINDSHIELD WIPER AND WASHER SYSTEMS
MOTOR RUNS
I MOTOR RUNS | BLADES SLAP

BLADES D O AGAINST
N O T PARK BUT OUTPUT BLADES
C R A N K DOES WINDSHIILD CHATTER
NOT TURN MOULDINGS
I O N DRY GLASS
•
X
M O T O R STOPS • M O T O R STOPS! M O T O R WILL
IN ANY N O T STOP LINKAGE NOT FOREIGN
BLADES D O
POSITION I W H E N SWITCH | FASTENED ARMS LOOSE SUBSTANCE SUCH
N O T PARK
W H E N SWITCH IS T U R N E D PROPERLY TO ON PIVOT SHAFT AS BODY POLISH
IS T U R N E D PROPERLY "OFF" MOTOR OUTPUT ON GLASS OR
"OFF" SHAFT BLADES
3 J
TWISTED ARM
HOLDS BLADE AT
WRONG ANGLE
TO GLASS
1 _ _
REPLACE FUSE
MOTOR BLOWS
OUTPUT OUTPUT
SHAFT SHAFT f
STATIONARY ROTATES CHECK CHECK
T t WIRING SWITCH
JE
REPLACE LOOSE BAD
MOTOR LINKAGE ARMS LOOSE
MOTOR ON PIVOT SHAFT
CRANK CONNECTION
RF80B
WINDSHIELD WIPER AND WASHER SYSTEMS 8K - 3
(a) If motor now runs and draws less than 3

VOLTMETER
amps, repair linkage system.
(b) If motor continues to draw more t h a n 3 amps,
replace motor assembly.
(3) Check motor wiring harness for shorting be
tween high and low speed wires as follows:
(a) Connect a voltmeter or test lamp to motor
ground strap.
(b) Set wiper switch to LOW position.
(c) Connect other lead of voltmeter (test lamp) to
TERMINAL "L"
terminal "H" of the wiring harness.
(d) If voltage is present, there is a short in the
wiring or wiper switch. If no voltage is present pro
ceed to step (e).
GROUND J928K-13 (e) Set wiper switch to HIGH position.
(f) Move voltmeter (test lamp) lead from termi
Fig. 1 Voltmeter Between Terminal "L" and Ground nal "H" to terminal "L" of the wiring harness.
(b) If there is still no indication of voltage, the (g) If voltage is present, there is a short in the
problem is an open circuit in the wiring harness or wiring or wiper switch.
wiper switch.
(c) If no noticeable increase (greater t h a n 3 volts) CONDITION
in voltage is observed, the problem is a faulty mo Motor will run at h i g h speed, but not at l o w
tor assembly. speed. Motor will run at low speed, but not at
(5) Disconnect motor wiring connector and replace high speed.
fuse.
(a) If fuse does not blow, motor is defective. PROCEDURE
(b) If fuse blows, switch or wiring is at fault. (1) If motor will not r u n on high speed, put switch
in HIGH position and connect a test lamp between
CONDITION motor terminal "H" and ground (Fig. 3).
Motor runs slowly at all speeds.
TERMINAL TEST
"H" LAMP
PROCEDURE
(1) Disconnect wiring harness connector at motor.
Remove wiper arms and blades. Connect an ammeter
between battery and terminal "L" on motor (Fig. 2).
TERMINAL AMMETER
"L
WIPER
MOTOR J928K-15
Fig. 3 Test Lamp Between Terminal "H" and

WIPER Ground
MOTOR
If motor will not run on low speed, put switch in
LOW position and connect a test lamp between motor
J928K-14 terminal "L" and ground.
(2) If test lamp does not light at motor terminal,
Fig. 2 Ammeter Between Terminal "L" and Battery
there is an open in wiring or switch. If test lamp
(a) If motor runs and average ammeter reading lights at motor terminal, replace motor assembly.
is more than 6 amps, proceed to step 2.
(b) If motor runs and average ammeter reading CONDITION
is less than 6 amps, proceed to step 3. Motor will k e e p running with switch in OFF
(2) Check to see if wiper linkage or pivots are position.
binding or caught. Disconnect drive link from motor.
8K - 4 WINDSHIELD WIPER AND WASHER SYSTEMS •
PROCEDURE
(1) Remove wiring harness. Connect jumper from
Terminal P2 to terminal "L" of wiper motor (Fig, 4).
TERMINALS
Fig. 5 Ohmmeter Between Terminal "L" and "P2"

(b) If there is no continuity, the problem is an
open circuit in the wiper control switch or wiring
Fig. 4 Om Jumper Wire Between Terminal "P2" and harness.
"L". One Jumper Wire Between Terminal "P1" and
"B+" MULTIFUNCTION (TWO SPEED WIPER) SWITCH
(2) Connect second jumper from terminal " P I " to TESTING PROCEDURES
battery. If motor runs to PARK position and stops, The multifunction switch contains circuitry for:
wiper switch is faulty. If motor keeps running and • t u r n signal
does not park, replace motor assembly. • hazard warning
• headlamp beam select
CONDITION • headlamp optical horn
Motor will stop w h e r e v e r it is, w h e n column • windshield wiper
switch is p u t in O F F p o s i t i o n . (Wipers do n o t • pulse wipe
continue running t o P A R K position). • and windshield washer switching.
This integrated switch assembly is mounted to the
PROCEDURE left-hand side of the steering column. Should any
(1) Remove motor wiring connector and clean ter function of the switch fail, the entire switch assem
minals. Reconnect connector and test motor. If prob bly must be replaced.
lem persists, proceed to step No. 2. To test the switch:
(2) P u t wiper switch to OFF and ignition switch to (1) Disconnect negative cable from battery.
ACC position. Disconnect motor wiring connector. (2) Remove tilt lever (Tilt column only).
Connect a voltmeter or test lamp to the motor (3) Remove upper and lower column covers to gain
ground strap. Connect the other lead to terminal access to the switch connector (Fig. 6).
"PI" of wiring connector. (4) Remove lower fixed column cover.
(a) If voltage is not present, check for an open (5) Loosen steering column upper bracket nuts. Do
circuit in the wiring harness or wiper control Not remove nuts.
switch or fuse. (6) Move upper fixed column cover to gain access
(b) If voltage is present, proceed to step (3). to rear of multifunction switch.
(3) Remove wiper motor from vehicle and connect (7) Remove switch connector (Figs. 7 and 8).
an ohmmeter or continuity tester between terminals (8) Using an ohmmeter, test for continuity (no re
"L" and "P2" (Fig. 5). sistance) between the terminals of the switch as
(a) If there is continuity between these termi shown in the following continuity chart (Fig. 9).
nals, the problem is a defective motor. (9) Refer to Service Procedures for assembly.
WINDSHIELD WIPER AND WASHER SYSTEMS 8K - §
UPPER SHROUD GROUND UPPER MULTIFUNCTION

KEY-IN S W I T C H &
CLIP FIXED SHROUD SWITCH
H A L O LIGHT
SUPPORT BRACKET
TURN SIGNAL
S W I T C H & LEVER
STUD
NUT WASHER IGNITION SPEED

Fig. 8 Steering Column Connectors
LOWER
LOWER FIXED
SHROUD SHROUD J9119-22
Fig. 6 Steering Column Covers

STEERING MULTIFUNCTION SWITCH PINS
COLUMN
ASSY. T W O SPEED W I P E R SWITCH
CONTINUITY CHART
SWITCH CONTINUITY
POSITION BETWEEN
OFF & PARK PIN 1 & PIN 2
LOW P I N 1 & PIN 4
TURN SIGNAL
HIGH PIN 4 & PIN 5
MULTI SWITCH A N D
FUNCTION LEVER WASH PIN 3 & P I N 4
SWITCH
J918J-1 CONNECTOR J918K-5
Fig. 7 Multifunction Switch Connector Fig. 9 Standard Two Speed Wipe Switch Continuity
Chart
INTERMITTENT WINDSHIELD WIPER FUNCTION A N D SWITCH TESTING
PROCEDURES
INTERMITTENT WIPER FUNCTION TESTING
PROCEDURES
The intermittent wipe and standard two speed mo
24
17
23 22 2
1 2
0 1
9
16 15 14 /V~\M3 12 11 10
L
tors are identical. Refer to previous sections for diag 9 8 7 6 5^4
V
3 .2 1
nosis of system problems which do not involve the
DELAY function. If problem occurs only in the DE i EZJ CZ3 CZ3 C3
Jr
JT
LAY mode, the following tests are to be performed. MU LT
F
IUN
CTO
IN S
WTICH P N
IS
These tests involve disconnecting the intermittent SWITCH CONTINUITY
POSITION BETWEEN
wipe control unit which can be found on the steering
OFF PIN 6 AND PN
I 7
column support bracket (Fig. 2).
PN
I 8 AND PNI 9
PN
I 2 AND PNI 4
CONDITION DELAY PN
I 1 AND PNI 2
Excessive delay (more than 30 seconds) or in PN
I 1 AND PNI 4
adequate variation in delay. LOW PN
I 4 AND PN
I 6
H GIH PN
I 4 AND PN
I 5
PROCEDURE W AS
H PN
I 3 AND PN
I 4
Variations in delay should be as follows: *RE
SSIT
ANCE AT A AA
XM
IUM D ELA Y P O S
TI
O
IN S H O
U L
D BE
(1) Minimum delay (delay control to extreme coun B
ET
W EE
N2 70
0
,00OHMS AND 3 3
00,0 0O HMS.
terclockwise position before first detent) 1/2 to 2 sec R
•ES
SITA
N C
E AT M N
IM
IUM D EL
AYP O S
T
I
OIN S HO U
LD BE
Z
ERO W TIH O H
MMET
ER SET ON H GI H OHM SC
A LE
.
onds.
(2) Maximum delay (delay control to extreme 9
18J
-
4
clockwise position before off detent) 10 to 30 seconds.
Fig. 11ntermittent Wipe Switch Continuity Chart
(3) If there is excessive delay or no variations in
delay proceed to intermittent wipe switch test. INTERMITTENT WIPE MODULE LOCATION
The intermittent wipe module is located to the
CONDITION
right of the steering column on the back side of the
In DELAY m o d e wipers run continually w h e n
w a s h is operated but do not provide an extra instrument panel (Fig. 2).
w i p e w h e n the w a s h control is released.
BUZZER
PROCEDURE MODULE
Replace the control unit.
CONDITION '
Wipers start erratically during DELAY mode.
PROCEDURE
(1) Verify t h a t the ground connection at the in
strument panel is making good connection (free from
paint) and is tight.
(2) Verify t h a t the motor ground strap is making
good contact and t h a t the motor mounting bolts are
tight. INTERMITTENT
WIPE MODULE
(3) Verify t h a t the wiring ground connections for
the intermittent wipe control unit and the wiper Fig. 2 Intermittent Wipe Module Location
switch are tight.
(4) If condition is not corrected, replace control
unit.
MULTIFUNCTION (INTERMITTENT WIPER) SWITCH

TESTING PROCEDURES
Refer to Multifunction (Two Speed Wiper) Switch
Testing Procedures using the following continuity
chart.
WINDSHIELD WIPER SYSTEM SERVICE PROCEDURES
INDEX
page page
Installation 9 Wiper Blades 7
Linkage Replacement (Fig. 6) 8 Wiper Motor Replacement . . . . . . . . . . . . . . . . . . . 8
Wiper Arm Replacement 7 Wiper Switch Replacement . . . . . . . . . . . . . . . . . . 9
Wiper Blade Element Change 7
WIPER BLADES TYPE A— To remove blade assembly from arm,

Wiper blades exposed to the weather for a long pe insert a small screwdriver blade into release slot of
riod of time tend to lose their wiping effectiveness. wiper blade and pry slightly upward (Fig. 1).
Periodic cleaning of the wiper blade is suggested to To remove wiping element from blade assembly,
remove the accumulation of salt and road film. The pinch lock on end of blade assembly and withdraw
wiper blades, arms and windshield should be cleaned wiping element (blade) out of claws.
with a sponge or cloth and a mild detergent or nona- Check each release point for positive locking when
brasive cleaner. If the blades continue to streak or installing blade element and blade assembly.
smear, they should be replaced. Type B—To remove blade, lift up on release tab on
center bridge pivot (Fig. 2).
WIPER BLADE ELEMENT CHANGE Lift lock tab on one of end links and squeeze link
There are two types of wiper blade assemblies. The to remove from center bridge. Slide end link off ele
assemblies are identified as "Type A" (Fig. 1) and ment and slide element from claws of other link (Fig,
"Type B" (Figs. 2 and 3). 3).
LIFT RELEASE TAB END LINK RH526
Fig. 3 Removing Wiping Element From Blade

Fig. 1 Removing Blade and Wiping Element from Assembly Type "B"
Blade Assembly Type'A" Check each release point for positive locking when
installing blade element and blade assembly.
WIPER ARM REPLACEMENT

REMOVAL
(1) Lift the arm to permit the latch (Fig. 4) to be
pulled out to the holding position and remove the
arm from the pivot using a rocking motion.
Fig. 2 Removing Blade from Arm Type "B"

(1) Turn wiper switch ON, position blades to a con
venient place by turning the ignition switch ON and
OFF.
(2) Lift wiper arm to raise blade off glass.
(3) Remove blade assembly from arm and wiping
element from blade, depending on type, as follows:
Fig. 4 Removing Wiper Arm
C A U T I O N : The u s e of a screwdriver or other prying LINKAGE REPLACEMENT (Fig. 8)

tool to remove an arm may distort it. This distortion
could allow the arm to come off the pivot shaft, re CRANK ARM
gardless of how carefully it is installed.
REMOVAL
(1) Remove wiper motor as previously described.
INSTALLATION (2) Remove nut attaching crank arm to motor
With wiper motor in park position, mount arms on drive shaft.
pivot shafts. Choose a serration engagement which (3) Remove crank arm.
locates blades so t h a t distance between the intersec
tion of arm and the blade and the weatherstrip is as INSTALLATION
shown in Fig. 5. (1) Position crank arm on motor drive shaft, mak
ing sure slot is indexed properly. Install mounting
n u t and tighten to 11 N*m (95 in. lbs.) torque.
(2) Install wiper motor.
DRIVE LINK ASSEMBLY LEFT PIVOT

ASSEMBLY
REMOVAL
(1) Remove wiper arms.
(2) Remove screws attaching louvered cowl cover
ADJUST WIPER ARM SO TIP OF to cowl panel.
BLADE IS ABOVE THE WEATHERSTRIP (3) Remove cowl cover by pulling forward with a
IN PARK POSITION AS SHOWN J908K-34 slight upward movement.
(4) Reach through access hole and remove drive
Fig. 5 Adjusting Wiper Arms
link from right pivot by prying retainer bushing
WIPER MOTOR REPLACEMENT from pivot pin with a suitable size screwdriver.
(5) Remove crank arm from drive link by prying
REMOVAL
retainer bushing from crank arm pin with a suitable
size screwdriver.
(2) Disconnect wires from wiper motor.
(6) Remove left pivot mounting screws and let
(3) Remove motor mounting screws.
pivot hang loose.
(4) Lower motor down far enough to gain access to
(7) Working through access holes remove drive
crank arm to drive link retainer bushing.
links and left pivot as an assembly.
(5) Remove crank arm from drive link by prying
(8) Remove drive link from left pivot by prying re
retainer bushing from crank arm pin with a suitable
tainer bushing from pivot pin with a suitable size
size screwdriver.
screwdriver.
(6) Remove motor.
(7) Remove n u t attaching crank arm to motor INSTALLATION
drive shaft. (1) Install left pivot pin in drive link retainer
(8) Remove crank arm. bushing by snapping together with channel lock pli
ers.
INSTALLATION
(2) Maneuver drive links and pivot assembly
(1) Position crank a r m on motor drive shaft, mak
through access hole and position into place.
ing sure slot is indexed properly. Install mounting
(3) Position left pivot into place, install mounting
n u t and tighten to 11 N»m (95 in. lbs.) torque.
screws and tighten to 11 N*m (95 in. lbs.) torque.
(2) Install crank a r m pin in drive link retainer
(4) Install crank arm pin in drive link retainer
bushing by snapping together with channel lock pli
ers.
ers.
(3) Position motor into place, install mounting
(5) Install right pivot pin in drive link retainer
screws, and tighten to 6 N»m (55 in. lbs.) torque.
(4) Connect wires to wiper motor.
ers.
(5) Connect battery cable.
(6) Position cowl cover into place, install mounting
(7) Install wiper arms, refer to wiper arm adjust
ment procedure.
WINDSHIELD WIPER AND WASHER SYSTEMS 8K - S
BLADE PIVOT ASSEMBLY
WIPER MOTOR RK755
Fig. 6 Wiper Linkage

RIGHT PIVOT ASSEMBLY (4) Remove multifunction switch tamper proof
mounting screws.
REMOVAL (5) Gently pull switch away from column. Loosen
(1) Remove wiper arms. connector screw. The screw will remain in the con
(2) Remove screws attaching louvered cowl cover nector.
to dash panel. (6) Remove wiring connector from multifunction
(3) Remove cowl cover by pulling forward with a switch (Fig. 7).
slight upward movement.
(4) Reach through access hole and remove drive HAZARD WARNING
BUTTON
link from right pivot by prying retainer bushing
from pivot pin with a suitable size screwdriver. WINDSHIELD WASHER
(5) Remove right pivot mounting screws. BUTTON
(6) Remove pivot through access hole.
INSTALLATION
(1) Position pivot into place, install mounting
screws, and tighten to 11 N*m (95 in. lbs.) torque.
(2) Install right pivot pin in drive link retainer
bushing by snapping together with channel lock pli WINDSHIELD WIPER
CONTROL
ers. MULTI-FUNCTION
SWITCH
(3) Position cowl cover into place, install mounting
908J-9
(4) Install wiper arms.
Fig. 7 Multifunction Switch
WIPER SWITCH REPLACEMENT
(1) Disconnect negative cable from battery. INSTALLATION
(2) Remove tilt lever (Tilt column only). (1) Install wiring connector to switch and tighten
(3) Remove both upper and lower steering column connector retaining screw to 2 Nnn (17 in. lbs.).
covers.
(2) Mount multifunction switch to column and (4) Install tilt lever (tilt column only),
torque retaining screws to 2 N»m (17 in. lbs.). (5) Install battery cable.
(3) Install steering column covers. Torque retain- (6) Check all functions of switch for proper opera-
ing screws to 2 N»m (17 in. lbs.). tion.
WINDSHIELD WASHERS
GENERAL INFORMATION WINDSHIELD WASHER PUMP REPLACEMENT (Fig.
All models are equipped with electric operated 2)
windshield washer pumps.
REMOVAL
The electric pump assembly is mounted directly to
(1) Remove liquid from reservoir.
the reservoir. A permanently lubricated sealed motor (2) Remove reservoir mounting screws and remove
is coupled to a rotor type pump. Fluid, gravity fed reservoir and pump assembly.
from the reservoir, is forced by the pump through (3) Disconnect electrical lead and rubber hose from
rubber hoses to the nozzles which direct the streams bottom of pump.
to the windshield. (4) Using an extension and deep well socket, reach
These vehicles are equipped with special plastic through reservoir filler neck, and remove pump
washer nozzles (Fig. 1). Because they are inserted di mounting n u t and plastic washer.
rectly into the cowl panel, there is no adjustment re (5) Remove pump from bottom reservoir.
quired. (6) Remove rubber grommet from reservoir and
throw away.
Fig. 2 Washer Pump

INSTALLATION
(1) Install new rubber grommet into place in bot
tom of reservoir.
(2) Position pump into place in reservoir. Install
plastic washer then mounting nut, and tighten to 3
N»m (25 in. lbs.) torque. Do not overtighten.
(3) Connect electrical leads and hose to pump.
Fig. 1 Windshield Washer System (4) Position reservoir into place, install mounting
(5) Fill reservoir with water and/or washer fluid,
inspect for leaks and test system.
WINDSHIELD WASHER DIAGNOSIS
WASHER DOES
NOT
OPERATE PROPERLY
T
P U M P MOTOR
PUMP MOTOR
RUNS
T
PUMP R U N S -
P U M P NOT
• MOTOR R U N S
PUMP PUMPING
FLUID
SYSTEM O P E R A T E S
INTERMITTENTLY
S Y S T E M OPERATES
W I T H O U TT
IATES
I N T E R R U P T IIOONN
S Y S T E M OUTPUT
LOW
I
I
j
DOES NOT R U N
P U M P I N G FLUID
LOOSE WIRING, N O FLUID IN LOOSE W I R I N G NOZZLES

TERMINALS, CORRODED RESERVOIR CONNECTIONS AIMED LOW
TERMINALS
X X
NOZZLE JET UNDER PINCHED OR
BROKEN WIRES COWL PANEL FAULTY SWITCH LEAKY HOSES
t X
NOZZLE JETS LEAKY OR RESTRICTED
POOR G R O U N D PLUGGED FAULTY MOTOR PLASTIC HOSE
CONNECTOR
X
BROKEN OR POOR ELECTRICAL
FAULTY SWITCH LOOSE HOSE CONNECTIONS
FAULTY MOTOR FAULTY PUMP DEFECTIVE MOTOR
J908K-27
• LAMPS 8L - 1
LAMPS
CONTENTS
page page
BULB APPLICATION 11 EXTERIOR LAMPS SERVICE PROCEDURES ... 3

EXTERIOR LAMPS 1 INTERIOR LAMPS 10
EXTERIOR LAMPS
GENERAL INFORMATION Conventional and halogen headlamps are inter
Each vehicle is equipped with various lamp assem changeable. It is recommended t h a t they not be in
blies. A good ground is necessary for proper lighting termixed on a given vehicle.
operation.
When changing lamp bulbs check the socket for MULTI-FUNCTION SWITCH TESTING PROCEDURES
corrosion. Clean corrosion with a wire brush. Coat The multi-function switch contains electrical cir
the inside of the socket lightly with Mopar® Multi- cuitry for:
Purpose Grease or equivalent. • Headlamp Dimmer Switch
• Passing Lights
DIAGNOSTIC PROCEDURES • Turn Signals
Always begin any diagnosis by testing all of the • Hazard Warning
fuses and circuit breakers in t h e system. Refer to • Windshield Wiper
Group 8W, Wiring Diagrams. • Pulse Wiper
• Windshield Washer
HEADLAMP DIAGNOSIS
HEADLAMPS H I M SEALED BEAM HEADLAMPS D I M
][ [
HEADLAMPS HEADLAMPS
ENGINE I D L I N G
OR I G N I T I O N OFF
O R BULB B U R N S
OUT FREQUENTLY
ENGINE R U N N I N G
ABOVE IDLE
][ R A N D O M FLASH WILL NOT LIGHT
POORLY GROUNDED LOOSE CONNECTION

TEST CHARGING TEST CHARGING TEST CHARGING HEADLAMP IN HEADLAMP
SYSTEM SYSTEM SYSTEM CIRCUIT CIRCUIT
HIGH RESISTANCE LOOSE CONNECTION HIGH RESISTANCE LOOSE CONNECTION OPEN OR CORRODED
IN HEADLAMP IN HEADLAMP IN HEADLAMP IN HEADLAMP CONTACT IN
CIRCUIT CIRCUIT CIRCUIT CIRCUIT HEADLAMP SWITCH
CRACKED LENS ON OPEN OR CORRODED

HALOGEN SEALED FAULTY SEALED CONTACT IN DIMMER
BEAM ONLY BEAMS OR BULBS SWITCH
FAULTY SEALED FAULTY SEALED

BEAMS OR BULBS BEAMS OR BULBS
RR8LD21
8L - 2 LAMPS •
This switch is mounted to the left hand side of the
steering column. Should any function of the switch STEERING
COLUMN
fail, the entire switch must be replaced. ASSY.
SWITCH TEST
(2) Remove tilt lever.
(3) Remove upper and lower column covers to gain
access to the switch connector (Fig. 1).
(4) Remove lower fixed column cover.
(5) Loosen steering column upper bracket nuts. Do
not remove nuts. TURN SIGNAL
(6) Move upper fixed column cover to gain access MULT I SWITCH A N D
*® FUNCTION LEVER
to rear of multi-function switch. SWITCH
(7) Remove switch connector (Figs. 2 and 3). J918J-1 CONNECTOR
(8) Use an ohmmeter to test for continuity. Check
between the terminals of the switch as shown in the Fig. 2 Multi-function Switch Connector
continuity chart (Fig. 4). KEY-IN SWITCH & MULTIFUNCTION
(9) Refer to Service Procedures for assembly. HALO LIGHT SWITCH
UPPER SHROUD GROUND UPPER

CLIP FIXED SHROUD
SUPPORT BRACKET
TURN SIGNAL
SWITCH & LEVER
IGNITION SPEED
Fig. 3 Steering Column Connectors
24 23 22 21 20 19 18
EZJ C=3 C=3 E = 3 CZZJ E = 3 E=3
17 16 15 14 13 12 11 10
8 = 3 1 = 3 1 = 3 1 = 3
a a a ( ( ) )
LOWER
FIXED 9 8 7 6 \ 5 _ y 4 3 2 1
LOWER
SHROUD SHROUD J9119-22
Fig. 1 Steering Column Covers

VIEW FROM TERMINAL SIDE
SWITCH POSITION CONTINUITY BETWEEN
LOW BEAM 18 AND 19

HIGH BEAM 19 AND 20
OPTICAL HORN 20 AND 21
908J-5
Fig. 4 Beam Select Switch Continuity Chart

• LAMPS 8L - 3
EXTERIOR LAMPS SERWICE PROCEDURES
INDEX
page page
Cargo Lamp 7 Headlamp Switch 4
Clearance Lamps for Dual Wheel Model . . . . . . . . 5 License Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Daytime Running Light Module (Canada Only) ... 8 Sealed Beam Replacement 4
Front Park and Turn Signal Lamp Bulb 4 Side Marker Lamp and Bulb . 5
Headlamp Adjustment Using Alignment Screen . . . 3 Tail, Stop, Turn Signal, Rear Side Marker and
Headlamp Alignment 3 Back-Up Lamps 5
Headlamp Alignment Preparation 3 Underhood Lamp 8
HEADLAMP ALIGNMENT (4) Clean headlamp lenses.

Headlamps can be aligned using the screen method (5) Verify t h a t luggage area is not heavily loaded.
provided in this section. Alignment Tool C4466-A or (6) Fuel tank should be FULL. Add 2.94 k g (6.5
equivalent can also be used. Refer to instructions lbs.) of weight over the fuel t a n k for each estimated
provided with t h e tool for proper procedures. The gallon of missing fuel.
p r e f e r r e d h e a d l a m p a l i g n m e n t s e t t i n g is 0 for
the left/right a d j u s t m e n t a n d 1" d o w n for t h e u p / HEADLAMP ADJUSTMENT USING ALIGNMENT
down adjustment. SCREEN
HEADLAMP ALIGNMENT PREPARATION ALIGNMENT SCREEN PREPARATION

(1) Verify headlamp dimmer switch and high beam (1) Position vehicle on a level surface perpendicu
indicator operation. lar to a flat wall 7.62 meters (25 ft) away from front
(2) Correct defective components t h a t could hinder of headlamp lens.
proper headlamp alignment. (2) If necessary, tape a line on the floor 7.62
(3) Verify proper tire inflation. meters (25 ft) away from and parallel to the wall.
CENTER OF LOW BEAM HOT FLOOR TO
VEHICLE TO SPOT AREA CENTER OF
CENTER OF HEADLAMP
HEADLAMP LENS
LENS
VEHICLE
CENTERLINE"
PREFERRED
HOT SPOT
LOCATION
7.62 METERS
(25 FEET)
FRONT OF
HEADLAMP 938L-25X
Fig. 1 Headlamp Alignment Screen —Typical

8L - 4 LAMPS •
(3) Up 1.27 meters (5 feet) from the floor, tape a (3) Separate sealed beam from seat and disconnect
line on the wall at the centerline of the vehicle. from the socket.
Sight along the centerline of the vehicle (from rear of To install, reverse the removal procedures.
vehicle forward) to verify accuracy of the line place
ment.
(4) Rock vehicle side-to-side three times to allow HEADLAMP
suspension to stabilize. BEZEL
(5) Jounce front suspension three times by pushing

downward on front bumper and releasing.
(6) Measure the distance from the center of head
lamp lens to the floor. Transfer measurement to the
alignment screen (with tape). Use this line for up/
down adjustment reference.
(7) Measure distance from the centerline of the ve
hicle to the center of each headlamp being aligned.
Transfer measurements to screen (with tape) to each
side of vehicle centerline. Use these lines for left/
right adjustment reference.
HEADLAMP ADJUSTMENT
A properly aimed low beam headlamp will project
top edge of high intensity pattern on screen from 50
mm (2 in.) above to 50 mm (2 in.) below headlamp
: ') J918L-29
centerline. The side-to-side outboard edge of high in
tensity pattern should be from 50 mm (2 in.) left to
50 mm (2 in.) right of headlamp centerline (Fig. 1). Fig. 3 Headlamp Bezel
The preferred h e a d l a m p a l i g n m e n t is 0 for the
up/down a d j u s t m e n t and 1" d o w n for the left/
right a d j u s t m e n t . The high beam pattern should be
correct when the iow beams are aligned properly
(Fig. 2).
To adjust headlamp aim, rotate alignment screws
to achieve the specified high intensity pattern. RETAINING
RING
SCREWS
J918L-28
Fig. 4 Sealed Beam Replacement

HEADLAMP SWITCH
To remove or replace the headlamp switch see in
structions in Group 8E - Instrument Panel and
Gauges.
1. HORIZONTAL ADJ. SCREW - RH
2. VERTICAL ADJ. SCREW FRONT PARK AND TURN SIGNAL LAMP BULB
3. HORIZONTAL ADJ. SCREW - LH (1) Remove 2 screws securing the Park/Turn signal
J908L-24 lamp (Fig. 5)
(2) Twist out lamp socket from back of lamp hous
Fig. 2 Sealed Beam Headlamp Alignment ing.
SEALED BEAM REPLACEMENT (3) Replace bulb.
(1) Remove the headlamp bezel (Fig. 3). To install, reverse removal procedures.
(2) Remove four screws from retaining ring (Fig.
4).
• LAMPS 8L - 5
J918L-27
Fig. 5 Park and Turn Signal Lamp

SIDE MARKER LAMP AND BULB
(1) From inside engine compartment, twist out Fig. 6 Tail, Stop, Turn Signal, Rear Side Marker and
socket from back of housing. Back-Up Lamp
(2) Remove nuts attaching lamp to fender.
(3) Lift lamp away from outside of fender.
To install, reverse the removal procedures.
TAIL, STOP, TURN SIGNAL, REAR SIDE MARKER

AND BACK-UP LAMPS
SWEPTLINE MODELS
REMOVAL
(1) Remove screws and remove lamp assembly.
(2) Twist out socket.
INSTALLATION
(1) Twist in socket.
(2) Position the lamp and install screws.
CAB CHASSIS MODELS
REMOVAL
LAMP
(1) Remove 4 screws holding lens to lamp.
ASSEMBLY PR1086
(2) Twist out bulb.
INSTALLATION Fig. 7 Tail, Stop, Turn Signal, and Back-Up Lamp
(1) Install bulb. INSTALLATION
(1) Twist in socket.
(2) Position lens and install screws.
(2) Position the lamp and install screws.
SPORT UTILITY MODELS
CLEARANCE LAMPS FOR DUAL WHEEL MODEL
REMOVAL
WHEEL FLARE AND TAILGATE CLEARANCE
(1) Remove screws and remove lamp assembly. LAMPS
(2) Twist out socket. To change bulb, remove lamp as follows:
(3) Replace bulb. (1) Pry out retaining clamps.
(2) Pull lens away from mounting plate.
8L - 6 LAMPS •
J908L-73
ASSEMBLY * J908L-63
Fig. 9 Wheel Flare Clearance Lamp

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

• LAMPS 8L - 7
(4) To install, reverse procedures. Make sure the

grounding eyelet is under a mounting screw.
Fig. 11 Cab Clearance Lamps

CARGO LAMP
STANDARD CAB
(1) Remove two mounting screws.
(2) Pull assembly out and disconnect wiring con
nector.
(3) To install, reverse the procedures.
Fig. 14 License Plate Lamp - Standard Rear Bumper

STEP BUMPER
J908L-59.
(1) Remove 2 lamp assembly mounting screws
(Fig. 15)
Fig. 12 Cargo Lamp—Standard Cab
(2) Remove lamp from bumper.
CLUB CAB (3) Disconnect wire connector.
(1) Remove two mounting screws. (4) Remove lens from lamp.
(2) Pull assembly out and disconnect wiring con (5) Twist out bulb.
nectors. (6) To install, reverse the removal procedures.
(3) To install, reverse the procedures.
WITHOUT REAR BUMPER
LICENSE LAMP (1) Remove screws holding lamp assembly to li
STANDARD BUMPER cense bracket (Fig. 16).
(1) Remove rear license plate. (2) Disconnect electrical connector and remove
(2) Remove 2 lamp mounting screws. lamp assembly.
(3) Remove lamp assembly. (3) Install new lamp assembly with screws and
(4) Remove 2 screws attaching lamp lens to hous connect electrical connector.
ing.
8L - 8 LAMPS
C
ONN
EC
TO
R (2) Rotate the bulb counter-clockwise. Remove it
from the lamp base socket (Fig. 18).
CUP
(3) Remove the screw t h a t attaches the lamp re
flector and support bracket to the hood inner panel
F
RON
T (Fig. 17).
(4) Remove the lamp from the hood inner panel.
INSTALLATION
L
AMPA S SE
M BLY (1) Position the underhood lamp on the hood inner
L
C
IEN
SE P LATE panel.
(2) Install the screw through the lamp and into the
hood panel (Fig. 17). Tighten the screw securely.
SCREW LAMPA SS
EMBL
Y
L
C
IENSE P L
ATE (3) Insert a replacement bulb in the lamp base
RR8LD
24 socket (Fig. 18). Rotate it clockwise.
(4) Connect the wire connector to the lamp (Fig.
Fig. 15 License Plate Lamps - Step Bumper 17).
H
OOD
TO T A L
I, S
TOP
,
T
URN SGI . AND B A
CK UP L
AMP
S
L
CIE
NSEPL
ATE LC
IE
NSEP L
ATELA
MP AND
L
AM PCON
NE
CTOR BRA
CKE
TA S
SE
MBL
Y J 908
L-
74 J9223-446
Fig. 16 License Plate Lamp Without Rear Bumper Fig. 17 Underhood Lamp
UNDERHOOD LAMP DAYTIME RUNNING LIGHT MODULE (CANADA
When equipped, the underhood lamp is installed on ONLY)
the hood left, rear inner panel (Fig, 17). The lamp is The headlamps on vehicles sold in Canada will il
illuminated when the hood is opened (Fig. 18). luminate when the ignition is ON. The module also
receives a signal from the distance sensor. This pro-
UNDERHOOD LAMP BULB REPLACEMENT
S
UP
PORT R
ETA
N
IE
R L
Q
IU DI
REMOVAL B
RAC
KE
T T
AB SWTI
C H
(1) Disconnect the wire connector from the under E
NCL
O S U
RE
hood lamp (Fig. 17).
W
RIE HA
RNE
SS
(2) Rotate the bulb counter-clockwise. Remove it CONN
ECT
OR
from the lamp base socket (Fig. 18).
1
INSTALLATION \
(1) Insert the replacement bulb in the lamp base
socket. Rotate it clockwise.
(2) Connect the wire connector to the lamp (Fig.
17).
d ^—1—l
1
L/
UNDERHOOD LAMP REPLACEMENT CMD>

LAMP
REMOVAL 9281 1
R
EF
L
ECT
OR B
UL
B (105) B
ASE J "
(1) Disconnect the wire connector from the lamp
(Fig. 17). Fig. 18 Underhood Lamp Components
LAMPS 8L - 9
vides a constant Lights On condition while the vehi

cle is rolling. The lamps illuminate at less t h a n 50%
of normal intensity.
The Daytime Running Light Module is located on
the right inner fender (Fig. 19).
(1) Remove the bolt holding the module and
bracket to the vehicle.
(2) Disconnect the electrical connector.
(3) To install the module, reverse the removal pro
cedures.
Fig. 19 Daytime Running Light Module

8L - 10 LAMPS •
I
N TERI
O RLAMPS
DOME LAMP
STANDARD CAB
(1) Remove two screws and lens.
(2) Twist bulb to remove.
LENS
SCREW J908L-65
Fig. 1 Dome Lamp (Standard Cab)

EXTENDED CAB LENS J918L-30
(1) Squeeze the front and rear of the lens together Fig. 3 Dome Lamp (Sport Utility)
and pull down to remove (Fig. 2). (2) Remove 2 screws holding the dome and reading
(2) Pull bulb down to remove from socket. lamp assembly to the mounting bracket.
SPORT UTILITY (3) Lower the assembly.
(1) Squeeze the front and rear of the lens together (4) Remove the bulb.
and pull down to remove (Fig. 3).
(2) Pull bulb down to remove from socket. ROOF
READING LAMP (SPORT UTILITY)

(1) Squeeze the front and rear of the lens together
and pull down to remove (Fig. 4).
MOUNTING
J908L-66 SCREW J918L-31
Fig. 2 Dome Lamp (Extended Cab) Fig. 4 Reading Lamp
• LAMPS 8L - 11
BULB APPLICATION
GENERAL INFORMATION A/C Heater Control 158
The following Bulb Application Table lists the Ash Receiver ..158
lamp title on the left side of t h e column and part Gear Shift Selector...........................................PC194
number on t h e right. Heater Control 158
Instrument Cluster.. PC 194
C A U T I O N : D o not u s e bulbs that have a higher can Radio ASC
dle power than the bulb listed in the Bulb Applica Snow Plow Control .158
tion Table. D a m a g e to lamp can result.
INDICATOR LAMPS
Service procedures for most of t h e lamps in the in
strument panel, and switches are located in Group
EXTERIOR LAMPS
8E, Instrument Panel and Gauges.
Auxiliary Turn Signal (Snow Plow) 2057
Anti-lock Brake PC194
Auxiliary Headlamps (Snow Plow) .6054 Brake Warning PC194
Back-up....................... .......1156 Check Engine PC194
Cargo Lamp.. 922 Engine Oil Pressure 158
Clearance Lamps 194 Fasten Seat Belts.. PC 194
Front Side Marker 168 Four Wheel Drive ....158
Headlamp/Sealed Beam .6052 Hazard Flasher 194
License Plate 168 High Beam PC194
Park/Turn Signal 2057 Low Fuel....... JPC194
TaiyStop/Turn Signal ...2057 Maintenance Required PC 194
Transmission Temperature ..PC 194
INTERIOR LAMPS Turn Signal PC194
DIMMER CONTROLLED LAMPS NON-DIMMING LAMPS

Service procedures for most of t h e lamps in the in Service procedures for most of t h e lamps in the fol
strument panel are located in Group 8E, Instrument lowing list can be found in Group 23, Body.
Panel and Gauges. Some components have lamps Dome 1004
t h a t can only be serviced by an Authorized Service Engine Compartment ...105
Center (ASC). These components must be removed Glove Compartment.... 1891
from the vehicle for service. Contact local dealer for Ignition Lock ASC
location of nearest ASC. Reading Lamp 912
• REAR WINDOW DEFOGGER 8N - 1
REAR WINDOW DEFOGGER
CONTENTS
page page
REPAIR PROCEDURES (GRID LINES, SERVICE PROCEDURES 4
TERMINALS, AND PIGTAILS) 3 TEST PROCEDURES 1
GENERAL INFORMATION cleaning the g l a s s or removing foreign materials,

The electrically heated rear window defogger is decals or stickers. Normal g l a s s cleaning solvents
available on Ramcharger with sunscreen glass only. or hot water used with rags or toweling is recom
The system consists of a rear window with two ver mended.
tical bus bars and a series of electrically connected
grid lines baked on the inside surface.
Circuit protection for t h e heated grid circuit is pro SYSTEM DESCRIPTION
vided by a 18 gauge fusible link wire located in the
engine compartment. The relay circuit is protected CONTROL SWITCH/TIMER RELAY MODULE
by a 20 amp fuse, located in the fuse block. The control switch and timer relay are integrated
When the rear window defogger switch is placed in into a single panel mounted assembly. Actuating t h e
the ON position, current is directed to rear window switch energizes the electronic timing circuit. This
grid lines. The heated grid lines in t u r n heat the allows current to flow through the grid system for
rear window to clear t h e surface of fog or snow. approximately 10 minutes, or until either the control
switch or ignition is turned off. An indicating lamp
C A U T I O N ; Grid lines c a n be damaged or scraped
off with sharp instruments. Care should be taken in illuminates a lens inlaid in t h e control switch.
TEST PROCEDURES
SYSTEM TEST VOLTMETER
Electrically heated rear window defogger operation
can be checked in-vehicle in the following manner:
(1) Turn the ignition ON.
(2) Turn rear window defogger control switch ON.
(3) Monitor vehicle voltmeter. With the control
switch ON, a distinct needle deflection should be
noted.
(4) The rear window defogger operation can be
checked by feeling the glass. A distinct difference in
temperature between t h e grid lines and adjacent
clear glass can be detected in 3 to 4 minutes of oper
ation.
(5) Contact negative lead of a DC voltmeter (Fig.
1), to terminal "B" (passenger side). Contact positive Fig. 1 Grid Line Test
lead to terminal " A " (driver side). The voltmeter (2) Ensure t h a t heated rear window feed wire is
should read 10-14 volts. connected to terminal or pigtail and t h a t ground wire
Only steps (3) and (4) or (5) above will confirm sys is in fact grounded.
tem operation. Indicator light illumination means (3) Ensure t h a t fuse is operational and all electri
that there is power available at the output of the re cal connections are secure.
lay only, and does not verify system operation. When above steps have been completed and t h e
If rear window defogger does not operate, the prob system is still inoperative, one or more of the follow
lem should be isolated in the following manner: ing is defective:
(1) Confirm that ignition switch is ON. (a) Control switch/timer relay module.
8N - 2 REAR WINDOW DEFOGGER •
(b) Rear window grid lines (all grid lines would nals B, I and L (Figs. 2 and 3). Terminals B and I
have to be broken) or one of the feed wires are not should confirm a voltage of 10 to 14 volts to ground.
connected for the system to be inoperative. Terminal L should confirm 0 volts to ground. When
The following paragraphs outline component check terminals B and I show no voltage, trace circuit up
out procedures. stream of switch/relay module for cause:
If turning the switch ON produces severe voltmeter • wiring cut
deflection, t h e circuit should be closely checked for a • fusible link faulty
shorting condition. • circuit breaker inoperative
If system operation has been verified but indicator • bulkhead connection bad, etc.
bulb does not light, check and replace bulb. If terminal L indicates voltage, place switch in
For detailed wiring information, refer to Group 8W OFF position. If voltage at L is still indicated or in
- Wiring Diagrams.
dicator lamp remains on, switch/relay module should
be replaced.
REAR WINDOW GRID LINES TEST
Horizontal grid lines and vertical bus bar lines "XI F
US FUSE #3
E #14 r r ~ B
AT
TE
RY
printed and baked on inside surface of rear window 20 AAAP
glass (Fig. 1) comprise an electrical parallel circuit. P 3 AAAP P
The electrically conductive lines are made of a silver-
ceramic material. When baked onto glass they be
come bonded to the glass and are highly resistant to H E ATE D R E
AR
abrasion. It is possible, however, t h a t a break may W N
IDO W D E
FO
GGER
18 G
AUGE
exist or occur in an individual grid line resulting in SW TIC H
FU
SB
IL
E
no current flow through the line. To detect breaks in N
I
(STR U M EN TP A
NEL
)
ILLUMINATION
L
N
IK
grid lines, the following procedure is required: LAMP
-©-
(1) Turn ignition on and push control switch to fez T
M
IER
ON. Indicator light should come on. ON
O
/FF
G
IN
TIO
IN
(2) Contact negative lead of a DC voltmeter, to
L.
E .
I
vertical bus bar connecting grid lines on passenger INDICATOR
LIGHT
side of vehicle (point A of Fig. 1). Contact positive
lead of voltmeter, to vertical bus bar on driver side of
P
OWER MD
IP
ONIT "C"
vehicle (point B of Fig. 1). Voltmeter should read C
ONN
ECT
OR T
(YP
C
IA L
)
10-14 volts.
(3) With negative lead of voltmeter, contact a good P
ONIT "A" P
ONIT "B" G
ROUN
D
body ground point. Voltage reading should not CO
NNE
CT
OR
change. A different reading indicates a poor ground
connection.
(4) Connect negative lead of voltmeter to Point A
on passenger side bus bar and touch each grid line at
Mid-Point with positive lead. A reading of approxi R
EA
RWN
ID
OWGR
D
I L
N
IE S
TR
UCT
URE
mately 6 volts indicates a line is good. A reading of 0
J
928
N 5
-
volts indicates a break in line between Mid-Point C
and Point B. A reading of 10-14 volts indicates a Fig. 2 Systems Electrical Circuit
break between Mid-Point C and ground Point A.
Move toward break and voltage will change as soon (4) If the relay checks out to this point, momen
as break is crossed. tarily operate switch to ON position. The indicator
lamp should come on and remain on for approxi
CONTROL SWITCH/TIMER MODULE TEST mately 10 minutes. Terminal L should confirm volt
Control switch/timer relay module may be tested age. If the indicator lamp fails to light or voltage at
in-vehicle or bench tested. In vehicle testing is ac terminal L is not confirmed the switch/relay module
complished in the following manner: should be replaced.
(1) Remove switch from instrument panel (refer to Bench checking of the relay may be accomplished
Control Switch Replacement) and leave switch con in the following manner. By following the in-vehicle
nector plugged in. procedure except Step 2: With a DC power supply,
(2) Turn ignition ON. apply 12 volts to terminal B and I and ground termi
(3) Using a DC voltmeter, check voltage at termi nal G.
e , REAR WINDOW DEFOGGER 8N - 3
L - TO BACK GLASS
B - HIGH AMP SUPPLY
I - IGNITION
G - GROUND
S - ILLUMINATION LIGHT
RELAY-TIMER
SWITCH ASSEMBLY J908N-8
Fig. 3 Rear Window Defogger Switch, Timer, Relay

Connector
REPAIR PROCEDURES (GRID LINES, TERMINALS* AND PIGTAILS)

The repair of grid lines or t h e terminal is possible BREAK GRID LINE
using t h e MOPAR Repair Kit No. 4267922 or equiv
alent.
W A R N I N G : R E P A I R KIT M A Y C A U S E S K I N O R E Y E
IRRITATION.
CONTAINS EPOXY RESIN A N DAMINE TYPE
H A R D E N E R , H A R M F U L IF S W A L L O W E D . A V O I D
C O N T A C T WITH S K I N A N D E Y E S . F O R S K I N , W A S H
A F F E C T E D A R E A S WITH S O A P A N D W A T E R . D O
N O T T A K E I N T E R N A L L Y . IF T A K E N I N T E R N A L L Y ,
MASKING TAPE PR1509A
INDUCE VOMITING; CALL A PHYSICIAN IMMEDI
A T E L Y . IF IN C O N T A C T W I T H E Y E S , F L U S H W I T H Fig. 4 Grid Line Repair (Typical)
PLENTY O F W A T E R . U S E WITH A D E Q U A T E VENTI
well as b u s bar. Apply a thin layer of epoxy to area
LATION. D O NOT U S E N E A R FIRE O R F L A M E .
where terminal was fastened and to adjacent line.
CONTENTS CONTAIN 3 % F L A M M A B L E SOLVENTS.
(7) Apply a thin layer of conductive epoxy on ter
K E E P OUT OF R E A C H O F CHILDREN.
minal and place terminal on desired location. To pre
vent terminal from moving while t h e epoxy is curing,
(1) Mask repair area so conductive epoxy can be
it must be wedged or clamped.
extended onto t h e line or t h e bus b a r (Fig. 4).
(8) Carefully remove masking tape from grid line.
(2) Follow instructions in repair kit for preparing
damaged area. C A U T I O N : Do not allow the g l a s s surface to exceed
(3) Remove package separator clamp and mix plas 400°F, g l a s s may fracture.
tic conductive epoxy thoroughly. Fold in half and cut
center corner to dispense epoxy. (9) Allow epoxy to cure 24 hours a t room tempera
(4) For grid line, m a r k off area to be repaired with ture or use heat gun with a 260°-371°C (500°-700°F)
masking tape or a template (Fig. 4). range for 15 minutes. Hold gun approximately
(5) Apply epoxy through slit in masking tape. 254mm (10 inches) from repaired area.
Overlap both ends of t h e break by a t least 19mm (10) After conductive epoxy is properly cured re
(0.75 in). move wedge from terminal and check out operation
(6) For a terminal or pigtail replacement, mask ad of rear window defogger. Do not attach connectors
jacent areas so epoxy can be extended onto line as until curing is complete.
81 - 4 REAR WINDOW DEFOGGER •
SERVICE PROCEDURES
HEATED REAR WINDOW CONTROL SWITCH (3) Remove connector from switch.
REPLACEMENT
INSTALLATION
REMOVAL (1) Connect electrical connector to switch.
(1) Locate chime module. Grasp chime module and (2) Insert switch into bezel making sure retaining
twist it to remove it from the bracket. tangs lock into position.
(2) Squeeze rear window defogger switch retaining (3) Install chime module on to bracket.
tangs and pull switch from rear of bezel.
• POWER DOOR LOCKS 8P - 1
POWER DOOR LOCKS
CONTENTS
page page
GENERAL INFORMATION The right and left front door on all vehicles can be
Both doors, when electrically equipped, can be locked or unlocked mechanically from t h e outside
locked or unlocked electrically by operating the with t h e key or electrically as described above. The
switch on a door panel. left door can also be unlocked by actuation of the in
Both doors can be locked or unlocked mechanically side remote door handle.
with t h e locking knob regardless of electrical locking
and unlocking actuation.
TEST PROCEDURES
FUSE TEST VOLTAGE TEST
Locate t h e fuse in fuse cavity number 6 on t h e fuse The following wiring test sequence determines
block. If fuse is blown, replace it. If fuse blows again whether or not voltage is continuous through the
refer to Switch Test and Voltage Test procedures to body harness to switch.
find t h e short circuit. After removing switch from trim panel for testing
purposes, carefully separate multiple terminal block
SWITCH TEST on wiring harness from switch body. Connect one
For switch testing, remove t h e switch from its lead of test light to black wire terminal and touch
other test light lead to red wire terminal. If the test
mounting location. Using a n ohmmeter, refer to (Fig.
light comes on, t h e wiring circuit between t h e bat
1) to determine if continuity is correct in t h e Lock
tery and switch is functional. If light does not come
and Unlock switch positions. If these results are not on, check 20 amp fuse or for a broken wire.
obtained, replace t h e switch.
ELECTRIC MOTOR TEST
Make certain battery is in normal condition before
SWITCH CONTINUITY circuits are tested.
POSITION BOWEIN To determine which motor is defective, check each
OFF
PINS 1 & 4 individual door switch for lock and unlock or discon
PINS 2 & 5 nect t h e motors, one at a time, then operate t h e door
® LOCK
PINS 2 & 3
lock switch. In t h e event t h a t none of t h e motors
work, the problem may be caused by a shorted motor.
3 PINS 1 & 4
Disconnecting t h e defective motor will allow t h e
PINS 3 & 4 other to work.
UNLOCK PINS 2 & 5 To test a n individual door lock motor, disconnect
t h e wire connector at the motor. Apply 12 volts
PIN IDENTIFICATION across t h e motor terminals to check its operation in
PIN SIDE OF SWITCH one direction. Reverse t h e polarity to check t h e oper
ation in t h e other direction. If t h e motor works,
Fig. 1 Door Lock Switch Continuity check t h e wire harness for broken wires or bad con
nections. If the motor does not work, replace it.
Should t h e motor malfunction be t h e result of bro
ken wiring or a n internal open circuit, it should have
no effect on t h e operation of the other motor.
8P - 2 POWER DOOR LOCKS •
SERVICE P R O C E D U R E S
DOOR LOCK MOTOR REPLACEMENT
REMOVAL
(1) Remove remote control handle (Fig. 2).
TRIM PANEL
CLIPS (6)
REMOTE
CONTROL
HANDLE
SCREW
TRIM
PANEL
TRIM PANEL
J908P-12
CLIPS
Fig. 2 Door Trim Panel

(2) Remove power window/lock switch by inserting D O O R LOCK
MOTOR
a standard blade screwdriver into notch on forward
end of switch housing and push to depress locking
tab. Pull out and forward to remove switch bezel
from door panel.
(3) Remove 2 screws at bottom front and rear of J918P-9
trim panel.
(4) Remove screw behind remote handle. Fig. 3 Door Lock Motor Replacement
(5) Using a device such as a trim stick, pry trim INSTALLATION
panel away from door around perimeter. (1) Attach motor mounting bracket to door inside
(6) Roll door watershield away from lower rear cor panel and install 2 screws.
ner of door to reveal inside panel access opening. (2) Connect link to motor rod and connect wires.
(7) Remove motor link at motor (Fig. 3). (3) Reset watershield at lower rear corner of door.
(8) Disconnect motor lead wires. (4) Install door trim panel.
(9) Remove 2 motor mounting bracket screws and (5) Install door panel attaching screws.
remove motor assembly from mounting. (6) Install remote control handle.
(7) Install power window/lock switch.
• POWER WINDOWS 8S - 1
POWER WINDOWS
CONTENTS
page page
SERVICE PROCEDURES 3 TEST PROCEDURES ....................... 1
GENERAL INFORMATION and down in the glass channels or tubes and tracks.
Power window motors are of the permanent mag If t h e window is not free to move up and down, the
net type. A positive and negative battery connection window motor will not be able to move the glass.
to either of the two motor terminals will cause the To determine if the glass is free, disconnect the
motor to rotate in one direction. Reversing current electric window regulator lift a r m sliders from the
through these same two connections will cause the glass lift channels. Slide the window up and down by
motor to rotate in the opposite direction. hand.
Both motors are grounded through the master A less positive method is to shake the glass in the
switch by a black wire attached to a ground stud. door, (with glass positioned between the up and down
The stud is located on the back of the instrument stop positions). If the glass will move slightly from
panel, on the right side of the steering column. side to side, front to rear, and u p and down, the win
It is necessary t h a t the window be free to slide up dow is probably not bound tight in the tracks.
TEST PROCEDURES
SWITCH VOLTAGE TEST both terminals of circuit breaker for battery voltage.
The following wiring test sequence determines If only one terminal checks at battery voltage, circuit
whether or not voltage is continuous through the breaker is defective and must be replaced. If neither
body harness to switch. terminal shows battery voltage, check for open or
(1) Remove power window/lock switch by inserting shorted circuit to circuit breaker.
end of switch housing. Push screwdriver to depress SWITCH TEST
locking tab. Pull bezel out and forward to remove For switch testing, remove t h e switch from its
from door panel. mounting location. Using an ohmmeter, refer to Figs.
(2) Carefully separate multiple terminal block on 1 and 2 to determine if continuity is correct in the
wiring harness from switch body. U P and DOWN switch positions. If continuity is cor
(3) Connect one lead of test light to black (BK) rect perform window lift motor test.
wire terminal. Touch other test light lead to t a n (TN)
wire terminal. If test light comes on, the wiring cir WINDOW MOTOR TEST
cuit between the battery and switch is functional. If (1) Connect positive lead (from a test battery) to
light does not come on, check 30 amp circuit breaker, either of the two motor terminals.
or for a broken wire or poor ground. (2) Connect negative lead (from test battery) to re
maining motor terminal.
CIRCUIT BREAKER TEST (3) The motor should now rotate in one direction to
Locate the circuit breaker in fuse cavity number 12
either move window up or down.
on fuse block. Pull out slightly but be sure t h a t cir
(a) If window happens to already be in full U P
cuit breaker terminals still contact terminals in fuse
position and motor is connected to rotate in U P di
block. Connect ground wire of voltmeter to a good
ground. With probe of voltmeter positive wire, check rection, no movement will be observed.
8S - 2 POWER WINDOWS •
P O W E R W I N D O W SYSf EM DIAGNOSIS
SYSTEM OPERATES CHECK SYSTEM

SYSTEM
BUT G L A S S SYSTEM OPERATES
DOES NOT
TRAVEL IS COCKED OPERATE OPERATION CORRECTLY
OR INCOMPLETE
I CHECK FOR
MANUALLY
CHECK TRAVEL
12 VOLTS AT N O VOLTAGE
OF G L A S S
MOTOR CHECK WIRING
TERMINAL AND/OR SWITCHES
I
GLASS TRAVEL
I
VOLTAGE OKAY
OKAY CHECK FOR SYSTEM BINDING
REMOVE
REMOVE MOTOR BINDING OF GLASS CORRECT
REGULATOR
FROM REGULATOR GUIDANCE SYSTEM BINDING
FROM DOOR
ASSEMBLY CONDITION
REPLACE
ARM & SECTOR BENCH TEST
GLASS MOVES REGULATOR REGULATOR
PORTION OF FREELY
REGULATOR ASSEMBLY OPERATES
CORRECTLY
I I I
REASSEMBLE REGULATOR
REMOVE DOES NOT REINSTALL
REGULATOR MOTOR FROM REGULATOR
OPERATE
REGULATOR* INTO DOOR
REINSTALL CHECK
REGULATOR ARM & SECTOR NONE OF THESE
INTO DOOR ASSEMBLY FOR CONDITIONS EXIST
FREE MOVEMENT, ANY OF THESE
MISSING AND/OR CONDITIONS EXIST
DAMAGED REPLACE
IF PROBLEM GEAR TEETH, ARM & SECTOR
STILL EXISTS MISSING OR DAMAGED ASSEMBLY
CORRECT GLASS ROLLER,
GUIDANCE OR BENT ARM
PROBLEM PINION ROTATES
APPLY VOLTAGE TO CORRECTLY
PINION DOES NOT MOTOR AND CHECK REASSEMBLE
ROTATE FOR PINION REGULATOR AND
REMOVE GEAR & PINION ROTATION INSTALL INTO DOOR
AND EXAMINE FOR
MISSING AND/OR
DAMAGED GEAR TEETH
GEAR & PINION WITH
ASSEMBLY GEAR & PINION
TEETH CHECK REMOVED
OKAY APPLY VOLTAGE TO
MISSING AND/OR
MOTOR TERMINAL
DAMAGED GEAR TEETH
AND CHECK FOR
REPLACE
ARMATURE
GEAR & PINION
SHAFT ROTATION
ASSEMBLY ARMATURE SHAFT
* COUNTERBALANCE SPRING
MUST BE REMOVED BEFORE
REMOVING MOTOR FROM
REGULATOR. IF NOT,
DOES NOT ROTATE
REPLACE MOTOR I
REASSEMBLE ARMATURE SHAFT
INJURY MAY RESULT
REGULATOR ROTATES
ASSEMBLY CORRECTLY
J918S-7
• POWER WINDOWS 8S - 3
FROM PIN SIDE OF SWITCH
MASTER WINDOW LIFT SWITCH PIN IDENTIFICATION S H O W N

FROM PIN SIDE OF SWITCH
SWITCH CONTINUITY
POSITION BETWEEN
SWITCH CONTINUITY
PINS 1 & 2 POSITION BETWEEN
PINS 2 & 3
OFF PINS 2 & 4 PINS 1 & 4
PINS 2 & 6 OFF
PINS 2 & 5
PINS 3 & 5
PINS 3 & 4
DRIVER'S UP
PINS 2 & 6
MP PINS 2 & 5
PINS 1 & 5
PASSENGER'S PINS 2 & 4 PINS 2 & 3
DOWN
PINS 5 & 6 PINS 1 & 4
DRIVER'S
PINS 2 & 3
TOWN 898S-12
PINS 1 & 2
PASSENGER'S
PINS 4 & 5
Fig. 2 Passenger's Door Mounted Switch Continuity
898S-11
(4) Reverse battery leads (opposite to steps 1 and
Fig. 1 Master Window Lift Switch Continuity 2) and window should now move. If window does not
move, remove motor. Refer to Service Procedures for
(b) Likewise, motor connected to DOWN direc
motor removal from vehicle for bench test.
tion rotation, no movement will be observed if win If window moved completely up or down, motor
dow is already in full down position. should be reversed one more time (reverse leads from
step 4) to complete a full window travel inspection.
SERVICE PROCEDURES
GEAR AND PINION REPLACEMENT AND (1) Remove remote control handle (Fig. 3).
LUBRICATION (2) Remove power window/lock switch by inserting
If gear and pinion assembly are replaced in gear a standard blade screwdriver into notch on forward
box, lubrication of gear box, gear pinion and seal is end of switch housing. Push screwdriver to depress
necessary. locking tab. Pull bezel out and forward to remove
In the event there is no lubricant in gear box, fill from door panel.
with MOPAR, multi-mileage lubricant or equivalent. (3) Remove screws at bottom front and rear of trim
Apply a liberal amount of lubricant to inside area of panel.
seal and sealing surface at center area of gear and (4) Remove screw behind remote handle.
pinion coupling. Also lubricate center housing shaft (5) Using a device such as a trim stick, pry trim
and worm gear. panel away from door around perimeter and remove
trim panel.
REGULATOR AND MOTOR ASSEMBLY (6) Roll door watershield away from bottom of door
to reveal inside panel access opening.
REMOVAL (7) Remove speaker if equipped.
To repair or inspect the entire electric window reg (8) Lower glass to full down position.
ulator, remove from door as follows: (9) Disconnect wiring connectors from motor.
8S - 4 POWER WINDOWS •
BENCH REPAIR
If entire regulator is not being replaced, repair as
follows:
(1) Remove regulator as previously described.
W A R N I N G : S T E P S (2) A N D (3) A R E V E R Y I M P O R -
T A N T . IF N O T D O N E B E F O R E M O T O R R E M O V A L
INJURY M A Y RESULT.
(2) Secure regulator in vise to prevent sector gear

from rotating.
(3) Remove counter balance spring. (Must be done
for safety before removing motor).
(4) Remove 3 motor attaching screws and remove
motor (Fig. 5).

(10) Remove inner weatherstrip being careful not
to scratch the belt-line paint.
(11) Free the clip on the inner section of the
weatherstrip with a wire hook or suitable tool.
(12) Pull back upper glass run 8 to 20-25 cm (10
inches).
(13) Remove upper and lower vent wing attaching
screws.
(14) Remove vent wing, being careful to avoid
paint damage from glass lower pivot adjusting
screws.
(15) Remove down stop bumper bracket (Fig. 4).
Fig. 5 Motor Attaching Screws

(5) Inspect regulator for:
(a) Sector gear teeth must not be broken or se
verely worn.
(b) All rivets and sliders must be securely at
tached.
(c) Parts must not be bent or cracked.
(d) Sector gear must rotate freely.
(e) Perform window lift motor test as described
above.
(6) Install motor and attach with three motor at
taching screws.
(7) Install counter balance spring.
Fig. 4 Electric Window Regulator Mounting INSTALLATION

(1) Insert upper regulator arm into door mounted
(16) Disengage glass from regulator arms and channel.
lower to door bottom. (2) Mount regulator to door panel with 1/4-20
(17) Remove regulator mounting screws. screws torqued to 11 N*m (105 in. lbs.).
(18) Remove regulator through large access hole. (3) Slide glass onto regulator arms and into rear
glass run.
• POWER WINDOWS 88 - §
(4) Connect motor electrical connector. (9) Install belt weatherstrip by aligning clips to
(5) Install plastic n u t and "U" n u t on vent wing holes in door and press in.
assembly. (10) Raise or lower vent to maintain a 1.6mm (.06
(6) Install vent wing assembly into door. in.) fore-aft glass free-play then with glass up,
(7) Install upper and lower vent wing attachment tighten upper screws.
screws. (11) Hold vent against glass (glass down) and
(8) Move glass r u n back to vent wing by placing tighten lower screws.
run adjacent to door channel and press into channel (12) Raise glass to full up position.
using wide blade screwdriver or similar tool. Press in (13) Install speaker if equipped.
both inside corners to ensure hidden lip engages in (14) Install down stop bumper.
channel. (15) Install watershield and trim panel.
POWER MIRRORS
CONTENTS
page page
SERVICE PROCEDURES 2 TEST PROCEDURES ...................... 1
GENERAL INFORMATION
Electrically-operated remote control mirrors are
available as an option on D-body vehicles. The mir
rors are controlled by a single switch assembly lo
cated on the instrument panel to the right of t h e
headlamp switch (Fig. 1).
D-body vehicles use a toggle-type switch. The
switch is rotated clockwise (Right mirror) or counter
clockwise (Left mirror) for mirror selection. The
switch is moved UP, DOWN, RIGHT, or LEFT for
mirror movement direction.
The motors which operate the mirrors are part of
the mirror assembly and cannot be serviced sepa
rately.
Fig. 1 Power Mirror and Headlamp Switches
TEST PROCEDURES
MIRROR MOTOR TEST PROCEDURE MIRROR TEST CHART
(1) Remove power mirror switch from mounting
position (refer to Service Procedures). M I R R O R REACTION
(2) Disconnect wiring harness at switch connector. 12 Volts Ground Right Left
(3) Use 2 jumper wires. Connect one to a 12-volt Yl/BK 1 WT/BK UP
source, and the other to a good body ground. Refer to YL WT UP
the MIRROR TEST CHART for wire hookups at the WT/BK YL/BK DOWN
switch connector (harness side, not switch side), WT YL DOWN
(4) If results shown in chart are not obtained, WT/BK DB/WT RIGHT
check for broken or shorted circuit, or replace mirror WT DB RIGHT
assembly as necessary. DB/WT WT/BK LEFT
DB WT LEFT
J908K-22
8T - 2 POWER MIRRORS •
MIRROR SWITCH TEST PROCEDURE MIRROR SWITCH CONTINUITY CHART
(1) Remove power mirror switch from mounting
position (refer to Service Procedures).
(2) Disconnect wiring harness at switch connector. M I R R O R SELECTOR K N O B I N " L " P O S I T I O N
(3) Test for continuity (no resistance) between the M o v e Lever Continuity Between
terminals of the switch as shown in the MIRROR WT and BK
SWITCH CONTINUITY CHART. YL and PK and YL/BK and PK
WT and PK,
(4) If results shown in the chart are not obtained, DB/WT and BK and DB & BK
replace the switch. YL/BK and BK, YL and BK
WT and PK
WT and BK, DB/WT and PK
DB and PK
M I R R O R SELECTOR K N O B I N " R " P O S I T I O N
M o v e Lever Continuity Between
WT/BK and BK, YL and PK
YL/BK and PK
WT/BK and PK, DB and BK
• DB/WT and BK
WT/BK and PK, YL and BK
YL/BK and BK
WT/BK and BK, DB and PK
« DB/WT and PK
J928T-6
SERVICE PROCEDURES
MIRROR SWITCH REMOVAL AND INSTALLATION (5) Remove bezel by pulling top edge rearward to
(1) Disconnect negative cable from battery. clear brow. Disengage attaching clips around bottom
(2) Remove 2 screws holding map lamp and re of bezel and complete removal of bezel.
move map lamp. (6) If the bezel has a four wheel drive indicator, re
(3) Remove 6 screws which attach instrument clus move bulb socket as bezel is removed.
ter bezel to instrument panel (Fig. 2). Make sure the (7) Disconnect message center wires.
screw below the Heater/C control is removed. (8) Remove instrument cluster bezel assembly.
(9) Pull headlamp switch to ON position.
INSTRUMENT (10) Reach under instrument panel and depress
button on side of switch while pulling stem out.
(11) Remove switch bezel retaining screws and pull
bezel out of instrument panel (Fig. 1).
(12) Pull harness out through opening in instru
ment panel and disconnect mirror switch connector.
(13) Remove 2 switch mounting-plate-to-bezel re
taining screws.
(14) Remove switch-to-mounting-plate nut.
For Installation, reverse removal procedures.
MIRROR ASSEMBLY REMOVAL AND

CLUSTER BEZEL J938E-51 INSTALLATION
(1) Remove remote control handle (Fig. 3).
Fig. 2 Instrument Cluster Bezel (2) Remove power window/lock switch by inserting
(4) Place column shift lever in Position 1. end of switch housing and push to depress locking
tab. Pull out and forward to remove switch bezel
from door panel.
• POWER MIRRORS 8T - 3
(8) Remove mirror mounting bracket cover (1

screw) and slide up on mirror stem (Fig. 4).

(3) Remove 2 screws at bottom front and rear of
trim panel.
(4) Remove screw behind remote handle.
(5) Using a device such as a trim stick, pry trim
panel away from door around perimeter.
(6) Roll door watershield away from lower rear cor
ner of door to reveal inside panel access opening.
(7) Reach inside door and disconnect mirror wiring Fig. 4 Power Mirror Replacement
at connector. (9) Remove 3 mirror mounting bracket nuts.
Spray grommet on mounting bracket cover (10) Pull mirror loose from door, and feed wiring
with silicone to avoid grommet c o m i n g off w h e n harness out through hole in outer door panel.
cover is m o v e d u p on mirror stem. For Installation, reverse Removal procedure.
- CHIME/BUZZER WARNING SYSTEMS 8U - 1
CHIME/BUZZER WARNING SYSTEMS
CONTENTS
page page
DIAGNOSIS 1 KEY-IN SWITCH REPLACEMENT 3
GENERAL INFORMATION 1 OPERATION 1
GENERAL INFORMATION KEY IN IGNITION

The buzzer module is located to the right of the To sound t h e "key in ignition" alarm, the module
steering column (Fig. 1). The buzzer sounds an audi needs:
ble warning tone in any of the following conditions: • the ignition key warning switch must be closed
• Vehicle lights are ON when t h e driver's door is • the driver's door jamb switch must be closed.
opened. These conditions ground pin 6 of the module. These
• The key is in the ignition and the driver's door is switches are closed when the driver's door is open
open. and the key is in the ignition.
• The ignition is switched ON and the driver's seat
belt is not buckled. Buzzer will quit after 4 to 8 sec LIGHTS ON
onds. In addition to the buzzer, a seat belt light in To sound the "lights on" warning, the module
dicator turns on as a reminder to fasten seat belt. needs:
• the headlamp switch m u s t be closed
*> the driver's door jamb switch must be closed.
BUZZER These conditions ground pin 6 of the module. These
MODULE
switches are closed when the driver's door is open
and the headlamp switch is on.
DIAGNOSIS
If the buzzer unit does not operate as described,
check the two fuses for pins 1 and 7 (Figs. 2, 3 and 4)
and replace as required. If the fuses are not defec
tive, perform the following tests to determine if the
problem is in the module or in the wiring. Using a
flat blade screwdriver, release the locking plastic clip
while carefully pulling out the module. Plug in a
INTERMITTENT known good module and check its operation. If the
WIPE MODULE problem is not corrected by replacing the module, re
move the module and continue as follows:
Fig, 1 Buzzer Module Location
OPERATION VOLTAGE TESTS
Battery voltage for module operation is supplied to Ignition in run, m e a s u r e b e t w e e n the following
two pins. Battery voltage is present at pin 7 at all pins and vehicle ground.
times (Figs. 2 and 3). Pin 1 receives voltage when • Measure voltage at buzzer module connector pin 1.
the ignition switch is turned ON. Meter should read battery voltage. If not, repair open
to ignition switch.
SEA T BELT WARNING Turn ignition off a n d remove k e y from igni
To sound the seat belt warning, the module needs: tion.
• battery voltage at the ignition switch input (Pin 1) • Measure voltage at buzzer module connector pin 7.
• a ground at the seat belt switch. Meter should read battery voltage. If not, repair open
• a ground at Pin 3 to activate the timer. to fuse. Battery voltage is present at Pin 7 at all
This occurs when t h e seat belt switch is closed be times regardless of key position.
cause the driver's seat belt is not buckled. The "fas
ten belt" light will also turn on along with the
warning sound.
8U - 2 CHIME/BUZZER WARNING SYSTEMS •
TERMINAL 7 TERMINAL 6 tive). Meter should read open circuit if drivers seat
TO B + TO DOOR SWITCH belt is buckled. If not, repair short to ground (or
KEY IN SWITCH A N D
buckle switch may be defective).
HEADLAMP O N
SWITCH • Buzzer module connector pin 6. Open driver's door,
key in ignition, (in OFF position). Meter should read
zero ohms. If not, repair open to ground.
• Buzzer/chime module connector pin 6. Open driv
er's door, headlamp switch on, meter should read
!cO=f M i c£K *£h\
• CZ3 EZZ3 EZI 1 r—i DOORSW
± 7 (SHOWN DOOR CLOSED)
rFY<;w M UGHTS SW
(SHOWN KEW/ f(SHOWN^JGHTS OFF)
TERMINAL 4 TERMINAL 1 #5
TO SEAT BELT TO IGNITION
BUCKLE SWITCH SWITCH
TERMINAL 2
TERMINAL 3 TO SEAT BELT
TO GROUND WARNING LIGHT J928U-12 SEAT BELT SW
-^•^Y BELT(I) /. (SHOWN
Fig. 2 Buzzer Module Connector Terminal IGN SW
SW LAMP JL - BUCKLED)
(SHOWN IGN OFF)
Identification—Front View PIN VIEW (SAME AS REAR SIDE [WIRE SIDE]
LIGHTS-ON/KEY-IN-IGNITION CONNECTOR VIEW)
WARNING X = Do Not Care
FUNCTION DESCRIPTION IGN. SEAT DRIVER'S HEAD
BATTERY ( + ) BELT DOOR KEY LAMPS
4 to 8 Second ^ O n Not
Tone and X X X
Seat Lamp Output O P Bckld
Belt
Reminder 4 to 8 Second ^ O n
Lamp Output Bckld X X X
Only OfP
IS SI S K|
Key and Continuous, In X
Head Lamp Steady X X Open
Reminder* Tone X On
SEAT BELT *On some vehicles, the key switch opens when the ignition is
SWITCH switched on.
IGNITION SEAT BELT GROUND
WARNING LIGHT J928U-9 J928U-8
Fig. 3 Buzzer Module Terminal Identification—Front Fig. 4 Buzzer Module Schematic
View
RESISTANCE TESTS
o o o o
C A U T I O N : Before making resistance measurements, 4 3 2 1
turn ignition switch O F F and disconnect negative WIRE CONTINUITY
cable from battery to avoid damaging ohmmeter. CAVITY APPLICATION BETWEEN
1 H d o lamp 1 & 2 Almost zero ohms
2 Halo lamp (bulb filament)
Measure b e t w e e n the following pins a n d vehi
cle ground. 3 Key-in warning switch 3 & 4 with key in ignition
4 Key-in warning switch
• Buzzer module connector pin 2. Meter should read
J918M-3
almost zero ohms (bulb filament). If not, replace seat
belt indicator bulb.
Fig. 5 Halo Lamp And Key-In Warning Switch
• Buzzer module connector pin 3. Meter should read
Continuity Chart
• Buzzer module connector pin 4. Drivers seat belt
not buckled. Meter should read zero ohms. If not, re
pair open to ground (or buckle switch may be defec
• CHIME/BUZZER WARNING SYSTEMS 8U - 3
KEY-IN SWITCH REPLACEMENT (b) Use a small screw driver to depress key cyl
inder retaining pin flush with key cylinder surface
REMOVAL (Fig. 8).
(2) Tilt column only—remove tilt lever (counter IGNITION SWITCH
clockwise). MOUNTING
SCREWS (3)
(3) Carefully remove both upper and lower steer
ing column covers. Requires removal of 3 screws
(torx T-20).
(4) Remove 3 ignition switch mounting screws
(tamper proof torx bit Snap On TTXR15A2 or equiv
alent required) (Fig. 6).
STEERING
IGNITION
COLUMN
SWITCH 938 D-1
Fig. 8 Key Cylinder Pin

(c) Rotate key clockwise to Off position. The key
cylinder should now be unseated from ignition
switch assembly.
C A U T I O N : D o not try to remove key cylinder at this

STEERING
COLUMN IGNITION time.
SWITCH 908D-14
(d) The key cylinder is unseated and the key cyl
Fig. 6 Ignition Switch Screw Removal inder bezel should be about 1/8 inch above ignition
(5) Gently pull switch away from column. Release switch halo light ring (Fig. 9). Rotate key counter
2 connector locks on 7 terminal wiring connector, clockwise to Lock position and remove key.
then remove connector from ignition switch. KEY CYLINDER
(6) Release connector lock on 4 terminal Key In BEZEL
and Halo light connector then remove connector from
ignition switch (Fig. 7).
KEY-IN SWITCH & MULTIFUNCTION
HALO LIGHT SWITCH
TURN SIGNAL
SWITCH & LEVER
IGNITION SPEED
HALO LIGHT
RING 908D-16
Fig. 7 Key In Switch And Halo Lamp Connector
(7) Remove key cylinder from ignition switch as Fig. 9 Unseated Key Cylinder
follows:
(a) Insert key in ignition switch and move switch
to Lock position.
8U - 4 CHIME/BUZZER WARNING SYSTEMS •
(e) Remove key cylinder (Fig, 10).
908D-18
Fig. 11 Ignition Switch—View From Column
Fig. 10 Key Cylinder Removal

INSTALLATION
(1) Install 2 wiring connectors to the switch. Make
sure t h a t switch locking tabs are fully seated in the
wiring connectors.
(2) Mount ignition switch to column with 3 screws.
When equipped with column shift:
• the shifter must be in P a r k position
• the park lock dowel pin on the ignition switch as
sembly must engage with column park lock slider
linkage (Figs. 11 and 12).
Verify ignition switch is in lock position (flag is
parallel with ignition switch terminals). Apply a
daub of grease to flag and pin. Position park lock
link and slider to mid-travel. Position ignition switch Fig. 12 Ignition Switch Mounting Pad
against lock housing face, making sure pin is in (a) With key cylinder and ignition in the Lock
serted into park lock link contour slot. Torque retain position, gently insert key cylinder into the igni
ing screws to 2 N*m (17 in. lbs.). tion switch assembly until it bottoms.
(b) Insert key, while gently pushing on key cyl
(3) Assemble cover to the column with 3 screws.
inder inward toward the ignition switch, rotate key
Torque screws to 2 N*m (17 in. lbs.).
clockwise to the Run position.
(4) Tilt column only—install tilt lever (clockwise). (7) Check for proper operation of push-to-lock, halo
(5) Install negative cable to battery. lighting, Accessory, Lock, Off, Run, Start, Column
(6) Install key cylinder as follows: Lock and Shift Lock (if applicable).
• WIRING DIAGRAMS 8W - 1
WIRING DIAGRAMS
CONTENTS
page page
COMPONENT IDENTIFICATION ............. 9 SPLICE LOCATIONS 29

GENERAL INFORMATION 1 WIRING DIAGRAMS AD-BODY 37
GENERAL INFORMATION
INDEX
page page
Circuit Identification 2 Secondary Ignition Wiring 1
Component Identification 3 Splice Locations 3
Connectors 3 Symbols and F u s e s 5
Fusible Links 3 Troubleshooting Wiring Problems 3
Harness Repair 3 Wire Code Identification 2
Locating A System or Component 2 Wiring Diagram Sheets and Indexes 1
The wiring diagrams contain the latest information SPARK PLUGS

available at time of publication. Throughout out this RIGHT BANK
group references may be made to a particular vehicle
by letter or number designation. A chart showing the
breakdown of these designations is included in the
Introduction Section of this service manual.
SECONDARY IGNITION WIRING

Secondary ignition wiring is shown in Figures 1
and 2. For information on ignition systems or distrib SPARK PLUGS
utor operation refer to Group 8D Ignition Systems. LEFT BANK
EIGHT CYLINDER DISTRIBUTOR-CLOCKWISE ROTATION
FOR 318 AND 360 CUBIC INCH ENGINES
FIRING ORDER-1-8^-3-63-7-2 RP899
Fig. 2 Secondary Ignition Wiring 5.2L and 5.9L
Engine
not covered. The diagram pages are identified by a
sheet number which is located at the lower right or
left hand corner of each sheet. P a g e n u m b e r s at t h e
top of e a c h p a g e d o n o t apply to diagram sheets.
Diagram sheets show all information relating to
the system. This includes feeds, grounds, switch in
3.9L SIX-CYLINDER ENGINE
DISTRIBUTOR—CLOCKWISE ROTATION ternal circuity, connectors, splices, and pin identifica
FIRING ORDER 1-6-5-4-3-2 RN755 tion for controllers and modules.
In certain instances a wire may be referenced to
Fig. 1 Secondary Ignition Wiring 3.9L Engine another sheet. When this happens, the wire will be
identified as to where it is going.
WIRING DIAGRAM SHEETS AND INDEXES
The index used for the diagrams is located at the
The wiring diagram sheets are organized so that
beginning of the diagrams. It covers all systems
systems relating to the basic vehicle and all of its op
tions are shown. Add-on or non-factory options are shown in the diagrams and is in alphabetical order.
8W - 2 WIRING DIAGRAMS •
WIRE CODE IDENTIFICATION STANDARD STANDARD
COLOR COLOR COLOR TRACER
Each wire shown in the diagrams contains a code TRACER
CODE
COLOR
CODE
(Fig. 3) which identifies the main circuit, part of the COLOR CODE
main circuit, gauge of wire, and color. The color is BL BLUE WT OR ORANGE BK
shown as a two letter code which can be identified by
referring to the Wire Color Code Chart (Fig. 4). If BK BLACK WT PK PINK BK OR WT
the wire has a tracer and it is a standard color an
BR BROWN WT RD RED WT
asterisk will follow the main wire color. If the tracer
is non-standard the main wire color will have a slash DB DARK WT TN TAN WT
(/) after it followed by the tracer color. BLUE
18 LB/YL* DG DARK WT VT VIOLET WT

GREEN
GY GRAY BK WT WHITE BK
LB LIGHT BK YL YELLOW BK
COLOR OF WIRE
(Light Blue with Yellow Tracer) BLUE
LG LIGHT BK * WITH TRACER

. GAUGE OF WIRE GREEN
(18 Gauge)
918W-136
PART OF AAAIN CIRCUIT
(Varies Depending on Equipment) Fig. 4 Wire Color Code Chart
LOCATING A SYSTEM OR COMPONENT
AAAIN CIRCUIT IDENTIFICATION
918W-16
To locate a system or component in the diagrams,
refer to the alphabetical index at the front of the di
Fig. 3 Wire Color Code Identification agrams. Determine the diagram sheet number. Sheet
numbers are located at the lower right or left hand
CIRCUIT IDENTIFICATION
corner of each sheet. P a g e n u m b e r s at the top of
All circuits in the diagrams use an alpha/numeric
t h e p a g e do n o t a p p l y to d i a g r a m sheets.
code to identify the, wire and its function. To identify
The diagram index identifies the main system and
which circuit code applies to a system, refer to the
all components t h a t relate to t h a t system. There are
Circuit Identification Code Chart. This chart shows
also sections of the index t h a t identify specific com
the main circuits only and does not show the second
ponents only (for example modules, lamps, etc.). Re-
ary codes t h a t may apply to some models.
M A I N CIRCUIT I D E N T I F I C A T I O N
CIRCUIT DESCRIPTION CIRCUIT DESCRIPTION
A Battery Feed: Fused and Unfused P Power Assist System: Locks, Mirrors
B ABS System Q Power Assist System: Windows
C Air Conditioning System R Airbag System
D CCD (+), CCD (-) S Air Suspension, Automatic Load Leveling
E Interior Lamp Illumination T Electronic Automatic Transaxle
F Battery Feed: Fused and Unfused V Windshield Wipers and Washers,
G Sensors, Sending Units, Switches Vehicle Speed Control System
K Powertrain Central Module W Power Assist System: Windows
L Exterior Lighting, Stop Lamp Switch X Horn, Radio, Radio Speakers, Power Locks
M Interior Lamps Z Ground Circuits: Includes power and signal
grounds for PCM
9
38W1
-7
fer to a components name in the index if you are (5) Repair t h e problem.
unclear as to what a system may be called. (6) Verify proper operation. For this step check for
Diagram pages are arranged starting with the bat proper operation of all items on the circuit repaired.
tery and fuses. Then working into charging, starting, Refer to the wiring diagram fuse application chart.
and ignition systems. After this they s t a r t at t h e
front of the vehicle and work to rear of the vehicle. FUSIBLE LINKS
The diagrams end with connector identification Vehicle wiring harnesses a r e equipped with fusible
pages. links. For protection against harness damage in the
event of a short. Fusible links are color coded as to
COMPONENT IDENTIFICATION wire gauge size. Refer to t h e fusible link chart for
To find a components actual location on the vehicle color and gauge identification (Fig. 6).
refer to the wiring and components section index. This
section shows the wire harness routing and the compo Wire a n d G a u g e Color Code Color
nents location in the vehicle. When using this section
12 G a . BK Black
refer to the wiring diagrams for the general location of
the component. Then use the component identification 14 G a . RD Red
index to locate the proper figure number. 16 G a . DB Dark Blue
SPLICE LOCATIONS 18 G a . GY Gray

Splices are indicated in the wiring diagrams by a 20 G a . OR Orange
diamond with splice circuit code within it (Fig. 5 ex
ample 1). If there is more t h a n one splice per circuit 22 G a . WT White
splice code a small box will be connected to the dia 918W-19
mond with the splice number in it (Fig. 5 example 2). Fig. 6 Fusible Link Chart
To locate a splice in the wire harness determine
the splice number from the wiring diagrams, then re HARNESS REPAIR
fer to the splice location index. This section shows
the general location of the splice in the harness. FUSIBLE LINK REPLACEMENT
C A U T I O N : Do not replace blown fusible links with a

standard wire. Only u s e fusible type wire with hyp-
alon insulation or damage to the electrical system
could occur. A l s o make sure correct g a u g e of wir
ing is used. Refer to the wiring diagrams for proper
EXAMPLE 1 EXAMPLE 2 g a u g e and color.
918W-18
Fig. 5 Wiring Splice Examples When a fusible link blows it is important to find
out what the problem is. They are placed in the elec
CONNECTORS trical system for protection against shorts to ground
The connectors shown in the diagram are viewed from
t h a t can be caused by a component or various wiring
the terminal end unless otherwise specified. For view
failures. D o not just replace the fusible link to
ing bulkhead and engine controller connectors refer to
correct the problem.
the back of the wiring diagrams. This area shows major
connectors for pin and cavity identification. When diagnosing a faulty fusible link it is impor
t a n t to check the wire carefully. In some instances
TROUBLESHOOTING WIRING PROBLEMS the link may be blown and it will not show through
When troubleshooting wiring problems there are the insulation, the wire should be checked over its
six steps which can aid in the procedure. The steps entire length for internal breaks.
are listed and explained below. (1) Disconnect battery negative cable.
(1) Verify the problem. (2) Cut out the blown portion of the fusible link.
(2) Verify any related symptoms. Perform opera (3) Strip 1 inch of insulation from each end of the
tional checks on components in the same circuit as existing fusible link.
the problem area. Refer to the wiring diagram fuse (4) Place a piece of heat shrink tubing over one
application chart for circuit information. side of the fusible link. Make sure the tubing will be
(3) Analyze the symptoms. Use the wiring dia long enough to cover and seal the entire repair area.
grams to determine what the circuit is doing, where (5) Cut a replacement piece of fusible link approx
the problem most likely is occurring and where the imately two inches longer t h a n the piece removed.
diagnosis will continue. (6) Remove one inch of insulation from each end of
(4) Isolate t h e problem area. the replacement fusible link.
8W - 4 WIRING DIAGRAMS
(7) Spread the strands of wire apart on each of the and heat using a heat gun. Heat the joint until the
exposed wires (Fig. 7 example 1). tubing is tightly sealed and sealant comes out of both
(8) Push the two ends of the wire together until ends of the tubing.
the strands of wire are close to the insulation (Fig. 7 (9) Secure the wire to the existing ones to prevent
example 2). chafing or damage to the insulation.
(9) Twist the wires together (Fig. 7 example 3). (10) Connect battery and test all affected systems.
(10) Solder the wires together using rosin core type
solder only. D o n o t u s e a c i d c o r e t y p e s o l d e r . CONNECTOR REPLACEMENT
(11) Center the heat shrink tubing over the joint (1) Disconnect battery.
and heat using a heat gun. Heat the joint until the (2) Disconnect the connector t h a t is to be repaired
tubing is tightly sealed and sealant comes out of both from its mating half.
ends of the tubing. (3) Remove connector locking wedge (Fig. 8).
(12) Secure the fusible link to the existing ones to
CONNECTOR
prevent chafing or damage to the insulation.
(13) Connect battery and test all affected systems.
CONNECTOR LOCKING
928W-143
W E D G E TAB
Fig. 8 Connector Locking Wedge Tab

(4) Position the connector locking finger away from
the terminal. Pull on the wire to remove the termi
nal from the connector (Fig. 9).
(5) Reset the terminal locking tang, if it h a s one.
(6) Insert the removed wire in the same cavity on
the repair connector.
918W-20 (7) Repeat steps four thru six for each wire in the
Fig. 7 Wire Repair connector. Check t h a t all wires are inserted into the
WIRING REPAIR proper cavities. For connector pin out identification
When replacing or repairing a wire, it is important refer to the wiring diagrams.
t h a t the correct gauge be used as shown in the wir (8) Insert the connector locking wedge into the re
ing diagrams. The wires must also be held securely paired connector.
in place to prevent damage to the insulation. (9) Connect connector to its mating half.
(1) Disconnect battery negative cable. (10) Connect battery and test all affected systems.
(2) Remove 1 inch of insulation from each end the
wire. CONNECTOR AND TERMINAL ASSEMBLY
(3) Place a piece of heat shrink tubing over one REPLACEMENT
side of the wire. Make sure the tubing will be long (1) Disconnect Battery.
enough to cover and seal the entire repair area. (2) Disconnect the connector being repaired form
(4) Spread the strands of the wire apart on each its mating half.
part of the exposed wires (Fig. 7 example 1). (3) Cut off the existing wire connector directly be
(5) Push the two ends of wire together until t h e hind the insulator and remove six inches of tape
strands of wire are close to the insulation (Fig. 7 ex from the harness.
ample 2). (4) Stagger cut all wires on the harness side about
(6) Twist t h e wires together (Fig. 7 example 3). 1/2 inch apart (Fig. 10).
(7) Solder the connection together using rosin core (5) Remove 1 inch of insulation from each wire on
type solder only. D o n o t u s e a c i d c o r e s o l d e r .
the harness side.
(8) Center the h e a t shrink tubing over the joint
WIRING DIAGRAMS SW - 5
CONNECTOR (14) Repeat steps 8 t h r u 13 for each wire.

(15) Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair.
(16) Reconnect the repaired connector.
TERMINAL REPLACEMENT
(1) Disconnect battery.
(2) Disconnect the connector being repaired form
its mating half.
CONNECTOR LOCKING
FINGER (3) Remove connector locking wedge (Fig. 8).
LOCKING WEDGE (4) Position the connector locking finger away from
the terminal. Pull on the wire to remove the termi
nal from t h e connector (Fig. 9).
If 928W-144 (5) Cut the wire 6 inches from the back of the con
nector.
Fig. 9 Connector Locking Finger and Locking Wedge
(6) Remove 1 inch of insulation from the wire on
(6) Stagger cut the matching wires on the repair the harness side.
connector assembly in the opposite order as was done (7) Select a wire from the terminal repair assem
on the harness side of the repair. Allow extra length bly that best matches t h e color wire being repaired.
for soldered connections. Check t h a t the overall (8) Cut the repair wire to the proper length and re
length is the same as the original (Fig. 10). move 1 inch of insulation.
(9) Place a piece of heat shrink tubing over one of
REPAIR SIDE STAGER CUTS
WIRES side of the wire. Make sure the tubing will be long
enough to cover and seal the entire repair area.
(10) Spread the strands of the wire apart on each
part of the exposed wires (Fig. 7 example 1).
(11) Push the two ends of wire together until the
strands of wire are close to the insulation (Fig. 7 ex
ample 2).
(12) Twist the wires together (Fig. 7 example 3).
(13) Solder the connection together using rosin
core type solder only. D o not u s e acid core solder.
(14) Center the heat shrink tubing over the joint
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
HARNESS WIRES 928W-145
(15) Insert the repaired wire into the connector.
Fig. 10 Stagger Cutting Wires (16) Install the connector locking wedge and recon
(7) Remove 1 inch of insulation from each wire. nect the connector to its mating half.
(8) Place a piece of heat shrink tubing over one (17) Re-tape the wire harness starting 1-1/2 inches
side of the wire. Make sure the tubing will be long behind the connector and 2 inches past the repair.
enough to cover and seal the entire repair area.
(9) Spread the strands of the wire apart on each
SYMBOLS AND FUSES
part of the exposed wires (Fig. 7 example 1). Various symbols are used throughout wiring dia
(10) Push the two ends of wire together until the grams. These symbols can be identified by referring
strands of wire are close to the insulation (Fig. 7 exam to symbol identification chart (Fig. 11).
ple 2). For fuse block and relay bank information refer to
(11) Twist the wires together (Fig. 7 example 3). (Fig. 12).
(12) Solder the connection together using rosin
C A U T I O N : When replacing a blown fuse, it is impor
core type solder only. Do not use acid core solder.
tant to replace it with a fuse having the correct a m
(13) Center the heat shrink tubing over the joint
perage rating. The use of a fuse with a rating other
and heat using a heat gun. Heat the joint until the than indicated may result in a dangerous electrical
tubing is tightly sealed and sealant comes out of both overload. If a proper rated fuse continues to blow, it
ends of the tubing. indicates a problem that should be corrected.
LEGEND OF SYMBOLS USED O N WIRING DIAGRAMS
+— POSITIVE CONNECTOR
NEGATIVE —> MALE CONNECTOR
_L_
GROUND > FEMALE CONNECTOR
FUSE S
DENOTES WIRE CONTINUES ELSEWHERE
DENOTES WIRE GOES TO ONE OF TWO
GANG FUSES WITH BUSS BAR CIRCUITS
CIRCUIT BREAKER SPLICE
2
CAPACITOR
<3> i SPLICE IDENTIFICATION
A OHMS cftP— THERMAL ELEMENT
RESISTOR | TIMER | TIMER

1 ^ ^ ^ |
VARIABLE RESISTOR 1
MULTIPLE CONNECTOR
'YY Y
WIRING WITH
SERIES RESISTOR OPTIONAL
o-l WIRING WITHOUT
COIL
Y "Y" WINDINGS
—o STEP UP COIL
BB-BB DIGITAL READOUT
OPEN CONTACT -0- SINGLE FILAMENT LAMP
M K #
CLOSED CONTACT
-(5- DUAL FILAMENT LAMP
CLOSED SWITCH LE.D. - LIGHT EMITTING DIODE
OPEN SWITCH —^— THERMISTOR
CLOSED GANGED SWITCH GAUGE
mi OPEN GANGED SWITCH SENSOR
TWO POLE SINGLE THROW SWITCH FUEL INJECTOR
PRESSURE SWITCH
E | #36 DENOTES WIRE GOES THROUGH
BULKHEAD DISCONNECT
3i SOLENOID SWITCH #
" STRG
COLUMN
DENOTES WIRE GOES THROUGH
STEERING COLUMN CONNECTOR
DENOTES WIRE GOES THROUGH
MERCURY SWITCH
frt | PANEL J
INSTRUMENT PANEL CONNECTOR
DENOTES WIRE GOES THROUGH GROMMET
H«- DIODE OR RECTIFIER j ENG |
TO ENGINE COMPARTMENT
BY-DIRECTIONAL ZENER DIODE DENOTES WIRE GOES THROUGH GROMMET
MOTOR HEATED GRID ELEMENTS

- o -
0 ARMATURE AND BRUSHES 908W-191
Fig. 11 Symbol identification

FUSE/ FUSE/
CAVITY ITEMS FUSED CAVITY ITEMS FUSED
COLOR COLOR
2 AMP VEHICLE SPEED CONTROL

GY ILLUMINATION LAMPS, A/C HEATER LAMP, ASH
3 AMP RECEIVER LAMP, RADIO LAMP, TRANSMISSION
GAUGES, BRAKE WARNING LAMP, SEAT BELT WARNING 14 OVERDRIVE SWITCH LAMP, TACHOMETER LAMP,
VT
LAMP, BUZZER, LOW OIL LAMP, CHECK ENGINE LAMP, HEATED REAR W I N D O W SWITCH LAMP.
5 AMP
TN ANTI-LOCK LAMP, TAILGATE OPEN LAMP, 4WD LAMP,
O / D MODULE, LOW FUEL LAMP, WAIT TO START LAMP
WATER-IN-FUEL LAMP
RADIO A N D CLOCK MEMORY, POWER MIRRORS, GLOVE
20 A M P 10 A M P BOX LAMP, DOME LAMP, READING LAMP, M A P LAMP,
BACK-UP LAMP, HEATED REAR WINDOW 15
YL RD C A R G O LAMP, IGNITION SWITCH LAMP, UNDERHOOD
LAMP
FUSE CAVITY #14, TAIL LAMPS, PARKING LAMPS, SIDE

20 A M P
AAARKER LAMPS, LICENSE LAMPS, FRONT A N D REAR
YL AMPS FUSE COLOR
CLEARANCE LAMPS, RADIO INTENSITY, HORNS
TURN 2 GY GRAY
SIGNAL VT VIOLET
3
FLASHER 5 TN TAN
20 A M P STOP LAMPS, KEY-IN & HEADLAMP O N BUZZER, RWAL 30 A M P
YL MODULE CIRCUIT 10 RD RED
15 BL BLUE
BREAKER
20 YL YELLOW
20 A M P
POWER DOOR LOCKS 30 LG LIGHT GREEN
YL
15 A M P CIGAR LIGHTER
BL
10 A M P
RADIO A N D CLOCK
RD HAZARD
FLASHER
20 A M P TURN SIGNALS, TACHOMETER PROVISION,
YL RWAL MODULE
20 A M P
10 WINDSHIELD WIPERS
YL
30 A M P
11 A/C - HEATER BLOWER MOTOR
LG
30 A M P
12 POWER WINDOWS
C/BRKR
20 A M P
13 HAZARD FLASHER
YL
J938W-94
Fig. 12 Fuse Block and Relay Bank

COMPONENT IDENTIFICATION
INDEX
Caption Fig. Caption Fig^
A/C-Heater Wiring 15 Instrument Panel Wiring 12
Cab Wiring (Extended Cab) 8 Interior Wiring (Sport Utility) 6
Cab Wiring (Standard Cab) 7 Liftgate Wiring (Sport Utility) . . . . . . 4
Door Wiring (Body Side) 10 Rear Clearance Lamp Wiring 3
Door Wiring 9 Roof Wiring (Sport Utility) 5
Engine Compartment Wiring 3.9L, 5.2L, and 5.9L Gas Starter Wiring 19
Engines .17 Steering Column Wiring . 11
Engine Compartment Wiring 5.9L Diesel Engine . 18 Stop Lamp Switch Wiring . 14
Engine Wiring 3.9L M P I Engine 23 Tail Lamp Wiring 1
Engine Wiring 5.2L and 5.9L M P I Engine 24 Transmission Wiring (Diesel Engine) . .22
Engine Wiring 5.9L Diesel Engine 25 Transmission Wiring (Gas Engines) 21
Four Wheel Drive Wiring .20 Underhood Lamp Wiring . .16
Frame Wiring 2
Instrument Panel Wiring (Right Side) 13
BACK-UP
LAMP J928W-169
Fig. 1 Tail Lamp Wiring

J908W-82
Fig. 2 Frame Wiring

J908W-84
GROUND
Fig. 4 Liftgate Wiring (Sport Utility)

WIRING DIAGfiAlS 8W - 13
TO FRONT REAR DOME

D O M E LAMP LAMP
TO
ROOF
WIRING
TO
VIEW
VIEWX J908W-85
SPEAKER
Fig. 5 Roof Wiring (Sport Utility)

TO DOME
TO LAMP
LIFTGATE TO BODY
WIRING
TO SEAT
BELT
WIRING
GROUND
TO REAR
SPEAKER J928W-170
Fig. 6 Interior Wiring (Sport Utility)

Fig. 7 Cab Wiring (Standard Cab)
TO DOOR SWITCH
MAIN CONNECTORS
HARNESS
2
POWER CD
WINDOW POWER
MOTOR WINDOW
MOTOR >
CONNECTOR •3
TO SPEAKER
VIEW IN DIRECTION
OF ARROW Z
TO DOOR
TO POWER SWITCHES
MIRROR
TO
SPEAKER
VIEW IN DIRECTION OF ARROW

XWITH POWER MIRRORS
SPEAKER J908W-88
Fig. 9 Door Wiring
TO D O O R
WIRING
TO INSTRUMENT PANEL
WIRING
TO
POWER
MIRRORS TO
REAR
SPEAKERS
TO
DOOR
WIRING
J908W-89
Fig. 10 Door Wiring (Body Side)
KEY
CYLINDER
TO VEHICLE SPEED
CONTROL
SWITCH
HALO LAMP
CONNECTOR
IGNITION
SWITCH
MULTI-FUNCTION
SWITCH
CONNECTOR
SEE VIEW Z
WIRING
TROUGH
TO
INSTRUMENT TO FOG LAMP
PANEL WIRING WIRING J938W-95
Fig. 11 Steering Column Wiring

CLUTCH PEDAL POSITION TO RADIO
SWITCH TO REAR
TO M A P LP , , TO PRINTED SPEAKERS
T Q R G H T
CIRCUIT BOARD TO BODY WIRING
TO MESSAGE CENTER \ \ DOOR WIRING
TO A/C-HTR WRG
TO HTR SW LP'
1
(2-WAY C O N N )
LIFTGATE AJAR
LAMP
25
n
CLUTCH o
PEDAL >
VIEW N a
TO CHASSIS
(CLUTCH PEDAL POSITION SWITCH)
C O N N (R.W.A.L.;
>
2
TO RADIO m
TO LEFT DOOR
TO CIGAR LIGHTER SWITCH
TO STOP LAMP & BRAKE SW
(DIESEL)
INSTRUMENT TO TRANSMISSION
PANEL OVERDRIVE
SWITCH
TO MESSAGE CENTER
4WD
INTERMITTENT INDICATOR
WIPER CONTROL
VIEW IN DIRECTION
VIEW IN DIRECTION VIEW P OF ARROW R
OF ARROW S (R.W.A.L. DATA LINK CONNECTOR) J938W-96
Fig. 12 instrument Panel Wiring

WIRING DIAGRAMS 8W - 19
HEATER/AC
BLOWER MOTOR
RESISTOR
INSTRUMENT
PANEL HARNESS
GLOVE BOX
LAMP A N D SWITCH
*REAR WHEEL ANTI-LOCK

DATA LINK CONNECTOR
R.W.A.L.
CONTROL
'TO REAR WHEEL ANTI-LOCK VIEW IN DIRECTION

BRAKE CONTROL MODULE OF ARROW Z
RIGHT DOOR SWITCH INSTRUMENT PANEL RIGHT SIDE J938W-97
Fig. 13 Instrument Panel Wiring (Right Side)
PARK STEERING
CONNECTOR
BRAKE COLUMN
SWITCH SUPPORT
PARK STOP LAMP

BRAKE SWITCH
LEVER
J908W-92
Fig. 14 Stop Lamp Switch Wiring

TRANSMISSION
OVERDRIVE
MODULE
TRANSMISSION OVERDRIVE
SWITCH (GAS)
TO TRANSMISSION
OVERDRIVE
A/C
SWITCH (DIESEL)
HEATER
MODE SWITCH J938W-98
Fig. 15 A/C-Heater Wiring
Fig.-16 Underhood Lamp Wiring

WINDSHIELD
WIPER MOTOR
TO FUSIBLE LINK
CIRCUITS
TO RIGHT
HEADLAMP
PARK/TURN
SIGNAL LAMP TO VEHICLE SPEED
CONTROL SEE VIEW Z
LEFT HEADLAMP
GROUND
ENGINE
STARTER
EEMC A/C RELAY
RELAY COMPRESSOR A/C
CLUTCH RELAY AUTOMATIC SHUT LOW PRESSURE
D O W N RELAY SWITCH
FUEL PUMP TO BLOWER MTR &
RELAY WINDSHIELD
SIDE MARKER WASHER MTR
LAMP
BULKHEAD TO UNDERHOOD
DISCONNECT LAMP WIRING
a
o
>
POWERTRAIN o
CONTROL A/C 30
MODULE CYCLING >
VEHICLE VIEW IN DIRECTION 2
SWITCH
SPEED CONTROL
VIEW IN DIRECTION OF ARROW W m
SERVO
OF ARROW Z
J938W-99
Fig. 17 Engine Compartment Wiring 3.9L, 5.2L, and 5.9L Gas Engines
BLOWER T O U N D E R H O O D LAMP AIR
MOTOR HEATER
T O WINDSHIELD
WINDSHIELD WIPER M O T O R
WASHER M O T O R
T O RIGHT
HEADLAMP
PARK/TURN
SIGNAL
LAMP
B E Y O N D THIS POINT
SEE VIEW Z
DATA LINK
CONNECTOR SIDE MARKER LAMP
A / C LOW
PRESSURE
SWITCH
BULKHEAD
DISCONNECT
FUSIBLE POWERTRAIN
LINKS CONTROL
MODULE
VIEW I N DIRECTION
A / C CYCLING OF ARROW W
AIR HEATER
SWITCH
RELAYS
T O VEHICLE V I E W I N DIRECTION
SPEED CONTROL OF ARROW Z J938W-100
Fig. 18 Engine Compartment Wiring 5.9L Diesel Engine

J938W-101
Fig. 19 Starter Wiring
Fig. 20 Four Wheel Drive Wiring

CRANKSHAFT
POSITION SENSOR 1
TO CRANKSHAFT POSITION
(SEE VIEW X)
CONVERTER
CLUTCH 2
SOLENOID
>
a
so
>
w
TO VEHICLE SPEED
SENSOR BEYOND
THIS POINT
SEE MAIN VIEW
TO HEATED OXYGEN
SENSOR
(SEE VIEW X)
VEHICLE
SPEED
SENSOR
VIEW A VEHICLE
4X4 TRANSFER CASE SPEED
SENSOR J938W-102
(TYPICAL)
Fig. 21 Transmission Wiring (Gas Engines)

FUEL FUEL
INJECTOR #4 INJECTOR #2 BEYOND THIS POINT
FUEL
SEE VIEW Z
INJECTOR # 6
INS
A / C COMPRESSOR m
EGR SOLENOID/ CLUTCH
TRANSDUCER
ASSEMBLY
a
GENERATOR GROUND o
>
o
POWER STEERING >
PUMP 2
m
THROTTLE EVAP/ IDLE AIR

POSITION PURGE CONTROL
AAAP
(SENSOR) SOLENOID MOTOR
SENSOR
TO A / C
COMPRESSOR CLUTCH
ENGINE ENGINE OIL
COOLANT PRESSURE
DISTRIBUTOR TEMPERATURE SENDING UNIT/
IGNITION COIL ENGINE COOLANT SENSOR (PCM) SWITCH
TEMPERATURE
SENSOR (GAUGE)
DISTRIBUTOR
, N J E C T O R # 1
CONNER INJECTOR # 3
TO
FUEL 'TRANSMISSION
INJECTOR #5 WIRING
VIEW IN DIRECTION
OF ARROW 1
J938W-85
Fig. 23 Engine Wiring 3.9L MPI Engine

FUEL
FUEL INJECTOR #2
FUEL INJECTOR #4 THROTTLE
INJECTOR #8 BODY
CHARGE AIR ^DISTRIBUTOR
TEMPERATURE SENSOR
BEYOND THIS POINT

SEE VIEW, Z
EGR TO A / C
SOLENOID/ COMPRESSOR CLUTCH
TRANSDUCER
ENGINE OIL
PRESSURE SENDING
UNIT/SWITCH
GENERATOR
GROUND VIEW IN DIRECTION
OF ARROW Y
POWER TO TRANSMISSION
STEERING WIRING
PUMP
THROTTLE
POSITION
(SENSOR) IDLE AIR EVAP/PURGE
CONTROL MOTOR SOLENOID
MAP FUEL
DISTRIBUTOR GENERATOR INJECTOR # 7
SENSOR
IGNITION ENGINE COOLANT
COIL TEMPERATURE SENSOR
(PCM) FUEL
FUEL INJECTOR. #5
INJECTOR #3
ENGINE
\
COOLANT
TEMPERATURE
SENSOR (GAUGE) FUEL
INJECTOR #1
o
>
VIEW IN DIRECTION
OF ARROW Z 30
A / C CLUTCH >
2
w
J938W-86
Fig. 24 Engine Wiring 5.2L and 5.9L MPI Engine oo
!\3
VIEW IN DIRECTION VIEW IN DIRECTION
OF ARROW Z ~ OF ARROW X J938W-104
Fig. 25 Engine Wiring 5.9L Diesel Engine

SPLICE LOCATIONS
Splice Number Fig^ Splice Number Fit^

AO Diesel Engine 6 M2 4
AO Gas Engine 5 M2-1 Sport Utility 1
A3 4 P33 • 1
A4 4 P34 1
A21 Diesel Engine 6 T41 Gas Engine 9
A21 Gas Engine 9 V6 4
A21-1 Gas Engine 5 X2 Diesel Engine 6
A21-2 Diesel Engine 6 X2 Gas Engine 5
A21-3 Diesel Engine 6 X2-1 2
A142 Gas Engine 9 X2-4 3
A142-1 Gas Engine 9 X2-5 3
C4 8 X2-6 3
C7 8 X2-7 2
E2 4 X53 4
F21 7 X54 • 4
F35 7 Z1-1 4
G5 4 Z1-2 4
G7 5 Z1-3 4
G7-1 Diesel Engine 6 Z1-4 Diesel Engine 6
G7-1 Gas Engine 9 Z1-4 Gas Engine 5
K4 Gas Engine 9 Z1-5 Diesel Engine 6
K4-1 Gas Engine 9 Z1-5 Gas Engine 5
K6 Gas Engine 9 Z1-6 Diesel Engine 6
K7 Gas Engine 9 Z1-6 Gas Engine 5
L1 3 Z1-7 3
L1 Sport Utility 3 Z1-7 Sport Utility 3
L6 Club Cab 1 Z1-8 3
L7 Diesel Engine 6 Z1-8 Sport Utility 3
L7-1 4 Z1-9 7
L7-2 3 Z1-10 7
L7-2 Sport Utility 3 Z1-11 1
L7-3 3 Z11 Diesel Engine 6
L7-4 3 Z12 Gas Engine 9
L7-5 3 Z12-1 Gas Engine 5
L50 4 Z12-1 Diesel Engine 6
M1 4 Z12-2 Diesel Engine 6
M1-1 Sport Utility 1
Fig. 2 Rear End Splices
Fig. 4 Instrument Panel Splices •
Fig. 8 Heater-A/C Splices
Fig. 9 Engine Splices 3.9L, 5.2L, and 5.9L Engines
WIRING DIAGRAMS AD-BODY
INDEX
Wiring Diagram Name Sheet Number Wiring Diagram Name Sheet Number
A/C Heater System with Diesel Engine . . . . . . . . . . . . .69,70 Brake Warning Indicator Lamp Switch (Gas Engine) 32
Blower Motor . .69 Bulkhead Disconnect 50-Way .85,86
Compressor .70 Buzzer-Combined Headlamp, Key In, and Seat Belt . . . .27,28
Cycling Switch .70 Bypass Jumper (Clutch Pedal Position) 8
Diodes 70 Cargo Lamp .49,50
Fuse 69 Cargo Lamp Switch 49
Low Pressure Switch 70 Charging System with Diesel Engine . . . . . . . . . . . . . . .5,6
Resistor . 69 Battery 5
Switch-Blower . 69 Generator . .6
Vacuum Control Switch .69 Charging System with Gas Engine .3,4
Wide Open Throttle Cut-Out Relay 70 Battery 3
A/C Heater System with Gas Engine .67,68 Generator , . .4
Blower Motor .67 Cigar Lighter, Ash & Glove Box Lamps 52
Compressor .68 Circuit Breakers
Cycling Switch 68 Power Windows 2,71
Low Pressure Switch .68 Clearance Lamps Duel Rear Wheels . .41,43
Diodes . .68 Clearance Lamps Roof Mounted 40
Fuse . .67 Clockspring 30,36,38
Resistor 67 Clutch Pedal Position Switch .8
Switch-Blower 67 Cold Start Advance Motor 24
Vacuum Control Switch .67 Compressor, A / C 68,70
Wide Open Throttle Cutout Relay 68 Data Link Connector 17,23,31,33
Air Heater Relay Diesel Engine .21 Data Link Connectors
Air Intake Heater Diesel Engine 22 Rear Wheel Anti-Lock Diesel Engine .33
Anti-Lock Rear Brake System with Diesel Engine . . . . . .33,34 Rear Wheel Anti-Lock Gas Engine 31
Brake Warning Lamp Switch 34 Daytime Running Light Module 46
Data Link Connector 33 Diesel Control System .21,22,23,24,25,26
Duel Solenoid Hydraulic Valve 34 Air Heater Relay . .21
Electronic Vacuum Sensor .34 Air Intake Heater 21
Fuse 33 Automatic Shut Down Relay 22
Module .33 Cold Start 24
Park Brake Switch .33 Crankshaft Position Sensor . .25
Resistor 34 Data Link Connector . .23
Rolls Test Connector 33 Engine Coolant Temp Switch .26
Sensor 34 Fuel Heater 24
Stop Lamp 34 Fuel Solenoid 24
Anti-Lock Rear Brake System with Gas Engine .31,32 Intake Air Temp Sensor 25
Brake Warning Lamp Switch .32 Powertrain Control Module 21,22,23,25,26
Data Link Connector . .31 Resistor .24
Dual Solenoid Hydraulic Valve 32 Thermo Switch 24
Fuse 31 Throttle Position (Sensor) 26
Module 31 Transmission Thermo Switch . . .26
Park Brake Switch .31 Vehicle Speed Sensor 25,26
Resistor 32 Water in Fuel Sensor .25
Rolls Test Connector 31 Dimmer Switch-Headlamp . .47
Sensor 32 Diode 68,70
Stop Lamp Switch 32 Diode and Mold Assembly 51
Back-Up Lamp Switch with Diesel Engine .7 Dome and Cargo Lamp 50
Back-Up Lamp Switch with Gas Engine .9 Door Jamb Switches 49
Battery .1,3,5 Left Switch .49
Brake Warning Indicator Lamp (Diesel Engine) .57 Right Switch 49
Brake Warning Indicator Lamp (Gas Engine) 58 Dual Solenoid Hydraulic Valve .32
Brake Warning Indicator Lamp Switch (Diesel Engine) . . . .34 EMCC System (3-Speed) . .11
EMCC Relay 11 Horn System 30
EMCC Solenoid 11 Identification Lamps-Dual Rear Wheels 41,42
Ground 11 Identification Lamps-Roof Mounted . 40
EMCC Relay with Gas Engine 11,16 Ignition Coil .16
EMCC Solenoid with Gas Engine 11,12 Ignition Switch .2,10
Engine Oil Pressure Sending Unit .27,28 Ignition Switch System 10
Engine Starter Motor 7,9 Ignition System (Gas Engine) . . . . . . . . . .15,16,17,18,19,20
Engine Starter Relay .7,9 Automatic Shut Down Relay .16
Engine Starter System 1,7,8,9 Camshaft Position Sensor 20
Back-Up Lamp Switch .7,9 Crankshaft Position Sensor .18
Bypass Jumper (Clutch Pedal Position) 8 Data Link Connector * . . .17
Clutch Pedal Position Switch 8 Engine Coolant Temp Sensor 20
Fuse . 7,9 EVAP Purge Solenoid 16
Motor 7,9 Exhaust Gas Recirculation Solenoid 16
Park/Neutral Position Switch . .7,9 Fuel Pump Relay .16
Relay 7,9 Heated Oxygen Sensor . . . 17
Engine Temp Sending Unit . .27,28 Idle Air Control Motor .19
Flasher-Hazard Warning .56 Ignition Coil .15
Flasher-Turn Signal 56 Injectors .15
Four Wheel Drive Indicator Lamp 13 Intake Air Temp Sensor . .20
Front End Lighting . . .43,44 Map Sensor . .20
Front End Lighting (Canada) 45,46 Powertrain Control Module .15,16,17,18,19,20
Fuel Gauge 81,82 Throttle Position (Sensor) .18
Fuel Tank Gauge Level Sending Unit Diesel Engine 77 Vehicle Speed Sensor .20
Fuel Tank Gauge Level Sending Unit with Gas Engine 78 Ignition Time Delay Relay 49
Fuel Heater Diesel Engine 24 Injectors .15
Fuel Solenoid Diesel Engine .24 Intermittent Wiper System .53,54
Fuse Application Chart 1,2 Control Unit .54
Fuse Block Module and Relay Bank 82 Intermittent Windshield Wiper Motor 54
Fuses Windshield Washer Pump Motor 53
Fuse 1 2,36 Wiper Switch 53
Fuse 2 . . . . . . . . . 2,10,12,13,14,58,77,78 Key-In Switch 49
Fuse 3 2,7,9,10,39 Key-In Warning Buzzer 77,78
Fuse 4 1,30,47 Lamps
Fuse 5 1,77,78 Air-Conditioning and Heater Switch Lamp 48
Fuse 6 . . . . . . .1,73 Ash Receiver .48,52
Fuse 7 1,10,52 Back-Up Lamps . . . . . . 79,80,81
Fuse 8 .2,10,61,63 Cargo Lamp . .49,50
Fuse 9 .2,10,31,33,56 Clearance Lamps-Dual Rear Wheels .41,42
Fuse 10 .2,10,54,55 Clearance Lamps Roof Mounted .40
Fuse 11 2,10,66,67,69 Cluster Illumination Lamps . .57,58,59
Fuse 12 2,10,71 Dome Lamp 50,51
Fuse 13 1,56 Four Wheel Drive Indicator .13
Fuse 14 1,47,52,61,63 Glove Box Lamp 52
Fuse 15 1,49,51,52,61,63,75 Headlamp-Left 43,45
Fusible Links 1,2,3,4,5,6,21 Headlamp-Right 44,46
Gas Engine Wiring Connector 89 Headlamp Switch Controlled Interior Lamps . 48
Gauge-Fuel .77,78 Heater Switch Lamp .48
Generator .4,6 High Beam Indicator Lamp .59
Glove Box Lamp Switch 52 Identification Lamp . .40,41
Hazard Warning System . .56 Ignition Switch Lamp .49
Headlamp Dimmer Switch 47 Instrument Panel Illumination Lamps . .57,58,59
Headlamp Switch 1,47 License Lamp . . . 80
Headlamp Switch Controlled Interior Lamps . .48 Low Engine Oil Pressure Lamp 59
Headlamps 43,44, 45,46 Map Lamp 49
Heated Rear Window (Sport Utility) . .39 Parking Lamp-Left Front 43,45
Heater Motor Resistor 66,67 Parking Lamp-Right Front 44,46
Heater System . .66 Rear End Lighting System .79,80,81
Service Reminder Lamp .58 Right Motor 76
Side Marker Lamp Left Front 43,45 Switch 76
Side Marker Lamp Right Front . .44,46 Powertrain Control Module . . . . . . . . .11,12,14,15,16,17,18,
Stop Lamp-Left Rear 79,81 19,20,21,22,23,24,35,37
Stop Lamp-Right Rear 80,81 Powertrain Control Module Connector .83,84
Tachometer .48 Power Window System 71,72
Tail Lamp-Left Rear .79,81 Circuit Breaker 71
Tail Lamp-Right Rear 80,81 Left Door Switch 71
Turn Signal Indicator Lamps .79,80,81 Left Motor 71
Turn Signal Lamp-Left Front 43,45 Right Door Switch 72
Turn Signal Lamp-Right Front 44,46 Right Motor 72
Turn Signal Lamp-Left Rear .79,81 Printed Circuit Board Connectors 60
Turn Signal Lamp-Right Rear 80,81 Radio-4 Speakers 61,62,63,64
Underhood Lamp 29 Radio-2 Speakers 65
Left Printed Circuit Board .59 Rear Lighting System 79,80
Left Printed Circuit Board Connector 60 Rear Wheel Anti-Lock Brake System (Diesel) 33,34
Liftgate Ajar Switch 51 Brake Warning Lamp Switch .34
Map Lamp and Cargo Lamps .49 Data Link Connector 33
Message Center (Diesel Engine) 57 Dual Solenoid Hydraulic Valve 34
Message Center (Gas Engine) .58 Electronic Vacuum Sensor 34
Modules Fuse .33
Daytime Running Lamp . .46 Module 33
Intermittent Wiper .54 Park Brake Switch 33
Key -In 77,78 Rolls Test Connector .33
Seat Belt Warning 77,78 Resistor .34
Motors Sensor . .34
Blower-A/C with Diesel Engine .69 Stop Lamp Switch . .34
Blower-A/C with Gas Engine 67 Rear Wheel Anti-Lock Brake System (Gas) . .31,32
Blower-Heater .66 Brake Warning Lamp Switch .32
Engine Starter with Diesel Engine . .7 Data Link Connector .31
Engine Starter with Gas Engine 9 Dual Solenoid Hydraulic Valve 32
Heater Blower 66,67 Fuse 31
Idle Air Control . . . . . . . . . . . . . . . . . . . . . . . .19 Module 31
Intermittent Windshield Wiper 54 Park Brake Switch 31
Power Door Lock-Left .73 Resistor 32
Power Door Lock-Right 74 Rolls Test Connector 31
Power Mirror Left 75 Sensor 32
Power Mirror Right .76 Stop Lamp Switch 32
Power Window-Left 71 Relays
Power Window-Right .72 Air Heater (Diesel Engine) .21
Windshield Washer Pump 53 Automatic Shut Down with Diesel Engine 22
Neutral/Park Position Switch with Diesel Engine 7 Automatic Shut Down with Gas Engine 16
Neutral/Park Position Switch with Gas Engine 9 EMCC Relay 11
Oil Pressure Sending Unit with Diesel Engine 27 Engine Starter Relay .7,9
Oil Pressure Sending Unit with Gas Engine 28 Fuel Pump 16
Oil Pressure Switch with Diesel Engine 27 Horn 30
Oil Pressure & Temperature System (Diesel) 27 Ignition Lamp Time Delay 49
Oil Pressure & Temperature System (Gas) . 28 Wide Open Throttle Cut-Out Diesel Engine 70
Oil Pressure Warning Lamp • -59 Wide Open Throttle Cut-Out Gas Engine 68
Parking Brake Switch .31,33 Resistor 24,32,34,36,38
Power Door Lock System . . 73,74 Right Printed Circuit Board 59
Left Door Motor . .73 Right Printed Circuit Board Connector 60
Left Door Switch . 73 Rolls Test Connector .31,33
Right Door Motor . -74 Seat Belt Warning System 77,78
Right Door Switch 74 Sending Units
Power Mirrors 75,76 Fuel Gauge-Diesel Engine 77
Fuse 75 Fuel Gauge-Gas Engine 78
Left Motor 75 Oil-Diesel Engine 27
Oil-Gas Engine 28 Splice P34 . . . . .74
Temperature-Diesel Engine . . . . , 27 Splice T41 . . . . . . . . . . . . . . .9
Temperature-Gas Engine . .28 Splice V6 . . .54,55
Sensors Splice X2 . .30
Camshaft Position . . .20 Splice X2-1 . . . . .79,81
Crankshaft Position . . .18,25 Splice X2-4 41
Engine Coolant Temperature 20 Splice X2-5 .41
Electronic Vacuum-Diesel Engine . .34 Splice X2-6 . . . . .41
Heated Oxygen 17 Splice X2-7 80,81
Intake Air Temperature 25 Splice X53 .65
Map 20 Splice X54 . . . . . . . . . . . . 65
Rear Wheel Anti-Lock Brake 32,34 Splice Z1-1 .48
Throttle Position with Diesel Engine 26 Splice Z1-2 48,52
Vehicle Speed .20,25 Splice Z1-3 . . 48
Water In Fuel-Diesel Engine 25 Splice Z1-4 . . . .44,46
Solenoids Splice Z1-5 . . . . . . . . . -43,45
EMCC Solenoid 1 1 , 12 Splice Z1-6 11,23
EVAP Purge with Gas Ignition .16 Splice Z1-7 . .41,79
Exhaust Gas Recirculating Gas Engine .16 Splice Z1-8 77,78
Fuel .24 Splice Z1-9 . . . . . . . . . . . . . . .71,73,75
Transmission Overdrive 12,14 Splice Z1-10 . 71,73
Speakers 62,64 Splice Z1-11 .77,78
Splices Splice Z11 23
Splice AO 1,2,4,6 Splice Z12 ' 17
Splice A3 30,47 Splice Z12-1 17,23
Splice A4 39 Steering Column Connector . 87,88
Splice A21 16,23 Stereo Radio 61,63,65
Splice A21-1 . .68 Stop Lamp Switch 32,34
Splice A21-2 24 Stop/Turn System .56
Splice A21-3 21 Switches
Splice A142 .15 A/C Low Pressure with Gas Engine 67
Splice A142-1 15 A/C Low Pressure with Diesel Engine 70
Splice C4 .67,69 A/C Heater Blower with Diesel Engine 69
Splice C7 .67,69 A/C Heater Blower with Gas Engine 67
Splice E2 .48,52,61,63,65 A/C Vacuum with Diesel Engine 69
Splice F21 . , 71 A/C Vacuum with Gas Engine 67
Splice F35 73 Automatic Transmission Neutral Start with Diesel Engine . .7
Splice G5 12,13,14,58,77,78 Automatic Transmission Neutral Start with Gas Engine . . .9
Splice G7 . . . . . . . . . . . .19,25 Back-Up Lamp .7,9
Splice G7-1 . . .20 Brake Warning Lamp Diesel Engine 34
Splice K4 20,26 Brake Warning Lamp Gas Engine . .32
Splice K4-1 . . . . . . . . . ; . 18,20 Cargo Lamp 49
Splice K6 , 20 Clutch 8
Splice K7 .20 Clutch Cycling . . . .68,70
Splice L1 .79 Dimmer-Headlamp 47
Splice L6 . .50 Dome Lamp-Front . .50
Splice L7 43,45 Dome Lamp-Rear 50
Splice L7-1 40,41,47,61,63,65 Door Jamb . 49
Splice L7-2 .41,79 Engine Coolant Temp .26
Splice L7-3 .41 Four Wheel Drive 13
Splice L7-4 41 Front Axle 13
Splice L7-5 .41 Glove Box Lamp . .52
Splice L50 . . . . . . . . . . . . . . . . . . .32,34,36,38,56 Hazard Warning .56
Splice M 1 49,51,52,61,63,65,75 Headlamp 1,47
Splice M1-1 51 Heated Rear Window 39
Splice M 2 . .49 Heater . . .66,67
Splice M2-1 .51 Horn .30
Splice P33 . 74 Ignition 2,10
Wiring Diagram Name _ Sheet Number Wiring Diagram Name ^ Sheet Number
Illumination Lamps-Instrument Panel . . . . . . . . . . . .12,14 2-Speed Wiper Motor 55
Intermittent Wiper . . . . . . . . . . . . . . . . . . . . . . . . . .53 Washer Pump Motor . . . . . . . . . . . . . . . . . . . . . . . .55
Key-In . . . . . . . .49 Switch 55
Liftgate Ajar . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 Turn Signal System . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Park Brake .31,33 Flasher 56
Power Door Lock-Left . . . . . . . . . . . . . . . . . . . . . . . .73 Fuse .56
Power Door Lock-Right .74 Lamps-Front 43,44,45,46
Power Mirrors .75,76 Lamps-Rear . 79,80,81
Power Window-Left 71 Switch Control 56
Power Window-Right . .72 Underhood Lamp 29
Seat Belt Warning with Diesel Engine 77 Valve Hydraulic, Dual Solenoid .32,34
Seal Belt Warning with Gas Engine .78 Vehicle Speed Control (Diesel) .37,38
Speed Control . . . . . . . . . . . ,32,36,38 Clockspring 42
Standard Windshield Wiper . .55 Connector .37
Stop Lamp .32,34,36,38 Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Transfer Case Switch . 13 Lamp Switch . . .38
Transmission Thermo . . . . . . . . . . . . . . . . . . . . . . . .24 Resistor .38
Turn Signal .56 Servo • .37
Windshield Washer Intermittent Wiper . .53 Vehicle Speed Control (Gas) .35,36
Windshield Washer-Standard .55 Clockspring 36
Windshield Wiper-Intermittent 53 Connector .35
Stereo Radio-4 Speakers .61,62,63,64 Fuse . . . . . . . . . 36
Fuse .61,63 Lamp Switch .36
Speaker-Left . . . . . . . . . . . . . . . . . . . . . 62,64 Resistor .36
Speaker-Right . .62,64 Servo . 35
Stereo Radio-Dual Speakers .65 Vehicle Speed Sensor .20,25,26
Temperature Sending with Diesel Engine . .27 Wide Open Throttle Cutout Relay . .68,70
Temperature Sending Unit with Gas Engine . . . . . . . . . . .28 Windshield Wiper-intermittent . . . . . . . . . . . . . .53,54
Trailer Tow Wiring 81 Windshield Wiper-Standard 55
Transmission Overdrive Solenoid . . . . . . . . . . . . . . . .12,14
Transmission Overdrive System 12,14
- J _ ENGINE
= GROUND
BODY
— GROUND
FUSIBLE LINK
{ 1 0 0 0 ) 5 0 / 1 2 0 AMP
BATTERY All
( L E F T FRONT WHEELHOUSE)
FUSIBLE LINK 6BK/GY
-A 15 22WT- (18GY)
( L E F T FRONT WHEELHOUSE) CHARGING
^— F U S I B L E LINK A3
(22WT) 12RD SYSTEM
( L E F T FRONT WHEELHOUSE) WT SH 3,4,5.6
A15
16PK 4-
IT-
13#-ZI F U S E #13
O FUSE # 6 FUSE # 5 F U S E #15
20 AMP F U S E #4
20 AMP J—1| 20 AMP 10 AMP
| ft 20 AMP
L9 F32
18BK F33 A3 18PK
WT 18PK 12RD DB
RD WT
i POWER DOOR L O C K S
SH 73 I UNDERHOOD LAMP
SH 29
HAZARD STOP LAMPS
FLASHER CIRCUIT SH 7 9 , 8 0 GLOVE BOX LAMP
SH 56 BREAKER KEY-IN I SH 52
HEADLAMP ON RADIO ELECTRONICS
F33 -L2 BUZZER SH 6 1 . 6 3 . 6 5
18PK SH 7 7 . 7 8 MAP LAMP
RD HEADLAMP
REAR WHEEL SH 49
•VWf SWITCH HEADLAMPS
ANTI-LOCK IGNITION
DIMMER S W I T C H LAMP
SWITCH SH 3 1 . 3 3
SH 47 SH 49
SH 47 DOME LAMP
HORNS
SH 30 SH 5 0 . 5 1
EI L7 18BK/YL- CARGO LAMPS
18TN SH 4 9 . 5 0
POWER M I R R O R S
SH 75
3
A31 14BK/WT -
FUSE #14 P A R K I N G LAMPS
3AMP
D SH 4 3 . 4 4 . 4 5 , 4 6
T A I L LAMPS
SH 7 9 . 8 0
E2 L I C E N S E LAMP LI FUSE # 7
200R SH 80 2h-i 15 AMP
7*3
X FRONT S I D E MARKER
LAMPS
SH 4 3 . 4 4 . 4 5 . 4 6
C L U S T E R LAMPS
SH 59 RADIO DISPLAY INTENSITY
R A D I O LAMPS SH 6 1 . 6 3 . 6 5 F30
SH 6 1 . 6 3 . 6 5 C L E A R A N C E AND 16RD
A / C AND HEATER I D E N T I F I C A T I O N LAMPS TN
1
CONTROL LAMP SH 4 0 . 4 1
SH 48
ASH R E C E I V E R LAMP
SH 48 CIGAR LIGHTER
TACHOMETER LAMP SH 52
SH 48
TRANSMISSION OVERDRIVE INDICATOR LAMP
SH 12
HEATED REAR WINDOW
S W I T C H LAMP
SH 39
AD 1 FUSE APPLICATION CHART J938W-U

FUSIBLE LINK
(18GY)
FUSIBLE LINK FUSIBLE LINK
(200R) (200R)
(LEFT FRONT (LEFT FRONT
WHEELHOUSE) WHEELHOUSE)
12BK/RD
HEATED ENGINE
REAR WINDOW IGNITION
STARTER
SH 39 SWITCH -A41 14YL-
SYSTEM
-A22 12BK/0R-
RUN ONLY SH 10 SH 7 . 8 . 9
A31
14BK/WT
A21
I—A22 12BK/0R 14DB
RUN AND ACC
RUN AND START
1 30 AMPS
J
CIRCUIT FUSE #11
,— BREAKER
h
30 AMP
IT — P CAVITY #12
FUSE # 1 FUSE # 3 D
F21 3 2 AMP 20 AMP FUSE # 2
12TN
CI 3 5 AMP
12DG A2I
14DB G5
V34
20WT/RD F20 20DB/WT
18WT
A/C AND HEATER
POWER WINDOW BLOWER MOTOR WAIT TOTO 4tART
START LAMP
SH 71 SH 6 6 . 6 7 . 6 9 VEHICLE SH 57
SPEED CONTROL LOW FUEL LAMP
(GAS) SH 57
BACK-UP LAMP
SH 36 GAUGES
SH 79.80
VEHICLE SH 59
HEATER REAR
SPEED CONTROL BRAKE LAMP
WINDOW
(DIESEL) SH 57.58
SH 39
SH 38 SEAT BELT LAMP
AND BUZZER
AUTOMATIC A/C SH 77 78
WATER IN FUEL LAMP
O SHUT DOWN ELECTRONIC
SH 57
S FUSE #10 FUSE #8 FUSE #9 RELAY CYCLING
SH 16.22 SWITCH 4 WHEEL DRIVE
10 20 AMP 310 AMP 120 AMP INDICATOR LAMP
*ZJ TRANSMISSION
OVERDRIVE
SH 68.70
3 . R . L . MODULE SH 13
SOLENOIDS SH 46 LOW ENGINE OIL LAMP
SH 12.14 EMCC RELAY SH 59
V6 L5
FUEL PUMP RELAY SH 11 MALFUNCTION
18DB 18RD
SH 16 FUEL HEATER INDICATOR LAMP
WINDSHIELD RADIO AND CLOCK TURN SIGNAL

i GENERATOR
SH 4
VACUUM SENSOR
AND PUMP
SH 24
SH 59
ANTI-LOCK LAMP
SH 57 58
FLASHER SH 34 LIFTGATE OPEN LAMP
WIPER SH 6 1 . 6 3 . 6 5
SH 56 AIR SWITCHING SH 58
SYSTEM TRANSMISSION
SH 54.55 TACHOMETER SOLENOIDS
PROVISIONS SH 16 CONTROL MODULE
SH 48 PMC SH 12.14
REAR WHEEL SH 16 SERVICE REMINDER
ANTI-LOCK AIR HEATER INDICATOR LAMP
MODULE CONTROLLER SH 58
SH 31.33 SH 21
WOT RELAY
SH 68.70
J938W-11 FUSE APPLICATION CHART AD 2

TO ENGINE
STARTER r
MOTOR r -Al 6RD-

(SEE SH 9)
(REAR OF BATTERY)
BLACK RED^
Ai 6BK
A2 BLACK
10BK
BATTERY
(LEFT FRONT TO FUSE #15
OF ENGINE) (SEE SH 49)
AND
ENGINE
GROUND
(LEFT FRONT
TO
<8> SPLICE
[SPORT UTILITY ONLY)

BODY OF ENGINE) (SEE SH 39)
GROUND
(LEFT YOKE
FRONT OF
BATTERY)
BLACK AO
6BK
(REAR OF
BATTERY)
FUSIBLE LINK
(HYPALON WIRE)
I.O.D.
CONNECTOR
NATURAL
AO 6BK-
(FRONT LEFT
S I D E SHIELD)
A4 18GY
FUSIBLE LINK
(HYPALON WIRE)
TO HAZARD TO ENGINE
FLASHER STARTER K
MOTOR r -AOA 12RD-

(SEE SH 56)
(SEE SH 9)
CHARGING SYSTEM WITH

AD 3 GAS E N G I N E S J938W-11
• WIRING DIAGRAMS 8W - 4S
Zl 6BK/WT• All
6BK
90A ONLY-
BLACK -
GROUND
(REAR OF ENGINE)
TO
POWERTRAIN
CONTROL .
MODULE 1 1 (PCM Il)r -K20 18DG
CAVITY 20
(SEE SH 19)
A142 18DB
SPLICE
(SEE SH 15) 3 5 / 7 5 . 4 0 / 9 0 AND 50/120 GENERATOR
(RIGHT SIDE FORWARD OF ENGINE)
yr-BLACK
All
6BK
£ _
(RIGHT FENDER S I D E SHIELD)
All
6BK
FUSIBLE LINK
(HYPALON WIRE) . TO WIDE OPEN
C26 14BR 1 THROTTLE RELAY

(SEE SH 68)
50
All
10DG A2 200R A2 12PK/BK » A2 12PK/BK £
FUSIBLE LINK TO IGNITION

49 SWITCH
(HYPALON WIRE)
m (SEE SH 10)
Al 200R • Al 12RD »- •Al 12RD-
FUSIBLE LINK
(HYPALON WIRE)
k % A 1 C D n >T0 FUEL PUMP RELAY
A14 22WT
-AM 16RD 1 (SEE SH 16)
AOA 12RD A3 18GY A3 12RD/WT » A3 12RD/WT- -^TO < A 3 > S P L I C E
1 (SEE SH 47)
CHARGING SYSTEM WITH

J938W-11 GAS E N G I N E S AD 4
(REAR OF BATTERY)
AO 6BK
BLACK
I— A4 14BK/RD-
TO FUSE # 15
BATTERY
( S E E SH 49)
(LEFT FRONT
OF ENGINE)
Al
ENGINE 2 / 0 RD
GROUND I.O.D.
~ (LEFT FRONT CONNECTOR
A3
BODY OF ENGINE) 14PK NATURAL
GROUND (FRONT LEFT
(LEFT YOKE
SIDE SHIELD)
FRONT OF
BATTERY)
23
TO HAZARD r
FLASHER y A15 16PK

( S E E SH 56)
Al 2/0 RD-
Al A15 16PK- -A15 22WT

2 / 0 RD
-T40 14BR T40 14BR-
-BLACK TO ENGINE STARTER

TO ENGINE STARTER
MOTOR (REAR OF BATTERY) RELAY
( S E E SH 7) ( S E E SH 7) FUSIBLE LINK
(HYPALON WIRE)
CHARGING SYSTEM WITH DIESEL

AD 5 5.9L ENGINE J938M-11
Zl 6BK/WT-
GROUND
(ON ENGINE)
TO POWERTRAIN
CONTROL MODULE I I
(PCM I I )
(SEE SH 21) All
i! B 6BK
K20
18DG
K20 18DG
J
ffl A142 18DB-
mm
"K>nrTTH>
ttt
flTTTTf
(RIGHT S I D E
c ttt
AM2 OF INTAKE) CTTTTT}
16DG D
OR mm
50/120 GENERATOR
TO AUTOMATIC SHUT (RIGHT S I D E FORWARD OF ENGINE)
DOWN RELAY
(SEE SH 22) BLACK All
6BK
(RIGHT FENDER S I D E SHIELD)
FUSIBLE LINK
(HYPALON WIRE)
TO ENGINE
AOA 12RD ? STARTER
1 l h
< T O WIDE fJ^ Jn\ c
C26 14BR -J OPEN THROTTLE (SEE SH 7)
FUSIBLE LINK RELAY
HYPALON WIRE) (SEE SH 70)
50
A2 200R A2 12PK/BK- •A2 12PK/BK •
TO IGNITION
SWITCH
-Al 12RD — (SEE SH 10)
Al 200R- -Al 12RD—
49 TO AUTOMATIC
SHUT DOWN
•A14 16RD RELAY
-A14 22WT- (SEE SH 22)
FUSIBLE L I N K -
(HYPALON WIRE) TO PCM I I
-A14 16RD- CAVITY3
(SEE SH 22)
T0<(A3>SPLICE
A3 18GY- A3 12RD/WT• A3 12RD/WT-
(SEE SH 47)
CHARGING SYSTEM WITH D I E S E L

J938W-11 5 . 9 L ENGINE AD 6
8W - 48 WIRING-DIAGRAMS
TO CHARGING
SYSTEM
ENGINE (SEE SH 5 , 6 )
STARTER
RELAY
(LEFT S I D E
SHIELD)
TO ENGINE
\v A 9 1 u n Q f IGNITION STARTER MOTOR
A 2 1 1 4 0 8 (LEFT LOWER
»— 5 SWITCH REAR OF ENGINE)
(SEE SH 10)
AD 7 5.3L D I E S E L ENGINE STARTER SYSTEM J938W-11

TO IGNITION
SWITCH
( S E E SH 10)
• A41 16YL—»- S21 14YL/BK
31
MANUAL
TRANSMISSION
BLACK J
18BK C L U K H 18BK
PEDAL P O S I T I O N
(SWITCH)
(ON CLUTCH ROD)
BYPASS JUMPER
(TAPED TO WIRE HARNESS)
SWITCH CLOSES WHEN

CLUTCH I S DEPRESSED
J938W-11 5.9L D I E S E L E N G I N E STARTER S Y S T E M AD 8

TO C H A R G I N G
A41 16YL SYSTEM
ENGINE T40
STARTER SEE SH 3 )
14BR
RELAY
(LEFT S I D E
SHIELD)
-T41 18BR/YL
F20 18WT
-T41 18BR/YL-
T41 18BR/YL
LI 18VT/BK
\ 14
PARK/NEUTRAL \ MANUAL T R A N S M I S S I O N
P O S I T I O N AND \ B A C K - U P LAMP S W I T C H :—|ENG|—
BACK-UP SWITCH \ (ON T R A N S M I S S I O N )
(ON T R A N S M I S S I O N ) \
\
TO
POWERTRAIN
CONTROL
MODULE I I
(PCM I I )
(AUTO/TRANS)
CAVITY 30
( S E E SH 19)
T41
18BR T41
YL 20BR
YL
! |
- jt '
__._-._j
r—~Z1 18BK-
T41 18BR/YL 1
MANUAL T R A N S ONLY
Zl 14BK
TO A / C
HENGh COMPRESSOR
CLUTCH
( S E E SH 68)
Zl
14BK
--[bi T0<Z1>41 SPLICE
( S E E SH 44.46)
LI 18VT/BK-
F U S E #3
( 2 0 AMP) TO B A C K - U P L A M P S
( S E E SH 79)
F20 ENGINE
18WT S T A R T E R MOTOR
TO
( L E F T LOWER
TO )_ 2i
A 14DB—( IGNITION REAR OF E N G I N E )
R
H E A T E D REAR ™ SWITCH
WINDOW S W I T C H ( S E E SH 10)
( S E E SH 39)
GAS E N G I N E S
AD 9 STARTER SYSTEM J938W-11
TO HEATED REAR „
WINDOW SWITCH Y- F20 18WT- TO BACK-UP
(SEE SH 39) FUSE # 3 LAMP SWITCH
(20 AMP) (SEE SH 7 , 9 )
TO CHARGING
SYSTEM -F20 18WT
(SEE SH 4 , 6 ) I G N I T I O N SWITCH A21 14DB-(-
(ON STEERING COLUMN) >-G5 20DB/WT-£ TO < G 5 > S P L I C E
T FUSE # 2
(5 AMP) (SEE SH 5 8 )
Al
12RD
14DB TO <A21> 1 T0<A21,

49 OR
•Al 12RD SPLICE SPLICE
( S E E SH 68) (SEE SH 23)
GAS DIESEL
TO
ENGINE ,
STARTER Y- -A41 14YL- TO
SYSTEM AIR CONDITIONING
(SEE SH 8 , 9 ) AND HEATER FEED
(SEE SH 6 6 , 6 7 , 6 9 )
FUSE #11
(30 AMP)
-A2 12PK/BK
12BK/0R CI 12DG-
GROUND TO
(THRU STEERING FUSE # 1 2 F21 12TN- < POWER
COLUMN (30 AMP ^WINDOWS
50 A2 ATTACHMENT) CIRCUIT (SEE SH 71)
12PK BREAKER)
BK
X Gil 20WT/BK
TO CHARGING
SYSTEM — Gil 20WT/BK-
(SEE SH 4 , 6 )
20PK/BK-
TO MESSAGE
CENTER
FUSE # 7 FUSE # 9 (SEE SH 57)
(15 AMP) (20 AMP) D I E S E L ONLY TO
FUSE # 8 FUSE #10 BRAKE WARNING
(10 AMP) (20 AMP) LAMP SWITCH
A41 14YL
(SEE SH 31)
A21 14DB (GAS ENGINE)
Gil 20WT/BK TO WIPER
G i l 20WT/BK
18DB—5 SYSTEMS
A2 12PK/BK (SEE SH 5 4 , 5 5 )
18DB-5
A22 12BK/0R Gil
14RD 20WT
A3! 14BK/WT BK
F30
Al 12RD 16RD
TN
TO
X12 MESSAGE
20RD CENTER
WT (SEE SH 58)
(GAS ENGINE)
TO CIGAR LIGHTER TO RADIO TO TURN SIGNAL TO R.W.A.L.

(SEE SH 52) (SEE SH SYSTEM MODULE
61.63.65) ( S E E SH 56) ( S E E SH 3 1 , 3 3 )
J938W-11 IGNITION SWITCH AD 10

Zl 16BK- -4—11 18BK-
EMCC
RELAY
(LEFT SIDE Zl TO TRANSFER
DASH PANEL) 18.BK CASE SWITCH
(SEE SH 13)
Zl 14BK•
RIGHT
HEADLAMP
GROUND T0<Z124j SPLICE
(CENTER DASH
PANEL) (SEE SH 44.46)
EMCC
SOLENOID
(3 SPEED AUTO-TRANS)
(MOUNTED ON TRANSMISSION
LEFT SIDE)
T22
T22 HOB
14DB WT
WT
EMCC S Y S T E M
AD 1 1 3 - S P E E D AUTOMATIC T R A N S M I S S I O N J938W-11
FUSE # 2
-A21 14DB «• (5 AMP)
TO IGNITION 65
SWITCH TRANSMISSION 20DB
(SEE SH 1 0 ) CONTROL
SWITCH (SEE SH 5 8 ) < G 5
ILLUM 6
w
-65 20DB/WT-
E2 (RIGHT OF
200R
i —j— STEERING
COLUMN ON
TO /
/r I/P)
/ T6 200R/WT-
SPLICE /
(SEE SH 48) /
T61 20BK/0R"
44
24
Zl 18BK-
TO SPLICE
T61
-G5 20DB/WT (SEE SH 48) 20BK
OR T6
200R
3_— WT
T6 200R/WT-
T61 20BK/0R-
18
Zl 18BK- •E2 200R -UNG}- 17
L—_ — . — , j
POWERTRAIN 10 T6 200R/WT-
CONTROL
MODULE I I 37 •T61 20BK/0R-
(PCM I I )
CONNECTOR
(SEE SH 84)
54 — » - K 5 4 200R/BK-
55
(ON T R A N S M I S S I O N )
T 0 < A 2 1 > SPLICE EMCC SOLENOID
T60 \S
200R (SEE SH 16)
LG
•K54 20QR/BK
A21 14DB •A21 14DB
-T60 200R/LG
-A21 14DB-
J
-T60 200R/LG
TRANSMISSION-
3.9L T R A N S M I S S I O N
OVERDRIVE
T
R
OV EB A N n
5
- 9 L E N G I N E S
o v e r d r i v e s y s t e m SOLENOID
(ON TSSSION) ( A U T O / T R A N S M I S S I O N )
J938W-H G A S M P I E N G I N E S A D 12
TO I G N I T I O N
SWITCH
f
r A21 HOB- \\
it G5 2008/WT
(SEE SH 58)
(SEE SH 10)
G5
FUSE # 2 20DB
(5 AMP) WT
FOUR WHEEL
DRIVE INDICATOR
LAMP
Gl
20DG
TO GY
REAR WHEEL <
Gl 20DG/GY -
ANTI-LOCK MODULE^
(SEE SH 3 1 , 3 3 ) 40
r X4 20LG/BR —-
DIESEL
BLACK
(REAR OF GAS ENGINE
ENGINE'
TRANSFER TO
CASE •X4 20LG/BR
SWITCH -Z12 18BK/TN
(DIESEL
ENGINE) SPLICE
(SEE SH 24)
205 TRANSFER BLACK
CASE ON TRANSFER
CASE)
X4
20LG
BR
TRANSFER
CASE
SWITCH
r3 V~X4
—Zl
20LG/BR
18BK
TO
/ V E H I C L E SPEED
(GAS ENGINE) "31 > CONTROL SERVO
(SEE SH 35)
205 TRANSFER BLACK

CASE (ON TRANSFER BLACK
CASE) (LEFT S I D E
DASH PANEL)
Zl
18BK
FRONT
AXLE DO •X4 20LG/BR 1
3 3
SWITCH r -Zl 1SBK — TO < Z 1 ^ 6 l S P L I C E
(SEE SH 11)
241 TRANSFER (LEFT S I D E
(GAS ONLY)
CASE FRONT AXLE)
AD 13 4 WHEEL D R I V E I N D I C A T O R LAMP jsasu-n

FUSE #2
-A21 14DB (f (5 AMP)
TO I G N I T I O N
SWITCH TRANSMISSION G5
t
(SEE SH 10) CONTROL 20DB

SWITCH WT
(SEE SH 5 8 ) < G 5
-» G5 20DB/WT-
0 Q
(RIGHT OF
STEERING
V ' >S
COLUMN ON
I/P)
T6 200R/WT-
T61 2 0 B K / 0 R -
44
24
Zl 18BK-
TO <Z1^1| S P L I C E T61
-G5 20DB/WT 20BK
( S E E SH 48) OR T6
200R
3r—Ji WT
T6 200R/WT- c o
T61 2 0 B K / 0 R - c o
c)_p
Zl 18BK-
I i
POWERTRAIN
CONTROL 10 •T6 200R/WT-
MODULE I I
(PCM I I )
q 7
J / •T61 2 0 B K / 0 R -
CONNECTOR
(SEE SH 83)
55
T60 DARK GRAY

200R
LG REAR OF ENGINE)
T60 2 0 0 R / L G
TO <A21>21 S P L I C E TRANSMISSION-
-A21 14DB-
OVERDRIVE
( S E E SH 24) SOLENOID
TRANSMISSION
OVERDRIVE SYSTEM
D I E S E L E N G I N E S (PCM I I )
J938W-11 AD 14
IGNITION
COIL
(ON E N G I N E )
16 15 14 13 38 58 17 18 19 57
INJ INJ INJ INJ INJ INJ INJ INJ IGNITION ASD
#1 Ml #3 #4 # 5 #6 Ul #8 COIL B+
DRIVER
P O W E R T R A I N CONTROL MODULE II (PCM II) CONNECTOR ( S E E SH 84)
(LEFT FENDER S I D E SHIELD)
I G N I T I O N SYSTEM
AD 15 GAS M F I E N G I N E S J938W-11
A21 HOB
A14 16RD-
A14 A14
16RD 16RD
A21
14DB
K51 K51
A142 200B 20DB
16DG Y L YL
_ OR
AUTOMATIC F U E L PUMP
SHUT DOWN RELAY
RELAY (LEFT S I D E
(LEFT S I D E SHIELD) SHIELD)
-K51 20D8/YL"— F T O F U E L PUMP
^ ( S E E SH 78)
TO
K51 20DB/YL
TO CHARGING —[ENGT—
SPLICE
SYSTEM
( S E E SH 4)
AH 16RD- —«—
(SEE SH 68)
A21 HOB
A21 MOB A21 HOB

1 -\ ENG f-
€ TO DATA L I N K
S CONNECTOR
( S E E SH 17)
- A142 160G/0R
•A142 16DG/0R-
TO
A142 16DG/0R TRANSMISSION
TL OVERDRIVE
SOLENOID
TO H E A T E D ( S E E S H 12)
OXYGEN S E N S O R S K51 K52
( S E E SH 17) AH A21 EVAP
20DB 20PK EGR S O L E N O I D
16RD HDB PURGE S O L E N O I D
YL BK K 3 5 (RIGHT REAR
( L E F T REAR 2 0GY OF E N G I N E )
OF E N G I N E ) YL
3 51 9 52 35
BATTERY ASD I G N I T I O N EVAP EGR
RELAY FEED PURGE SOLENOID
SOLENOID
POWERTRAIN CONTROL MODULE II (PCM II) CONNECTOR ( S E E SH 84)
( L E F T FENDER S I D E SIELD)
J938H-11 GAS MFI E N G I N E S AD 16
18 WT -
18 GY
M
rff®®]TH- 20BK/LB-
45 5 25 11 I2 23 41
DATA S I G N A L DATA
I I HEATED
POWER
L I N K GROUND LINK OXYGEN
GROUND
RECEIVE TRANSMIT SENSOR
AD 17 GAS MFI E N G I N E S J938W-U
CRANKSHAFT
POSITION
SENSOR
THROTTLE
RIGHT POSITION
REAR OF (SENSOR)
ENGINE)
(ON THROTTLE
BODY)
K4
20BK/LB —j T0<K6
SPLICE
( S E E SH 2 0 )
-KB 20VT/WT-
K4 18BK/LB
rtM-
-K4 18BK/LB-
x
TO
<8>
SPLICE
TO VEHICLE ( S E E SH 2 0 )
SPEED
SENSOR
( S E E SH 20)
TO
TO E N G I N E
WIRING
TO A / C AND
SPLICE<K4> SPLICE HEATER S Y S T E M
[ S E E SH 2 0 ) ( S E E SH 6 8 )
(SEE SH 20)
K22
180R
DB
25
-[ENGh —[FNG]—
C13
K24 20DB
18GY OR
BK C20
18BR
24 22 27 34
REF. TP(S) A/C W.O.T.
PICKUP CYCLING RELAY
SWITCH
J938U-11 GAS MFI E N G I N E S AD 18
IDLE AIR GRAY

CONTROL MOTOR
nrrrrnrj
pnrn
(ON THROTTLE
BODY) las
2 3 ^ 4
1 G7
•G3 20BK/PK—
20WT
TO PRINTED OR
4 32 1
CIRCUIT BOARD
CONNECTOR
(SEE SH 60)
43
TO DAYTIME
RUNNING LAMP G7
MODULE 20WT TO
OR
<8>-\
(CANADA ONLY) MESSAGE CENTER
(SEE SH 46) SERVICE
REMINDER
INDICATOR
G7 2 0 W T / 0 R ~ H > (SEE SH 58)
G3 G24
20BK 22 GY
PK PK
G7
20WT
38
13 OR 42
'T
G3 G24
20BK 20GY
PK PK
33 24
•-{ENGf- ;HENG}~ —[ETTGI—
TO
G7 20WT/0R
TO
CHARGING
SPLICE SYSTEM
(SEE SH 9) (SEE SH 4)
K59
T
T41 K40 K60 K39
T G3 G24
18VT 18BR 18YL 18GY K20 20BK 20GY
18BR 18DG
BK YL WT BK RD PK PK
i
59 30 40
.1
60
n39 20 32 56
IAC PARK/ IAC IAC IAC GENERATOR MIL SRI
NEUTRAL FIELD
SWITCH
POWERTRAIN CONTROL MODULE I I (PCM II] CONNECTOR (SEE SH 84)

AD 19 GAS M F I E N G I N E J938W-11
INTAKE AIR
TEMPERATURE
SENSOR
21 2 44 7 4 6 47 1
CHARGE ECT CMP 8 VOLT SENSOR 5 VOLT VEHICLE MAP
AIR INPUT RETURN SUPPLY SPEED SENSOR
TEMP SENSOR
P O W E R T R A I N CONTROL MODULE I I (PCM II) CONNECTOR (SEE SH 84)
( L E F T FENDER S I D E SHIELD)
J938H-11 GAS MFI ENGINE AD 20
TO W.O.T. „
RELAY Y
f-A8 12BK—dp) BATTERY (OTJ A5 1 2 B K — f (SEE SH 70)
j \ ^ POSITIVE J
A8
6BK •FUSIBLE LINK
A21 160B
(LEFT (LEFT
AIR
FENDER FENDER
HEATER
SIDE SIDE
RELAY
SHIELD) SHIELD)
A21 M D B
A7
6BK T0<^2!)
" SPLICE
(SEE SH 23)
"-no) ten-
(ON INTAKE
UNDER INLET
PIPE)
AIR
INTAKE
HEATER
TO CHARGING
SYSTEM
(SEE SH 6)
TO ENGINE
STARTER
RELAY
(SEE SH 7) S21
K20
18YL
T BK
18DG
T41
20BR
YL
JL
130 16 20 15
PARK/NEUTRAL HEATER GENERATOR HEATER IGNITION
POSITION (SWITCH) #1 RELAY FIELD #2 RELAY FEED
POWERTRAIN CONTROL MODULE I I (PCM I I ) CONNECTOR (SEE SH 83)

AD 21 D I E S E L CONTROL SYSTEM J938W-11

TO CLUSTER
MALFUNCTION
INDICATOR LAMP
(SEE SH 60)
TO TACHOMETER
PROVISIONS
(SEE SH 48)
Al42 A142
16DG 16DG
OR OR
L._ , . I
TO F U S I B L E L I N K
(SEE SH 6)
A21 14DB
TO GENERATOR
( S E E SH 6) G3 G21
A14 20BK 20GY
16RD PK LB
AUTOMATIC
SHUT DOWN A142
RELAY 16DG
(LEFT S I D E OR
SHIELD)
16
K51 A142 A14 G3 G21

20DB 16DG 16RD 20BK 20GY
YL OR PK LB
51 57 3 32 43
A.S.D. A.S.D. BATTERY MIL TACH
RELAY BATTERY FEED
POWERTRAIN CONTROL MODULE I I (PCM II) CONNECTOR ( S E E SH 83)

(LEFT FENDER SIDE SHIELD)
J938W-11 D I E S E L CONTROL SYSTEM AD 22

TO D A Y T I M E
RUNNING L I G H T S
MODULE C — A 2 1 140R
S E E SH 4 6 ) l 4 U K
BLACK ( R E A R OF E N G I N E )
TO A / C
ELECTRONIC A21 14DB
CYCLING ^ A 2 1 h o b
SWITCH Z12 14BK/TN

( S E E SH 70)
TO IGNITION TO A / C
A21 1 4 D B - 4 , SWITCH COMPRESSOR
^ ( S E E S H 10) 71 14BK-C, C L U T C H
v
Zl j(SEE SH 70)
TO M E S S A G E BLOWER MOTOR f-
< T 0
Z l 14BK Zl 18BK-A UNDERHOOD

CENTER ( D I E S E L ) ( S E E SH 6 6 . 6 9 T LAMP
( S E E SH 5 7 ) ( S E E SH 2 9 )
TO < Z 1 ^ 4 l S P L I C E 5" Zl 14BK

TO VACUUM
( S E E SH 4 4 , 4 6 ) SENSOR
RIGHT
HEADLAMP ( S E E SH 34)
RED
GROUND
(RIGHT S I D E —
SHIELD)
A21 1408
TO LEFT
HEADLAMP GROUND
( S E E SH 4 3 , 4 5 )
G86 G85
20DG 20TN Zll
WT OR TO D A Y T I M E 18BK
RUNNING L I G H T S WT
MODULE
( S E E SH 46)
DATA L I N K
CONNECTOR
(RIGHT
REAR OF
ENGINE
COMPARTMENT)
11 20
E5 K31
20DG 20BK
WT PK
020
20LG
56 54 11 12 45 25 5
WAIT-TO- WATER-IN- POWER POWER DATA L I N K DATA L I N K SIGNAL
START LAMP FUEL LAMP RECEIVE TRANSMIT GROUND
GROUND GROUND
CONNECTOR
POWERTRAIN CONTROL MODULE II (PCM I I ) ( S E E SH 83)
AD 23 D I E S E L CONTROL S Y S T E M J938W-11
TO
TRANSMISSION
A21 14DB 4 OVERDRIVE
>
SOLENOID
(SEE SH 14)
A21 HOB
THERMO
SWITCH
TO TRANSFER
CASE SWITCH
(SEE SH 13)
Z12 18BK/TN — '

T41 18BR/YL—i
TO ENGINE
STARTER RELAY
(MANUAL TRANS ONLY) A 2 i
(SEE SH 7) HOB
A21 A21
14DB 18BL
•BLACK
I 1
EIZZll
FUEL
SOLENOID
(LEFT FRONT
OF ENGINE)
FUEL
HEATER
(ON TOP OF COLD START
FUEL WATER ADVANCE
SEPARATOR)
( K . S . B MOTOR)
(ON PUMP)
(FRONT OF
ENGINE)

WATER-1N-FUEL SENSOR CRANKSHAFT P O S I T I O N INTAKE AIR
( I N FUEL F I L T E R ) SENSOR TEMPERATURE
FRONT SENSOR
OF IN INTAKE
ENGINE) LEFT S I D E )
VEHICLE
SPEED SENSOR
(ON REAR
OF TRANSMISSION
MANUAL TRANSMISSION
AND 205
TRANSFER CASE
TO LEFT
PRINTED CIRCUIT
BOARD CONNECTOR
[SEE SH 60)
TO DAYTIME
RUNNING LIGHT
MODULE
(CANADA ONLY)
(SEE SH 46)
47 7 2 1 21 24 28
VEHICLE 8 VOLT ECT WATER - 1 N - INTAKE CKP THERMO
SPEED SENSOR INPUT SENSOR FUEL AIR TEMP PICK-UP SWITCH
PICK-UP SENSOR CONNECTOR
POWERTRAIN CONTROL MODULE I I (PCM I I ) (SEE SH 83)
(LEFT FENDER SIDE SHIELD)
AD 25 D I E S E L CONTROL S Y S T E M J938H-11
E N G I N E COOLANT
TEMPERATURE TRANSMISSION
SWITCH THERMO S W I T C H
(LEFT
S I D E REAR
OF E N G I N E
BLOCK)
-K4 18BK/LB
-K4 18BK/LB
-K4 18BK/LB
-K4 20BK/LB
K2 20TN/BK
-T25 20LG/RD
\BLACK
/ (LEFT REAR OF ENGINE)
L
- h - - K44 20TN/YL
O o oo O
O 9 99 O
K4 20BK/LB ^-flf
G7 20WT / O R A
VEHICLE SPEED TO A / C S Y S T E M
SENSOR ( S E E SH 70)
(ON REAR OF
TRANSMISSION)
AUTOMATIC TRANS
2 W . D . ONLY
K22 K4 K6 C13
180R 20DB C20
18BK 20VT
DB OR 18BR
LB WT
22 4 6 34 27
T.P.(S.) SENSOR 5 VOLT W.O.T. A/C
RETURN SUPPLY RELAY COMPRESSOR
CLUTCH
POWERTRAIN CONTROL MODULE II (PCM II) CONNECTOR ( S E E SH 83)

TO LEFT
PRINTED CIRCUIT
BOARD CONNECTOR
(SEE SH 60) 17
8 5 4 „ 32
G20 20VT/YL « G20 20VT/YL •
GRAY 18
G6 20GY- -66 20GY-

BLACK
19
G60 20GY/YL « G60 20GY/YL
TO RIGHT
PRINTED CIRCUIT
BOARD CONNECTOR
(SEE SH 60)
BLACK
(REAR OF ENGINE
LEFT S I D E )
G20
20VT
YL
G60
20GY
YL
G6
G60 20GY/YL- 20GY
G6 20GY-
ENGINE
OIL PRESSURE
SENDING UNIT
AND SWITCH
(LEFT S I D E
OF BLOCK
CENTER)
ENGINE
TEMPERATURE
SENDING UNIT
(LEFT REAR
OF CYLINDER
HEAD)
G60 20GY/YL-
G6 20GY-
O I L P R E S S U R E AND TEMPERATURE
AD 27 SYSTEM FOR D I E S E L E N G I N E jsaew-n
WIRING DIAGRAMS 8W - 6S
BLACK
GRAY TO LEFT
PRINTED CIRCUIT
BOARD CONNECTOR
( S E E SH 60)
TO RIGHT
PRINTED CIRCUIT
BOARD CONNECTOR
(SEE SH 6 0 '
17
19
G20
G60 20VT
G6 YL
20GY
20GY
YL
26
15 16 ENG h
ENG y •v — ENG
G60
G6
20GY
20GY
YL
G20
ENGINE
OIL PRESSURE
SENDING UNIT
AND SWITCH
(REAR OF
INTAKE MANIFOLD
CENTER)
ENGINE
TEMPERATURE
SENDING UNIT
(RIGHT S I D E
FRONT OF
ENGINE)
OIL P R E S S U R E AND TEMPERATURE SYSTEM

FOR E L E C T R O N I C
U938W-H FUEL I N U E C T I O N IGNITION AD 28
(LEFT S I D E BLACK
OF STEERING
COLUMN
33 TO BOOY
WIRING
Ml 18BK/TN - Ml 18PK (SEE SH 50)
Ml
Zl 1BK 18PK
(RIGHT S I D E TO <M^> SPLICE

BLACK
COWL PANEL)
TO < Z 1 > 4 | SPLICE (SEE SH 49)
GAS
(SEE SH 4 4 , 4 6 )
T 0 < Z 1 > 6 | SPLICE

DIESEL
(SEE SH 23)
Zl 18BK
Ml 18PK
UNDERHOOD LIGHT
(CENTER OF
HOOD INNER PANEL)
MERCURY
SWITCH
AD 29 UNDERHOOD LAMP J938W-11

TO F U S I B L E
LINK (HIGH NOTE)
(SEE SH 4 , 6 ) LOW NOTE) HORN
HORN
(LEFT S I D E (RIGHT S I D E
OF RADIATOR OF RADIATOR
SUPPORT) SUPPORT)
(GAS) (GAS)
(LEFT S I D E
(LEFT S I D E
SHIELD
SHIELD ( D I E S E L )
(DIESEL)
BLACK BLACK
:X2
X2 18DG/RD
SPLICE X2 NOTE: HORNS ON D I E S E L

( S E E SH 47) 18DG ARE ON LEFT S I D E
RD NEAR BATTERY
32
FUSE # 4
(20 AMP)
X2
F33 18DG
18PK HORN RELAY RD
RD [ON FUSE BLOCK)
(SEE SH 82)
F33 ( I N STEERING COLUMN)

18PK
RD
X3 20BK/RD
HORN
SWITCH
CLOCK SPRING
OR
HORN RING
( I N COLUMN)
TO HEADLAMP
SWITCH STEERING COLUMN
( S E E SH 47) GROUND
(THROUGH CENTER SHAFT)
J938W-11 HORN SYSTEM AD 30

TO TO
TURN SIGNAL
FLASHER »~-A31 14BK/WT—j »gjj}{J" J-
r
(SEE SH 56) Y L5 18R0 (SEE SH 10)
FUSE #9 Gil
FEED 3 -»- -L5 14RD
(20 AMP) 20WT
BK
ISO SOLENOID 1 •B101 16LG/BK-
DUMP SOLENOID 8 -B108 14WT/BR-
RESET 11 -yy Bill 18LB—-

TO
4WD INDICATOR
pa
<
4WD SWITCH 4 -»- Gl 20DG/GY ") LAMP SWITCH
(SEE SH 13) 3 D
B113 18RD/VT
RWAL
»\
SENSOR 3
B114 8WT/VT D
TWISTED PAIR
REAR WHEEL 3 D•
ANTI-LOCK
CONTROL MODULE
(BEHIND I / P
ROLLS TEST CONNECTOR *
( I N PLANT USE ONLY) \
2J3
RIGHT S I D E ) B114 18WT/VT•
BRAKE -»- L50 18WT/TN -

SWITCH
F32 20PK/DB
BRAKE G9 20GY/BK -
I AMP
DATALINK
GROUND ~~y B102 180R
10 12 6
^ A N T I - L O C K LAMP
\
IGN FEED
Gil 20WT/BK
2 3 ^ 4 5 6
TO
B112 18BK/WT MESSAGE
CENTER r Q
TO
INTERMITTENT SEE SH 58) 2
g» Y
12 18BK/LG WIPER MODULE

(SEE SH 54) BLACK
Gil
GRAY 20WT
BK
L50 18WT/TN -B113 18RD/VT
DATA LINK
Gil 20WT/BK -B114 18WT/VT CONNECTOR
(LOWER RIGHT
G9 20GY/BK -B112 18BK/WT S I D E COWL) TO (ON PARK
Gl 2QDG/GY - B i l l 18LB IGNITION BRAKE
SWITCH LEVER)
L5 14RD -12 18BK/LG (SEE SH 10)
B102 180R • F32 20PK/DB
B101 16LG/BK •B108 14WT/BR
PARK BRAKE
SWITCH
REAR WHEEL ANT I - L O C K BRAKE SYSTEM

AD 31 (GAS E N G I N E ) J938W-11
( R I G H T OF BLACK
STEERING ( L E F T REAR
FRAME R A I L )
RESET SWITCH
DUMP S O L
/
#- YYTP i
ISO SOL
DUAL S O L E N O I D
H Y D R A U L I C VALVE
B R A K E WARNING
LAMP S W I T C H
; L E F T FRONT
FRAME R A I L )
„ TO HAZARD
L50 18WT/TN — ( F L A S H E R SWITCH
( S E E SH 5 6 )
TO
POWERTRAIN
CONTROL
MODULE I I
C A V I T Y 29
( S E E SH 3 5 ) O S T O P LAMP S W I T C H
WITHOUT V E H I C L E
R . W . A . L . SENSOR S T O P LAMP AND V E H I C L E
( I N REAR D I F F E R E N T I A L ) S P E E D CONTROL S W I T C H S P E E D CONTROL
W I T H S P E E D CONTROL
REAR WHEEL A N T I - L O C K BRAKE S Y S T E M
J938W-11
(GAS E N G I N E ) AD 32
SW - 74 WIRING DIAGRAMS
TO TO
TURN SIGNAL J IGNITION
FLASHER f
A31 14BK/WT > SWITCH
( S E E SH 5 6 ) y L5 18R0 ( S E E SH 10)
FUSE # 9
FEED 3 - L 5 14RD
'20 AMP)
ISO SOLENOID 1 8101 16LG/BK
DUMP SOLENOID 8 B108 14WT/BR
RESET 11 B i l l 18LB
TO
< 4WD INDICATOR
4WD SWITCH 4 Gl 20DG/GY -} LAMP SWITCH
<
(SEE SH 13)
.14 B113 18RD/VT•
RWAL
SENSOR
43 -»- -B114 18WT/VT
TWISTED PAIR
REAR WHEEL
ANTI-LOCK
CONTROL MODULE ROLLS TEST CONNECTOR m
(BEHIND I / P ( I N PLANT USE ONLY) %
RIGHT S I D E ) B114 18WT/VT
BRAKE L50 18WT/TN •

SWITCH
F32 20PK/DB
BRAKE
LAMP
Gil 20WT/BK- TO
DATALINK
GROUND
10 12
7 5>
B102 180R •
MESSAGE
CENTER
(DIESEL)
( S E E SH 5 7 )
-ANTI LOCK LAMP
BRAKE LAMP
G9 2 0 G Y / B K - Gil 20WT/BK-
Bl12 18BK/WT
TO
INTERMITTENT
Z2 18BK/LG• WIPER MODULE
( S E E SH 5 4 ) BLACK
-GRAY
L50 18WT/TN -B113 18RD/VT

DATA LINK
Gil 20WT/BK -B114 18WT/VT
CONNECTOR
G9 20GY/BK -B112 18BK/WT (LOWER RIGHT
S I D E COWL) (ON PARK
Gl 20DG/GY B i l l 18LB
BRAKE
L5 14RD -Z2 18BK/LG LEVER)
B102 180R F32 20PK/DB
B101 16LG/BK to (g)S B108 14WT/BR
PARK BRAKE
SWITCH
REAR WHEEL ANT I--LOCK BRAKE S Y S T E M

AD 33 ( D I E S E L ENGINE) J938W-11
_rrrRv_ ( R I G H T 0 F
( L E F T REAR
Z8 18GY
LL1 FRAME R A I L )
~ U) | STEERING COLUMN)
PANEL GROUND
BLACK
Z09 18GY/BK
Bill 18LB - RESET SWITCH
B108 14WT/BR -j=rf

DUMP
B101 16LG/BK
I S O SOL
-BLACK 18BK-
G11 18WT/BK
DUAL S O L E N O I D
HYDRAULIC VALVE
BRAKE WARNING GRAY

LAMP S W I T C H
( L E F T FRONT
FRAME R A I L )
BLUE
(LEFT SIDE-UNDER INSTR/PANEL)
Bl13 18RD/VT
Gil
20WT
BK B114 18WT/VT
TO
HAZARD
•
L50 18WT/TN L50 18WT/TN ? FLASHER
^ SWITCH
( S E E SH 56)
F32 20PK/DB
TO 8113 B l 1 4
BUZZER 18RD 18RD
( S E E SH 77) ( T A P E D TO H A R N E S S
VT VT
NEAR CONNECTOR)
F32 18PK/DB 150 20WT/TN TWISTED

Z l 18BK PAIR
Zl 20BK
BLACK
RESISTOR
V40 18WT/PK
GROUND
SPLICE
20PK
( S E E SH 48) 41
V40
18WT
18WT PK
i
TO P O W E R T R A I N
TO CONTROL MODULE I I
DATA L I N K C A V I T Y 29
CONNECTOR (SEE SH 37)
( S E E SH 23)
S T O P LAMP SWITCH R . W . A . L . SENSOR
(LEFT FENDER (IN REAR D I F F E R E N T I A L )
SIDE SHIELD) R E A R W H E E L ANT I - L O C K BRAKE S Y S T E M

U938w-ii ( D I E S E L ENGINE) AD 34
28
—[eng]—
ON/OFF 49 - » — - V32 20 YL / RD - —)>—
SET 48 ~» V31 20BR/RD- V32
20YL
RESUME 5 0 -» V 3 3 20WT/LG • RD
BRAKE
S E N S E 29 -» V 4 0 18WT/PK-
27
VACUUM 3 3 - » V36 20TN/RD- -[ENG]-
29
POWERTRAIN 31 12 HENGV-
CONTROL -{ENG}-: —[ENG]— •V31 20BR/RD •
MODULE I I
(PCM I I )
VENT 5 3 • V35 20LG/RD
30 V33 20WT/LG-
-{ENG}-:
CONNECTOR
( S E E SH 84)
V30 20DB/RD-
TO REAR WHEEL
ANTI-LOCK
CONTROL MODULE
(SEE SH 3 1 )
TO T R A N S F E R
CASE SWITCH
(SEE SH 13) Zl 20BK
V30 V36
20DB 20TN
RD RD -F32 20PK/DB•
TO S E A T B E L T F
V35 WARNING S Y S T E M y -F32 18PK/DB

20LG (SEE SH 78)
RD F U S E D BATTERY
FEED
TO < Z ^ ¥ ] S P L I C E
(SEE SH 1 1 ) •V40 18WT/PK
DIRECT- 7
CONNECTION
V E H I C L E S P E E D CONTROL S E R V O
(UNDER B A T T E R Y T R A Y )
GAS E N G I N E S
AD 35 VEHICLE S P E E D CONTROL SYSTEM J938W-11
TO IGNITION f
SWITCH >
( S E E SH 10)
STOP LAMP AND V E H I C L E S P E E D

CONTROL S W I T C H W I T H VEHICLE S P E E D CONTROL
V E H I C L E S P E E D CONTROL SWITCH
(IN S T E E R I N G WHEEL)
GAS E N G I N E S
J938W-11 V E H I C L E S P E E D CONTROL SYSTEM AD 36
ON/OFF 49 -» V32 20YL/RD-

SET 48 -» V31 20BR/RD-
RESUME 50 -» V33 20WT/LG-
BRAKE
SENSE 29 •V40 18WT/PK-
VACUUM 33 V36 20TN/RD-
POWERTRAIN
CONTROL MODULE II
•V31 20BR/RD•
(PCM I I )
VENT 53 •V35 20LG/RD
V33 20WT/LG-
CONNECTOR
(SEE SH 83)
V30 20DB/RD-
TO REAR WHEEL
ANTI-LOCK
CONTROL MODULE
(SEE SH 33)
TO < Z Q 5 l S P L I C E y Zl 20BK
(SEE SH 43,45)
-F32 18PK/DB•
TO SEAT BELT f
WARNING S Y S T E M r -F32 18PK/DB-

(SEE SH 77)
FUSED BATTERY
FEED
V40 18WT/PK
DIRECT
CONNECTION
TO SERVO
VEHICLE SPEED CONTROL SERVO

5 . 9 L D I E S E L ENGINE
AD 37 V E H I C L E S P E E D CONTROL S Y S T E M J938W-11
TO IGNITION f
SWITCH y
( S E E SH 10)
STOP LAMP AND V E H I C L E S P E E D

CONTROL S W I T C H W I T H
VEHICLE S P E E D CONTROL
V E H I C L E S P E E D CONTROL
SWITCH
(IN S T E E R I N G WHEEL)
5 . 9 L D I E S E L ENGINE
J938W-11 V E H I C L E SPEED CONTROL SYSTEM AD 38
FUSE* 3
[20 AMP
TO BACK-UP LAMP TO
SWITCH FUSIBLE
SEE SH 9) LINK
(SEE SH 3)
TO I G N I T I O N
SWITCH J—A21 14DB-<<
( S E E SH ior
A4
A4 Zl 12BK
SPLICE RD
12BK 20BK
(SEE SH 48)
nnn T 0 < E 2 > SPLICE J - Zl

F20
18WT
rvm • 1 Jl T7< 1 j ( S E E SH 48) E2
20BK 48
(ILLUM LAMP FEED) 220R
CIS F20 E2
12BK/0R 18WT 220R
ON (jz
e-
TIMER
OFF OF
MECHANICAL- L.E.D
OFF/ON SWITCH A4 12BK/RD
HEATED REAR
WINDOW DEFOGGER
SWITCH A4
(INSTRUMENT 12BK
CIS RD
PANEL)
BLACK 12BK
WT
CIS 12BK/WT- TO FUSE BLOCK

FUSE #15
(SEE SH 49)
BLACK (LEFT S I D E
(LEFT 'C'PILLAR) KICK PANEL)
, E L E C T R I C A L L Y HEATED REAR WINDOW

AD 39 (SPORT U T I L I T Y ) vJ938w~n
TO
HEADLAMP
SWITCH SPLICE
L7 18BK/YL L7 18BK/YL •
L7 18BK/YL
BLACK BLACK
Onj )-L7 18BK/YL L7 18BK
(LEFT S I D E OF
cur CLEARANCE
LAMP
INSTRUMENT PANEL) (AT LAMP)
L7
18BK BLACK
YL
CDX L7 18BK-
IDENTIFICATION
LAMP
(AT LAMP)
L7
18BK
YL -BLACK
L7 18BK-
an: IDENTIFICATION
LAMP
[AT LAMP)
L7
18BK
YL -BLACK
L7 18BK-
an IDENTIFICATION
LAMP
(AT LAMP)
L7
-BLACK
18BK
YL
L7 18BK-
an CLEARANCE
LAMP
(AT LAMP)
FRONT CLEARANCE AND I D E N T I F I C A T I O N

J938W-11 LAMPS (ROOF) AD 40
CLEARANCE
LAMP
IDENTIFICATION
LAMP
IDENTIFICATION
LAMP
IDENTIFICATION
LAMP
CLEARANCE
LAMP
X2 18GY-
X2 18GY-
-L7 18BK/YL L7 18BK/YL -

-L7 18BK/YL L7 18BK/YL •
CLEARANCE AND I D E N T I F I C A T I O N LAMPS

AD 41 (DUAL REAR WHEELS) J938W-11
-L7 16BK- an
•X2 16GY- an:
L E F T FENDER
CLEARANCE
LAMPS
•L7 16BK-
arr-7^f\
X2 16GY- an:
X2
16GY
L7 16BK- am
-X2 16GY- an:
R I G H T FENDER
BLACK CLEARANCE
(REAR-UNDERBOOY LAMPS
LEFT S I D E )
•L7 16BK-
an-y^TN
X2 16GY- an:-
X2
18GY
BLACK
(REAR-UNDERBODY
RIGHT S I D E )
-X2 18GY-
•L7 18BK/YL•
FENDER CLEARANCE LAMPS

J938W-H (DUAL REAR WHEELS) AD 42
BLACK TO DIMMER SWITCH •L4 16VT/WT

(SEE SH 47) -L3 14RD/0R-
TO RIGHT •L60 18TN •

PRINTEO CIRCUIT TO TURN •L60 18TN-
BOARD CONNECTOR SIGNAL SYSTEM
G34 ( S E E SH 6 0 ) (SEE SH 56)
16RD -L61 18LG-
GY
-L61 18LG-
T 0 < L 7 j T | SPLICE 5 L7 18BK/YL-

( S E E SH 47) 21
26
L7
I8BK
YL
L3 14RD/0R L3 14RD/0R -
GAS
L7
18BK • L7 18BK/YL-
YL
LEFT 1
L4 16VT/WT — L 4 16VT/WT-
HEADLAMP
TO
n ,
t r r r VEHICLE SPEED
DIESEL CONTROL SERVO
(SEE SH 37)
Zl 22BK
( D I E S E L ONLY)
i
Zl
LEFT S I D E L61 5<Z1 20BK
MARKER LAMP 18LG
L7
18BK
YL
L7
18BK Zl Zl
YL 18BK 18BK
Zl 18BK-
N8> LEFT
Z12
14BK
TN
HEADLAMP
L61 18LG
GROUND
(LEFT FENDER
SIDE SHIELD)
L7 18BK/YL
L7 18BK/YL
LEFT PARK
AND TURN [LEFT REAR RADIATOR
SIGNAL LAMP YOKE PANEL)
(GAS ENGINE ONLY) TO
SPLICE
( S E E SH 17)(GAS ENGINE ONLY)
( S E E SH 2 3 ) ( D I E S E L ENGINE ONLY)
AD 43 FRONT END L I G H T I N G J938W-11

TO
Zl 14BK
SPLICE
(SEE SH 2 3 )
( D I E S E L ENGINE ONLY)
Zl 14BK
L60
18TN
Zl 18BK-
L60
18TN
TO
RIGHT HEADLAMP SPLICE

GROUND (SEE SH 11)
22 (CENTER DASH (GAS ENGINE ONLY)
PANEL)
-L3 14RD/0R
Zl 22BK
RIGHT
L4 16VT/WT-
HEADLAMP
d
L7
18BK
YL
L3 14RD/0R 3
f TO ENGINE WIRING
Zl 14BK -j ( S E E SH 9)
(GAS ENGINE ONLY)
Zl „ TO BLOWER MOTOR
22BK Zl 14BK A ( S E E SH 6 6 , 6 7 )
(GAS ENGINE ONLY)
L60
18TN
RIGHT S I D E
MARKER LAMP
RIGHT PARK
AND TURN
SIGNAL LAMP
TO -18TN-
UNDERHOOD (RIGHT REAR
LAMP RADIATOR YOKE)
( S E E SH 2 9 ) (GAS ENGINE ONLY)
(GAS ENGINE ONLY)
J938W-11 FRONT END L I G H T I N G AD 44

-G34 16RD/GY-
•BLACK TO DIMMER SWITCH •L4 16VT/WT •

(SEE SH 47) -L3 14RD/0R-
Q>
V© Q <n>
TO RIGHT -L60 18TN
PRINTED CIRCUIT TO TURN •L60 18TN-
BOARD CONNECTOR SIGNAL SYSTEM
-L61 18LG-
5- -L61 18LG-
TO<L7>T| S P L I C E 5 L7 18BK/YL-
21
(SEE SH 47) |
26
L7
18BK
YL
L3 14RD/0R L3 14RD/OR-
GAS
L7
18BK • L7 18BK/YL-
YL
LEFT I
L4 16VT/WT -L4 16VT/WT-
HEADLAMP
k^ n T F . F 1 VEHICLE SPEED
l DIESEL CONTROL SERVO
! (SEE SH 37)
Zl 22BK
D I E S E L ONLY)
i
Zl
LEFT S I D E L61 j | <Z1 20BK
5
MARKER LAMP 18LG I

i
L7
18BK
YL
L7
18BK Zl
YL 18BK
Zl 18BK-
LEFT Z12
HEADLAMP 14BK
L61 18LG TN
GROUND
(LEFT FENDER
SIDE SHIELD)
L7 18BK/YL
L7 18BK/YL TO <Z12>1
LEFT PARK
AND TURN (LEFT REAR RADIATOR SPLICE
SIGNAL LAMP YOKE PANEL) ( S E E SH 1 7 ) ( G A S E N G I N E ONLY) 4
(GAS ENGINE ONLY) ( S E E SH 2 3 ) ( D I E S E L E N G I N E ONLY)
AD 45 FRONT END L I G H T I N G (CANADA) Jsaew-n

TO HEADLAMP.
SWITCH >
v
(SEE SH 47
LEFT PARK
AND TURN
SIGNAL LAMP
TO BLOWER
MOTOR
(SEE SH 6 6 , 6 7 ) SPLICE
(GAS ENGINE) (SEE SH 23)
(DIESEL ENGINE)
RIGHT
HEADLAMP SPLICE
GROUND (SEE SH 11)
(CENTER (GAS ENGINE)
DASH P A N E L ) =
J938W-11 FRONT END L I G H T I N G (CANADA) AD 46
. „ _ fTO F U S I B L E
A3 12RD/WT—5 LINK FUSE #14
j ( S E E SH 4 , 6 )
(3 AMP)
,616 2 0 B K / L B
JG16 2 0 B K / L B
G26 20LB
G26 20LB
IF33 18PK/RD
M2 20YL jD cb B3
L2 14LG
H,P<A
^ BlLH— A3 12RD/WT
TO DAYTIME
L7 18BK/YL RUNNING LAMP,
MODULE f-L20 20LG/WT-
AD 47 H
(Janada oJEJ) headlamp switch J938W-11
P R O V I S I O N FOR
Z l 18BK TACHOMETER
E2 200R (NEAR F U S E
BLOCK)
(OIESEL)
E2 200R
TO
TRANSMISSION V 200R
BLACK
OVERDRIVE
CONTROL
SWITCH
( S E E S H 12) TO TO PCM I I
RADIO (SEE SH 22)
[SEE SH
TO 61,63,65)
TRANSMISSION TO TURN
OVERDRIVE TO HEATED REAR SIGNAL
CONTROL WINDOW S W I T C H FLASHER
SWITCH ( S E E SH 39) (SEE SH 56)
( S E E SH 1 2 ) G A S ( S P O R T U T I L I T Y ONLY)
( S E E SH M ) D I E S E L TO R I G H T
PRINTED
C I R C U I T BOARD
CONNECTOR
BLACK
(SEE SH 60)
Zl BLACK
18BK
-Zl 22BK -J M O
TO M E S S A G E
CENTER
(DIESEL)
(SEE SH 57)
TO S E A T GROUND
X BELT SWITCH
^ ( S E E SH 7 7 , 7 6 )
A / C AND
f T O K E Y - I N LAMP HEATER
> ( S E E SH 49) SWITCH
LAMP
„ TO C H A S S I S
{ WIRING
^ ( S E E SH 4 1 , 7 9 )
TO I N T E R M I T T E N T
WIPER MODULE
TO CARGO LAMP
€
(SEE SH 5 3 )
j SWITCH
( S E E SH 49)
TO C I G A R
LIGHTER
Zl 12BK ( S E E SH 5 2 )
TO A / C AND
HEATER W I R I N G
( S E E SH 6 7 , 6 9 )
TO GLOVE
BOX LAMP
( S E E SH 5 2 )
TO HEATEO
TO B R A K E TO MAP LAMP TO POWER DOOR L O C K S REAR WINDOW
SWITCH ( S E E AND R E A D I N G ( S E E SH 73) ( S E E SH 39)
SH 3 2 . 3 4 , ( S E E SH 49) TO POWER M I R R O R S SPORT U T I L I T Y
36,38) ( S E E SH 7 5 ) ONLY)
TO POWER WINDOWS
( S E E SH 71)
HEADLAMP SWITCH CONTROLLED

J938W-U INTERIOR LIGHTING AD 48
TO COMBINED
BUZZER
( S E E SH 7 7 , 7 8 )
L30 18BR/YL
Z l 20BK
Ml 18PK
BLUE
AD 49 MAP LAMP AND CARGO LAMP msu-n

T 0 < Z Q > 1 ll S P L I C E DOME

CARGO LAMP
(SEE SH 77.78) LAMPS
18BK 18BK
Zl
18BK
BLACK
DOME NEAR LAMP)
LAMP
BLACK
CARGO
LAMP
r©i V
L6
180R
Y
L6
180R
(NEAR LAMP)
VT VT
L30 M2 Ml
180R 18BK 18BK
VT YL PK
M2 18BK/YL-
fcLJSL (LEFT S I D E
OF S T E E R I N G
Ml 18BK/PK
COLUMN)
BLACK BLACK
STANDARD \ / CLUB CAB

CAB \
TO UNDERHOOD
Ml 18PK 4 LAMP
>
( S E E SH 29)
•BLACK
TO BODY W I R I N G
M2 20YL- M2 20YL — — ^ (SPORT U T I L I T Y ONLY)
( S E E SH 5 1 )
Mi 18PK
L30 18BR/YL
J938W-11 DOME LAMP AND CARGO LAMP AD 50

BW - 92 WIRING DIAGRAMS •
TO
BATTERY F E E D A4 12BK/RD- -Ml 20PK-
( S E E SH 3.5K
FUSE # 1 5
(10 AMPS)
BLACK
TO M E S S A G E (SEE SH 49)
CENTER 4fO
REAR DOME LAMP ( S E E SH 5 8 ) 5 0 G78 20TN/BK
BLACK-
(UNDER B U L K H E A D J
CONNECTOR)
GREEN
(LEFT 'B' PILLAR)
M2 18BK/YL
M2 18BK/YL
Ml 18PK/PK
M2 G78
18BK 18TN
YL BK
TO UNDERHOOD
LAMP
( S E E SH 2 9 )
D I O D E AND
MOLD A S S E M B L Y
(LEFT ' C PILLAR)
FRONT D O M E / BOOY
R E A D I N G LAMP GROUND
( L E F T REAR
' C PILLAR)
BLACK
BLACK
C3 M4 18TN/BK•
(LEFT
PILLAR)
' C
3 ^ - @ Z > —Zl 12BK —
LIFTGATE
AJAR S W I T C H
(LIFTGATE LATCH)
L I F T G A T E AJAR WARNING S Y S T E M AND REAR

AD 51 DOME LAMPS ( S P O R T U T I L I T Y ONLY) JSMIMI
• WIRING DIAGRAMS SW - 93
TO <
BATTERY FEED V A4 12BK/RD
(SEE SH 3 . 5 )
GLOVE
BOX LAMP
CIGAR
AND
LIGHTER
SWITCH
nU nU tn t
1
(CENTER OF
INSTRUMENT
PANEL)
BLACK
TO I G N I T I O N
SWITCH
(SEE SH 10)
TO HEADLAMP
SWITCH
( S E E SH 47)
C I G A R L I G H T E R , A S H R E C E I V E R LAMP
J938W-11 AND GLOVE BOX LAMP AD 52
-V10 20BR- Zl 20BK ' TO BLOWER MOTOR

-yy (SEE SH 6 6 . 6 7 , 6 9 )
V10 20BR WINDSHIELD WASHER

Zl 20BK PUMP MOTOR
(UNDER WINDSHIELD
WASHER RESERVOIR)
29
V17 18DG/YL•
•V10 18BR- •VIO 18BR-

-V8 18VT-
•V10 20BR- V9 18WT/BK-
•V7 18DG/WT-
3
Z2 18BK/LG-
)>—V6 18DB- — V6 18DB —
)>—V8 18VT-
INTERMITTENT
WIPER SWITCH
"ON STEERING
COLUMN)
» — V9 18WT/BK
)X"V3 18BR/WT •V3 18BR/WT-
»—V4 18RD/YL
-V4 18RD/YL-
))—V7 18DG/WT •
' 18DG/YL
STEERING COLUMN
CONNECTOR
(SEE SH 87)
Zl 12BK- -JTO <Jlj2
SPLICE
V3 18BR/WT- PANEL GROUND (SEE SH 48)
(RIGHT OF
— STEERING COLUMN)
AD 53 I N T E R M I T T E N T WIPER SYSTEM J938W-11

•NOT USED ON 2 S P E E D
WIPER S Y S T E M
V8 18VT-
-V17 18DG/YL
V7 18DG/WT-
12 18BK/LG- -12 18BK/LG
-V5 18DG
V6 18DB-
-V10 18BR
V9 18WT/BK -
I 5,_ 1
I N T E R M I T T E N T WIPER (MOUNTED ON BRACKET

V17 18DG/YL• 7 CONTROL U N I T UNDER S T E E R I N G
TO IGNITION
2 8 1 6 3 4 5 COLUMN)
SWITCH
( S E E SH 10)
-V10 18BR
- V 8 18VT
•V9 18WT/BK
•V7 18DG/WT
•12 18BK/LG
•V6 18DB
V3 18BR/WT
¥4 18RD/YL
INTERMITTENT WINDSHIELD
W I P E R MOTOR
( I N PLENUM-LEFT S I D E )
t=C4—V3 18BR/WT PARK

1— K)=t~V6 18DB SWITCH
NC4—V5 1 8 D G / Y L
KM-V4 18RD/YL
J938W-11 I N T E R M I T T E N T WIPER SYSTEM AD 54

WINDSHIELD WIPER SWITCH (F0R__CONNECTOR-SEE SH 88)

LO
w
W PARK ft _
HI TV HI
TO A / C
8LOWER MOTOR
( S E E SH 6 6 .
67.69)
AD 55 W I N D S H I E L D WIPER SYSTEM J938W-11

A31 1 4 B K / W T — ( TO IGNITION A15 16PK

SWITCH
( S E E SH 10)
A15 23 TO CHARGING
16PK SYSTEM
TO REAR WHEEL
( S E E SH 3 . 5 )
ANTI-LOCK
FUSE # 9 (RWAL) MODULE
( 2 0 AMP) ( S E E SH 31 , 3 3 )
FUSE # 1 3
L5 14RD- ( 2 0 AMP)
HAZARD WARNING
FLASHER
MOUNTED ON
TO TACHOMETER RELAY BANK)
_T PROVISION SEE SH 82)
> ( S E E SH 48)
L19 18PK
TURN S I G N A L
FLASHER
(MOUNTED ON TO BRAKE
RELAY B A N K ) SWITCH
( S E E SH 8 2 ) S E E SH 3 6 , 3 8 )
L50
18WT
TN
L19 18PK
TO REAR WHEEL
< ANTI-LOCK
•L50 18WT/TN •L50 18WT/TN• i (RWAL) MODULE
GRAY ( S E E SH 3 2 . 3 4 )
CL50
,000/
4 5 6
HAZARD F L A S H E R CONNECTOR TO L E F T P R I N T E D
SWITCH ( S E E SH 8 7 , 8 8 ) C I R C U I T BOARD
L61 CONNECTOR
18LG ( S E E SH 60)
-L61 1 8 L G - 5
L61 18LG LSI 18LG - £
TO
21 FRONT END
22
LIGHTING
11 ( S E E SH
43.45)
»-L6G 18TN- L60 18TN—5
•L60 18TN—^
L60
TURN S I G N A L 18TN TO R I G H T
SWITCH PRINTED CIRCUIT
(ON S T E E R I N G COLUMN) BOARD CONNECTOR
(SEE SH 60)
L63 18DG/RD
TO
REAR L I G H T I N G BLACK
( S E E SH 79)
L62 18BR/RD
d938w-n STOP/TURN AND HAZARD FLASHER SYSTEMS AD 56

G85 20TN/0R WATER-IN-FUEL G86 20DG/WT WAIT-TO-START SWITCH
(SEE SH 23) ( S E E SH 23)
G9 20GY/BK REAR WHEEL B102 180R ANTI-LOCK MODULE

ANTI-LOCK BRAKE MODULE (SEE SH 33)
(SEE SH 33)
G9 20GY/BK PARK BRAKE WARNING SWITCH G5 20DB/WT IGNITION-12V FEED
(SEE SH 33 (SEE SH 58)
G14 20PK/BK TO I G N I T I O N SWITCH GROUND Zl 22BK GROUND - < Z 1 > 1 | S P L I C E

BULB TEST) SEE SH 48)
(SEE SH 10)
Gil 20WT/BK BRAKE WARNING SWITCH G40 2 0 L B / B K FUEL TANK

AND VACUUM SWITCH LOW FUEL SWITCH
G i l 20WT/BK REAR WHEEL

ANTI-LOCK BRAKE MODULE
(SEE SH 33)
AD 57 MESSAGE CENTER ( D I E S E L ) J938W-11

DIODE-
BRAKE LAMP
GATE OPEN LAMP
SERVICE REMINDER
INDICATOR LAMP
REAR WHEEL
ANT1-LOCK LAMP
TO
TRANSMISSION
O V E R D R I V E CONTROL
S W I T C H ( D I E S E L ONLY
( S E E S H 14)
I TO FOUR
I WHEEL D R I V E
I I N D I C A T O R LAMP
I ( S E E SH 13)
Gil 20WT/BK TO IGNITION S W I T C H GROUND
S E E SH 10)
G5
20DB Gil 20WT/BK~ TO REAR
WT WHEEL A N T I - L O C K
MODULE
B 1 0 2 180R ( S E E SH 3 1 )
BLACK
G24 2 2 G Y / P K S E R V I C E REMINDER
I N D I C A T O R ( S E E SH 19)
i , G78 2 0 T N / B K GATE OPEN LAMP

( S E E SH 5 1 )
G9 2 0 G Y / B K TO REAR WHEEL ANTI-LOCK

-BLACK TO MODULE ( S E E SH 3 1 )
TRANSMISSION G9 2 0 G Y / B K TO B R A K E LAMP WARNING
G5 20DB/WT OVERDRIVE SWITCH S W I T C H ( S E E SH 3 1 )
( S E E S H 12)
( G A S ONLY)
GRAY
TO L E F T
PRINTED CIRCUIT
BOARD CONNECTOR
TO R I G H T ( S E E SH 60)
G5 20DB/WT
PRINTED CIRCUIT
BOARD CONNECTOR
( S E E SH 6 0 )
TO
COMBINED
BUZZER
TO IGNITION
( S E E SH 7 7 , 7 8 )
A21 14DB- SWITCH
( S E E S H 10)
FUSE # 2
( 5 AMP)
J938W-11 MESSAGE CENTER ( G A S ) AD 58

ILLUMINATION LAMP
E N G I N E COOLANT
TEMPERATURE GAUGE
ILLUMINATION L A M P
VOLTMETER
LEFT TURN SIGNAL LAMP
SEAT BELT WARNING L A M P
ILLUMINATION L A M P
MALFUNCTION
INDICATOR
LAMP
V E H I C L E S P E E D SENSOR
( E L E C T R I C SPEEDOMETER)
NOT USED
ILLUMINATION L A M P HIGH-BEAM
I N D I C A T O R LAMP
LOW E N G I N E
OIL PRESSURE
LAMP
RIGHT TURN SIGNAL L A M P
ILLUMINATION LAMP
LOW E N G I N E
OIL PRESSURE
GAUGE
FUEL GAUGE
ILLUMINATION LAMP
AD 59 C L U S T E R - P R I N T E D C I R C U I T BOARD J938W-11
GRAY
G20 2 0 V T / Y L
E N G I N E COOLANT
TEMPERATURE GAUGE S E N D I N G U N I T G13 2 0 D B / R D S E A T B E L T WARNING LAMP SWITCH
( S E E SH 2 7 , 2 8 ) ( S E E SH 7 7 , 7 8 )
L61 18LG LEFT TURN S I G N A L LAMP

( S E E SH 56)
G3 2 0 B K / P K M A L F U N C T I O N INDICATOR LAMP)
( S E E SH 58)
G7 2 0 W T / 0 R V E H I C L E SPEED SENSOR G5 20DB/WT I G N I T I O N FEED-12 VOLTS

( S E E SH 1 9 , 2 5 ) ( S E E SH 58)
LEFT CONNECTOR
G6 20GY E N G I N E O I L P R E S S U R E LAMP SWITCH

( S E E SH 2 7 , 2 8 )
BLACK
G5 2 0 D B / W T I G N I T I O N FEED-12 VOLTS
( S E E SH 5 8 , 7 7 , 7 8 )
E2 200R I L L U M I N A T I O N LAMP FEED
( S E E SH 48)
G34 1 6 R D / G Y H I G H - B E A M INDICATOR LAMP

Zl 20BK GROUND ( S E E SH 4 3 , 4 5 )
(SEE SH 48)
L60 18TN R I G H T TURN S I G N A L LAMP

G4 20DB FUEL GAUGE S E N D I N G U N I T ( S E E SH 5 6 )
( S E E SH 7 7 , 7 8 )
G60 2 0 G Y / Y L E N G I N E O I L P R E S S U R E GUAGE
SENDING UNIT
( S E E SH 2 7 , 2 8 )
RIGHT CONNECTOR
J938w-ii P R I N T E D C I R C U I T BOARD CONNECTORS AD 60

•BLACK
TO
HEADLAMP
SWITCH
3
[ S E E SH 47
TO IGNITION
SWITCH
( S E E SH 10)
T
A31
14BK
WT
GRAY-
FUSE # 8
BEHIND
s^ (10 AMP)
RADIO)
qoc •X56 18DB/RD
N X55 18BR/RD
TO •X58 18DB/0R
BATTEF Y
FEED
( S E E SH 3 , 5
X57 18BR/LB
-X54 18VT —
- X53 18DG —
-X52 18DB/WT -
-X51 18BR/YL
SEE
•X12 20RD/WT—|
Ml 20PK
[•••••• aTl
BLACK FOR 2 S P E A K E R S
GRAY
WIRING
( S E E SH 6 5 )
STEREO RADIO
AD 61 STEREO R A D I O - 4 SPEAKERS J938W-11

LEFT X51 18BR/YL- X52 18DB/WT RIGHT

REAR REAR
SPEAKER X57 18BR/LB- -X58 18DB/0R SPEAKER
(BELOW BULKHEAD Lb dl GREEN

CONNECTOR)
X56 18DB/RD (COWL T O P -

BLACK- RIGHT S I D E )
X55 18BR/RD
-X58 18DB/0R
X56 18DB/RD
X57 18BR/LB
X54 18VT —
•X53 18DG —
X52 18DB/WT
X51 18BR/YL-
-X53 18DG-
X55
18BR
RD
R I G H T FRONT
LEFT FRONT
DOOR S P E A K E R
DOOR S P E A K E R
J938W-11 STEREO R A D I O - 4 S P E A K E R S AD 62
BW - 104 WIRING DIAGRAMS •
BLACK
TO
HEADLAMP
SWITCH
( S E E SH 47)
TO IGNITION
SWITCH
( S E E SH 10)
T
A31
14BK
WT
GRAY-
FUSE # 8
(BEHIND
- (10 AMP)
RADIO)
qoc | T 7 X56 18DB/RD
X55 18BR/RD
FUSE # 1 4
TO ( 3 AMP) •X58 18DB/0R
BATTERY
FEED
( S E E SH 3 , 5
•X57 18BR/LB •
-X54 18VT —
- X53 18DG —
-X52 18DB/WT -
-X51 18BR/YL
(SEE SH 48) \
E2
200R
— X12 20RD/WT•
Ml 20PK
• • • • • • • [••••• ••T
BLACK FOR 2 S P E A K E R S
GRAY
WIRING
( S E E SH 6 5 )
STEREO RADIO
STEREO R A D I O - 4 S P E A K E R S
AD 63 (SPORT U T I L I T Y ) J938W-11
+
+
LEFT
REAR
SPEAKER
P 3
r- 9 RIGHT
REAR
SPEAKER
+ +
-X58 18DB/0R
•X52 18DB/WT
-X57 18BR/LB
(LEFT 'B' PILLAR) GREEN

X56 18DB/RD
•X55 18BR/RD
X52 18DB/WT
•X58 18DB/0R X58 18DB/0R •
X57 18BR/LB
• X54 18VT
• X53 18DG
X52 18DB/WT
X51 18BR/YL
R I G H T FRONT
L E F T FRONT
DOOR S P E A K E R
DOOR S P E A K E R
STEREO R A D I O - 4 S P E A K E R S
J938W-11 (SPORT U T I L I T Y ) AD 64
(SEE SH 49)
STEREO RADIO
AD 65 STEREO RADIO-DUAL SPEAKERS Jaasw-

TO
IGNITION CI 12DG
c
SWITCH Y A22 12BK/0R

( S E E S H 10)
FUSE # 1 1
( 3 0 AMP)
HEATER BLOWER
MOTOR
(RIGHT S I D E
DASH P A N E L )
TO
WINDSHIELD „
WASHER V SPLICE SPLICE
MOTOR ( S E E SH 2 3 ) ( S E E SH 4 4 , 4 6 )
( S E E SH 5 3 , 5 5 ) ( D I E S E L ONLY) ( G A S ONLY)
J938W-11 HEATER AD 66
FUSE # 1 1
NATURAL- (30 AMP)
C5 16LG
TO IGNITION „
SWITCH S
C6 14LB--|7][7}-C3 12WT/DG (SEE SH 10 v
C7 12DG—[5] [2]— C4 12TN
HEATER BLOWER
MOTOR
(RIGHT SIDE
DASH P A N E L ) SPLICE
(SEE SH 44,46)
TO WASHER
MOTOR
( S E E SH 5 3 , 5 5
A / C AND HEATER
AD 67 GAS E N G I N E S J938W-11
TO ENGINE
AIR CONDITIONING STARTER C26 14BR-
COMPRESSOR RELAY
(RIGHT SIDE (SEE SH 9) A21 14DB-
FORWARD OF
ENGINE)
I
I
I ca h d b / b k ^ £ 3 E 5 | H
!
C9 C2 Zl
18BK C13 20DB/0R — J
18BK 18BK
^MANUAL TRANS
ONLY \ TO POWERTRAIN
\ CONTROL MODULE I I
\ CAVITY 27,34
BLACK Zl 14BK- (SEE SH 18)
(LEFT OF TO FUSIBLE
COMPRESSOR) LINK
(SEE SH 4)
:-4ENG]~ 2
Zl
BI-DIRECTIONAL 14BK
ZENER DIODE
TO 34 WIDE OPEN
TO IGNITION EMCC RELAY :-[ENG|~ THROTTLE
SWITCH (SEE SH 11) CUTOUT
(SEE SH 10) RELAY
(LEFT FENDER
T 0 < Z 1 > 4 | SPLICE SIDE S H I E L D '
(SEE SH 44.46)
-C3 14DB/BK
A21 14DB
A21 14DB
TO DAYTIME
r
I—A21 14DB A21 14DB — ) RUNNING LIGHTS

MODULE
(SEE SH 46)
TO<A21> SPLICE C21 18DB/0R ~<f
(SEE SH 16)
A/C LOW PROBE
PRESSURE SWITCH = £ 3 :
(RIGHT FENDER
S I D E SHIELD) (RIGHT A/C
SIDE CYCLING
SHIELD) SWITCH
C2 18DB/WT-
•A21 14DB A21 14DB-
C20 18BR-
C21 18DB/0R C20 18BR-
A / C AND H E A T E R -
J938W-11 GAS E N G I N E S AD 68
FUSE #11
NATURAL 30 AMP
"^V[T[V-C5 16LG TO IGNITION „
SWITCH £
C6 14LB-{T][T}---C3 12WT/DG ( S E E SH 10)
C7 12DG—[¥] [2]— C4 12TN
HEATER BLOWER
MOTOR
(RIGHT S I D E
DASH P A N E L ) SPLICE
( S E E SH 23)
TO WASHER
MOTOR
( S E E SH 5 3 . 5 5 )
A / C AND H E A T E R -
AD 69 D I E S E L ENGINES J938W-11
AIR CONDITIONING
i
COMPRESSOR C26 14BR-
(RIGHT S I D E A21 14DB-
FORWARD OF
ENGINE)
C 3 i4DB/BK-ffi£^]QLJ
I86K 18BK C13 20DB/0R-
\ TO POWERTRAIN
\ CONTROL MODULE I I
(LEFT OF \ CAVITY 27,34
COMPRESSOR) \ (SEE SH 26)
TO FUSIBLE „
LINK $- r
(SEE SH 6) \
\
\
T C20
18BR
Zl BI-DIRECTIONAL
18BK ZENER DIODE
WIDE OPEN
THROTTLE
CUTOUT
RELAY
(LEFT FENDER
S I D E SHIELD)
(RIGHT FENDER
SIDE SHIELD)
C13 14DB/BK
Zl
14BK
TO C21 18DB/0R SPLICE

(SEE SH 21)
SPLICE A/C LOW PROBE

TO<A21> SPLICE
(SEE SH 23) PRESSURE SWITCH
(SEE SH 23) (RIGHT FENDER
SIDE SHIELD) (RIGHT A/C
SIDE CYCLING
SHIELD) SWITCH
C2 18DB/0R-
A21 14DB A21 14DB-
C20 18BR-
C20 18BR-
A / C AND HEATER-
J938W-H D I E S E L ENGINES AD 70
LEFT DOOR
•21 14BK
B + B-
WINDOW AND MOVEMENT
POLARITY POLARITY
LB WT LEFT FRONT UP Qll 14LB Q16 14BR/WT
WT LB LEFT FRONT DOWN Q21 14WT- A Aflk Q26 14VT/WT
4 W ^ V
BR/WT VT/WT RIGHT FRONT UP ] 4*\ 6
VT/WT BR/WT RIGHT FRONT DOWN

• F21 14TN
TN BK FEED AND GROUND
UP CONNECTOR GAGE LEFT FRONT DOOR
FORWARD- • MASTER SWITCH
TO IGNITION „ 11
SWITCH 12BK/0R—~
(SEE SH 10)
14VT—i
1
DN
)
UP
«
14DG-
LEFT DOOR
WINDOW LIFT MOTOR
-» -026 14VT/WT •
DOWN 7 XX
LEFT DOOR
WINDOW SWITCH
AD 71 POWER WINDOW SYSTEM J938W-11

RIGHT DOOR RED

B + B~ FORWARD IN CAR
WINDOW MOVEMENT AND SWITCH
POLARITY POLARITY
VT BR DOWN FROM DOOR SWITCH 1
Q26A 14VT- -Q16 14BR/WT
BR VT UP FROM DOOR SWITCH
VT/WT BR/WT DOWN FROM MASTER SWITCH .• -F21 12TN
-Q16A 14BR UP
BR/WT VT/WT UP FROM MASTER SWITCH Q26 14VT/WT-
TN FEED
RIGHT FRONT WINDOW LIFT SWITCH CONNECTOR
•14VT
1 RED
1 (AT MOTOR)
DN
)
Q26A 14VT
L — i•14DG
UP SWITCH
(VIEW FROM
RIGHT DOOR TERMINAL END)
WINDOW LIFT MOTOR
•Q16A 14BR
Q26 14VT/WT
016 14BR/WT
F21 12TN
BLACK
OVER HEATER
OR A/C UNIT)
J938W-11 POWER WINDOW SYSTEM AD 72

TO <g> SPLICE
(SEE SH 47)
FUSE # 6
(20 AMP)
A3 12RD/WT
F35 16RD 3 Zl 12BK- -5 TO <Z1^3]SPLICE
•BLACK (SEE SH 48)
F35 16R0 G= (BEHIND

RADIO)
TO POWER „
WINDOWS 5 Zl 16BK—. v 0:
( S E E SH 7 1 )
LEFT DOOR S W I T C H CONNECTOR
10<Z1
Zl Zl r-GRAY
16BK 16BK P37 160R/VT
Zl 16BK
(LOCK)
TO POWER F35 16RD
Ml
F35 i LK MIRROR S W I T C H (FEED)
16RD ( S E E SH 7 5 )
Zl 16BK P36 1 6 P K / V T
(UNLOCK)
UNLK FORWARD
' L E F T FRONT UP
DOOR S W I T C H TERMINAL END
( V I E W FROM
TERMINAL END)
•P36 16PK/VT
1
1 ^ — F 3 5 16RD •P35 160R/VT
•P34 16PK/BK
P33 160R/BK
P36
—F35 16RD 16PK
VT
R I G H T DOOR
COWL TOP
DISCONNECT
LEFT FRONT
(OVER HEATER
DOOR MOTOR
OR A / C U N I T )
F35 16RD-
P36 16PK/VT•
P35 160R/VT
P33 160R/BK
P34 16PK/BK
AD 73 POWER DOOR LOCKS J938W-11

RIGHT DOOR S W I T C H CONNECTOR
-BLUE
P33 160R/BK
(LOCK) P36 16PK/VT
P35 160R/VT
] —E • F35 16RD
P34 1BPK/BK
t
(UNLOCK)
FORWARD
UP
TERMINAL END
y-—• • •—'
RIGHT F R O N T DOOR
SWITCH /
( V I E W FROM /
TERMINAL END) /
B L A C K — ^ fTOPl /
VLK
P36 P34 P35

F35
16PK 16PK 160R
16RD
VT BK VT
R I G H T FRONT
DOOR MOTOR
L K
^ LK X — \ U N
F35 16RD-
t o
P34
16PK
P36 16PK/VT -J BK
P35 160R/VT-
P33 160R/BK- P33 160R/BK-
P34 16PK/BK P34 16PK/BK
J938W-11 POWER DOOR L O C K S AD 74

BLACK
P75 18DB/WT
P71 18YL
P73 18YL/PK
P74 18DB
Zl 12BK—' P72 18YL/BK-
Ml 18PK - P70 18WT -
BLACK
(RIGHT OF
STEERING
COLUMN)
Zl
12BK Ml 20PK
Ml
18PK
S23 Sll
18DB 18WT
S13
18YL HORIZONTAL
Sll
18DG
.Ml
LT RT
P74 20DB/WT•
(SEE SH 49)
P72 20YL-
UP DN Ml Zl
20PK 12BK
VERTICAL
TO LEFT MIRROR
BATTERY FEED MOTORS
(SEE SH 3.5) FUSE #15
(10 AMP)
T •A4 14BK/RD TO <ZJS] SPLICE
(SEE SH 48)
AD 75 POWER MIRRORS J938W-11

GRAY
P74 18DB
P70 18WT
P72 18YL/8K
S24 S12
18DB 18WT
COWL RIGHT TOP

HORIZONTAL
BLACK S12
180G
lT RT
o V
UP —"' ON
VERTICAL
RIGHT MIRROR
MOTORS
POWER MIRROR SWITCH
—up
—r
Ii
• L H # is A # # G M
r— # C
Zl # K E # # P J #
DN UP LT - RT
20BK
IIS II T O P # R
LEFT RIGHT
MIRROR MIRROR
•P71 20YL/BK-
— P 7 3 20WT —
P70 20WT/BK•
P75 20DB
P74 20DB/WT
P72 20YL-
UP(A)
POWER MIRROR SWITCH FUNCTION
LEFT RIGHT
MIRROR MIRROR
LEVER MIRROR
POSITION CIRCUIT
DIRECTION
LT(D) RT(B)
A SK.TL.PB UP
B NG.VP.RC RIGHT
C SD.TE.PH DOWN
DN(C)
D NA.VM.RJ LEFT
V I E W OF S W I T C H INDEXING
FROM F R O N T OF SWITCH
J938W-11 POWER M I R R O R S AD 76
SPLICE
F32 18PK/DB
G26 20LB
F32 18PK/DB
TO IGNITION SPLICE
SWITCH (SEE SH 47)
(SEE SH 10 IcQa c£h c O ,
p • • n i
^ cjâ cQa cBn\
G10 20LG/RD G5 20DB/WT
G10 20LG/RD G13 20DB/RD
Zl 20BK-
HEADLAMP K E Y - I N
SEAT BELT
COMBINED BUZZER TO STOP
(RIGHT OF STEERING COLUMN) j LAMP SWITCH
(SEE SH 3 4 , 3 7 )
TO HEADLAMP
{ SWITCH
(SEE SH 4 7 . 4 9 )
TO RIGHT
PRINTED CIRCUIT
BOARD CONNECTOR TO LEFT
(SEE SH 6 0 ) PRINTED
BLACK CIRCUIT
BOARD
G5 20DB/WT G5 20DB/WT- CONNECTOR
(SEE SH 6 0 )
G10
Zl •G13 20DB/RD
20LG
(SEE SH 5 8 ) RD 20BK
TO MESSAGE BLACK BLACK
CENTER
(DIESEL)
(SEE SH 5 7 ) -G10 18LG/RD
(LEFT BASE OF
STEERING COLUMN
G40 20LB/BK
3 GROUND SEAT BELT
n / (LEFT S I D E SPLICE
SWITCH
DD ( I N SEAT
era DP
UNDER I / P ) [SEE SH 48)
BELT BUCKLE)
DD G4 18DB/YL-
Zl 16BK
•c TO CARGO LAMP
c
QC
I
DD obco }
b
Zl 18BK—$ [SEE SH 5 0 )
at DD Zl
16GY A61
TZ7 BK 16DG
BK ((ppoc?o)) T0
5 <§B] GROUND
SPLICE
(SEE SH 4 8 )
FUEL TANK LEVEL GAUGE

SENDING UNIT WITH
TO < Z 1 > 7 1 GROUND \ LOW

LAMP
FUEL
SWITCH
SPLICE 5— 21 16BK-HT
( S E E SH 7 9 )
D I E S E L F U E L TANK GAUGE
AND SEAT B E L T WARNING SYSTEM
AD 77 J938W-11
TO <A21> 1 | S P L I C E TO
F32 18PK/DB—,
(SEE SH 68)
r
G26 20LB
F32 18PK/DB
TO IGNITION SPLICE
SWITCH A21 ( S E E SH 4 7 )
( S E E SH 10) HOB lc£L
~1
iCZD • • • FUSE # 5
t 1
—A21 HOB
47
G10
G10
20 LG/RD-
20 LG/RD-
G5
G13
20DB/WT
20DB/RD
[20 AMP)
Zl 20BK-
HEADLAMP K E Y - I N
SEAT BELT \ F32
COMBINED BUZZER \ 18PK TO STOP
R I G H T OF S T E E R I N G COLUMN \ DB -\ LAMP S W I T C H
F32 ( S E E SH 3 2 , 3 5 )
18PK
DB < TO HEADLAMP
S SWITCH
( S E E SH 4 7 )
TO R I G H T
PRINTED CIRCUIT G26 GRAY
BOARD CONNECTOR 20LB
TO LEFT
( S E E SH 6 0 ) PRINTED
BLACK CIRCUIT
BOARD
G5 20DB/WT G5 20DB/WT- CONNECTOR
( S E E SH 6 0 )
G10
Zl •G13 20DB/RD
20LG
20BK
(SEE SH 58)
G10
, TO FUEL PUMP (AT SEAT ^ 18LG
Zl
Hi41 16DG/BK-A MOTOR F E E D Zl ( L E F T B A S E OF 8BK
B E L T
> 18BK
( S E E SH 16) 18BK S T E E R I N G COLUMN) ^
I , 18BK
TO < Z 1 > 3 GROUND

^ B L U E SEAT B E L T
r ( L E F T S I D E UNDER SPLICE SWITCH
INSTR/PANEL) [ S E E SH 48) ( I N SEAT
BELT B U C K L E )
Z1>11
G4 18DB/YL-
Zl 16BK Zl
18BK 7 1 . f
1 f t R TO CARGO LAMP
-Zl 18BK—^ ( S E E SH 5 0 )
XL
4o o o d
Zl
16GY A61
BK 16DG )c
BK it JJ -5 TO < Z ^ T ] GROUND
F. SPLICE
( S E E SH 48)
2 0
TO <Z1>7|GROUND \ z^ FUEL TANK MODULE
SPLICE 5~Zl 16BK -HT
( S E E SH 79)
E L E C T R O N I C FUEL I N J E C T I O N TANK GAUGE

J938W-11 AND S E A T BELT WARNING SYSTEM AD 78
TO TRANSMISSION
WIRING r
( S E E SH 7 D I E S E L ) J
( S E E SH 9 GAS)
BLUE
(LEFT S I D E UNDER I/P)
TO<L7^T] SPLICE
( S E E SH 47) S
TO TURN
SIGNAL SWITCH
( S E E SH 56)
T0<Z1>3 [SPLICE
( S E E SH 48)
LEFT
TAIL.
STOP i
TURN X2
SIGNAL 18GY
LAMP
SPORT
UTILITY
LEFT
BACK-UP
LAMP
LEFT
TAIL.
STOP I
TURN
SIGNAL
CAB I LAMP -
CHASSIS
LEFT
BACK-UP
LAMP
LEFT
TAIL,
STOP I
TURN Y 9
SIGNAL ,ppv
1 8 Y
LAMP f
SWEPT
LINE
BOX
TO < Z 1 > 8 1 S P L I C E
LEFT
BACK-UP ( S E E SH 7 7 . 7 8 )
LAMP B2 18VT/BK
AD 79 REAR LIGHTING J938W-11

LICENSE
LAMP
H4 18BK-
WITHOUT
BUMPER
LICENSE
H4 18BK LAMP
( L E F T REAR /
FRAME R A I L ) /
L7 18BK/YL- STEP
BLACK ' BUMPER
LICENSE
X2 18GY H4 18BK— LAMP
18BK/YL
L7 18BK/YL-
BLACK-
(CENTER OF REAR BUMPER)
LICENSE
-L7 18BK LAMP
^ STANDARD
BUMPER
BLACK
BLACK
RIGHT
X2 18GY TAIL.
STOP I
X2 TURN
18GY S I G N A L
LAMP
SPORT
UTILITY
L7
18BK RIGHT
YL BACK-UP
LAMP
RIGHT
TAIL.
STOP I
1 TURN
Zl 18BK—
SIGNAL
LAMP CAB I
CHASSIS
L62 18BR/RD•
RIGHT
BACK-UP
— Zl 18BK —
LAMP
RIGHT
TAIL.
STOP I
LI 18VT/BK-
TURN
SIGNAL
LAMP
SWEPT
LINE
BOX
RIGHT
BACK-UP
B2 18VT/BK- LAMP
J938W-11 REAR LIGHTING AD 80

-L7 18BK/YL- RIGHT

TAIL,STOP &
Zl 18BK- TURN SIGNAL
-D7 18BK/LG— LAMP
PART OF
C H A S S I S WIRING f ~ L 7
(SEE SH 80)
18BK/YL• 1 OO X2 18GY-
5~L62 18BR/RD
X2 18GY- X2 18GY
5—L1 18VT/BK- RIGHT
BACK-UP
LAMP
B2 18VT/BK-
J2-SL
OOh
OQ
•L7 18BK/YL-
L62 L2
18BR 18BR
R0 YL
LI
18VT
BK Zl
Zl 18BK
18BK
- LI 1 8 B K — BACK-UP LAMPS
- Zl 18WT— BODY GROUND
NOTE-INSERT TRAILER 62 18DG — RIGHT STOP ft TURN

TOW WIRING BETWEEN SIGNAL LAMP
C H A S S I S I TAIL LAMP
WIRING AS SHOWN, AND •r 7 .
1 P Y LEFT STOP ft TURN
MAKE CONNECTION TO TRAILER L63 18YL SIGNAL LAMP
CONNECTOR AS REQUIRED. TAIL I
L7 18BR- •RUNNING LAMPS
WIRE ENDS SEALED AND

UNTERMINATED, PROVISIONS
FOR TRAILER CONNECTOR
LEFT
T A I L , S T O P ft
TURN SIGNAL L7 18BK/YL—5
LAMP
Zl 1 8 B K — ^ PART OF
L I 18VT/BK-J C H A S S I S WIRING
(SEE SH 79)
L63 18DG/RD-5
LEFT
BACK-UP
LAMP B2 18VT/BK
AD 81 T R A I L E R TOW W I R I N G J938W-11
El 18TN E2 200R
F33 18PK/RD F30 16RD/TN
F33 18PK/RD A4 12BK/RD
BLUE DOT A4 12BK/RD
Ml 20PK
X12 20RD/WT
TURN SIGNAL L6 18RD/BK
FLASHER L5 18RD
L5 18RD L5 14RD
(SEE SH 56) _ L5 18RD
V34 20WT/RD V34 20WT/RD
GREEN DOT
F21 12TN
L19 18PK HAZARD
HAZARD FLASHER
A21 14DB L9 18BK/WT (SEE SH 56)
F20 18WT
F20 18WT X3 20BK/RD HORN
G5 20DB/WT F33 18PK/RD RELAY
A3 12RD/WT X2 18DG/RD_ (SEE SH 30)
F35 16RD
A15 16PK
A22 12BK/0R
F32 18PK/DB
V6 18DB
A31 14BK/WT
V6 18DB
FUSE NO. AMPS COLOR SHEET

1 2 GRAY 2,36,38
2 5 TAN 2 , 10, 1 2 . 1 3 , 1 4 , 5 8 , 7 7 , 7 8
3 20 YELLOW 2.7,9,10,39
4 20 YELLOW 1.30.47
5 20 YELLOW 1 .77.78
6 20 YELLOW 1 ,73
7 15 LT BLUE 1,10.52
8 10 RED 2,10,61.63.65
9 20 YELLOW 2.10,31.33.56
10 20 YELLOW 2.10.54.55
11 30 GREEN 2.10.66,67.69
12 30 CIRCUIT BREAKER S I L V E R CAN 2,10,71
13 20 YELLOW 1 ,56
14 3 VIOLET 1.47,52.61.63,65
15 10 RED 1,49,51.52,61,63,65,75
J938W-H F U S E BLOCK MODULE AND RELAY BANK AD 82

CAV IGNITION SYSTEM C I R C U I T S SHEET

K32 20WT/BK WATER IN FUEL SENSOR 25
2 K2 20TN/BK ENGINE COOLANT TEMP SENSOR 25
3 A H ioRD DIRECT BATTERY FEED 22
4 K4 18BK/LB SENSOR RETURN 26
5 Z l l 16BK/WT SIGNAL GROUND 23
e !<6 20VT/WT 5 VOLT SUPPLY 26
"7
/ K44 10TN/YL 8 VOLT INPUT 25
8 —
9 JA21 H O B IGNITION FEED 21
10 76 20 OR/WT TRANSMISSION OD CONTROL 14
11 Z12 18BK/TN POWER GROUND 23
13 — —
14 —
J.5
——« _ _ _
S22 180R/BK HEATER Ul RELAY 21
16 S21 18YL/BK HEATER #1 RELAY 21
17 — -- —
18 —
19 —
20 K20 18DG GENERATOR F I E L D DRIVER 20
21 IK21 18BK/RD TRANSMISSION OD LOCKOUT SOLENO 0 25
22 K22 180R/DB THROTTLE P O S I T I O N (SENSOR) 26
23 — —
24 K24 18GY/BK REFERENCE PICKUP 25
25 021 20PK DATA LINK TRANSMIT 23
26 — — —
27 J C20 18BR A / C COMPRESSOR CLUTCH INPUT 26
28 T25 20LG/RD TRANSMISSION THERMO SWITCH 25
29 V40 18WT/PK BRAKE SENSE 37
30 rTTF 18BR/YL " PARK/NEUTRAL P O S I T I O N SWITCH 21
31 — —
32 G3 20BK/PK MALFUNCTION INDICATOR LAMP 22
\j i i i i i i i i 1 I r 11 I I i I i M i
g 33 V36 20TN/RD VEHICLE SPEED CONTROL VACUUM 37
34 C I 3 20DB/0R W.O.T. CUTOUT RELAY 26
35 — —.
36 — — —
37 T61 20BK/0R TRANSMISSION OD LAMP SIGNAL 14
38 — — —
39 — — —
VIEWED FROM WIRE
END OF CONNECTOR 40 —
41 —
42 — —
43 G21 20GY/LB TACHOMETER P R O V I S I O N S 22
44 — —
45 D20 20LG DATA LINK RECEIVE 23
46 — —
47 G7 20WT/OR VEHICLE SPEED SENSOR PICKUP 25
48 V31 20BR/RD VEHICLE SPEED CONTROL-SET 37
49 V32 20YL/RD VEHICLE SPEED CONTROL-ON/OFF 37
50 V33 20WT/LG VEHICLE SPEED CONTROL-RESUME 37
5i K51 20DB/YL AUTOMATIC SHUT-DOWN RELAY 22
52 — — —
53 V35 20LG/RD VEHICLE SPEED CONTROL-VENT 37
54 K31 20BK/PK WATER-IN-FUEL LAMP 23
r
5: T60 2 0 0 R / L G TRANSMISSION OD SOLENOID 14
^ AUTO TRANSMISSION ONLY 56 E5 20DG/WT WAIT-TO-START LAMP 23
57 A142 16DG/0R A . S . D . - B A T T E R Y SENSE 22
50 — — —
53 — — —
60 — .—
POWERTRAIN CONTROL MODULE I I

AD 83 (PCM I I ) CONNECTOR ( 5 . 9 L D I E S E L ENGINE) J9 38w-n
CAV IGNITION S Y S T E M C I R C U I T S SHEET

1 K l 200G/RD MAP S E N S O R 20
2"-1 K2 2 0 T N / B K ENGINE COOLANT TEMPERATURE SENSOR 20
3 A14 IBRD D I R E C T BATTERY 16
4 K4 1 8 B K / L B S E N S O R RETURN 20
5 Z l l 16BK/WT S I G N A L GROUND 17
6 K6 20VT/WT 5 VOLT S U P P L Y 20
7 K7 180R 8 VOLT INPUT 20
8 — —
9 A21 14DB I G N I T I O N FEED 16
10 T6 200R/WT T R A N S M I S S I O N OD CONTROL 12
13 | K l 4 18LB/BR INJECTOR DRIVER 4 15
14 K13 18YL/WT INJECTOR DRIVER 3 15
15 K12 18TN INJECTOR DRIVER 2 15
16 K l 1 18WT/DB INJECTOR DRIVER 1 15
17" K17 18DB/TN INJECTOR DRIVER 7 15
5.2L £ 5.9L ENGINE
18 K18 18RD/YL INJECTOR DRIVER 8 15
19 K19 18GY I G N I T I O N COIL DRIVER 15
20 K20 18DG GENERATOR F I E L D D R I V E R 19
21 K21 18BK/RD TB S U R F A C E TEMP S E N S O R 20
22 K22 180R/DB THROTTLE P O S I T I O N ( S E N S O R ) 18
23 K141 18TN/WT HEATED OXYGEN SENSOR ( 5 . 9 L HD) 17
24 K24 18GY/BK R E F E R E N C E P I C K U P 18
25 021 20PK DATA L I N K T R A N S M I T 17
26 — —
27
28
C20 18BR A/C
—
CYCLING SWITCH INPUT
_18
29 V40 18WT/PK BRAKE S E N S E 35

30 T41 20BR/YL PARK/NEUTRAL POSITION SWITCH 19
31 — —
32 G3 20BK/PK MALUNCTION I N D I C A T O R LAMP 19
33 V36 20TM/RD V E H I C L E S P E E D CONTROL-VACUUM 35
34 C13 20DB/OR W . O . T . CUTOUT RELAY 18
35 K35 20GY/YL EGR SOLENOID 16
36 — — —
37 TBI 20BK/0R T R A N S M I S S I O N OD LAMP S I G N A L 12
38 K15 18PK/BK INJECTOR DRIVER 5 15
39 K 3 9 1 8 G Y / R D I D L E A I R CONTROL MOTOR 19
"40 K40 18BR/WT I D L E A I R CONTROL MOTOR 19
V I E W E D FROM WIRE 41 HEATED OXYGEN SENSOR
K41 18BK/DG 17
END OF CONNECTOR
42 — —
43 — — —
44 K44 18GY CAMSHAFT P O S I T I O N SENSE 20
45 020 20LG DATA L I N K R E C E I V E 17
46 — — —
47 G7 20WT/OR V E H I C L E S P E E D SENSOR P I C K U P 20
48 V31 20BR/RD V E H I C L E SPEED CONTROL-SET 35
49 V32 20YL/RD VEHICLE SPEED CONTROL-ON/OFF 35
50 Y33 20WT/LG V E H I C L E SPEED CONTROL-RESUME 35
51 K51 20DB/YL AUTOMATIC SHUT-DOWN RELAY 16
52 K52 20PK/BK EVAP/PURGE SOLENOID 16
53 V35 20LG/RD V E H I C L E SPEED CONTROL-VENT 35
54 K54 200R/BK EMCC S O L E N O I D 11.12
55 T60 200R/LG T R A N S M I S S I O N OD SOLENOID 12
5G G24 20GY/PK S E R V I C E R E M I N D E R I N D I C A T O R LAMP 13
57 A142 16DG/0R A . S . D . - BATTERY S E N S E 15
58 K16 18LG/BK INJECTOR DRIVER 6 15
59 K59 18VT/BK I D L E A I R CONTROL MOTOR 19
60 K60 18YL/BK I D L E A I R CONTROL MOTOR 19
POWERTRAIN CON TROL MODULE I I

J938W-H (PCM I I ) CONNECTOR (GAS MFI E N G I N E S ) A D 84
CAVITY ENGINE COMPARTMENT C I R C U I T S

1 A3 12RD/WT HEADLAMP SWITCH
C7 12BK/TN A/C AND HEATER BLOWER MOTOR
A141 16DG/BK FUEL PUMP FEED (GAS ONLY)
L4 16VT/WT HEADLAMP LOW BEAM (2 WIRES)

L3 14RD/0R HEADLAMP HIGH BEAM (2 WIRES)
V30 20DB/RD VEHICLE SPEED CONTROL
V31 20BR/RD VEHICLE SPEED CONTROL
V33 20WT/LG VEHICLE SPEED CONTROL
10 V32 20YL/RD VEHICLE SPEED CONTROL
11 E5 20DG/WT WAIT TO START LAMP ( D I E S E L Q N L Y r
12 G34 16RD/GY HIGH BEAM INDICATOR LAMP
13 L20 14LG/WT HIGH BEAM FEED
14
15
16 G21 20GY/LB TACHOMETER SIGNAL ( D I E S E L )
17 G20 20VT/YL ENGINE COOLANT TEMPERATURE SENDING UNIT
18 G6 20GY ENGINE OIL PRESSURE SWITCH
19 G60 20GY/YL ENGINE OIL PRESSURE SENDING UNIT
20 G85 20TN/OR WATER-IN FUEL LAMP ( D I E S E L )
SMALL 21 L61 18LG LEFT TURN SIGNAL LAMP
INDEX 22 L60 18TN RIGHT TURN SIGNAL LAMP
23 A15 16PK BATTERY-HAZARD FLASHER
24 T61 20BK/0R TRANSMISSION OVERDRIVE INDICATOR LAMP
25 LI 18VT/BK BACK-UP LAMPS
50 49 48 47 46 45 26 L7 18BK/YL PARKING LAMPS (2 WIRES)
44 43 42 41 40 39 38 37 36 35 27 F20 18WT BACK-UP LAMP SWITCH
34 33 32 31 30 29 28
28 27 26
22 21 20
© 25 24 23
19 18 17
29
30
31
V10
A41
20BR
16YL
WINDSHIELD WASHER MOTOR
ENGINE STARTER RELAY - 1 G N I T I ON

16 15 14 13 12 11 10 9 8 7
32 X2 18DG/RD HORN
6 5 4 3 2 1
33 Ml 18BK/TN UNDERHOOD LAMP
34 Gil 20WT/BK ELECTRIC VACUUM SENSOR ( D I E S E L ) (2 WIRES)
35 V5 18DG/YL WINDSHIELD WIPER MOTOR
36 V6 18DB WINDSHIELD WIPER MOTOR
LARGE 37 C21 18DB/0R AIR CONDITIONING DAMPED PRESSURE SWITCH
INDEX 38 G3 20BK/PK MALFUNCTION INDICATOR LAMP
TERMINAL END 39
OF DISCONNECT 40 X4 20LG/BR 4 WHEEL DRIVE SWITCH
41 V40 18WT/PK BRAKE SENSOR
42 G24 20GY/PK S R I LAMP (GAS ENGINE ONLY)
ENGINE COMPARTMENT 43 G7 2GWT/0R VEHICLE SPEED SENSOR
44 T6 200R/WT TRANSMISSION OVERDRIVE
45 V3 18BR/WT WINDSHIELD WIPER MOTOR
46 V4 18RD/YL WINDSHIELD WIPER MOTOR
47 A21 14DB S P L I C E - I G N I T I O N RUN CIRCUIT
48 A4 12BK/RD I G N I T I O N OFF DRAW
Al 12RD I G N I T I O N SWITCH
50 A2 12PK/BK I G N I T I O N SWITCH
AD 85 50-WAY BULKHEAD D I S C O N N E C T J938W-11

CAVITY INSTRUMENT PANEL CIRCUITS SHEET NO

1 A3 12RD/WT BATTERY FEED 4,6.30,47
C7 12BK/TN A/C AND HEATER BLOWER MOTOR 66,67,68
A61 16DG/BK FUEL PUMP FEED ( G A S ONLY) 78
L4 16VT/WT HEADLAMP-LOW BEAM

43,45,47
L3 16RD/0R HEADLAMP-HIGH BEAM
V30 20DB/RD VEHICLE SPEED CONTROL
V31 20BR/RD VEHICLE SPEED CONTROL
V33 20WT/LG VEHICLE SPEED CONTROL 36,38
V32 20YL/RD
10 VEHICLE SPEED CONTROL
V32 20YL/RD
11 G86 20DG/WT WAIT TO START LAMP (DIESEL ONLY) 23
12 G34 16RD/GY HIGH BEAM INDICATOR LAMP 43,46
13 L20 20LG/WT HIGH BEAM FEED (D.R.L. MODULE) 46,47
14
T E R M I N A L END
15 OF D I S C O N N E C T
16 G21 20GY/LB TACHOMETER (DIESEL) 22
17 G20 18VT/YL ECT SEND/UNIT OR SWITCH
18 G6 20GY ENGINE O I L PRESSURE LAMP 27,28
19 G60 20GY/YL ENGINE O I L PRESSURE GAUGE-SEND UNIT
20 G85 20TN/0R WATER I N FUEL LAMP (DIESEL) 23
L61 18LG
21
L61 18LG
LEFT FRONT TURN S I G N A L LAMP 43.45,56 ff p
46 47 48 49 50
45
L60 18TN 35 36 37 38 39 40 41 42 43 44
22 RIGHT FRONT TURN S I G N A L LAMP 43,45.56
L60 18TN 29 30 31 32 33 34
23
24
A15
T61
16PK
20BK/OR
HAZARD F L A S H E R
TRANSMISSION OVERDRIVE INDICATOR LAMP
3,5,56
12,14
23 24 25
17 18 19
© 26 27 28
20 21 22
25 LI 18VT/BK B A C K - U P LAMPS 7.79 7 8 9 10 11 12 13 14 15 16
26 L7 18BK/YL P A R K I N G LAMPS 43,45,47 1 2 3 4 5 &
^ 1. J *j
27 F20 18WT B A C K - U P LAMP FEED 7.9
28
29 V10 20BR WINDSHIELD WASHER MOTOR 53.55
30
LARGE
31 A41 14YL IGNITION START 8,9 INDEX
31 S21 14YL/BK IGNITION START (DIESEL)
32 X2 18DG/R0 HORNS 30
33 Ml 18PK UNDERHOOD LAMP 29
34 Gil 20WT/BK E L E C T R I C VACUUM SENSOR (DIESEL) 34
35 V5 18DG WINDSHIELD WIPER SWITCH
54,55
36 V6 18DB WINDSHIELD WIPER SWITCH
37 C2 18DB/YL A/C COMPRESSOR CLUTCH 67,69
38 G3 20BK/PK MALFUNCTION INDICATOR 19,22
39
40 Gl 20DG/GY 4 WHEEL D R I V E SWITCH 13
41 V40 18WT/PK BRAKE SENSOR 32,34,36,38
42 G24 22GY/PK SRI LAMP (GAS ENGINE ONLY) 19
43 G7 20WT/0R VEHICLE S P E E D SENSOR (2 WIRES) 19,25
44 T6 200R/WT TRANSMISSION OVERDRIVE SWITCH 12,14
45 V3 18BR/WT WINDSHIELD WIPER LOW S P E E D
54.55 INSTRUMENT PANEL
46 V4 18RD/YL WINDSHIELD WIPER HIGH SPEED
A21 14DB
47 IGNITION-RUN I START 10,23.77,78
A21 14DB
48 A4 12BK/RD BATTERY FEED 3.5.39
49 Al 12RD IGNITION SWITCH (Bl) 4,6.10
50 A2 12PK/BK IGNITION SWITCH (B3) 4.6.10
J938W-11 50-WAY BULKHEAD DISCONNECT AD 86

10 11 12 13 14 15 16 17
18 19 20 22 23 24
21
STEERING COLUMN INSULATOR

AS VIEWED FROM WIRE END
CAV CIRCUIT DESCRIPTION SHEET

1 V9 18WT/BK INTERMITTENT WIPER MODULE
2 V8 18VT INTERMITTENT WIPER MODULE
3 V10 20BR WINDSHIELD WASHER MOTOR
4 V6 18DB WIPER SWITCH FEED
5 V4 18RD/YL WIPER MOTOR-HIGH SPEED 53
V3 18BR/WT WIPER MOTOR-LOW SPEED
6
V3A 18BR/WT WIPER SWITCH
7 V7 18DG/WT INTERMITTENT WIPER MODULE
8 V17 18DG/YL INTERMITTENT WIPER MODULE
9 V3A 18BR/WT WIPER SWITCH
— —
10
11 L60 18TN
—RIGHTFRONT TURN SIGNAL
12 L62 18BR/RD RIGHT REAR TURN SIGNAL
13 L19 18PK HAZARD FLASHER FEED
14 L50 18WT/TN STOP LAMP FEED 56
15 L63 18DG/RD LEFT REAR TURN SIGNAL
16 L61 18LG LEFT FRONT TURN SIGNAL
17 L6 18RD/WT TURN SIGNAL FLASHER FEED
18 L4 14VT/WT LOW BEAM-HEADLAMPS
19 L2 14LG HEADLAMP FEED
47
20 L3 14RD/0R HIGH BEAM-HEADLAMPS
21 L20 14LG/WT HEADLAMP-OPT HORN FEED
—
22
23 —
— —
—
—
24
— —-
S T E E R I N G COLUMN CONNECTOR
AD 87 WITH INTERMITTENT WIPERS (PULSE WIPE) J938W . n
1
1 2 3 4 5 6 7 8 9
10 11 12 13
( \ 14 15 16 17
18 19 20
\ ^-— -
21
) 22 23 24
S T E E R I N G COLUMN I N S U L A T O R
AS V I E W E D FROM W I R E END
CAV CIRCUIT DESCRIPTION SHEET

1 V3 18BR/WT WIPER MOTOR-LOW SPEED
2 V5 18DG WIPER-PARK
3 V10 20BR WASHER MOTOR 55
4 V6 18DB WIPER-IGNITION FEED

5 V4 18RD/YL WIPER MOTOR-HIGH SPEED
6 — — —
7 — — —
8 — — —
9 — — —
10 — — —
11 L60 18TN RIGHT FRONT TURN SIGNAL
12 L62 18BR/RD RIGHT REAR TURN SIGNAL
13 L19 18PK HAZARD F L A S H E R FEED
14 L50 18WT/TN STOP LAMP FEED 56
15 L63 18DG/RD LEFT REAR TURN SIGNAL

16 L61 18LG LEFT FRONT TURN SIGNAL
17 L6 18RD/WT TURN SIGNAL-FLASHER FEED
18 L4 14VT/WT LOW B E A M - H E A D L A M P S
19 L2 14LG HEADLAMP FEED
47
20 L3 14RD/OR HIGH BEAM-HEADLAMPS
21 L20 14LG/WT HEADLAMP-OPT HORN FEED
22 — — —
23 — — —
24 — — —
S T E E R I N G COLUMN CONNECTOR
J938H-11 WITH 2 S P E E D W I P E R S AD 88
1 2 3 A 4 5 6 7 8
/ \
9 10 11 12 13 14 15 16
17
27
18
28
19
29
20
30
21
31
u 22
32
23 24
33
25 26
34
35 36 37 38 39 40 41 42
HEADLAMP I DASH
VIEW FROM WIRE END WIRING
CAV I G N I T I O N SYSTEM C I R C U I T S SHEET NO

1 A21 14DB I G N I T I O N FEED 16
2 Zl 14BK GROUND 9.68
3
4 L I 18VT/BK BACK-UP LAMPS 9
5 K54 2 0 0 R / B K EMCC SOLENOID 11
6 A141 16DG/BK FUEL PUMP 16
7 C20 18BR A / C COMPRESSOR CLUTCH 18
8 G3 2 0 B K / P K MALFUNCTION INDICATOR LAMP 19
9 A14 16RD BATTERY FEED 16
10
11 Z l l 16BK/WT SIGNAL GROUND 17
&GjCUQjQ
UXJUXj O
12 V40 18WT/PK BRAKE SIGNAL 35 "IT
mJKXTV
14 T41 18BR/YL ENGINE STARTER RELAY COIL 9
15 G60 20GY/YL ENGINE OIL PRESSURE SEND/UNIT 28
16 G6 20GY ENGINE OIL PRESSURE SWITCH 28
17 T6 200R/WT TRANSMISSION OD OVERRIDE 12
18 T61 2 0 B K / 0 R TRANSMISSION OD LAMP SIGNAL 12
19
20 F20 18WT BACK-UP LAMP SWITCH 9
21
22 T22 14DB/WT EMCC 11
23
24 G24 20GY/PK S R I LAMP 19
25 C13 20DB/0R A / C COMPRESSOR CLUTCH RELAY 18
26 G20 2 0 V T / Y L ECT SEND/UNIT 28
27 V31 20BR/RD VEHICLE SPEED CONTROL- SET 35
28 V32 2 0 Y L / R D VEHICLE SPEED CONTROL- OFF/ON 35
29 V33 20WT/LG VEHICLE SPEED CONTROL- RESUME 35
30 V35 20LG/RD VEHICLE SPEED CONTROL- VENT 35
31 V36 20TN/RD VEHICLE SPEED CONTROL- VACUUM 35
32 ENGINE WIRING
33 G7 20WT/0R VEHICLE SPEED SENSOR 19
34 C3 14DB/BK A / C COMPRESSOR CLUTCH FEED 68
35
36
37
38
39 - ENG
40
41
42
AD 89 GAS E N G I N E W I R I N G CONNECTOR J938W-11

• ENGINES 9 - 1
ENGINES
CONTENTS
page page
3.9L ENGINE SERVICE PROCEDURES 17 5.9L ENGINE SERVICE PROCEDURES 77

5.2L ENGINE SERVICE PROCEDURES 47 ENGINE DIAGNOSIS 5
5.9L (DIESEL) ENGINE SERVICE PROCEDURES . 107 STANDARD SERVICE PROCEDURES 1
STANDARD SERVICE PROCEDURES
INDEX
page page
Engine Performance 2 Hydrostatic Lock 4
Form-ln-Place Gaskets 1 Measuring with Plastigage 3
Honing Cylinder Bores 2 Repair Damaged or Worn Threads . 4
FORM-IN-PLACE GASKETS SURFACE PREPARA TION

There are several places where form-in-place gas Parts assembled with form-in-place gaskets may be
kets are used on the engine. D O N O T u s e form-in- disassembled without unusual effort. In some in
p l a c e g a s k e t m a t e r i a l u n l e s s specified. Care must stances, it may be necessary to lightly tap the part
be taken when applying form-in-place gaskets. Bead with a mallet or other suitable tool to break the seal
size, continuity and location are of great importance. between the mating surfaces. A flat gasket scraper
Too thin a bead can result in leakage while too much may also be lightly tapped into the joint but care
can result in spill-over. A continuous bead of the must be taken not to damage the mating surfaces.
proper width is essential to obtain a leak-free joint. Scrape or wire brush all gasket surfaces to remove
Two types of form-in-place gasket materials are all loose material. Inspect stamped parts to ensure
used in the engine area (Mopar Silicone Rubber Ad gasket rails are flat. Flatten rails with a hammer on
hesive Sealant and Mopar Gasket Maker). Each have a flat plate, if required. Gasket surfaces must be free
different properties and cannot be used interchange of oil and dirt. Make sure the old gasket material is
ably. removed from blind attaching holes.
MOPAR SILICONE RUBBER ADHESIWE GASKET APPLICATION

SEALANT Assembling parts using a form-in-place gasket re
Mopar Silicone Rubber Adhesive Sealant, normally quires care.
black in color, is available in 3 ounce tubes. Moisture Mopar Silicone Rubber Adhesive Sealant should be
in the air causes the sealant material to cure. This applied in a continuous bead approximately 3 mm
material is normally used on flexible metal flanges. (0.12 inch) in diameter. All mounting holes must be
It has a shelf life of 1 year and will not properly cure circled. For corner sealing, a 3 or 6 mm (1/8 or 1/4
if over aged. Always inspect the package for the ex inch) drop is placed in the center of the gasket con
piration date before use. tact area. Uncured sealant may be removed with a
shop towel. Components should be torqued in place
MOPAR GASKET MAKER while the sealant is still wet to the touch (within 10
Mopar Gasket Maker, normally red in color, is minutes). The use of a locating dowel is recom
available in 6 cc tubes. This anaerobic type gasket mended during assembly to prevent smearing the
material cures in the absence of air when squeezed material off location.
between smooth machined metallic surfaces. It will Mopar Gasket Maker should be applied sparingly
not cure if left in the uncovered tube. DO NOT use to one gasket surface. The sealant diameter should
on flexible metal flanges. be 1.Q0 mm (0.04 inch) or less. Be certain the mate-
9 - 2 ENGINES
rial surrounds each mounting hole. Excess material bled to determine the cause of l o w compression
can easily be wiped off. Components should be unless some malfunction is present.
torqued in place within 15 minutes. The use of a lo (4) Clean or replace spark plugs as necessary. Ad
cating dowel is recommended during assembly to pre just gap (refer to Group 8D, Ignition System for gap
vent smearing the material off location. adjustment and torque).
(5) Test resistance of spark plug cables (refer to
ENGINE PERFORMANCE Group 8D, Ignition System.
To provide best vehicle performance and lowest ve (6) Inspect the primary wire. Test coil output volt
hicle emissions, it is most important t h a t the tune-up age, primary and secondary resistance. Replace parts
be done accurately. Use the specifications listed on as necessary (refer to Group 8D, Ignition System and
the Vehicle Emission Control Information label make necessary adjustment).
found on the engine compartment hood. (7) Set ignition timing to specifications (refer to
(1) Test cranking amperage draw (refer to Group Specification Label on engine compartment hood).
8B, Battery/Starter/Generator Service for the proper (8) Perform a combustion analysis.
procedures). (9) Test fuel pump for pressure and vacuum (refer
(2) Tighten the intake manifold bolts (refer to to Group 14, Fuel System for the proper specifica
Group 11, Exhaust System and Intake Manifold for
tions).
the proper specifications).
(10) Inspect air filter element (refer to Group 0,
(3) Perform cylinder compression test:
Lubrication and Maintenance for the proper proce
(a) Check engine oil level and add oil, if neces
dure).
sary.
(b) Drive the vehicle until engine reaches normal (11) Inspect crankcase ventilation system (refer to
operating temperature. Group 0, Lubrication and Maintenance for the proper
(c) Select a route free from traffic and other procedure).
forms of congestion, observe all traffic laws and (12) For emission controls refer to Group 25, Emis
briskly accelerate through the gears several times. sion Controls System for service procedures.
The higher engine speed may help clean out valve (13) Inspect and adjust accessory belt drives (refer
seat deposits which can prevent accurate compres to Group 7, Cooling System for the proper adjust
sion readings. ments).
(14) Road test vehicle as a final test.
C A U T I O N : D O N O T overspeed the engine.
H0NIN6 CYLINDER BORES
(d) Remove all spark plugs from engine. As Before honing, stuff plenty of clean shop towels un
spark plugs are being removed, check electrodes for der the bores and over the crankshaft to keep abra
abnormal firing indicators - fouled, hot, oily, etc. sive materials from entering the crankshaft area.
Record cylinder number of spark plug for future
(1) Used carefully, the Cylinder Bore Sizing Hone
reference.
C-823 equipped with 220 grit stones, is the best tool
(e) Disconnect coil wire from distributor and se
for this job. In addition to deglazing, it will reduce
cure to good ground to prevent a spark from start
ing a fire. taper and out-of-round as well as removing light
(f) Be sure throttle blades are fully open during scuffing, scoring or scratches. Usually a few strokes
the compression check. will clean up a bore and maintain the required lim
(g) Insert compression gage adaptor into the its.
No.l spark plug hole. Crank engine until maxi
C A U T I O N : D O N O T use rigid type hones to remove
mum pressure is reached on gauge. Record this
cylinder wall glaze.
pressure as No.l cylinder pressure.
(h) Repeat Step 3g for all remaining cylinders. (2) Deglazing of the cylinder walls may be done if
(i) Compression should not be less t h a n 689 kPa the cylinder bore is straight and round. Use a cylin
(100 psi) and not vary more t h a n 172 kPa (25 psi)
der surfacing hone, Honing Tool C-3501, equipped
from cylinder to cylinder.
with 280 grit stones (C-3501-3810). 20-60 strokes, de
(j) If cylinder(s) have abnormally low compres
pending on the bore condition, will be sufficient to
sion pressures, repeat steps 3a through 3h.
provide a satisfactory surface. Using honing oil
(k) If the same cylinder(s) repeat an abnormally
low reading, it could indicate the existence of a C-3501-3880 or a light honing oil available from ma
problem in the cylinder. jor oil distributors.
The r e c o m m e n d e d c o m p r e s s i o n pressures are
C A U T I O N : D O N O T u s e engine or transmission oil,
to b e u s e d only as a guide to diagnosing engine
mineral spirits or kerosene.
problems. A n engine should NOT be disassem
• ENGINES 9-3
(3) Honing should be done by moving the hone up • ALL E N G I N E S - W h e n checking No.2 main bear
and down fast enough to get a Crosshatch pattern. ing; shim No.l and No.3 main bearing.
The hone marks should INTERSECT at 50° to 60° for • ALL E N G I N E S - W h e n checking No.3 main bear
proper seating of rings (Fig. 1). ing; shim No.2 and No.4 main bearing.
• 5.2L, 5.9L AND 5.9L (DIESEL) EN
GINES—When checking No.4 main bearing; shim
No.3 and No.5 main bearing.
• 3.9L ENGINE—When checking No.4 main bear
ing; shim No.3 main bearing.
• 5.2L A N D 5.9L ENGINES—When checking No.5
main bearing; shim No.4 main bearing.
• 5.9L (DIESEL) E N G I N E - W h e n checking No.5
main bearing; shim No.4 and No.6 main bearing.
main bearing; shim No.5 and No.7 main bearing.
main bearing; shim No.6 main bearing.
Remove all shims before assembling engine.
M E T H O D - 2 (ALTERNATIVE)—The weight of
the crankshaft is supported by a jack under the coun
Fig. 1 Cylinder Bore Crosshatch Pattern terweight adjacent to the bearing being checked.
(4) A controlled hone motor speed b e t w e e n 200 and (3) Place a piece of Plastigage across the entire
300 RPM is necessary to o b t a i n the proper C r o s s h a t c h width of the bearing cap shell (Fig. 2). Position t h e
angle. The number of up and down strokes per Plastigage approximately 6.35 mm (1/4 inch) off cen
minute can be regulated to get t h e desired 50° to 60° ter and away from the oil holes. In addition, suspect
angle. Faster up and down strokes increase the cross- areas can be checked by placing the Plastigage in
hatch angle. t h a t area. Tighten the bearing cap bolts of the bear
(5) After honing, it is necessary t h a t the block be ing being checked to 115 N»m (85 ft. lbs.) torque. DO
cleaned to remove all traces of abrasive. Use a brush NOT rotate the crankshaft or the Plastigage m a y
to wash parts with a solution of hot water and deter be smeared, giving inaccurate results.
gent. Dry parts thoroughly. Use a clean, white, lint-
free cloth to check t h a t the bore is clean. Oil the
bores after cleaning to prevent rusting.
MEASURING WITH PLASTIGAGE

CRANKSHAFT MAIN BEARING CLEARANCE
Engine crankshaft bearing clearances can be deter
mined by use of Plastigage, or equivalent. The fol
lowing is the recommended procedures for the use of
Plastigage:
(1) Remove oil film from surface to be checked.
Plastigage is soluble in oil. Fig. 2 Placement of Plastigage in Bearing Shell
(2) The total clearance of the main bearings can (4) Remove the bearing cap and compare the width
only be determined by removing the weight of the of the flattened Plastigage with the scale provided on
crankshaft. This can be accomplished by either of the package (Fig. 3). Plastigage generally comes in 2
two methods: scales (one scale is in inches and the other is a met
METHOD - 1 ( P R E F E R R E D ) — S h i m the bear ric scale). Locate the band closest to the same width.
ings adjacent to the bearing to be checked. This will This band shows the amount of clearance. Differ
remove the clearance between upper bearing shell ences in readings between the ends indicate t h e
and the crankshaft. Place a minimum of 0.254 m m amount of taper present. Record all readings taken
(0.010 inch) shim between the bearing shell and the (refer to Engine Specifications).
adjacent bearing cap. Tighten the bolts to 18 N*m (13 (5) Plastigage is available in a variety of clearance
ft. lbs.) torque. ranges. The 0.025-0.076 m m (0.001-0.003 inch) range
• ALL ENGINES—When checking No.l main bear is usually the most appropriate for checking engine
ing; shim No.2 main bearing. bearing clearances.
9 - 4 ENGINES •
• Tapping the hole with a special Heli-Coil Tap, or
equivalent.
• Installing an insert into the tapped hole.
This brings the hole back to its original thread
size.
C A U T I O N : B e sure that the tapped holes maintain

the original center line.
Heli-Coil tools and inserts are readily available

RN861 from automotive parts jobbers.
Fig. 3 Clearance Measurement HYDROSTATIC LOCK

CONNECTING ROD BEARING CLEARANCE When an engine is suspected of hydrostatic lock
Engine connecting rod bearing clearances can be (regardless of what caused the problem), follow the
determined by use of Plastigage, or equivalent. The steps below.
following is the recommended procedures for the use (1) Perform the Fuel Pressure Release Procedure
of Plastigage: (refer to Group 14, Fuel System).
(2) Disconnect the negative cable from the battery.
(1) Remove oil film from surface to be checked. (3) Inspect air cleaner, induction system and in
Plastigage is soluble in oil. take manifold to ensure system is dry and clear of
(2) Place a piece of Plastigage across the entire foreign material.
width of the bearing cap shell (Fig. 2). Position the (4) Place a shop towel around the spark plugs to
Plastigage approximately 6.35 m m (1/4 inch) off cen catch any fluid t h a t may possibly be under pressure
ter and away from the oil holes. In addition, suspect in the cylinder head. Remove the plugs from the en
areas can be checked by placing the Plastigage in the gine.
suspect area.
(3) The crankshaft must be turned until the con C A U T I O N : D O N O T use the starter motor to rotate
necting rod to be checked starts moving toward the the crankshaft. Severe damage could occur.
top of the engine. Only then should the rod cap with
Plastigage in place be assembled. Tighten the rod (5) With all spark plugs removed, rotate the crank
cap n u t to 61 Nnn (45 ft. lbs.) torque. D O N O T r o shaft using a breaker bar and socket.
tate the crankshaft or the Plastigage may be (6) Identify the fluid in the cylinders (i.e. coolant,
s m e a r e d , giving i n a c c u r a t e r e s u l t s . fuel, oil, etc.).
(4) Remove the bearing cap and compare the width (7) Make sure all fluid has been removed from the
of the flattened Plastigage with the scale provided on cylinders.
the package (Fig. 3). Plastigage generally comes in 2 (8) Repair engine or components as necessary to
scales (one scale is in inches and the other is a met prevent this problem from occurring again.
ric scale). Locate the band closest to the same width. (9) Squirt engine oil into the cylinders to lubricate
This band shows the amount of clearance. Differ the walls. This will prevent damage on restart.
ences in readings between the ends indicate the (10) Install new spark plugs. Tighten the spark
#
amount of taper present. Record all readings taken plugs to 41 N m (30 ft. lbs.) torque.
(refer to Engine Specifications). (11) Drain engine oil. Remove and discard the oil
(5) Plastigage is available in a variety of clearance filter.
ranges. The 0.025-0.076 mm (0.001-0.003 inch) range (12) Install the drain plug. Tighten the plug to 34
is usually the most appropriate for checking engine N-m (25 ft. lbs.) torque.
bearing clearances. (13) Install a new oil filter.
(14) Fill engine crankcase with the specified
REPAIR DAMAGED OR WORN THREADS amount and grade of oil (refer to Group 0, Lubrica
Damaged or worn threads can be repaired. Essen tion and Maintenance).
tially, this repair consists of: (15) Connect the negative cable to the battery.
• Drilling out worn or damaged threads. (16) Start the engine and check for any leaks.
• ENGINES 9 -S
ENGINE D I A G N O S I S
Engine diagnosis is helpful in determining the Refer to the Service Diagnosis—Performance c h a r t
causes of malfunctions not detected and remedied by and t h e Service Diagnosis—Mechanical c h a r t for pos
routine tune-ups. sible causes and corrections of malfunctions. Refer to
These malfunctions may be classified as either per Group 14, Fuel System for the fuel system diagnosis.
formance (e.g., engine idles rough and stalls) or me
chanical (e.g., a strange noise).
SERWIGE DIAGNOSIS (GASOLINE ENGINES) - PERFORMANCE
CONDITION POSSIBLE CAUSES CORRECTION

ENGINE WILL NOT START 1. Weak battery. 1. Test battery specific gravity. Charge or replace as necessary.
2. Corroded or loose battery 2. Clean and tighten battery connections. Apply a coat of light
connections. mineral grease to the terminals.
3. Faulty starter. 3. Refer to Group 8A, Battery/Starter/Charging System
Diagnostics.
4. Moisture on ignition wires and 4. Wipe wires and cap clean and dry.
distributor cap.
5. Faulty ignition cables. 5. Replace any cracked or shorted cables.
6. Faulty coil or control unit. 6. Test and replace, if necessary (refer to Group 8D, Ignition
System).
7. Incorrect spark plug gap. 7. Set gap (refer to Group 8D, Ignition System).
8. Incorrect ignition timing. 8. Refer to Group 8D, Ignition System.
9. Dirt or water in fuel system. 9. Clean system and replace fuel filter.
10. Faulty fuel pump. 10. Install new fuel pump (refer to Group 14, Fuel System).
ENGINE STALLS OR 1. Idle speed set too low. 1. Refer to Group 14, Fuel System.
ROUGH IDLE 2. Idle mixture too lean or too rich. 2. Refer to Group 14, Fuel System.
3. Leak in intake manifold. 3. Inspect intake manifold gasket and vacuum hoses. Replace, if
necessary (refer to Group 11, Exhaust System & Intake
Manifold).
4. Worn or burned distributor rotor. 4. Install new distributor rotor.
5. Incorrect ignition wiring. 5. Install correct wiring.
6. Faulty coil. 6. Test and replace, if necessary (refer to Group 8D, Ignition
System).
7. EGR valve leaking. 7. Test and replace, if necessary (refer to Group 25, Emissions
Control System).
J9309-105
9 - 6 ENGINES •
SERVICE DIAGNOSIS (GASOLINE ENGINES) • PERFORMANCE (CONT.)
1 CONDITION POSSIBLE CAUSES ^ CORRECTION
1 ENGINE LOSS OF POWER 1. Incorrect ignition timing. 1. Refer to Group 8D, Ignition System.
2. Worn or burned distributor rotor. 2. install new distributor rotor.
3. Worn distributor shaft. 3. Remove and repair distributor (refer to Group 8D, Ignition
System).
4. Dirty or incorrectly gapped spark 4. Clean plugs and set gap (refer to Group 8D, Ignition System).
plugs.
6. Faulty fuel pump. 6. Install new fuel pump.
7. Incorrect valve timing. 7. Correct valve timing.
8. Blown cylinder head gasket. 8. Install new cylinder head gasket.
9. Low compression. 9. Test compression of each cylinder.
10. Burned, warped or pitted valves. 10. Install new valves.
11. Plugged or restricted exhaust 11. Install new parts, as necessary.
system.
12. Faulty ignition cables. 12. Replace any cracked or shorted cables.
13. Faulty coil. 13. Test and replace, as necessary (refer to Group 8D, Ignition
System).
ENGINE MISSES O N 1. Dirty or gap set too wide in spark 1. Clean spark plugs and set gap (refer to Group 8D, Ignition
ACCELERATION plug. System).
3. Dirt in fuel system. 3. Clean fuel system.
4. Burned, warped or pitted valves. 4. Install new valves.
5. Faulty coil. 5. Test and replace, if necessary, (refer to Group 8D, Ignition
System).
ENGINE MISSES AT HIGH 1. Dirty or gap set too wide in spark 1. Clean spark plugs and set gap (refer to Group 8D, Ignition
SPEED plug. System).
2. Worn distributor shaft. 2. Remove and repair distributor (refer to Group 8D, Ignition
System).
3. Worn or burned distributor rotor. 3. Install new distributor rotor.
4. Faulty coil. 4. Test and replace, as necessary (refer to Group 8D, Ignition
System).
6. Dirty injector in throttle body. 6. Clean injector.
J9309-106
• ENGINES 9 -7
SERVICE DIAGNOSIS (GASOLINE ENGINES) - MECHANICAL
C O N D I T I O N PSSSI1LI C A U S I S CORRECTION
NOISY VALVES 1. High or low oil level in 1. Check for correct oil level (refer to Group 0, Lubrication and
crankcase. Maintenance).
2. Thin or diluted oil. 2. Change oil (refer to Group 0, Lubrication and Maintenance).
3. Low oil pressure. 3. Check engine oil level.
4. Dirt in tappets/lash adjusters. 4. Clean hydraulic tappets/hydraulic lash adjusters.
5. Bent push rods. 5. Install new push rods.
6. Worn rocker arms. 6. Inspect oil supply to rocker arms.
7. Worn tappets/lash adjusters. 7. Install new hydraulic tappets/hydraulic lash adjusters.
8. Worn valve guides. 8. Ream and install new valves with oversize stems.
9. Excessive runout of valve seats on 9. Grind valve seats and valves.
valve faces.
CONNECTING ROD 1. Insufficient oil supply. 1. Check engine oil level (refer to Group 0, Lubrication and
NOISE Maintenance).
2. Low oil pressure. 2. Check engine oil level. Inspect oil pump relief valve and spring.
3. Thin or diluted oil. 3. Change oil to correct viscosity.
4. Excessive bearing clearance. 4. Measure bearings for correct clearance. Repair as necessary,
5. Connecting rod journal out-of- 5. Replace crankshaft or grind journals.
round.
6. Misaligned connecting rods. 6. Replace bent connecting rods.
M A I N BEARING NOISE 1. Insufficient oil supply. 1. Check engine oil level (refer to Group 0, Lubrication and
Maintenance).
2 Low oil pressure. 2. Check engine oil level. Inspect oil pump relief valve and spring.
3. Thin or diluted oil. 3. Change oil to correct viscosity.
4. Excessive bearing clearance. 4. Measure bearings for correct clearance. Repair as necessary.
5. Excessive end play. 5. Check No. 3 main bearing for wear on flanges.
6. Crankshaft journal out-of-round, 6. Grind journals or replace crankshaft.
worn,
7. Loose flywheel or torque 7. Tighten to correct torque.
converter.
OIL PRESSURE DROP 1. Low oil level. 1. Check engine oil level.
2. Faulty oil pressure sending unit. 2. Install new sending unit.
3. Low oil pressure. 3. Check sending unit and check main bearing oil clearance.
4.Clogged oil filter. 4. Install new oil filter.
5 Worn parts in oil pump. 5. Replace worn parts or pump.
6.Thin or diluted oil. 6. Change oil to correct viscosity.
7. Excessive bearing clearance. 7. Measure bearings for correct clearance.
8.Oil pump relief valve stuck. 8. Remove valve and inspect, clean and install.
9.Oil pump suction tube loose, bent 9. Remove oil pan and install new tube, if necessary.
or cracked.
10. Oil pump cover warped or 10. Install new oil pump.
cracked.
OIL LEAKS 1. Misaligned or deteriorated 1. Replace the gasket.
gaskets.
2. Loose fastener, broken or porous 2. Tighten, repair or replace the part.
metal part.
OIL PUMPING AT RINGS; 1. Worn, scuffed or broken rings. 1. Hone cylinder bores and install new rings.
SPARK PLUGS FOULING 2. Carbon in oil ring slot. 2. Install new rings.
3. Rings fitted too tightly in grooves. 3. Remove the rings. Check grooves. If grooves are not proper
width, replace piston.
4. Worn valve guides. 4. Ream guides and replace valves with oversize valves and seals.
5. Leaking intake gasket. 5. Replace gasket and tighten intake manifold to proper torque.
6. Leaking valve guide seals. 6. Replace seals.
7. Dislodged valve guide seals. 7. Seat valve guide seals or replace, as needed.
J9209-58
9 - 8 ENGINES •
SERVICE DIAGNOSIS (DIESEL ENGINE) - PERFORMANCE
CONDITION POSSIBLE CAUSES COtiECTION
ENGINE WILL NOT Starting motor operating, but Remove the starter motor. Check for broken flywheel teeth or
CRANK OR CRANKS not cranking the engine. a broken starting motor spring.
SLOWLY
Crankshaft rotation restricted. Rotate the engine to check for rotational resistance.
Starting circuit connections Clean and tighten connections.

loose or corroded.
Neutral safety switch or starter Check starter relay for supply voltage and proper operation of
relay inoperative. neutral safety. Replace defective parts.
Battery charge low. Check battery voltage. Replace battery if a charge cannot be
held.
No voltage to starter solenoid. Check voltage to solenoid. If necessary, replace the solenoid.
Solenoid or starting motor Replace starter motor.

inoperative.
ENGINE CRANKS, No fuel in supply tank. Fill fuel supply.

BUT WILL NOT
START—NO SMOKE Electrical fuel shutdown not Check for loose wires and verify that the valve is functioning.
FROM EXHAUST open. Check to be sure manual shutoff lever is in the run position.
Air intake or exhaust plugged. Remove the obstruction.
Fuel filter plugged. Drain fuel/water separator and replace fuel filter.
Injection pump not getting fuel Check fuel flow/bleed fuel system.
or fuel is aerated.
Worn or inoperative injection Visually check fuel delivery with an externally connected
pump. injector to one of the pump outlets. Replace the pump if fuel
is not being delivered.
Internal pump timing incorrect. Time the pump (refer to Group 14, Fuel System).
Camshaft out of time. Check/correct gear train timing alignment.
ENGINE HARD TO Incorrect starting procedure. The manual fuel shutoff control must be in the run position.
START, OR WILL
NOT START—SMOKE Cranking speed too slow. (a) Verify that the transmission is not engaged.
FROM EXHAUST
(b) Check the battery, starting motor and look for loose or
corroded wiring connections.
(c) Rotate the engine with a barring tool (Snap-On Tool SP371,
MTE No. 3377462, or equivalent) to check for internal
rotational resistance.
Cold starting aids not working Verify the aids are operating. Repair/replace inoperative
or are needed. parts.
Intake heater system not Verify system is working. Repair/replace inoperative parts.
working.
Insufficient intake air. Inspect or replace filter and check for obstructions to the air
supply tube.
Air in the fuel system or the Check the flow through the filter and bleed the system. Locate
fuel supply is inadequate. and eliminate the air source.
J9109-232
• ENGINES 9 - 9
SERVICE DIAGNOSIS (DIESEL ENGINE) • PERFORMANCE (CONT.)
ENGINE HARD TO Fuel pump Inoperative. Disconnect fuel line and verify fuel delivery. If needed replace
START, OR WILL pump.
NOT START—SMOKE
FROM EXHAUST Injection pump throttle linkage Visually check the linkage. Tighten/replace linkage.
(Cont'd) loose or damaged.
Contaminated fuel. Verify by operating the engine with clean fuel from a
temporary tank. Check for presence of gasoline. Drain and
flush fuel supply tanks. Replace fuel/water separator filter.
Worn or inoperative injection Visually check fuel delivery with an externally connected
pump. injector to one of the pump outlets. Replace the pump if fuel is
not being delivered.
Injection pump out of time. Check/time the pump (refer to Group 14, Fuel System).
Valves incorrectly adjusted. Adjust valves.
One or more injectors worn or Check/replace bad improperly operating injectors.

not operating properly.
ENGINE STARTS, Idle speed too low for the Adjust the idle speed.
BUT WILL NOT accessories.
KEEP RUNNING
Intake air or exhaust system Visually check for exhaust restriction and inspect the air intake.
restricted. Repair/replace restricting parts.
Air in the fuel system or the Check the flow through the filter and bleed the system. Locate
fuel supply is inadequate. and eliminate the air source.
Fuel waxing due to extremely Verify by inspecting the fuel filter. Clean the system and use
cold weather. climatized fuel. Replace fuel/water separator filter. Check fuel
heater for proper operation.
Contaminated fuel. Verify by operating the engine with clean fuel from a temporary
supply tank. Check for presence of gasoline. Replace fuel/water
separator filter.
SURGING (SPEED If the condition occurs at idle, Adjust the idle.

CHANGE) the idle speed is set too low for
the accessories.
High pressure fuel leak. Inspect/correct leaks in the high pressure lines. Fittings and
delivery valve sealing washers.
One or more injectors worn or

not operating properly. Check/replace the inoperative injectors.
Improperly operating injection

pump. Replace the injection pump.
ROUGH IDLE Cold engine. Refer to troubleshooting logic for intake manifold heater system
(IRREGULARLY FIRING (see Group 11, Exhaust System & Intake Manifold)
OR ENGINE SHAKING)
Idle speed too low for the
accessories. Adjust idle speed.
Engine mounts damaged or

loose. Repair or replace mounts.
J9109-233
9 - 10 ENGINES — _
•
CONDITION possmu CLOSES CORRECTION
ROUGH IDLE High pressure fuel leaks. Correct leaks in the high pressure lines, fittings or delivery
(IRREGULARLY FIRING valves.
OR ENGINE SHAKING)
(Cont'd) Air In the fuel system. Bleed the fuel system and eliminate the source of the air.
Sticking needle valve in an Check and replace the injector with the sticking needle valve.
injector.
ENGINE RUNS ROUGH Fuel injection lines leaking. Correct leaks in the high pressure lines, fittings, injector sealing
OR MISFIRING washers or delivery valves.
Air in the fuel or the fuel Check the flow through the filter and bleed the system. Locate
supply is inadequate. and eliminate the air source.
Contaminated fuel. Verify by operating the engine with clean fuel from a temporary
supply tank. Check for presence of gasoline. Replace fuel/water
separator filter.
Incorrect valve adjustment. Check for a bent push rod and adjust valves. Replace push rod,
if necessary.
Injection pump timing incorrect. Check/time pump (refer to Group 14, Fuel System).
Improperly operating injectors. Replace inoperative injectors.
Defective injection pump Replace injection pump.

(delivery valves).
Camshaft out of time. Check/correct gear train timing alignment.
Damaged camshaft or tappets. Inspect camshaft valve lift. Replace camshaft and tappets.
ENGINE RPM WILL NOT Engine overloaded. Verify high idle speed without load. Investigate operation to be
REACH RATED SPEED sure correct gear is being used.
Improperly operating Verify engine speed with hand tachometer—correct as required.

tachometer.
Throttle linkage worn or Adjust linkage for stop-to-stop fuel control lever travel. Replace
incorrectly adjusted. linkage if necessary.
Partially engaged mechanical Adjust and place shutdown lever in the run position.
shutdown lever.
Inadequate fuel supply. Check the fuel flow through the system to locate the reason for
inadequate fuel supply—correct as required.
Improperly operating injection Replace injection pump.

pump.
LOW POWER Fuel control lever not moving to Check/correct for stop-to-stop travel.
full throttle.
Mechanical/shutdown lever Check to see if the shutdown lever is in run position.

partially engaged.
High oil level. Check/correct oil level.
Engine overloaded. Check for added loading from accessories or driven units, brakes
dragging and other changes in vehicle loading. Repair/replace as
needed.
J9109-264
• ENGINES 9 - 11
SERVICE DIAGNOSIS (DIESEL ENGINE) - PERFORMANCE (CONT.)
LOW POWER SJow throttle response, leaking Tighten the fittings. Replace the pump if the controls are not
(Cont'd) air fuel control tube or functioning.
improperly operating control
in the pump.
Incorrect external injection Verify that injection pump timing marks are aligned (see Group
pump timing. 14, Fuel System).
Inadequate intake air flow. Inspect/replace air cleaner element. Look for other restrictions.
High pressure fuel leak. Inspect/correct leaks in the high pressure lines, fittings injector
sealing washers or delivery valve seals.
Inadequate fuel supply. Check the flow through the filter to locate the source of the
restriction.
High fuel temperature. Verify that fuel heater is off during warm weather. Check for a
restricted fuel drain manifold. Repair/replace as needed.
Poor quality fuel or fuel Verify by operating from a temporary tank with good fuel.
contaminated with gasoline. Check for presence of gasoline. Replace fuel/water separator
filter.
Air leak between the turbo- Check/correct leaks in the air crossover tube, hoses, gaskets,
charger and the intake and around mounting capscrews or through holes in the manifold
manifold. cover.
Exhaust leak at the manifold Check/correct leaks in the manifold or turbocharger gaskets.
or turbocharger. If manifold is cracked, replace manifold.
Improperly operating turbo- Inspect/replace turbocharger.

charger.
Valve clearance incorrect. Check/adjust valves.
Injection pump improperly Check/time pump (refer to Group 14, Fuel System).
operating.
Worn or improperly operating Check/replace injectors.

injectors.
Improperly operating injection Replace injection pump.

pump.
Excessive exhaust restriction. Check/correct the restriction in the exhaust system.
EXCESSIVE EXHAUST Engine running too cold (white Refer to troubleshooting logic for coolant temperature below
SMOKE smoke). normal (refer to Group 7, Cooling System). Inspect intake
manifold heater/KSB valve for proper operation.
Inadequate intake air. Inspect/change air cleaner. Look for other restriction.
Air leak between turbocharger Check/correct leaks in the air crossover tube, hoses, gaskets,
and intake manifold. mounting capscrews or through holes in the manifold cover.
Exhaust leak at the manifold Check/correct leaks in the manifold or turbocharger gaskets.
or turbocharger. If cracked replace manifold.
Improperly operating Inspect/replace turbocharger.

turbocharger.
J9209-57
9 - 12 ENGINES •
SERVICE DIAGNOSIS (DIESEL ENGINE) - PERFORMANCE (CONT.)
EXCESSIVE EXHAUST More than one sealing washer Check and remove extra washer.
SMOKE (Cont'd) under an injector.
Improperly operating injectors. Check and replace inoperative injectors.
Improperly operating or over- Replace injection pump.

fueled injection pump.
Piston rings not sealing Perform blow-by check. Correct as required.

(blue smoke).
ENGINE WILL NOT Fuel shutoff valve inoperative. Stop the engine mechanically with lever on the fuel pump.
SHUT-OFF Check/replace sealing washer, piston and spring.
Engine running on fumes drawn Check the air intake ducts for the source of the fumes.
into the air intake. WARNING: In ease of engine runaway due to flammable fumes
from gasoline spills or turbocharger oil leaks being sucked into the
engine, shut off engine ignition switch first then use a CO* or dry
chemical type fire extinguisher and direct the spray under the front
bumper to remove oxygen supply. The engine air intake is on the
passenger side behind the bumper. The fire extinguisher must bo
directed at this location for emergency shutdown conditions.
COOLANT TEMPERA Low coolant level. (a) Check coolant level. Add coolant, if necessary.
TURE ABOVE NORMAL
(b) Locate and correct the source of the coolant leak. Refer to
troubleshooting logic for coolant loss.
Incorrect/improperly operating Replace cap with the correct rating for the system.
pressure cap.
High lube oil level. Check/drain oil to correct level.
Loose drive belt on water Check/replace belt or belt tensioner.

pump/fan.
Inadequate air flow to the Check/repair radiator core, fan shroud and fan clutch as
radiator. required.
Radiator fins plugged. Blow debris from fins.
Collapsed radiator hose. Replace the hose.
Improperly operating tempera Verify that the gauge and temperature sensor are accurate.
ture sensor/gauge. Replace gauge/sensor, if bad.
Improperly operating, incorrect Check and replace the thermostat.

or no thermostat.
Air in the cooling system. (a) Make sure the fill rate is not being exceeded and the correct
vented thermostat is installed.
(b) Check for loose hose clamps. Tighten if loose.
(c) If aeration continued, check for a compression leak through

the head gasket.
Inoperative water pump. Check and replace the water pump.
incorrect injection pump timing. Verify pump timing marks are aligned. Check/time the injector
pump (refer to Group 7, Cooling System).
J9209-56
• ENGINES 9 - 13
CONDITION POSSIBLE CAUSES COfiiiECTION
COOLANT TEMPERA Overfueled injection pump. Replace the injection pump.

TURE ABOVE NORMAL
(Cont'd) Plugged cooling passages in Flush the system and fill with clean coolant.
radiator, head, head gasket or
block.
Engine overloaded. Verify that the engine load rating is not being exceeded.
COOLANT TEMPERA Too much air flow across the Check/repair viscous fan as required.
TURE BELOW NORMAL radiator.
Incorrect thermostat, broken Check and replace thermostat.

thermostat jiggle pin or
contamination in thermostat.
Temperature sensor or gauge Verify that the gauge and sensor are accurate. If not, replace
inoperative. gauge/sensor.
Coolant not flowing by Check and clean coolant passages.

temperature sensor.
J9109-254
9 - 14 ENGINES — — — •
SERVICE DIAGNOSIS (DIESEL ENGINE) • MECHANICAL
r— ———
CONDITION CORRECTION
POSSIBLE CAUSES
LUBRICATING OIL Low oil level. (a) Check and fill with clean engine oil.
PRESSURE LOW
(b) Check for a severe external oil leak that could reduce the
pressure.
Oil viscosity thin, diluted or Verify the correct oil is being used. Check for oil dilution. Refer
wrong specification. to Contaminated Lube Oil (Engine Diagnosis—Mechanical).
Improperly operating pressure Verify the pressure switch is functioning correctly. If not,
switch/gauge. replace switch/gauge.
Relief valve stuck open. Check/replace valve.
Plugged oil filter. Change oil filter. Oil filter change interval may need to be
revised.
If cooler was replaced, shipping Check/remove shipping plugs.

plugs left in cooler.
If pump replaced, four cylinder Verify that the correct pump is installed. If not, install an oil
oil pump installed in a six pump for a six cylinder engine.
cylinder engine.
Loose or missing cup plugs. Check and replace cup plugs.
Worn oil pump. Check and replace oil pump.
Suction tube loose or seal Check and replace seal.

leaking.
Loose main bearing cap. Check and install new bearings and tighten cap to proper torque.
Worn bearings or wrong inspect and replace connecting rod or main bearings. Check and
bearings installed. replace piston cooling nozzles.
J9109-237
• • — ENGINES 9 - 15
SERVICE DIAGNOSIS (DIESEL ENGINE) - MECHANICAL (CONT.)
LUBRICATING OIL Pressure switch/gauge not Verify the pressure switch is functioning correctly. If not,
PRESSURE TOO HIGH operating properly. replace switch/gauge.
Engine running too cold. Refer to Coolant Temperature Below Normal (Engine Diagnosis-
Performance)
Oil viscosity too thick. Make sure the correct oil Is being used. Refer to Group O,
Lubrication and Maintenance.
Oil pressure regulator valve Check and replace valve, and/or oil cooler cover.
stuck closed or binding.
LUBRICATING OIL LOSS External leaks. Visually inspect for oil leaks. Repair as required.
Crankcase being overfilled. Verify that the correct dipstick is being used.
incorrect oil specification or (a) Make sure the correct oil is being used.
viscosity.
(b) Look for reduced viscosity from dilution with fuel.
(c) Review/reduce the oil change intervals.
Oil cooler leak. Check and replace the oil cooler.
High blow-by forcing oil out Check the breather tube area for signs of oil loss. Perform the
the breather. required repairs.
Turbocharger leaking oil to the Inspect the air ducts for evidence of oil transfer.
air intake. Repair as required.
Worn valve seals. Inspect and replace the valve seals.
Piston rings not sealing (oil Perform blow-by check. Repair as required.
being consumed by the engine).
COMPRESSION Air in the fuel system. Bleed the fuel system (refer to Group 14, Fuel System).
KNOCKS
Poor quality fuel. Verify by operating from a temporary tank with good fuel. Clean
and flush the fuel supply tanks. Replace fuel/water separator
filter.
Engine overloaded. Verify that engine load rating is not being exceeded.
Incorrect injection pump timing. Check and time injection pump (refer to Group 14, Fuel System).
Improperly operating injectors. Check and replace inoperative injectors.
J9109-266
9 - 16 ENGINES •
SERVICE DIAGNOSIS (DIESEL ENGINE) - MECHANICAL (CONT.)
EXCESSIVE VIBRATION Loose or broken engine mounts. Replace engine mounts.
Damaged fan or improperly Check and replace the vibrating components.

operating accessories.
Improperly operating vibration Inspect/replace the vibration damper.

clamper.
Improperly operating fan hub. Inspect/replace the fan hub.
Worn or damaged alternator Check/replace the alternator.

bearing.
Flywheel housing misaligned. Check/correct flywheel alignment.
Loose or broken power Inspect the crankshaft and rods for damage that causes an
component. unbalance. Repair/replace as required.
Worn or unbalanced driveline Check/repair driveline components.

components.
EXCESSIVE ENGINE Drive belt squeal, insufficient Check the tensioner and inspect the drive belt. Make sure water
NOISES tension or abnormally high pump, tensioner pulley, fan hub and alternator turn freely.
loading.
Intake air or exhaust leaks. Refer to Excessive Exhaust Smoke (Engine Diagnosis—
Performance).
Excessive valve lash Adjust valves. Make sure the push rods are not bent and rocker
levers or adjusting screws are not severely worn. Replace bent
or severely worn pads.
Turbocharger noise. Check turbocharger impeller and turbine wheel for housing
contact. Repair/replace as required.
Gear train noise. Visually inspect and measure gear backlash. Replace gears as
required.
Power function knock. Check/replace rod and main bearings.
ALTERNATOR NOT Loose or corroded battery Clean/tighten battery connection.

CHARGING OR IN- connections.
SUFFICIENT CHARGING
Alternator belt slipping. Check/replace belt tensioner. Check/replace belt.
Alternator pulley loose on Tighten pulley.

shaft.
Improperly operating Check/replace alternator.

alternator.
J9109-253
• 3.9L ENGINE 9 - 17
3 . 9 L ENGINE SERVICE P R O C E D U R E S
INDEX
page page
Camshaft 31 General Information 17
Crankshaft 38 Hydraulic Tappets 27
Crankshaft Main Bearings 39 Oil Pan 34
Crankshaft Rear Oil Seals . 40 Oil Pump 34
Cylinder Block 41 Piston / Connecting R o d Assembly 36
Cylinder Head Cover ., 21 Rocker Arms 21
Cylinder Heads . 22 Specifications—3.9L Engine 43
Distributor 33 Timing Chain Cover 29
Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 20 Valve Stem Seal / Spring Replacement . . . . . . . . 27
Engine Front Mounts 17 Valve Timing 28
Engine Rear Mount 18 Valves / Valve Springs 25
Front Crankshaft Oil Seal Replacement . . . . . . . . 31 Vibration Damper 29
GENERAL INFORMATION
The 3.9 Liter (238 CID) six-cylinder engine is a
V-Type, lightweight, single cam, overhead valve en
gine with hydraulic roller tappets (Fig. 1).
Engine Type 90° V-6 OHV

Bore and Stroke 99.3 x 84.0 mm (3.91 x3.31 in.)
Displacement 3.9L (238 cu. in.)
Compression Ratio 9.1:1
Torque 305 N-m (225 ft. lbs.) @ 3,200 rpm
Firing Order.... 1-6-5-4-3-2
Lubrication Pressure Feed-Full Flow Filtration
Engine Oil Capacity 3.8L (4.0 Qts) with Filter
Cooling System Liquid Cooled-Forced Circulation J9309-26
Cooling Capacity 14.3L (15.1 Qts)

Fig. 2 Firing Order
Cylinder Block Cast Iron
Crankshaft Nodular Iron
Cylinder Head Cast Iron i M 3.9L T xxxx XXXXXXXX
Combustion Chambers "Fast Burn" Design
Camshaft Nodular Cast Iron
X = Last Digit of Model Year
Pistons Aluminum Alloy w/Strut M = Plant - M Mound Road
Connecting Rods Forged Steel S Sabillo
J9309-29 T Trenton
K Toluca
Fig. 1 Engine Description 3.9L = Engine Displacement
T = Usage - T Truck
This engine is designed for unleaded fuel. XXXX = Month/Day
Engine lubrication system consists of a rotor type XXXXXXXX - Serial Code - Last 8 Digits of VIN No.
oil pump and a full flow oil filter.
The cylinders are numbered from front to rear; 1,
3, 5 on the left bank and 2, 4, 6 on t h e right bank. J9209-72
The firing order is 1-6-5-4-3-2 (Fig. 2). Fig. 3 Engine identification Number
The engine serial number is stamped into a ma
chined pad located on the left, front corner of the cyl ENGINE FRONT MOUNTS
inder block. When component part replacement is
REMOVAL
necessary, use the engine type and serial number for
reference (Fig. 3).
9 - 18 3.9L ENGINE •
(2) Raise hood and position fan to assure clearance (2) If removed, position the bracket to the block
for radiator top t a n k and hose. (Figs. 4 and 5). Install the bolts and tighten to 41
CAUTION: D O N O T lift the engine by the intake (3) With engine raised SLIGHTLY, install insula
manifold. tors on front bracket (Figs. 4 and 5).
(4) Lower engine with lifting fixture while guiding
(3) Install engine lifting fixture. insulator studs into brackets.
(4) Raise vehicle on hoist. (5) Install attaching bolts and nuts (Figs. 4 and 5).
(5) Remove bolts and nuts from insulators (Figs. 4 Tighten the attaching bolts and nuts to 41 N«m (30
and 5). ft. lbs.) torque,
ATTACHING ATTACHING BRACKET (6) Install insulator stud nuts and washers.
BOLT NUT INSULATOR Tighten the stud nuts to 102 N»m (75 ft. lbs.) torque.
ATTACHING (7) Lower the vehicle.
BOLT
FRAME (8) Remove lifting fixture.
SIDE
ENGINE REAR MOUNT
REMOVAL-2WD
(1) Raise the vehicle on a hoist.
(2) Position a transmission jack in place.
(3) Remove rear mount insulator through-bolt and
n u t (Fig. 6).
(LEFT SIDE) (4) Raise rear of transmission and engine
INSULATOR?
SLIGHTLY.
(RIGHT SIDE) (5) Remove the flange nuts from the frame cross-
J9109-238
member support bracket (Fig. 6).
Fig. 4 Engine Front Mounts—2WD Vehicles (6) Raise rear of transmission enough to provide
insulator to crossmember clearance. Remove the in
ATTACHING INSULATOR BRACKET sulator and the crossmember support bracket. Re
NUT
move the flange nuts and separate the insulator from
FRAME the support bracket (Fig. 6).
SIDE (7) If necessary, remove the attaching bolts hold
STUD
BRACKET NUT ing the transmission support bracket to the transmis
STUD sion (Fig. 6).
NUT» FRONT
INSULATOR
BACKING. BRACKET
PLATE INSTALLA TION-2WD
STUD
ATTACHING
NUT
(1) If removed, position the transmission support
NUT bracket to the transmission. Install the attaching
ATTACHING
STUD bolts and tighten to 68 N*m (50 ft. lbs.) torque.
NUT
NUT (2) Position insulator in transmission support
(RIGHT SIDE)
bracket. Install through-bolt.
ATTACHING FRAME
BOLT s , d e
(3) Be sure insulator is secured in a LEVEL posi
J9109-239 tion relative to transmission rear support bracket.
Tighten the through-bolt n u t to 68 N*m (50 ft. lbs.)
Fig. 5 Engine Front Mounts—4WD Vehicles torque.
(4) Position the crossmember support bracket onto
(6) Raise engine with lifting fixture only far the insulator (Fig. 6). Install the insulator flange
enough to remove insulators. nut(s) and tighten to 41 Nnn (30 ft. lbs.) torque.
(7) If necessary, remove the bracket from the block (5) Using the transmission jack, lower the insula
(Figs. 4 and 5). tor and crossmember support bracket onto the cross-
(8) If necessary, remove the front bracket (4WD) member (Fig. 6).
from the crossmember (Fig. 5). (6) Tighten the crossmember flange nuts to 41 Nnn
INSTALLATION (7) Remove the transmission jack.
(1) If removed, position the front bracket (4WD) to (8) Lower the vehicle.
the crossmember (Fig. 5). Install the attaching n u t s
and tighten to 41 N»m (30 ft. lbs.) torque. HE MO VAL—4 WD
(1) Raise the vehicle on a hoist.
3.9L ENGINE 9 - 19
TRANSMISSION
T
RAN
SMS
IS
O
IN
ATTACHING
BOL
T
THROUGH
BOLT
N
IS
ULA
TOR TRANS
MSIS
O
IN
S
UPP
ORTB RAC
KE
T
N
IS
ULA
TOR
CROSS
M EM B
ER
SUPPORT BRACKET
CROSSMEMBER
FLANGE NUTS A A
TTA
CHN
IG
§^ BOL
T
TRANSMISSION
S
UPP
O RTB RACK
ET J
910
9-
241
Fig. 6 Rear Engine Support—2WD

(2) Remove the skid plate (if equipped) from the (7) Remove the insulator mounting plate (Figs. 8
rear crossmember and transmission crossmember and 9).
(Fig. 7).
T
RAN
SF
ER
(3) Position transmission jack under transmission CA
SE
and raise rear of transmission and engine
SLIGHTLY.
EXT
ENSO
IN
(4) AUTOMATIC TRANSMISSION—Remove A
SS
EM B
LY
the nuts and bolts holding the transmission support
T
RANSM
SIS
O
IN
spacer to the insulator mounting plate (Fig. 8). Re SUP
PORT
move the bolts and nuts holding the engine rear sup S
PA
CER
port plate to the insulator mounting plate (Fig. 8).
(5) MANUAL TRANSMISSION—Remove the
nuts and bolts holding the insulator mounting plate ^— —SPACER
E
NGN
IE RE
AR fjy.^ UPP
ER
to the transfer case (Fig. 9). S
UPP
ORT
(6) Remove insulator mounting bolts, spacers, P
LA
TE ^N
IS UL
A TOR
washers and upper/lower insulators (Figs. 8 and 9). N
IS
ULA
TO R
MOUNT
NIG
PLA
TE
L
OWER
N
IS
ULA
TOR
RA
L
I A
SS
EMB
L
Y J9109-243
Fig. 8 Rear Engine Support—4WD with Automatic

P
U87
3 Transmission
Fig. 7 Skid Plate

TRANSFER ft. lbs.) torque. Install the bolts and tighten the nuts
CASE (Fig. 9 - n u t B) to 41 N-m (30 ft. lbs.) torque.
(6) Install the skid plate.
ENGINE ASSEMBLY
REMOVAL
(1) Scribe hood hinge outlines on hood. Remove the
hood.
(2) Remove the battery.
SPACER (3) Drain cooling system (refer to Group 7, Cooling
INSULATOR UPPER
MOUNTING
System for the proper procedure).
INSULATOR
PLATE (4) Remove the air cleaner.
(5) Disconnect the radiator and heater hoses. Re
NUT® move radiator (refer to Group 7, Cooling System).
(6) Set fan shroud aside.
NUT(B (7) Remove the vacuum lines.
LOWER
INSULATOR (8) Remove the distributor cap and wiring.
RAIL (9) Disconnect the accelerator linkage.
ASSEMBLY J9109-242 (10) Remove MPI throttle body.
(11) Disconnect the fuel lines.
Fig. 9 Rear Engine Support—4WD with Manual (12) Disconnect the starter wires.
Transmission (13) Disconnect the oil pressure wire.
(8) If necessary, remove the transmission support (14) Discharge the air conditioning system, if
spacer (automatic transmission) from the extension equipped (refer to Group 24, Heating and Air Condi
assembly (Fig. 8). tioning for service procedures).
(9) If necessary, remove the engine rear support (15) Disconnect the air conditioning hoses.
plate (automatic transmission) from the transfer case (16) Disconnect the power steering hoses, if
(Fig. 8). equipped.
(17) Remove starter motor (refer to Group 8B, Bat
INSTALLATION-4WD tery/Starter/Generator Service).
(1) If removed, position the engine rear support (18) Remove the generator (refer to Group 8B, Bat
plate (automatic transmission) to the transfer case tery/Starter/Generator Service).
(Fig. 8). Install the bolts and tighten to 41 N-m (30 (19) Raise and support the vehicle on a hoist.
(20) Disconnect exhaust pipe at manifold.
ft. lbs.) torque.
(21) A U T O M A T I C T R A N S M I S S I O N :
(a) Support transmission. This will assure t h a t
spacer (automatic transmission) to the extension as
the torque converter will remain in proper position
sembly (Fig. 8). Install the bolts and tighten to 68
in the transmission housing.
N-m (50 ft. lbs.) torque. (b) Remove bell housing bolts and inspection
(3) Install insulator mounting plate, mounting plate.
bolts, spacers, washers and upper/lower insulators to (c) Attach a C-clamp on front bottom of trans
the rail assembly (Figs. 8 and 9). Tighten the mount mission torque converter housing to prevent torque
ing nuts to 204 N*m (150 ft. lbs.) torque. converter from falling out.
(4) A U T O M A T I C T R A N S M I S S I O N - A l i g n the (d) Remove torque converter drive plate bolts
engine rear support plate and the transmission sup from torque converter drive plate. Mark converter
port spacer to the insulator mounting plate (Fig. 8). and drive plate to aid in assembly.
Lower the engine and transmission onto the insula (22) M A N U A L T R A N S M I S S I O N :
tor mounting plate and install the bolts. Tighten the (a) Support transmission.
transmission support spacer nuts to 204 N-m (150 ft. (b) Disconnect clutch release mechanism and re
lbs.) torque. Tighten the engine rear support plate move transmission to clutch housing bolts.
bolts to 41 N-m (30 ft. lbs.) torque.
(5) M A N U A L TRANSMISSION—Align the C A U T I O N : D O NOT lift the engine by the intake
transfer case to the insulator mounting plate and manifold.
lower the engine and transmission. Install the bolts
(23) Install an engine lifting fixture.
and tighten the nuts (Fig. 9 - nut A) to 204 N-m (150 (24) Remove engine front mount bolts.
• 3.9L ENGINE 9 - 21
(25) Lower the vehicle. (25) Install the air cleaner.

(26) On automatic transmission vehicles, discon (26) Install the battery.
nect the engine from the torque converter drive (27) Warm engine and adjust.
plate. On manual transmission vehicles, move engine (28) Install hood and line up with the scribe
forward until drive pinion shaft clears the clutch marks.
disc. Remove engine from engine compartment. (29) Road test vehicle.
(27) Install engine assembly on engine repair
stand. CYLINDER HEAD COVER
A steel backed silicon gasket is used with the cyl
INSTALLATION inder head cover (Fig. 1). This gasket can be used
(1) Remove engine from the repair stand and posi again.
tion in the engine compartment.
(2) Install engine support fixture. CYLINDER HEAD
COVER GASKET \
(3) Raise and support the vehicle on a hoist.
(a) Position the torque converter and drive plate.
Install torque converter drive plate bolts. Tighten
the bolts to 31 Nnn (270 in. lbs.) torque.
(b) Install the engine front mounts.
(c) Install bell housing bolts. Tighten the bolts to
(d) Remove C-clamp. J9209-104
(e) Install the inspection plate.
(5) M A N U A L T R A N S M I S S I O N : Fig. 1 Cylinder Head Cover Gasket
(a) Position the drive pinion shaft to the clutch REMOVAL
disc. (1) Disconnect the negative cable from the battery.
(b) Connect the clutch release mechanism and
(2) Disconnect closed ventilation system and evap
install the transmission to clutch bolts. Tighten the
oration control system from cylinder head cover.
(3) Remove cylinder head cover and gasket. The
(c) Install the engine front mounts.
gasket may be used again.
(6) Remove transmission support.
(7) Install exhaust pipe to manifold.
CLEANING
Clean cylinder head cover gasket surface.
(9) Remove engine lifting fixture.
Clean head rail, if necessary.
(10) Install the generator (refer to Group 8B, Bat
tery/Starter/Generator Service). INSPECTION
(11) Install starter motor (refer to Group 8B, Bat
Inspect cover for distortion and straighten, if nec
tery/Starter/Generator Service).
essary.
(12) Connect power steering hoses, if equipped.
Check the gasket for use in "head cover installation.
(13) Connect air conditioning hoses.
If damaged, use a new gasket.
(14) Evacuate and charge the air conditioning sys
tem, if equipped (refer to Group 24, Heater and Air INSTALLATION
Conditioning for service procedures).
(1) The cylinder head cover gasket can be used
(15) Using a new gasket, install MPI throttle body.
again. Install the gasket onto the head rail.
Tighten the throttle body bolts to 23 N-m (200 in.
(2) Position the cylinder head cover onto the gas
lbs.) torque.
(16) Connect the accelerator linkage. ket. Tighten the bolts to 11 N-m (95 in. lbs.) torque.
(17) Connect the starter wires. (3) Install closed crankcase ventilation system and
(18) Connect the oil pressure wire. evaporation control system.
(19) Install the distributor cap and wiring. (4) Connect the negative cable to the battery.
(20) Connect the vacuum lines.
(21) Connect the fuel lines. ROCKER ARMS
(22) Install the radiator (refer to Group 7, Cooling
REMOVAL
System). Connect the radiator hoses and heater
(1) Disconnect spark plug wires by pulling on the
hoses.
boot straight out in line with plug.
(23) Install fan shroud in position.
(24) Fill cooling system (refer to Group 7, Cooling (2) Remove cylinder head cover and gasket.
System for the proper procedures).
(3) Remove the rocker arm bolts and pivots (Fig. SPARK SPARK INTAKE
2). Place them on a bench in the same order as re PLUGS PLUG VALVE
moved.
(4) Remove the push rods and place them on a
bench in the same order as removed.
ROCKER
ARMS
EXHAUST INTAKE EXHAUST

VALVE VALVES VALVES J9309-35
Fig. 3 Cylinder Head Assembly
J9209-66
Fig. 2 Rocker Arms

INSTALLATION
(1) Rotate the crankshaft until the "V6" mark
lines up with the TDC mark on the timing chain
case cover. This mark is located 147° ATDC from the
No.l firing position.
Fig. 4 Exhaust Manifold Heat Shields
C A U T I O N : D O N O T rotate or crank the engine dur
(4) Remove the intake manifold-to-generator
ing or immediately after rocker arm installation. Al
bracket support rod. Remove the generator.
low the hydraulic roller tappets adequate time to
(5) Remove closed crankcase ventilation system.
bleed down (about 5 minutes).
(6) Disconnect the evaporation control system.
(2) Install the push rods in the same order as re (7) Remove the air cleaner.
moved. (8) Disconnect the fuel lines.
(3) Install rocker arm and pivot assemblies in the (9) Disconnect accelerator linkage and if so
same order as removed. Tighten the rocker arm bolts equipped, the speed control and transmission kick-
to 28 N*m (21 ft. lbs.) torque. down cables.
(4) Install cylinder head cover. (10) Remove the return spring.
(5) Connect spark plug wires. (11) Remove distributor cap and wires.
(12) Disconnect the coil wires.
CYLINDER HEADS (13) Disconnect heat indicator sending unit wire.
The alloy cast iron cylinder heads (Fig. 3) are held (14) Disconnect heater hoses and bypass hose.
in place by 8 bolts. The spark plugs are located in (15) Remove cylinder head covers and gaskets.
the peak of the wedge between the valves. (16) Remove intake manifold and throttle body as
an assembly. Discard the flange side gaskets and the
REMOVAL front and rear cross-over gaskets.
(1) Disconnect the negative cable from the battery. (17) Remove exhaust manifolds.
(2) Drain cooling system (refer to Group 7, Cooling (18) Remove rocker arm assemblies and push rods.
System for the proper procedures). Identify to ensure installation in original locations.
(3) Remove the heat shields (Fig. 4).
• 3.9L ENGINE 9 - 23
(19) Remove the head bolts from each cylinder

head and remove cylinder heads. Discard t h e cylin
der head gasket.
(20) Remove spark plugs.
CLEANING
Clean all surfaces of cylinder block and cylinder
heads.
Clean cylinder block front and rear gasket surfaces
using a suitable solvent.
INSPECTION
Inspect all surfaces with a straightedge if there is
any reason to suspect leakage. If out-of-flatness ex
ceeds 0.00075 mm/mm (0.00075 inch/inch) times the
span length in any direction, either replace head or
lightly machine the head surface.
FOR EXAMPLE:—A 305 mm (12 inch) span is Fig. 6 Cylinder Head Bolt Tightening Sequence
0.102 mm (0.004 inch) out-of-flat. The allowable out- make sure the piston in that cylinder is N O T at
of-flat is 305 x 0,00075 (12 x 0.00075) equals 0.23 T D C . Contact between the valves and piston could
mm (0.009 inch). This amount of out-of-flat is accept occur.
able.
The cylinder head surface finish should be 1.78- (5) Install push rods and rocker arm assemblies in
3.00 microns (70-125 microinches). their original position. Tighten the bolts to 28 Nnn
Inspect push rods. Replace worn or bent rods. (21 ft. lbs.) torque.
(6) Place the 4 plastic locator dowels into the holes
INSTALLATION in the block Fig. 7).
(1) Apply Perfect Sealant No.5, or equivalent, to (7) Apply Mopar Silicone Rubber Adhesive Seal
both sides of the gasket (Fig. 5). ant, or equivalent, to the four corner joints. An ex
cessive amount of sealant is not required to ensure a
PERFECT SEALANT NO. 5 PERFECT SEALANT NO. 5
leak proof seal. However, an excessive amount of
sealant may reduce the effectiveness of the flange
gasket. The sealant should be slightly higher t h a n
the cross-over gaskets, approx. 5 mm (0.2 in).
(8) Install the front and rear cross-over gaskets
onto the dowels (Fig. 7).
FRONT CROSS-OVER GASKET
Fig. 5 Sealant Location on Cylinder Head Gasket

(2) Position the new cylinder head gaskets onto t h e
cylinder block.
(3) Position the cylinder heads onto head gaskets
and cylinder block.
(4) Starting at top center, tighten all cylinder head
bolts, in sequence, to 68 N»m (50 ft. lbs.) torque (Fig.
6). Repeat procedure, tighten all cylinder head bolts
to 143 N»m (105 ft. lbs.) torque. Repeat procedure to
confirm t h a t all bolts are at 143 N*m (105 ft. lbs.)
torque. REAR CROSS-OVER GASKET J9209-99
C A U T I O N : When tightening the rocker arm bolts, Fig. 7 Cross-Over Gaskets and Locator Dowels
(9) Install the flange gaskets. Be sure t h a t the ver INTAKE
tical port alignment tab is resting on the deck face of AAANIFOLD
the block. Also the horizontal alignment tabs must
be in position with the mating cylinder head gasket
tabs (Fig. 8). The words MANIFOLD SIDE should be
visible on the center of each flange gasket.
FLANGE GASKET
FRONT OF ENGINE
J9209-59
Fig. 9 Intake Manifold Bolt Tightening Sequence

(13) Adjust spark plugs to specifications (refer to
Group 8D, Ignition System). Install the plugs and
tighten to 41 N-m (30 ft. lbs.) torque.
(14) Install coil wires.
(15) Connect heat indicator sending unit wire.
(16) Connect the heater hoses and bypass hose.
(17) Install distributor cap and wires.
(18) Hook up the return spring.
(19) Connect the accelerator linkage and if so
CYLINDER equipped, the speed control and transmission kick-
HEAD GASKET J9209-101
down cables.
Fig. 8 Intake Manifold Flange Gasket Alignment (20) Install the fuel lines.
(21) Install the generator and drive belt. Tighten
(10) Carefully lower intake manifold into position generator mounting bolt to 41 N-m (30 ft. lbs.)
on the cylinder block and cylinder heads. Use the torque. Tighten the adjusting strap bolt to 23 N-m
alignment dowels in the cross-over gaskets to posi (200 in. lbs.) torque. Refer to Group 7, Cooling Sys
tion the intake manifold. After intake manifold is in tem for adjusting the belt tension.
place, inspect to make sure seals are in place. (22) Install the intake manifold-to-generator
(11) The following torque sequence duplicates the bracket support rod. Tighten the bolts.
expected results of the automated assembly system (23) Place the cylinder head cover gaskets in posi
(Fig. 9). tion and install cylinder head covers. Tighten the
• Step 1 - T i g h t e n bolts 1 and 2 to 8 N-m (72 in. lbs.) bolts to 11 N-m (95 in. lbs.) torque.
torque. Tighten in alternating steps 1.4 N-m (12 in. (24) Install closed crankcase ventilation system.
lbs.) torque at a time. (25) Connect the evaporation control system.
• Step 2—Tighten bolts 3 through 12, in sequence, (26) Install the air cleaner.
to 8 N-m (72 in. lbs.) torque. (27) Install the heat shields. Tighten the bolts to
• Step 3—Check t h a t all bolts are tighten to 8 N-m 41 N-m (30 ft. lbs.) torque.
(72 in. lbs.) torque. (28) Fill cooling system (refer to Group 7, Cooling
• Step 4—Tighten all bolts, in sequence, to 16 N-m System for proper procedure).
(12 ft. lbs.) torque. (29) Connect the negative cable to the battery.
• Step 5—Check t h a t all bolts are tighten to 16 N-m
(12) Install exhaust manifolds. Tighten the bolts
and nuts to 34 N-m (25 ft. lbs.) torque.
• 3.9L ENGINE 9 - 25
VALVES / VALVE SPRINGS

The valves are arranged in-line and inclined 18°.
The rocker pivot support and the valve guides are
cast integral with the heads.
This procedure requires the removal of the cylinder
head.
REMOVAL
(1) Remove the cylinder head.
(2) Compress valve springs using Valve Spring
Compressor Tool MD-998772A.
(3) Remove valve retaining locks, valve spring re
tainers, valve stem seals and valve springs.
(4) Before removing valves, remove any burrs from
valve stem lock grooves to prevent damage to the
valve guides. Identify valves to ensure installation in
original location. Fig. 11 Measuring Valve Guide Wear
VALVE CLEANING Reamer O / S Valve Guide Size

Clean valves thoroughly. Discard burned, warped
and cracked valves. 0.076 mm 8.026 - 8.052 mm
Remove carbon and varnish deposits from inside of (0.003 in.) (0.316 -0.317 in.)
valve guides with a reliable guide cleaner.
0.381 mm 8.331 -8.357 mm
VALVE INSPECTION (0.015 in.) (0.328-0.329 in.)
Measure valve stems for wear. If wear exceeds
0.051 mm (0.002 inch), replace the valve.
Measure valve stem guide clearance as follows:
(a) Install Valve Guide Sleeve Tool C-3973 over J9309-30
valve stem and install valve (Fig. 10). The special
Fig. 12 Reamer Sizes
sleeve places the valve at the correct height for
checking with a dial indicator. Use a 2 step procedure so the valve guides are
reamed true in relation to the valve seat:
• Step 1 - R e a m to 0.0763 mm (0.003 inch).
REFACING VALVES / VALVE SEATS

The intake and exhaust valves have a 43-1/4° to
43-3/4° face angle and a 44-1/4° to 44-3/4° seat angle
(Fig. 13).
VAL¥ES
Inspect the remaining margin after the valves are
refaced (Fig. 14). Valves with less than 1.190 mm
Fig. 10 Positioning Valve with Tool C-3973 (0.047 inch) margin should be discarded.
(b) Attach dial indicator Tool C-3339 to cylinder
VALVE SEATS
head and set it at right angle of valve stem being
measured (Fig. 11).
C A U T I O N : D O N O T un-shroud valves during valve
(c) Move valve to and from the indicator. The to
tal dial indicator reading should not exceed 0.432 seat refacing (Fig. 15).
mm (0.017 inch). Ream the guides for valves with
(1) When refacing valve seats, it is important that
oversize stems if dial indicator reading is excessive
the correct size valve guide pilot be used for reseat
or if the stems are scuffed or scored.
Service valves with oversize stems are available ing stones. A true and complete surface must be ob
(Fig. 12). tained.
Slowly turn reamer by hand and clean guide thor (2) Measure the concentricity of valve seat using a
oughly before installing new valve. R e a m the valve dial indicator. Total runout should not exceed 0.051
guides from s t a n d a r d t o 0.381 m m (0,015 inch). mm (0.002 inch) total indicator reading.
A - SEAT WIDTH - INTAKE 1.016 - 1.524 mm (0.040 - 0.060 in.) Fig. 15 Refacing Valve Seats
EXHAUST 1.524 - 2.032 mm (0.060 - 0.080 in.)
3
B - FACE ANGLE (INTAKE & EXHAUST) 4374° - 43 A° VALVE SPRING INSPECTION
C - SEAT ANGLE (INTAKE & EXHAUST) 4474° - 44%° Whenever valves have been removed for inspection,
D - CONTACT SURFACE
reconditioning or replacement, valve springs should
J9309-95 be tested. As an example t h e compression length of
the spring to be tested is 1-5/16 inch. Turn table of
Fig. 13 Valve Face and Seat Angles
Valve Spring Tester Tool C-647 until surface is in
i line with the 1-5/16 inch mark on t h e threaded stud.
Be sure t h e zero mark is to the front (Fig. 16). Place
\ MARGIN / "
INTAKE EXHAUST spring over stud on t h e table and lift compressing le
VALVE VALVE ver to set tone device. Pull on torque wrench until
>FACE'
ping is heard. Take reading on torque wrench a t this
instant. Multiply this reading by 2. This will give
the spring load a t test length. Fractional measure
•STEM" ments are indicated on the table for finer adjust
ments. Refer to specifications to obtain specified
height and allowable tensions. Discard t h e springs
t h a t do not meet specifications.
VALVE SPRING
RETAINER LOCK
GROOVE
J9209-127
Fig. 14 Intake and Exhaust Valves

(3) Inspect t h e valve seat with Prussian blue to de SPECIAL
TOOL C-647
termine where t h e valve contacts t h e seat. To do
this, coat valve seat LIGHTLY with Prussian blue
then set valve in place. Rotate t h e valve with light
pressure. If t h e blue is transferred to t h e center of
valve face, contact is satisfactory. If the blue is trans
ferred to t h e top edge of valve face, lower valve seat
with a 15° stone. If the blue is transferred to bottom 9209-37
edge of valve face raise valve seat with a 60° stone.
(4) When seat is properly positioned t h e width of Fig. 16 Testing Valve Spring for Compressed
intake seats should be 1.016-1.524 m m (0.040-0.060 Length with Tool C-647
inch). The width of t h e exhaust seats should be INSTALLATION
1.524-2.032 mm (0.060-0.080 inch). (1) Coat valve stems with lubrication oil and insert
them in cylinder head.
• 3.9L ENGINE 9 - 27
(2) If valves or seats are reground, check valve the pressure sending unit. The pressure should be be
stem height. If valve is too long, replace cylinder tween 207-552 kPa (30-80 psi) at 3,000 RPM.
head. Check the oil level after the engine reaches normal
(3) Install new seals on all valve guides. Install operating temperature. Allow 5 minutes to stabilize
valve springs and valve retainers. oil level, check dipstick.
(4) Compress valve springs with Valve Spring The oil level in the pan should never be above the
Compressor Tool MD-998772A, install locks and re FULL m a r k or below the ADD OIL mark on dipstick.
lease tool. If valves and/or seats are ground, measure Either of these 2 conditions could be responsible for
the installed height of springs. Make sure the mea noisy tappets.
surement is taken from bottom of spring seat in cyl
inder head to the bottom surface of spring retainer. If OIL LEWEL
spacers are installed, measure from the top of spacer.
If height is greater t h a n 42.86 mm (1-11/16 inches), HIGH
install a 1.587 mm (1/16 inch) spacer in head coun- If oil level is above the FULL mark, it is possible
terbore. This should bring spring height back to nor for the connecting rods to dip into the oil. With the
mal 41.27 to 42.86 mm (1-5/8 to 1-11/16 inch). engine running, this condition could create foam in
the oil pan. Foam in oil pan would be fed to the hy
VALVE STEM SEAL / SPRING REPLACEMENT draulic tappets by the oil pump causing them to lose
This procedure is done with the cylinder head in length and allow valves to seat noisily.
stalled.
(1) Set engine basic timing to TDC and remove air LOW
cleaner. Low oil level may allow oil pump to take in air.
(2) Remove cylinder head covers and spark plugs. When air is fed to the tappets, they lose length
(3) Remove coil wire from distributor and secure to which allows valves to seat noisily. Any leaks on in
good ground to prevent engine from starting. take side of oil pump through which air can be
(4) Using suitable socket and flex handle at crank drawn will create the same tappet action. Check the
shaft retaining bolt, t u r n engine so the No.l piston is lubrication system from the intake strainer to the
at Top Dead Center on the compression stroke. pump cover, including the relief valve retainer cap.
(5) Remove rocker arms. When tappet noise is due to aeration, it may be in
(6) With air hose attached to an adapter installed termittent or constant, and usually more t h a n 1 tap
in No.l spark plug hole, apply 620-689 kPa (90-100 pet will be noisy. When oil level and leaks have been
psi) air pressure. corrected, operate the engine at fast idle. Run engine
(7) Using Valve Spring Compressor Tool for a sufficient time to allow all of the air inside the
MD-998772A, compress valve spring and remove re tappets to be bled out.
tainer valve locks and valve spring.
(8) Install seals on the exhaust valve stem and po TAPPET NOISE DIAGNOSIS
sition down against valve guides. (1) To determine source of tappet noise, operate en
(9) The intake valve stem seals should be pushed gine at idle with cylinder head covers removed.
firmly and squarely over the valve guide using the (2) Feel each valve spring or rocker arm to detect
valve stem as a guide. DO NOT force seal against noisy tappet. The noisy tappet will cause the affected
top of guide. When installing the valve retainer spring and/or rocker arm to vibrate or feel rough in
locks, compress the spring only enough to install the operation.
locks. Worn valve guides or c o c k e d springs are some
(10) Follow the same procedure on the remaining 5 times mistaken for noisy tappets. If s u c h is the
cylinders using the firing sequence 1-6-5-4-3-2. Make case, noise m a y be d a m p e n e d by applying side
sure piston in cylinder is at TDC on the valve spring thrust o n the valve spring. If noise is not appre
that is being removed. ciably reduced, it c a n be a s s u m e d the noise is in
(11) Remove adapter from the No.l spark plug the tappet. Inspect the rocker arm p u s h rod
hole. sockets and p u s h rod e n d s for wear.
(12) Install rocker arms. (3) Valve tappet noise ranges from light noise to a
(13) Install covers and coil wire to distributor. heavy click. A light noise is usually caused by exces
(14) Install air cleaner. sive leak down around the unit plunger or by the
(15) Road test vehicle. plunger partially sticking in the tappet body cylin
der. The tappet should be replaced. A heavy click is
HYDRAULIC TAPPETS caused by a tappet check valve not seating or by for
Before disassembling any part of the engine to cor eign particles becoming wedged between the plunger
rect tappet noise, check the oil pressure. If vehicle and the tappet body. This will cause the plunger to
has no oil pressure gauge, install a reliable gauge at stick in the down position. This heavy click will be
9 - 28 3.9L ENGINE •
accompanied by excessive clearance between the PLUNGER PLUNGER
valve stem and rocker a r m as valve closes. In either SPRING CHECK RETAINER
BALL SPRING CLIP
case, tappet assembly should be removed for inspec
tion and cleaning.
The valve train generates a noise very much like a
light tappet noise during normal operation. Care
ROLLER
TAPPET
I PLUNGER
RETAINER
must be taken to ensure t h a t tappets are making the BODY
noise. In general, if more t h a n one tappet seems to CHECK VALVE PLUNGER
SPRING CAP J9109-220
be noisy, its probably not the tappets.
REMOVAL Fig. 17 Hydraulic Tappet Assembly

(1) Remove the air cleaner. (2) Install tappets and push rods in their original
(2) Remove cylinder head cover. positions. Ensure t h a t the oil feed hole in the side of
(3) Remove rocker assembly and push rods. Iden the tappet body faces up (away from the crankshaft).
tify push rods to ensure installation in original loca (3) Install aligning yokes with ARROW toward
tion. camshaft.
(4) Remove intake manifold. (4) Install yoke retainer. Tighten the bolts to 23
(5) Remove yoke retainer and aligning yokes. N*m (200 in. lbs.) torque. Install intake manifold.
(6) Slide Hydraulic Tappet Remover/Installer Tool (5) Install push rods in original positions.
C-4129-A through opening in cylinder head and seat (6) Install rocker arms.
tool firmly in the head of tappet. (7) Install cylinder head cover.
(7) Pull tappet out of bore with a twisting motion. (8) Start and operate engine. Warm up to normal
If all tappets are to be removed, identify tappets to operating temperature.
ensure installation in original location.
(8) If the tappet or bore in cylinder block is scored, C A U T I O N : To prevent damage to valve mechanism,
scuffed, or shows signs of sticking, ream the bore to engine must not be run above fast idle until all hy
next oversize. Replace with oversize tappet. draulic tappets have filled with oil and have become
quiet.
C A U T I O N : The plunger and tappet bodies are not
interchangeable. The plunger and valve must al
ways be fitted to the original body. It is advisable to VALVE TIMING
work on one tappet at a time to avoid mixing of (1) Turn crankshaft until the No.6 exhaust valve
parts. Mixed parts are not compatible. D O N O T dis is closing and No.6 intake valve is opening.
assemble a tappet on a dirty work bench. (2) Insert a 6.350 mm (1/4 inch) spacer between
rocker arm pad and stem tip of No.l intake valve.
DISASSEMBLE Allow spring load to bleed tappet down giving in ef
(1) Pry out plunger retainer spring clip (Fig. 17). fect a solid tappet.
(2) Clean varnish deposits from inside of tappet (3) Install a dial indicator so plunger contacts
body above plunger cap. valve spring retainer as nearly perpendicular as pos
(3) Invert tappet body and remove plunger cap, sible. Zero the indicator.
plunger, check valve, check valve spring, check valve (4) Rotate the crankshaft clockwise (normal run
retainer and plunger spring (Fig. 17). Check valve ning direction) until the valve has lifted 0.254 mm
could be flat or ball. (0.010 inch). The timing of the crankshaft should
now read from 10° before top dead center to 2° after
ASSEMBLE top dead center. Remove spacer.
(1) Clean all tappet parts in a solvent t h a t will re
move all varnish and carbon. C A U T I O N : D O N O T turn crankshaft any further
(2) Replace tappets t h a t are unfit for further ser clockwise a s valve spring might bottom and result
vice with new assemblies. in serious damage.
(3) If plunger shows signs of scoring or wear, in
stall a new tappet assembly. If valve is pitted, or (5) If reading is not within specified limits:
valve seat on end of plunger is prevented from seat (a) Check sprocket index marks.
ing, install a new tappet assembly. (b) Inspect timing chain for wear.
(4) Assemble tappets (Fig. 17). (c) Check accuracy of DC m a r k on timing indica
tor.
INSTALLATION
(1) Lubricate tappets.
• 3.9L ENGINE I - 21
VIBRATION DAMPER (7) Position the fan shroud and install the bolts.
Tighten the retainer bolts to 11 N*m (95 in. lbs.)
REMOVAL torque.
(1) Disconnect the negative cable from the battery, (3) Connect the negative cable to the battery.
(2) Remove fan shroud retainer bolts and set
shroud back over engine. TIMING CHAIN COVER
(3) Remove the cooling system fan.
REMOVAL
(4) Remove t h e serpentine belt (refer to Group 7,
Cooling System).
(2) Drain cooling system (refer to Group 7, Cooling
(5) Remove the vibration damper pulley.
System).
(6) Remove vibration damper bolt and washer from
(3) Remove the serpentine belt (refer to Group 7,
end of crankshaft. Cooling System).
(7) Install bar and screw from Puller Tool Set (4) Remove water pump (refer to Group 7, Cooling
C-3688. Install 2 bolts with washers through the System).
puller tool and into the vibration damper (Fig. 1). (5) Remove power steering pump (refer to Group
(8) Pull vibration damper off of the crankshaft. 19, Steering).
(6) Remove vibration damper.
(7) Remove fuel lines (refer to Group 14, Fuel Sys
tem).
(8) Loosen oil pan bolts and remove the front bolt
at each side.
(9) Remove the cover bolts.
(10) Remove chain case cover and gasket using ex
treme caution to avoid damaging oil pan gasket.
(11) Place a suitable tool behind the lips of the oil
seal to pry the oil seal outward. Be careful not to
J9209-81 damage the crankshaft seal surface of cover (Fig. 3).
Fig. 1 Vibration Damper Assembly
INSTALLATION
(1) Position the vibration damper onto the crank
shaft.
(2) Place installing tool, part of Puller Tool Set
C-3688 in position and press the vibration damper
onto the crankshaft (Fig. 2).
Fig. 3 Removal of Front Crankshaft Oil Seal

TIMING CHAIN STRETCH
(1) Place a scale next to the timing chain so t h a t
any movement of the chain may be measured.
(2) Place a torque wrench and socket over cam
shaft sprocket attaching bolt. Apply torque in the di
rection of crankshaft rotation to take up slack; 41
#
N m (30 ft. lbs.) torque with cylinder head installed
Fig. 2 Installing Vibration Damper or 2 0 N»m (15 ft. lbs.) torque with cylinder head re
(3) Install the crankshaft bolt and washer. Tighten moved. With a torque applied to the camshaft
the bolt to 183 N*m (135 ft. lbs.) torque. sprocket bolt, crankshaft should not be permitted to
move. It may be necessary to block the crankshaft to
(4) Install the crankshaft pulley. Tighten the pul
prevent rotation.
ley bolts to 23 N*m (200 in. lbs.) torque.
(3) Hold a scale with dimensional reading even
(5) Install the serpentine belt (refer to Group 7,
with the edge of a chain link. With cylinder heads
Cooling System).
installed, apply 14 N*m (30 ft. lbs.) torque in the re
(6) Install the cooling system fan. Tighten the verse direction. With the cylinder heads removed, ap-
bolts to 23 N*m (17 ft. lbs.) torque.
i - 30 3.9L ENGINE
CLEANING
Be sure mating surfaces of chain case cover and
cylinder block are clean and free from burrs.
INSTALLATION
(1) Using a new cover gasket, carefully install
chain case cover to avoid damaging oil pan gasket.
Use a small amount of Mopar Silicone Rubber Adhe
sive Sealant, or equivalent, at the joint between tim
ing chain cover gasket and the oil pan gasket. Finger
J9209-130
tighten the timing chain cover bolts at this time.
Fig. 4 Measuring Timing Chain Wear and Stretch (2) Place the smaller diameter of the oil seal over
Front Oil Seal Installation Tool 6635 (Fig. 6). Seat
ply 20 N*m (15 ft. lbs.) torque in the reverse direc the oil seal in the groove of the tool.
tion. Note the amount of chain movement (Fig. 4). (3) Position the seal and tool onto the crankshaft
(4) Install a new timing chain, if its movement ex (Fig. 7).
ceeds 3.175 mm (1/8 inch).
(5) If chain is not satisfactory, remove camshaft CRANKSHAFT > INSTALL THIS
sprocket attaching bolt and remove timing chain FRONT OIL END INTO
SEAL SPECIAL TOOL
with crankshaft and camshaft sprockets. 6635
(6) Place both camshaft sprocket and crankshaft
sprocket on the bench with timing m a r k s on exact
imaginary center line through both camshaft and
crankshaft bores.
(7) Place timing chain around both sprockets.
(8) Turn crankshaft and camshaft to line up with
keyway location in crankshaft sprocket and in cam
shaft sprocket.
(9) Lift sprockets and chain (keep sprockets tight
against the chain in position as described).
(10) Slide both sprockets evenly over their respec
tive shafts and use a straightedge to check alignment J9309-44
of timing marks (Fig. 5).
Fig. 6 Placing Oil Seal on Installation Tool 6635
SPECIAL TOOL \\ OIL
SEAL
TIMING
J9209-129
MARKS
Fig. 5 Alignment of Timing Marks

(11) Install the camshaft bolt. Tighten the bolt to
68 Nnn (50 ft. lbs.) torque.
(12) Check camshaft end play. The end play should
be 0.051-0.152 mm (0.002-0.006 inch) with a new
thrust plate and up to 0.254 m m (0.010 inch) with a
used thrust plate. If not within these limits install a
new thrust plate. TIMING'
CHAIN
COVER J9309-45-
Fig. 7 Position Tool and Seal onto Crankshaft

• 3.9L ENGINE 9 - 31
(4) Using the vibration damper bolt, tighten t h e tion/alignment tool 6635, should fit with minimum
bolt to draw the seal into position on the crankshaft interference. If tool does not fit, the cover must be re
(Fig. 8). moved and installed properly.
seal to pry t h e oil seal outward. Be careful not to
damage the crankshaft seal surface of cover.
(5) Place the smaller diameter of the oil seal over
the oil seal in the groove of the tool.
(6) Position the seal and tool onto the crankshaft
(Fig. 7).
(7) Using the vibration damper bolt, tighten the
bolt to draw the seal into position on the crankshaft
(Fig. 8).
(8) Remove the vibration damper bolt and seal in
stallation tool.
(9) Install t h e vibration damper.
(10) Connect the negative cable to the battery.
CAMSHAFT
This procedure requires t h a t the engine is removed
from the vehicle..
The camshaft has an integral oil pump and distrib
utor drive gear (Fig. 9).
J9309-46
CHAIN
Fig. 8 installing Oil Seal SPROCKET
(5) Tighten chain case cover bolts to 41 N-m (30 ft.

lbs.) torque. Tighten oil pan bolts to 24 N*m (215 in.
lbs.) torque.
(6) Remove the vibration damper bolt and seal in
stallation tool.
(7) Install vibration damper.
(8) Instajl fuel lines (refer to Group 14, Fuel Sys
tem).
(9) Install water pump and housing assembly us
ing new gaskets (refer to Group 7, Cooling System). Fig. 9 Camshaft and Sprocket Assembly
Tighten bolts to 41 N-m (30 ft. lbs.) torque. REMOVAL
(10) Install power steering pump (refer to Group (1) Remove intake manifold.
19, Steering). (2) Remove cylinder head covers.
(11) Install the serpentine belt (refer to Group 7, (3) Remove timing case cover and timing chain.
Cooling System). (4) Remove rocker arms.
(12) Install the cooling system fan. Tighten the (5) Remove push rods and tappets; identify each
bolts to 23 N-m (17 ft. lbs.) torque. part so it can be installed in the original location.
(13) Position the fan shroud and install the bolts. (6) Remove distributor and lift out the oil pump
Tighten the bolts to 11 N-m (95 in. lbs.) torque. and distributor drive shaft.
(14) Fill cooling system (refer to Group 7, Cooling (7) Remove camshaft thrust plate; note location of
System for the proper procedure). oil tab (Fig. 10).
(15) Connect the negative cable to the battery. (8) Install a long bolt into front of camshaft to fa
cilitate removal of the camshaft. Remove camshaft,
FRONT CRANKSHAFT OIL SEAL REPLACEMENT being careful not to damage cam bearings with the
The oil seal can be replaced without removing the cam lobes.
timing chain cover provided the cover is not mis
aligned. RE MO VAL-BEA RING
(1) Disconnect the negative cable from the battery. (1) With engine completely disassembled, drive out
(2) Remove vibration damper. rear cam bearing core hole plug.
(3) If front seal is suspected of leaking, check front (2) Install proper size adapters and horseshoe
oil seal alignment to crankshaft. The seal installa washers (part of Camshaft Bearing Remover/Installer
9 - 32 3.9L ENGINE •
INSTALLATION
(1) Lubricate camshaft lobes and camshaft bearing
journals and insert the camshaft to within 51 mm (2
inches) of its final position in cylinder block.
W h e n e v e r an e n g i n e h a s b e e n r e b u i l t , a n e w
camshaft and/or n e w t a p p e t s installed, a d d 1
p i n t of M o p a r C r a n k c a s e C o n d i t i o n e r , o r equiv
alent. T h e oil m i x t u r e s h o u l d b e left in e n g i n e
for a m i n i m u m of 805 k m (500 miles). D r a i n a t
t h e n e x t n o r m a l oil c h a n g e .
(2) Install Camshaft Gear Installer Tool C-3509
with tongue back of distributor drive gear (Fig. 12).
Fig, 10 timing Chain Oil Tab installation
Fig. 12 Camshaft Holding Tool C-3509 (Installed

Position)
(3) Hold tool in position with a distributor lock-
plate bolt. This tool will restrict camshaft from being
pushed in too far and prevent knocking out the welch
plug in rear of cylinder block. Tool should remain
installed until the camshaft and crankshaft
sprockets and timing chain h a v e b e e n installed.
(4) Install camshaft thrust plate and chain oil tab.
Make sure tang enters lower right hole in thrust
Fig, 11 Camshaft Bearings Removal and Installation
plate. Tighten bolts to 24 N*m (210 in. lbs.) torque.
with Tool C-3132-A
Top edge of tab should be flat against thrust plate in
Tool C-3132-A) at back of each bearing shell. Drive order to catch oil for chain lubrication.
out bearing shells (Fig. 11). (5) Place both camshaft sprocket and crankshaft
sprocket on the bench with timing marks on exact
INSTALLA TION— BEARING imaginary center line through both camshaft and
(1) Install new camshaft bearings with Camshaft crankshaft bores.
Bearing Remover/Installer Tool C-3132-A by sliding (6) Place timing chain around both sprockets.
the new camshaft bearing shell over proper adapter. (7) Turn crankshaft and camshaft to line up with
(2) Position rear bearing in the tool. Install horse keyway location in crankshaft sprocket and in cam
shoe lock and by reversing removal procedure, care shaft sprocket.
fully drive bearing shell into place. (8) Lift sprockets and chain (keep sprockets tight
(3) Install remaining bearings in the same man against the chain in position as described).
ner. Bearings must be carefully aligned to bring oil (9) Slide both sprockets evenly over their respec
holes into full register with oil passages from the tive shafts and use a straightedge to check alignment
main bearing. If the camshaft bearing shell oil holes of timing marks (Fig. 13).
are not in exact alignment, remove and install them (10) Install the camshaft bolt/cup washer. Tighten
correctly. Install a new core hole plug at the rear of bolt to 68 N*m (50 ft. lbs.) torque.
camshaft. B e s u r e t h i s p l u g d o e s n o t l e a k . (11) Measure camshaft end play. Refer to Specifi
cations for proper clearance. If not within limits in
stall a new thrust plate.
• 3.9L ENGINE 9 - 33

(12) Each tappet reused must be installed in the
same position from which it was removed. W h e n
c a m s h a f t Is r e p l a c e d , a l l o f t h e t a p p e t s m u s t b e
replaced.
DISTRIBUTOR
REMOVAL
Refer to Group 8D, Ignition Systems for the proper
procedure.
REMOVAL-DRIVE SHAFT BUSHING

(1) Insert Distributor Drive Shaft Bushing Puller Fig. 16 Burnishing Distributor Driveshaft Bushing
Tool C-3052 into old bushing and thread down until (1) Rotate crankshaft until No.l cylinder is at top
a tight fit is obtained (Fig. 14). dead center on the firing stroke.
(2) Hold puller screw and tighten puller n u t until (2) When in this position, the timing mark on vi
bushing is removed. bration damper should be under "0" on the timing in
dicator.
(3) Coat shaft and drive gear with engine oil. In
stall t h e shaft so t h a t after the gear spirals into
place, it will index with the oil pump shaft. The slot
on top of drive gear should be aligned towards left
front intake manifold attaching bolt hole (Fig. 17).
INSTALLATION
procedure.
Fig. 14 Distributor Driveshaft Bushing Removal

INSTALLATION-DRIVE SHAFT BUSHING
(1) Slide new bushing over burnishing end of Dis
tributor Drive Shaft Bushing Driver/Burnisher Tool
C-3053. Insert the tool and bushing into the bore.
(2) Drive bushing and tool into position, using a
hammer (Fig. 15).
(3) As the burnisher is pulled through the bushing,
the bushing is expanded tight in the block and bur
nished to correct size (Fig. 16). D O N O T r e a m t h i s
bushing.
DISTRIBUTOR TIMING
Before installing the distributor and oil pump drive
shaft, time engine as follows: Fig. 17 Position of Installed Distributor Drive Gear
OIL PAN
REMOVAL
(2) Remove engine oil dipstick.
(3) Raise vehicle.
(4) Drain engine oil.
(5) Remove exhaust pipe.
(6) Remove left engine to transmission strut.
(7) Remove oil pan and one-piece gasket.
CLEANING
Clean the block and pan gasket surfaces.
Trim or remove excess sealant film in the rear
main cap oil pan gasket groove. DO N O T r e m o v e
t h e s e a l a n t i n s i d e t h e r e a r m a i n c a p slots.
If present, trim excess sealant from inside the en
gine.
Clean oil pan in solvent and wipe dry with a clean
cloth. Fig. 2 Position of Dowels in Cylinder Block
Clean oil screen and pipe thoroughly in clean sol
vent. Inspect condition of screen. (7) Remove the dowels. Install the remaining oil
pan bolts. Tighten these bolts to 23 N-m (200 in. lbs.)
INSPECTION torque.
Inspect oil drain plug and plug hole for stripped or (8) Install the drain plug. Tighten drain plug to 34
damaged threads. Repair as necessary. N-m (27 ft. lbs.) torque.
Inspect oil pan mounting flange for bends or distor (9) Install the engine to transmission strut.
tion. Straighten flange, if necessary. (10) Install exhaust pipe.
(11) Lower vehicle.
INSTALLATION (12) Install dipstick.
(1) Fabricate 4 alignment dowels from 1 1/2 x 5/16 (13) Connect the negative cable to the battery.
inch bolts. Cut the head off the bolts and cut a slot (14) Fill crankcase with oil to proper level.
into the top of the dowel. This will allow easier in
stallation and removal with a screwdriver (Fig. 1). OIL P U 1 P
1
1 / " x 5/16"
2 BOLT REMOVAL
(1) Remove the oil pan.
(2) Remove the oil pump from rear main bearing
cap.
DISASSEMBLE
, DOWEL
(1) Remove the relief valve as follows:
(a) Remove cotter pin. Drill a 3.175 mm (1/8
inch) hole into the relief valve retainer cap and in
SLOT J9209-106 sert a self-threading sheet metal screw into cap.
(b) Clamp screw into a vise and while supporting
Fig. 1 Fabrication of Alignment Dowels oil pump, remove cap by tapping pump body using
(2) Install the dowels in the cylinder block (Fig. 2). a soft hammer. Discard retainer cap and remove
(3) Apply small amount of Mopar Silicone Rubber spring and relief valve (Fig. 3).
Adhesive Sealant, or equivalent in the corner of the (2) Remove oil pump cover (Fig. 4).
cap and the cylinder block. (3) Remove pump outer rotor and inner rotor with
(4) Slide the one-piece gasket over the dowels and shaft (Fig. 4).
onto the block. (4) Wash all parts in a suitable solvent and inspect
(5) Position the oil pan over the dowels and onto carefully for damage or wear.
the gasket.
(6) Install the oil pan bolts. Tighten the bolts to 23
N-m (200 in. lbs.) torque.
OIL PUMP ASSEMBLY or less or if the diameter is 62.7 mm (2.469 inches) or
less, replace outer rotor (Fig. 6).
SPRING COTTER PIN
RELIEF VALVE
RH174
• RETAINER CAP RH176
Fig. 3 Oil Pressure Relief Valve

Fig. 6 Measuring Outer Rotor Thickness
INNER ROTOR DISTRIBUTOR DRIVESHAFT
A N D SHAFT m m (REFERENCE) If inner rotor measures 20.9 mm (0.825 inch) or
less, replace inner rotor and shaft assembly (Fig. 7).
COTTER PIN
RELIEF VALVE RETAINER

CAP
SPRING
LARGE CHAMFERED
EDGE RY10B
Fig. 4 Oil Pump

INSPECTION
Mating surface of the oil pump cover should be RH177
smooth. Replace pump assembly if cover is scratched
or grooved. . Fig. 7 Measuring Inner Rotor Thickness
Lay a straightedge across the pump cover surface
(Fig. 5). If a 0.038 mm (0.0015 inch) feeler gauge can Slide outer rotor into pump body. Press rotor to t h e
be inserted between cover and straightedge, pump side with your fingers and measure clearance be
assembly should be replaced. tween rotor and pump body (Fig. 8). If clearance is
0.356 mm (0.014 inch) or more, replace oil pump as
STRAIGHT EDGE> sembly.
COVER
FEELER GUAGE
OUTER ROTOR
RH175
RH178
Fig. 5 Checking Oil Pump Cover Flatness PUMP BODY
Measure thickness and diameter of outer rotor. If Fig. 8 Measuring Outer Rotor Clearance in Housing
outer rotor thickness measures 20.9 mm (0.825 inch)
9 - 36 3.9L ENGINE •
Install inner rotor and shaft into pump body. If
clearance between inner and outer rotors is 0.203
mm (0.008 inch) or more, replace shaft and both ro
tors (Fig. 9).
OUTER
ROTOR
INNER RN98
ROTOR
Fig. 11 Proper Installation of Retainer Cap
(2) Position the oil pump cover onto the pump
RH179 body. Tighten cover bolts to 11 N-m (95 in. lbs.)
torque.
Fig. 9 Measuring Clearance Between Rotors (3) Install the relief valve and spring. Insert the
Place a straightedge across the face of the pump, cotter pin.
between bolt holes. If a feeler gauge of 0,102 mm (4) Tap on a new retainer cap.
(0.004 inch) or more can be inserted between rotors (5) Prime oil pump before installation by filling ro
and the straightedge, replace pump assembly (Fig. tor cavity with engine oil.
10).
INSTALLATION
(1) Install oil pump. During installation slowly ro
tate pump body to ensure driveshaft-to-pump rotor
shaft engagement.
(2) Hold the oil pump base flush against mating
surface on No.4 main bearing cap. Finger tighten
pump attaching bolts. Tighten attaching bolts to 41
(3) Install the oil pan.
PISTON / CONNECTING ROD ASSEMBLY

The pistons are elliptically turned so t h a t the di
ameter at the pin boss is less t h a n its diameter
across the thrust face. This allows for expansion un
Fig. 10 Measuring Clearance Over Rotors
der normal operating conditions. Under operating
Inspect oil pressure relief valve plunger for scoring temperatures, expansion forces the pin bosses away
and free operation in its bore. Small marks may be from each other, causing the piston to assume a more
removed with 400-grit wet or dry sandpaper. nearly round shape.
The relief valve spring has a free length of approx All pistons are machined to the same weight, re
imately 49.5 mm (1.95 inches). The spring should gardless of size, to maintain piston balance.
test between 19.5 and 20.5 pounds when compressed The piston pin rotates in the piston only and is re
to 34 mm (1-11/32 inches). Replace spring t h a t fails tained by the press interference fit of the piston pin
to meet these specifications (Fig. 11). in the connecting rod.
If oil pressure was low and pump is within specifi
cations, inspect for worn engine bearings or other REMOVAL
reasons for oil pressure loss. (1) Remove the engine from the vehicle.
ASSEMBLE (3) Remove the oil pan.
(1) Install pump rotors and shaft, using new parts (4) Remove top ridge of cylinder bores with a reli
as required. able ridge reamer before removing pistons from cyl
inder block. Be sure to keep tops of pistons covered
during this operation.
(5) Be sure the connecting rod and connecting rod (a) Measure piston ring gap 2 inches from bot
cap are identified with the cylinder number. Remove tom of cylinder bore. An inverted piston can be
connecting rod cap. Install connecting rod bolt guide used to push the rings down to ensure positioning
set on connecting rod bolts. rings squarely in the cylinder bore before measur
(6) Pistons and connecting rods must be removed ing.
from top of cylinder block. When removing piston (b) Insert feeler gauge in the gap. The top com
and connecting rod assemblies from the engine, ro pression ring gap should be between 0.254-0.508
tate crankshaft so t h a t the connecting rod is centered mm (0.010-0.020 inch). The second compression
in cylinder bore and at BDC. B e careful not to nick ring gap should be between 0.508-0.762 m m (0.020-
crankshaft journals. 0.030 inch). The oil ring gap should be 0.254-1.270
(7) After removal, install bearing cap on the mat mm (0.010-0.050 inch).
ing rod. (c) Rings with insufficient end gap may be prop
erly filled to the correct dimension. Rings with ex
INSPECTION cess gaps should not be used.
Check the crankshaft connecting rod journal for ex (2) Install rings and confirm ring side clearance:
cessive wear, taper and scoring. (a) Install oil rings being careful not to nick or
Check the cylinder block bore for out-of-round, scratch the piston.
taper, scoring and scuffing. (b) Install the compression rings using Installa
Check the pistons for taper and elliptical shape be tion Tool C-4184. The top compression may be in
fore they are fitted into the cylinder bore (Fig. 12). stalled with either side up. The second compression
DIAMETER (D) ring must be installed with the identification mark
SHOULD BE 98.704-98.831 mm face up (toward top of piston) and the chamfer
0.0000-0.0152 mm -(3.886-3.891 in.)-
(0.0000-0.0006 in.) 98.577-98.704 mm-
should face down. An identification m a r k on the
LARGER THAN (C). (3.881-3.886 in.) ring is a drill point, a stamped letter "O", an oval
depression or the word TOP.
(c) Measure side clearance between piston ring
and ring land (Fig. 13). Clearance should be 0.038-
0.076 mm (0.0015-0.0030 inch) for the compression
rings. The steel rail oil ring should be free in
groove, but should not exceed 0.203 m m (0.0080
inch) side clearance.
FEELER GAUGE
ELLIPTICAL SHAPE OF THE PISTON

SKIRT SHOULD BE 0.254-0.304 mm
(0.010-0.012 in.) LESS AT DIAMETER
(A) THAN ACROSS THE THRUST
FACES AT DIAMETER (B).
J9309-9
Fig. 12 Piston Measurements

FITTING PISTONS
Piston and cylinder wall must be clean and dry.
J9209-136
Specified clearance between the piston and the cylin
der wall is 0.013-0.038 mm (0.0005-0.0015 inch). Fig. 13 Measuring Piston Ring Side Clearance
Piston diameter should be measured at the top of
(d) Pistons with insufficient or excessive side
skirt, 90° to piston pin axis. Cylinder bores should be
clearance should be replaced.
measured halfway down the cylinder bore and trans
(3) Orient the rings:
verse to the engine crankshaft center line.
(a) Arrange top compression ring 90° counter
Pistons and cylinder bores should be measured at
clockwise from the oil ring rail gap (Fig. 14).
normal room temperature, 21°C (70°F).
(b) Arrange second compression ring 90° clock
FITTING RINGS wise from the oil ring rail gap (Fig. 14).
(1) Measurement of end gaps:
9 - 38 3.9L ENGINE •
OIL RING (5) Rotate crankshaft so t h a t the connecting rod
SPACER GAP
journal is on the center of the cylinder bore. Be sure
connecting rod and cylinder bore number are the
same. Insert rod and piston into cylinder bore and
guide rod over the crankshaft journal.
SECOND
COMPRESSION
(6) Tap the piston down in cylinder bore, using a
TOP hammer handle. At the same time, guide connecting
RING G A P
COMPRESSION
RING GAP
OIL RING RAiL rod into position on crankshaft journal.
G A P (TOP)
(7) The notch or groove on top of piston must be
pointing toward front of engine. The larger chamfer
of the connecting rod bore must be installed toward
crankshaft journal fillet.
(8) Install rod caps. Be sure connecting rod, con
OIL RING RAIL necting rod cap and cylinder bore number are the
G A P (BOTTOM) J9309-80 same. Install nuts on cleaned and oiled rod bolts and
Fig. 14 Proper Ring Installation tighten nuts to 61 N»m (45 ft. lbs.) torque.
CONNECTING ROD BEARINGS (10) Install the cylinder head.
Fit all rods on a bank until completed. DO NOT al (11) Install the engine into the vehicle.
ternate from one bank to another, because connect
ing rods and pistons are not interchangeable from CRANKSHAFT
one bank to another. A crankshaft which has undersize journals will be
The bearing caps are not interchangeable and stamped with 1/4 inch letters near the notch of the
should be marked at removal to ensure correct as No.6 crankshaft counterweight (Fig. 15).
sembly. FOR EXAMPLE:R2 stamped on the No.6 crank
Each bearing cap has a small V-groove across the shaft counterweight indicates t h a t the No.2 rod jour
parting face. When installing the lower bearing nal is 0.025 mm (0.001 in) undersize. M4 indicates
shell, make certain t h a t the V-groove in the shell is t h a t the No.4 main journal is 0.025 mm (0.001 in)
in line with the V-groove in the cap. This provides undersize. R3 M2 indicates t h a t the No.3 rod journal
lubrication of the cylinder wall in the opposite bank. and the No.2 main journal are 0.025 mm (0.001 in)
The bearing shells must be installed so t h a t the undersize.
tangs are in the machined grooves in the rods and
caps. Undersize Journal Identification Stamp
Limits of taper or out-of-round on any crankshaft ROD - 0.025mm (0.001 in.) Rl-R2-R3-Etc.
journals should be held to 0.025 mm (0.001 inch).
MAIN - 0.025mm (0.001 in.) M1-M2-M3 or M4
Bearings are available in 0.025 mm (0.001 inch),
0.051 mm (0.002 inch), 0.076 mm (0.003 inch), 0.254
STEEL STAMP IDENTIFICATION
mm (0.010 inch) and 0.305 mm (0.012 inch) under- R (ROD) A N D / O R M (MAIN) FOLLOWED
size. Install the bearings in pairs. DO NOT u s e a BY THE ROD OR M A I N NUMBER
n e w bearing half with an old bearing half. DO
NOT file the rods or bearing caps.
INSTALLATION
(1) Be sure t h a t compression ring gaps are stag
gered so t h a t neither is in-line with oil ring rail gap.
(2) Before installing the ring compressor, make
sure the oil ring expander ends are butted and the
rail gaps located properly (Fig. 14). Fig. 15 Location of Crankshaft Identification
(3) Immerse the piston head and rings in clean en
When a crankshaft is replaced, all main and con
gine oil. Slide Piston Ring Compressor Tool C-385
necting rod bearings should be replaced with new
over the piston and tighten with the special wrench
bearings. Therefore, selective fitting of the bearings
(part of Tool C-385). B e sure position of rings d o e s
is not required when a crankshaft and bearings are
not c h a n g e during this operation.
replaced.
(4) Install connecting rod bolt protectors on rod
bolts, the long protector should be installed on the REMOVAL
numbered side of the connecting rod. (1) Remove the oil pan.
• 3.9L ENGINE 9 - 39
(2) Remove the oil pump from the rear m a i n bear

ing cap.
( 8 ) Identify bearing caps before removal. Remove
bearing caps and bearings one at a time.
(4) Lift the crankshaft out of the block.
(5) Remove and discard the crankshaft rear oil
seals.
(6) Remove and discard the front crankshaft oil
seal.
INSPECTION OF JOURNALS
The crankshaft connecting rod and main journals
should be checked for excessive wear, taper and scor
ing. The maximum taper or out-of-round on any
crankshaft journal is 0.025 mm (0.001 inch). BEARING CAP J9309-72
Journal grinding should not exceed 0.305 mm
Fig. 16 Sealant Application to Bearing Cap
(0.012 inch) under the standard journal diameter. DO
NOT grind thrust faces of No.3 main bearing. DO ply enough sealant until a small amount is squeezed
NOT nick crank pin or bearing fillets. After grind out. Withdraw nozzle and wipe excess sealant off the
ing, remove rough edges from crankshaft oil holes oil pan seal groove.
and clean out all oil passages. (11) Install new front crankshaft oil seal.
(12) Immediately install the oil pan.
C A U T I O N : After any journal grind, it is important
MOPAR SILICONE SEALANT
that the final paper or cloth polish be in the s a m e RUBBER ADHESIVE APPLIED
direction a s the engine rotates.
INSTALLATION
(1) Lightly oil the new upper seal lips with engine
oil.
(2) Install the new upper rear bearing oil seal with
the yellow paint facing towards the rear of the en
gine.
(3) Position the crankshaft into the cylinder block.
(4) Lightly oil the new lower seal lips with engine
oil.
(5) Install the new lower rear bearing oil seal into
the bearing cap with the yellow paint facing towards
the rear of the engine. Fig. 17 Apply Sealant to Bearing Cap to Block Joint
(6) Apply 5 mm (0.20 in) drop of Loctite 515, or CRANKSHAFT MAIN BEARINGS
equivalent, on each side of the rear main bearing cap Bearing caps are not interchangeable and should
(Fig. 16). Do not over apply sealant or allow the seal be marked at removal to ensure correct assembly.
ant to contact the rubber seal. Assemble bearing cap Upper and lower bearing halves are NOT inter
to cylinder block immediately after sealant applica changeable. Lower main bearing halves of No.l and
tion. 3 are interchangeable.
(7) To align the bearing cap, use cap slot, align Upper and lower No.2 bearing halves are flanged
ment dowel and cap bolts. Do not remove excess ma to carry the crankshaft thrust loads. They are NOT
terial after assembly. Do not strike rear cap more interchangeable with any other bearing halves in the
t h a n 2 times for proper engagement. engine (Fig. 18). Bearing shells are available in stan
(8) Clean and oil all cap bolts. Install all main dard and the following undersizes: 0.25 mm (0.001
bearing caps. Install all cap bolts and alternately inch), 0.051 mm (0.002 inch), 0.076 mm (0.003 inch),
tighten to 115 N»m (85 ft. lbs.) torque. 0.254 mm (0.010 inch) and 0.305 mm (0.012 inch).
(9) Install oil pump. Never install an undersize bearing t h a t will reduce
(10) Apply Mopar Silicone Rubber Adhesive Seal clearance below specifications.
ant, or equivalent, at bearing cap to block joint to
REMOVAL
provide cap to block and oil pan sealing (Fig. 17). Ap-
S - 40 3.9L ENGINE
(3) Install the bearing caps. Clean and oil the

bolts. Tighten the capbolts to 115 N*m (85 ft. lbs.)
torque.
(4) Install the oil pump.
CRANKSHAFT REAR OIL SEALS

The service seal is a 2 piece, viton seal. The upper
seal half can be installed with crankshaft removed
from engine or with crankshaft installed. When a
new upper seal is installed, install a new lower seal.
39 The lower seal half can only be installed with the
rear main bearing cap removed.
Fig. 18 Main Bearing identification
UPPER SEAL REPLACEMENT (CRANKSHAFT
(2) Remove the oil pump from the rear main bear REMOVED)
ing cap. (1) Remove the crankshaft. Discard the old upper
(3) Identify bearing caps before removal. Remove seal.
bearing caps one at a time. (2) Lightly oil the new upper seal lips with engine
(4) Remove upper half of bearing by inserting oil.
Crankshaft Main Bearing Remover/Installer Tool (3) Install the new upper rear bearing oil seal with
C-3059 into the oil hole of crankshaft (Fig. 19). the yellow paint facing towards the rear of the en
(5) Slowly rotate crankshaft clockwise, forcing out gine.
upper half of bearing shell. (4) Position the crankshaft into the cylinder block.
(5) Lightly oil the new lower seal lips with engine
oil.
the rear of the engine.
(7) Apply 5 mm (0.20 in) drop of Loctite 515, or
equivalent, on each side of the rear main bearing cap
(Fig. 16). Do not over apply sealant or allow the seal
ant to contact the rubber seal. Assemble bearing cap
to cylinder block immediately after sealant applica
tion.
(8) To align the bearing cap, use cap slot, align
ment dowel and cap bolts. Do not remove excess ma
terial after assembly. Do not strike rear cap more
t h a n 2 times for proper engagement.
(9) Clean and oil all cap bolts. Install all main
Fig. 19 Upper Main Bearing Removal and bearing caps. Install all cap bolts and alternately
installation with Tool C-3059 tighten to 115 N*m (85 ft. lbs.) torque.
INSTALLATION (10) Install oil pump.
Only one main bearing should be selectively fitted (11) Apply Mopar Silicone Rubber Adhesive Seal
while all other main bearing caps are properly tight ant, or equivalent, at bearing cap to block joint to
ened. All bearing capbolts removed during service provide cap to block and oil pan sealing (Fig. 17). Ap
procedures are to be cleaned and oiled before instal ply enough sealant until a small amount is squeezed
lation. out. Withdraw nozzle and wipe excess sealant off the
When installing a new upper bearing shell, slightly oil pan seal groove.
chamfer the sharp edges from the plain side. (12) Install new front crankshaft oil seal.
(1) Start bearing in place, and insert Crankshaft (13) Immediately install the oil pan.
Main Bearing Remover/Installer Tool C-3059 into oil UPPER SEAL REPLACEMENT (CRANKSHAFT
hole of crankshaft (Fig. 19). INSTALLED)
(2) Slowly rotate crankshaft counterclockwise slid (1) Remove the oil pan.
ing the bearing into position. Remove Tool C-3059. (2) Remove the oil pump from the rear main bear
ing cap.
• 3.9L ENGINE 9 - 41
(3) Remove the rear main bearing cap. Remove ant to contact the rubber seal. Assemble bearing cap
and discard the old lower oil seal. to cylinder block immediately after sealant applica
(4) Carefully remove and discard t h e old upper oil tion.
seal. (8) To align the bearing cap, use cap slot, align
(5) Lightly oil the new upper seal lips with engine ment dowel and cap bolts. Do not remove excess ma
oil. To allow ease of installation of t h e seal, loosen at terial after assembly. Do not strike rear cap more
least the 2 main bearing caps forward of the rear t h a n 2 times for proper engagement.
bearing cap. (9) Install the rear main bearing cap with cleaned
(6) Rotate the new upper seal into the cylinder and oiled cap bolts. Alternately tighten the cap bolts
block being careful not to shave or cut the outer sur to 115 Nnn (85 ft. lbs.) torque.
face of the seal. To assure proper installation, use the (10) Install oil pump.
installation tool provided with the kit. Install the (11) Apply Mopar Silicone Rubber Adhesive Seal
new seal with the yellow paint facing towards the ant, or equivalent, at bearing cap to block joint to
rear of the engine. provide cap to block and oil pan sealing (Fig. 17). Ap
(7) Install the new lower rear bearing oil seal into ply enough sealant until a small amount is squeezed
the bearing cap with the yellow paint facing towards out. Withdraw nozzle and wipe excess sealant off the
the rear of the engine. oil pan seal groove.
(8) Apply 5 mm (0.20 in) drop of Loctite 515, or (12) Immediately install the oil pan.
(Fig. 16). Do not over apply sealant or allow the seal CYLINDER BLOCK
ant to contact the rubber seal. Assemble bearing cap Remove the engine assembly from the vehicle.
to cylinder block immediately after sealant applica
DISASSEMBLE
tion. Be sure the yellow paint faces toward the rear
of the engine.
ment dowel and cap bolts. Do not remove excess ma (3) Remove the piston/connecting rod assembly.
than 2 times for proper engagement. CLEANING
(10) Install the rear main bearing cap with cleaned Clean cylinder block thoroughly and check all core
and oiled cap bolts. Alternately tighten ALL cap hole plugs for evidence of leaking.
bolts to 115 N-m (85 ft. lbs.) torque. INSPECTION
(11) Install oil pump. Examine block for cracks or fractures.
(12) Apply Mopar Silicone Rubber Adhesive Seal The cylinder walls should be checked for out-of-
ant, or equivalent, at bearing cap to block joint to round and taper with Cylinder Bore Indicator Tool
provide cap to block and oil pan sealing (Fig. 17). Ap C-119. The cylinder block should be bored and honed
ply enough sealant until a small amount is squeezed with new pistons and rings fitted if:
out. Withdraw nozzle and wipe excess sealant off the • The cylinder bores show more t h a n 0.127 mm
oil pan seal groove. (0.005 inch) out-of-round.
(13) Immediately install the oil pan. • The cylinder bores show a taper of more than
0.254 mm (0.010 inch).
LOWER SEAL REPLACEMENT • The cylinder walls are badly scuffed or scored.
(1) Remove the oil pan. Boring and honing operation should be closely co
(2) Remove the oil pump from the rear main bear ordinated with the fitting of pistons and rings so
ing cap. specified clearances may be maintained.
(3) Remove the rear main bearing cap and discard Refer to Standard Service Procedures in the begin
the old lower seal. ning of this Group for the proper honing of cylinder
(4) Carefully install a new upper seal (refer to Up bores.
per Seal Replacement - Crankshaft Installed proce
dure above). OIL LINE PLUG
(5) Lightly oil the new lower seal lips with engine The oil line plug is located in the vertical passage
oil. at the rear of the block between the Oil-To-Filter and
(6) Install a new lower seal in bearing cap with Oil-From-Filter passages (Fig. 20). Improper installa
yellow paint facing the rear of engine. tion or plug missing could cause erratic, low or no oil
(7) Apply 5 mm (0.20 in) drop of Loctite 515, or pressure.
equivalent, on each side of the rear main bearing cap (1) Remove oil pressure sending unit from back of
(Fig. 16). Do not over apply sealant or allow the seal block.
(2) Insert a 3.175 mm (1/8 inch) finish wire or
equivalent into passage.
(3) Plug should be 192.0 to 195.2 mm (7-1/2 to
7-11/16 inches) from machined surface of block (Fig.
20). If plug is too high, use a suitable flat dowel drift
to position properly.
RIGHT OIL GALLERY
CYLINDER
BLOCK
PLUG
RH157
OIL FROM FILTER
TO SYSTEM
Fig. 21 Location of Cup Plugs in Oil Galleries
CYLINDER
OIL TO FILTER ^ BLOCK
/
Jr
SECOND
REMOVE PLUG
CRANKSHAFT FROM OIL PUMP J9209-147 WITH PLIERS
Fig. 20 Oil Line Plug

FIRST
(4) If plug is off position, remove oil pan and rear STRIKE HERE
main bearing cap. Use suitable flat dowel to remove WITH HAMMER
plug. Coat outside diameter of new plug with Mopar

(stud and bearing mount adhesive), or equivalent.
Plug should be 54.0 to 57.7 mm (2-1/8 to 2-5/16
inches) from bottom of the block. DRIFT 9209-41
(5) Assemble engine and check oil pressure.
Fig. 22 Core Hole Plug Removal
ENGINE CORE, OIL AND CAMSHAFT PLUGS INSTALLATION
Engine core plugs have been pressed into the oil
(1) Coat edges of plug and core hole with Mopar
galleries behind the camshaft t h r u s t plate (Fig. 21).
Gasket Maker, or equivalent.
This will reduce internal leakage and help maintain
higher oil pressure at idle. C A U T I O N : D O NOT drive cup plug into the casting
a s restricted coolant flow can result and cause s e
REMOWAL
rious engine problems.
(1) Using a blunt tool such as a drift or a screw
driver and a hammer, strike the bottom edge of the (2) Using proper drive plug, drive plug into hole.
cup plug (Fig. 22). The sharp edge of the plug should be at least 0.50
(2) With the cup plug rotated, grasp firmly with mm (0.020 inch) inside the lead-in chamfer.
pliers or other suitable tool and remove plug (Fig. It is not necessary to wait for curing of the sealant.
22). The cooling system can be filled and the vehicle
placed in service immediately.
CLEANING *
Thoroughly clean inside of cup plug hole in cylin ASSEMBLE
der block or head. Be sure to remove old sealer. (1) Install the piston/connecting rod assembly.
Make certain the new plug is cleaned of all oil or (2) Install the oil pan.
grease. (3) Install the cylinder head.
(4) Install the engine into the vehicle.
SPECIFICATIONS—3.9L ENGINE
ENGINE SPECIFICATIONS
Camshaft
Bearing Diameter End Play 0.051-0.178 mm
No. 1 50.800-50.825 mm (0.002-0.007 in)
(2.000-2.001 in) Max. Allowable . 0.254 mm
No. 2 . . . 50.394-50.419 mm (0.010 in)
(1.984-1.985 in) Main Bearing Journals
No. 3 49.606-49.632 mm Diameter 63.487-63.513 mm
(1.953-1.954 in) (2.4995-2.5005 in)
No. 4 39.688-39.713 mm Out-of-Round (Max.) . 0.0254 mm
(1.5625-1.5635 in) (0.001 in)
Diametrical Clearance 0.0254-0.0762 mm Taper (Max.) 0.0254 mm
(0.001-0.003 in) (0.001 in)
Max. Allowable 0.127 mm
(0.005 in) C y l i n d e r Block
End Play 0.051-0.254 mm Cylinder Bore
(0.002-0.010 in) Diameter . 99.314-99.365 mm
Bearing Journal Diameter (3.910-3.912 in)
No. 1 . . . . 50.749-50.775 mm Out-of-Round (Max.) 0.127 mm
(1.998-1.999 in) (0.005 in)
No. 2 50.343-50.368 mm Taper (Max.) . 0.254 mm
(1.982-1.983 in) (0.010 in)
No. 3 49.555-49.581 mm Oversize (Max.) . 1.016 mm
(1.951-1.952 in) (0.040 in)
No. 4 . . . . 39.637-39.662 mm Distributor Lower Drive Shaft
(1.5605-1.5615 in) Bushing (Press Fit in Block) . . . . 0.0127-0.3556 mm
(0.0005-0.0140 in)
Connecting R o d s Shaft-to-Bushing Clearance 0.0178-0.0686 mm
Bearing Clearance 0.0127-0.0559 mm (0.0007-0.0027 in)
(0.0005-0.0022 in) Tappet Bore Diameter 22.99-23.01 mm
Piston Pin Bore Diameter 24.940-24.978 mm (0.9051-0.9059 in)
(0.9819-0.9834 in)
Side Clearance (Two Rods) 0.152-0.356 mm Cylinder Head
(0.006-0.014 in) Compression Pressure 689 kPa
Total Weight (Less Bearing) 726 grams (100 psi)
(25.61 oz) Gasket Thickness (Compressed) 1.2065 mm
(0.0475 in)
Crankshaft Valve Seat
Connect Rod Journal Angle 44.25° - 44.75°
Diameter 53.950-53.975 mm Runout (Max.) 0.0762 mm
(2.124-2.125 in) (0.003 in)
Out-of-Round (Max.) . 0.0254 mm Width (Finish) - Intake 1.016-1.542mm
(0.001 in) (0.040-0.060 in)
Taper (Max.) 0.0254 mm Width (Finish) - Exhaust. 1.524-2.032 mm
(0.001 in) (0.060-0.080 in)
Diametrical Clearance H y d r a u l i c Tappets

No. 1 0.0127-0.0381 mm Body Diameter . . 22.949-22.962 mm
(0.0005-0.0015 in) (0.9035-0.9040 in)
Nos. 2, 3, and 4 0.0127-0.0508 mm Clearance in Block. . 0.0279-0.0610 mm
(0.0005-0.0020 in) (0.0011-0.0024 in)
Max. Allowable (Nos. 2, 3, & 4) . . . 0.0635 mm Dry Lash 1.524-5.334 mm
(0.0025 in) (0.060-0.210 in)
Push Rod Length 172.57-173.08 mm
(6.794-6.814 in)
J9309-96
ENGINE SPECIFICATIONS (CONT.f
Oil P u m p Piston Pins

Clearance Over Rotors ( M a x . ) . . . . . 0.1016 mm Clearance
(0.004 in) In Piston 0.00635-0.01905 mm
Cover Out-of-Flat (Max.) 0.0381 mm (0.00025-0.00075 in)
(0.0015 in) In Rod (Interference) 0.0178-0.0356 mm
Inner Rotor Thickness (Min.) . . . . . . 20.955 mm (0.0007-0.0014 in)
(0.825 in) Diameter. 24.996-25.001 mm
Outer Rotor (0.9841-0.9843 in)
Clearance (Max.) 0.3556 mm End P l a y . . NONE
(0.014 in) Length 75.946-76.454 mm
Diameter (Min.) 62.7126 mm (2.990-3.010 in)
(2.469 in)
Thickness (Min.) . . . . . . . . . . 20.955 mm Piston R i n g s
(0.825 in) Ring Gap
Tip Clearance Between Rotors (Max). . 0.2032 mm Compression Rings 0.254-0.508 mm
(0.008 in) (0.010-0.020 in)
Oil Control (Steel Rails) 0.254-1.270 mm
Oil Pressure (0.010-0.050 in)
At Curb Idle Speed* 41.4 kPa Ring Side Clearance
(6 psi) Compression Rings 0.038-0.076 mm
At 3000 rpm 207-552 kPa (0.0015-0.0030 in)
(30-80 psi) Oil Ring (Steel Rails) 0.06-0.21 mm
Oil Pressure Switch (0.002-0.008 in)
Actuating Pressure (Min.) . . . 34.5-48.3 kPa Ring Width
(5-7 psi) Compression Rings 1.971-1.989 mm
(0.0776-0.0783 in)
*CAUTION: If pressure is ZERO at curb idle, Oil Ring (Steel Rails) 3.848-3.975 mm
D O NOT run engine at 3,000 rpm. (0.1515-0.1565 in)
Oil Filter Valves

Bypass Valve Setting . 62-103 kPa Face Angle 43.25° - 43.75°
(9-15 psi) Head Diameter
Intake 48.666 mm
Pistons (1.916 in)
Clearance at Top of Skirt 0.0127-0.0381 mm Exhaust 41.250 mm
(0.0005-0.0015 in) (1.624 in)
Land Clearance (Diametrical) 0.635-1.016 mm Length (Overall)
(0.025-0.040 in) Intake 124.28-125.92 mm
Piston Length 86.360 mm (4.893-4.918 in)
(3.40 in) Exhaust 124.64-125.27 mm
Piston Ring Groove Depth (4.907-4.932 in)
Nos. 1 and 2 4.572-4.826 mm Lift (Zero Lash) 10.973 mm
(0.180-0.190 in) (0.432 in)
No. 3 3.810-4.064 mm Stem Diameter 7.899-7.925 mm
(0.150-0.160 in) (0.311-0.312 in)
Weight 592.6-596.6 grams Stem-to-Guide Clearance 0.0254-0.0762 mm
(20.90-21.04 oz) (0.001-0.003 in)
Max. Allowable (Rocking Method). . 0.4318 mm
(0.017 in)
Guide Bore Diameter (Std) 7.950-7.976 mm
(0.313-0.314 in)
J9309-32
ENGINE SPECIFICATIONS (CONT.)
Valve S p r i n g s V a l v e Timing
Free Length ( A p p r o x . ) 49.962 m m E x h a u s t Valve
(1.967 in) C l o s e s (ATC) 16°
S p r i n g Tension @ 41.66 m m = 378 N Opens (BBC) 52°
(Valve C l o s e d ) (@ 1.64 in = 85 lbs) Duration 248°
S p r i n g Tension @ 30.89 m m = 890 N Intake Valve
(Valve O p e n ) (@ 1.212 in = 200 lbs) Closes (ABC) 50°
N u m b e r of C o i l s 6.8 Opens (BTC) . . 10°
Installed H e i g h t . 41.66 mm Duration 240°
( S p r i n g S e a t to Retainer) (1.64 in) Valve Overlap 26°
W i r e Diameter 4.50 mm
(0.177 in)
J9309-33
OVERSIZE AND UNDERSIZE ENGINE COMPONENT MARKINGS
CONDITION IDENTIFICATION L O C A T I O N OF I D E N T I F I C A T I O N
CRANKSHAFT JOURNALS RorM Steel stamped (near notch) on n o . 6 crankshaft

(UNDERSIZE) M - 2 - 3 etc. (indicating no. 2 a n d 3 main bearing counterweight.
0 . 0 2 5 4 m m (0.001 in.) journal)
and/or
R-l-4 etc. (indicating no. 1 a n d 4 connecting rod
journal)
H Y D R A U L I C TAPPETS D i a m o n d - s h a p e d stamp
(OVERSIZE) Top p a d - front of engine a n d flat g r o u n d o n
0 . 2 0 3 2 m m ( 0 . 0 0 8 in.) outside surface of each O / S tappet bore.
VALVE STEMS (OVERSIZE) X Milled p a d adjacent to two tapped holes

0 . 1 2 7 mm ( 0 . 0 0 5 in.) ( 3 / 8 in.) on each end of cylinder head.
J9309-81
9 - 46 3.9L ENGINE
Adjusting Strap Bolt..... 23 N-m (200 in. lbs.) Rear Insulalor-to-Bracket

Camshaft Bolt 68 N-m (50 ft. lbs.j Through-Bolt (2WD) 68 N-rn (50 ft. lbs.)
Camshaft Thrust Plate Bolts 24 N-m (210 in. lbs.) Rear Insuiator-to-Crossmember
Support Bracket Nut (2WDJ .. 41 N-m (30 ft. lbs.
Chain Case Cover Bolts 41 N-m (30 ft. lbs.)
Rear Insulator Mounting Plate-to-
Connecting Rod Cap Bolts 61 N*m (45 ft. lbs.)
Rail Assembly Nuts (4WD) ...................... 41 N-m (30 ft. lbs.
Crankshaft Main Bearing Cap Bolts 115 N-m (85 ft. lbs.} Rear Support Bracket-to-Crossmember
Cylinder Head Bolts Flange Nuts.... 41 N-m (30 ft. lbs.
1st Step . 68 N-m (50 ft. lbs.) Rear Support Plate-to-lnsulator
2nd Step ............................................. 143 N-m (105 ft. lbs.) Mounting Plate Bolts (4WD) 41 N-m (30 ft. lbs.
Cylinder Head Cover Bolts 11 N-m (95 in. lbs.) Rear Support Plate-to-Transfer
Case Bolts 41 N-m (30 ft. lbs.
Exhaust ManifoId-to-Cylinder
Head Bolts/Nuts 34 N-m (25 ft. lbs.) Rocker Arm Bolts 23 N-m (200 in. lbs.
Front Insulator Attaching Spark Plugs....... 41 N-m (30 ft. lbs.

Bolts (2WD)... 41 N-m (30 ft. lbs.) Sfarfer Counting Bolts. 68 N-m (50 ft. lbs.
Front Insulator Stud Nuts 102 N-m (75 ft. lbs.) Throttle Body Bolts (MPI) 23 N-m (200 in. lbs.
Front Mount Adaptor-to-Block Bolts.. 41 N-m (30 ft. lbs.) Torque Converter Drive Plate Bolts 31 N-m (270 in. lbs.
Front Mount Bracket-to- Transfer Case-to-Insulator
Crossmember Bolts (4WD). 41 N-m (30 ft. lbs.) Mounting Plate Nuts.............. 204 N-m (150 ft. lbs.
Generator Mounting Bolt 41 N-m (30 ft. lbs.) Transmission Support Bracket
Bolts (2WD) 68 N-m (50 ft. lbs.
Intake Manifold Bolts Refer to Procedure in Transmission Support Spacer
Service Manual. Bolts (4WD). 68 N-m (50 ft. lbs.
Oil Pan Bolts 23 N-m (200 in. lbs.) Transmission Support Spacer-to-
Oil Pan Drain Plug 34 N-m (25 ft. lbs.) Insulator Mounting Plate Nuts (4WD) .... 204 N-m (150 ft. lbs.
Oil Pump Attaching Bolts 41 N-m (30 ft. lbs.)
Vibration Damper Retainer Bolt................ 183 N-m (135 ft. lbs.
Oil Pump Cover Bolts 11 N-m (95 in. lbs.)
Water Pump-to-Chain Case
Cover Bolt... 41 N-m (30 ft. lbs.)
J9309-S8
5.2L ENGINE 9 - 47
S.2L E N G I N E SERVICE PROCEDURES
INDEX
page page
Camshaft .,. 61 General Information . . . . . . . . . . . . . . . . . . . . . . . 47
Crankshaft Main Bearings 69 Oil Pan . 63
Crankshaft Rear Oil Seals . . . . . . ........ 70 Oil Pump . 64
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Piston / Connecting R o d Assembly 66
Cylinder Head Cover . . . . 51 Rocker Arms 51
Cylinder Heads 52 Specifications—5.2L Engine 73
Distributor 62 Timing Chain Cover ................ 59
Engine Assembly . 50 Valve Stem Shield / Spring Replacement 56
Engine Front Mounts 47 Valve Timing . 58
Engine Rear Mount ............... 48 Valves / Valve Springs 54
Front Crankshaft Oil Seal Replacement .. 61 Vibration Damper .. 58
GENERAL INFORMATION
The 5.2 Liter (318 CID) eight-cylinder engine is a
V-Type lightweight, single cam, overhead valve en
gine with hydraulic roller tappets (Fig. J).
Engine Type .... 90° V-8 OHV

Bore and Stroke ..... 99.3 x 84.0 mm (3.91 x 3.31 in.)
Displacement................ 5.2L(318cu. in.)
Compression Ratio ....... . 9.1:1
Torque .. 3 7 9 N-m (280 ft. lbs.) @ 3,200 rpm
Firing Order .... 1-8-4-3-6-5-7-2
Lubrication ....... Pressure Feed-Full Flow Filtration
Engine Oil Capacity...... 4.7L (5.0 Qts) with Filter
Cooling System ...... Liquid Cooled-Forced Circulation J908D-49
Cooling Capacity.......... 16.1L(17.0Qts)
Ramcharger 15.6L (16.5 Qts) Fig. 2 Firing Order
Cylinder Block , Cast Iron
Crankshaft Nodular Iron X M 5.2L T X X X X XXXXXXXX
Cylinder Head .............. Cast Iron
Combustion Chambers .. Wedge-High Swirl Valve Shrouding
Camshaft Nodular Cast Iron X ~ Last Digit of Model Year
Pistons Aluminum Alloy w/Strut M = Plant - M Mound Road
Forged Steel S Saltillo
Connecting Rods...........
T Trenton
J9309-41 K Toluca
5.2L = Engine Displacement
Fig. 1 Engine Description T = Usage - T Truck
XXXX = Month/Day
This engine is designed for unleaded fuel.
XXXXXXXX = Serial Code - Last 8 Digits of VIN No.
Engine lubrication system consists of a rotor type
The cylinders are numbered from front to rear; 1 ? J9209-73
3, 5, 7 on t h e left bank and 2 , 4, 6, 8 on the right
bank. The firing order is 1-8-4-3-6-5-7-2 (Fig. 2). Fig. 3 Engine Identification Number
The engine serial number is stamped into a ma ENGINE FRONT MOUNTS
chined pad located on the left, front corner of t h e cyl
inder block. When component part replacement is REMOVAL
necessary, use t h e engine type and serial number for (1) Raise hood and position fan to assure clearance
reference (Fig. 3). for radiator top t a n k and hose.
9 • 48 5.2L ENGINE •
C A U T I O N ; D O NOT lift the engine by the intake (6) Lower the vehicle.
manifold. (7) Remove lifting fixture.
(2) Install an engine lifting fixture. ENGINE REAR MOUNT

(4) Remove nuts from brackets and insulators (Fig. REMOVAL-2WD
4). (1) Raise vehicle on a hoist.
(5) Raise engine with lifting fixture only far (2) Position a transmission jack under the trans
enough to remove insulators. mission and raise rear of transmission and engine
SLIGHTLY.
SCREW <£> SCREW <1j> (3) Remove rear mount through-bolt from frame
crossmember (sport utility) or from the transmission
support bracket (Fig. 5).
FRONT (4) Remove the flange nuts from the crossmember
LOCATING PIN support bracket (Fig. 5).
" O N LEFT SIDE
ONLY (5) Raise rear of transmission enough to provide
USE FRONT HOLES insulator to crossmember clearance. Remove the in
FOR INSULATOR MTG, NUT
2-WHEEL DRIVE WASHER sulator flange nuts and remove the insulator (Fig. 5).
BRACKET' (6) If necessary, remove the attaching bolts hold
TIGHTENING TORQUE INSULATOR < ing the transmission support bracket to the transmis
75 FT. LBS.(102 N-m) LEFTSIDE sion (Fig. 5).
<B> 65 FT. LBS. (88 N.m) 4-WHEEL DRIVE
FRAME SHOWN INSTALLATION-2WD
<£> 30 FT. LBS. (41 N-m) INSULATOR
BRACKET bracket to the transmission (Fig. 5). Install the at
(FRONT ENG taching bolts and tighten to 68 N-m (50 ft. lbs.)
SUPPORT)
torque.
(2) Position insulator in transmission support
tion relative to transmission rear support bracket.
Tighten the through-bolt nut to 68 N-m (50 ft. lbs.)
torque.
the insulator (Fig. 5). Install the flange nut(s) and
(5) Using the transmission jack, lower the insula
Fig. 4 Engine Front Mounts
tor and crossmember support bracket onto the cross-
(6) If necessary, remove the bracket from the block member (Fig. 5).
(Fig. 4). (6) Tighten the crossmember flange nuts to 41 N-
(7) If necessary, remove the front engine support m (30 ft. lbs.) torque.
bracket (Fig. 4). (7) Remove the transmission jack.
INSTALLATION
(1) If removed, install the front engine support REMOVAL-4WD
bracket. Tighten the bolts to 41 N-m (30 ft. lbs.) (1) Raise the vehicle on a hoist.
torque. (2) Remove the skid plate (if equipped) from the
(2) If removed, position the bracket to the block. rear crossmember and transmission crossmember
Install the screws and tighten screw A to 102 N-m (Fig. 6).
(75 ft. lbs.) torque. Tighten screw B to 88 N-m (65 ft. (3) Position transmission jack under transmission
lbs.) torque. and raise rear of transmission and engine
(3) With engine raised slightly, install insulators. SLIGHTLY.
(4) Lower engine with lifting fixture while guiding (4) A U T O M A T I C TRANSMISSION-Remove
insulator studs into attaching holes in crossmember the nuts and bolts holding the transmission support
and brackets (Fig. 4). spacer to the insulator mounting plate (Fig. 7). Re
(5) Tighten attaching insulator nuts to 102 N-m move the bolts and nuts holding the engine rear sup
(75 ft. lbs.) torque. port plate to the insulator mounting plate (Fig. 7).
• 5.21 ENGINE 9 - 49
TRANSMISSION
SUPPORT
BRACKET
TRANSMISSION
TRANSMISSION
SUPPORT
BRACKET
INSULATOR
CROSSMEMBER
(SPORT UTILITY) J9109-240
Fig. 5 Rear Engine Supports—2WD

mSYALLATION-4WD
l^^Û.TRANSFERJCASE .
iSKID PLATE (1) If removed, position the engine rear support
S K I D R A T l f~
—
l!pW;;^ ni ® p
I ATTACHING BOLTS bracket (automatic transmission) to the transfer case
D
I P L A T E |
ATTACHING BOLTS 1|BS^
(Fig. 7). Install the bolts and tighten to 41 N-m (30
ft. lbs.) torque.
spacer (automatic transmission) to the extension as
sembly (Fig. 7). Install the bolts and tighten to 68
PU873 Nnn (50 ft. lbs.) torque.
(3) Install insulator mounting plate, mounting
Fig. 6 Skid Plate bolts, spacers, washers and upper/lower insulators to
(5) M A N U A L T R A N S M I S S I O N - R e m o v e the the rail assembly (Figs. 7 and 8). Tighten the mount
nuts and bolts holding the insulator mounting plate ing bolt nuts to 204 N-m (150 ft. lbs.) torque.
to the transfer case (Fig. 8). (4) A U T O M A T I C TRANSMISSION—Align the
(6) Remove insulator mounting bolts, spacers, engine rear support plate and the transmission sup
washers and upper/lower insulators (Figs. 7 and 8). port spacer to t h e insulator mounting plate (Fig. 7).
(7) Remove the insulator mounting plate (Figs. 7 Lower the engine and transmission onto the insula
and 8). tor mounting plate and install the bolts. Tighten the
(8) If necessary, remove the transmission support transmission support spacer nuts to 204 N-m (150 ft.
spacer (automatic transmission) from the extension lbs.) torque. Tighten the engine rear support plate to
assembly (Fig. 7). 41 N-m (30 ft. lbs.) torque.
(9) If necessary, remove the engine rear support (5) M A N U A L TRANSMISSION—Align the
bracket (automatic transmission) from the transfer transfer case to the insulator mounting plate and
case (Fig. 7). lower the engine and transmission. Install the bolts
and tighten the nuts (Fig. 8 - nut A) to 204 N-m (150
ft. lbs.) torque. Install the bolts and tighten the nuts
(Fig. 8 - n u t B) to 41 N-m (30 ft. lbs.) torque.
TRANSFER TRANSFER
CASE CASE
EXTENSION
ASSEMBLY
TRANSMISSION
SUPPORT
SPACER
SPACER
UPPER
SPACER INSULATOR L\ f INSULATOR
MOUNTING
PLATE
UPPER
ENGINE REAR INSULATOR
SUPPORT NUT®
PLATE INSULATOR
MOUNTING
PLATE
LOWER LOWER
INSULATOR RAIL INSULATOR
ASSEMBLY
ff
l6 RAIL I
fT^RAIL J9109-244 J9109-245
Fig, 7 Rear Engine Support—4WD with Automatic Fig. 8 Rear Engine Support—4WD with Manual
Transmission Transmission
(7) Lower the vehicle. (17) Remove starter motor (refer to Group 8B, Bat
ENGINE ASSEMBLY (18) Remove the generator (refer to Group 8B, Bat
REMOVAL
(1) Scribe hood hinge outlines on hood. Remove the (20) Disconnect exhaust pipe at manifold.
hood. (21) AUTOMATIC TRANSMISSION:
(2) Remove the battery. (a) Support transmission. This will assure t h a t
(3) Drain cooling system (refer to Group 7, Cooling the torque converter will remain in proper position
System for the proper procedure). in the transmission housing.
(4) Remove the air cleaner. (b) Remove bell housing bolts and inspection
(5) Disconnect the radiator and heater hoses. Re plate.
move radiator (refer to Group 7, Cooling System). (c) Attach a C-clamp on front bottom of trans
(6) Set fan shroud aside. mission torque converter housing to prevent torque
(7) Remove the vacuum lines. converter from falling out.
(8) Remove the distributor cap and wiring. (d) Remove torque converter drive plate bolts
(9) Disconnect the accelerator linkage. from torque converter drive plate. Mark converter
(10) Remove MPI throttle body. and drive plate to aid in assembly.
(11) Disconnect the fuel lines. (22) MANUAL TRANSMISSION;
(12) Disconnect the starter wires. (a) Support transmission.
(13) Disconnect the oil pressure wire. (b) Disconnect clutch release mechanism and re
(14) Discharge the air conditioning system, if move transmission to clutch housing bolts.
equipped (refer to Group 24, Heating and Air Condi
C A U T I O N : D O N O T lift the engine by the intake
tioning for service procedures).
manifold.
(15) Disconnect the air conditioning hoses.
(16) Disconnect the power steering hoses, if (23) Install an engine lifting fixture.
equipped. (24) Remove engine front mount bolts.
• 5.2L ENGINE 9 - 51

nect the engine from t h e torque converter drive (27) Warm engine and adjust.
stand. C Y L I i i E R HEAD COVER
(1) Remove engine from t h e repair stand and posi again.
(2) Install an engine support fixture. CYLINDER HEAD
the bolts to 31 N-m (270 in. lbs.) torque.
(5) M A N U A L T R A N S M I S S I O N : Fig. 1 Cylinder Head Cover Gasket
(a) Position the drive pinion shaft to the clutch
disc. REMOVAL
(b) Connect the clutch release mechanism and (1) Disconnect the negative cable from the battery.
install the transmission to clutch bolts. Tighten the (2) Disconnect closed ventilation system and evap
bolts to 68 N-m (50 ft. lbs.) torque. oration control system from cylinder head cover.
(c) Install the engine front mounts. (3) Remove cylinder head cover and gasket. The
(6) Remove transmission support. gasket may be used again.
(8) Lower the vehicle. CLEANING
(9) Remove engine lifting fixture. Clean cylinder head cover gasket surface.
(10) Install the generator (refer to Group 8B, Bat Clean head rail, if necessary.
(11) Install the starter motor (refer to Group 8B, INSPECTION
Battery/Starter/Generator Service). Inspect cover for distortion and straighten, if nec
(12) Connect power steering hoses, if so equipped. essary.
(13) Connect air conditioning hoses. Check the gasket for use in head cover installation.
(14) Evacuate and charge the air conditioning sys If damaged, use a new gasket.
tem, if equipped (refer to Group 24, Heater and Air
Conditioning for service procedures). INSTALLATION
(15) Using a new gasket, install MPI throttle body. (1) The cylinder head cover gasket can be used
Tighten the throttle body bolts to 23 N-m (200 in. again. Install the gasket onto the head rail.
lbs.) torque. (2) Position the cylinder head cover onto the gas
(16) Connect the accelerator linkage. ket. Tighten the bolts to 11 N-m (95 in. lbs.) torque.
(21) Connect the fuel lines, ROCKER ARMS
System). Connect the radiator hoses and heater REMOVAL
hoses. (1) Disconnect spark plug wires by pulling on the
(23) Install fan shroud in position. boot straight out in line with plug.
9 - 52 5.2L ENGINE •
(3) Remove the rocker arm bolts and pivots (Fig, EXHAUST SPARK EXHAUST SPARK EXHAUST
2). Place them on a bench in the same order as re VALVE PLUGS VALVES PLUGS VALVE
moved.
ROCKER CYLINDER
INTAKE INTAKE
VALVES VALVES J9309-37
J9209-65
Fig. 2 Rocker Arms
INSTALLATION
(1) Rotate the crankshaft until the "V8" m a r k
lines up with the TDC mark on the timing chain
C A U T I O N : D O NOT rotate or crank the engine dur

ing or immediately after rocker arm installation. Al
(2) Install the push rods in the same order as re

moved.
(3) Install rocker arm and pivot assemblies in the
same order as removed. Tighten the rocker arm bolts
to 28 N-m (21 ft. lbs.) torque. Fig. 4 Exhaust Manifold Heat Shields
(4) Install cylinder head cover.
(10) Remove the return spring.
(5) Connect spark plug wires.
(11) Remove distributor cap and wires.
CYLINDER HEADS (12) Disconnect the coil wires.
The alloy cast iron cylinder heads (Fig. 3) are held (13) Disconnect heat indicator sending unit wire.
in place by 10 bolts. The spark plugs are located in (14) Disconnect heater hoses and bypass hose.
the peak of the wedge between the valves. (15) Remove cylinder head covers and gaskets.
The 5.2L cylinder head is identified by the foundry (16) Remove intake manifold and throttle body as
mark NH. an assembly. Discard the flange side gaskets and the
front and rear cross-over gaskets.
REMOVAL (17) Remove exhaust manifolds.
(1) Disconnect the negative cable from the battery. (18) Remove rocker arm assemblies and push rods.
(2) Drain cooling system (refer to Group 7, Cooling Identify to ensure installation in original locations.
System for the proper procedures). (19) Remove the head bolts from each cylinder
(3) Remove the heat shields (Fig. 4). head and remove cylinder heads. Discard the cylin
der head gasket.
(6) Disconnect the evaporation control system. CLEANING
(7) Remove the air cleaner.
heads.
(9) Disconnect accelerator linkage and if so
equipped, the speed control and transmission kick-
down cables.
• 5.2L ENGINE 9 - 53
INSPECTION
span length in inches in any direction, either replace
head or lightly machine the head surface.
F O R E X A M P L E : A 305 m m (12 inch) span is
0.102 mm (0.004 inch) out-of-flat. The allowable out-
of-flat is 305 x 0.00075 (12 x 0.00075) equals 0.23
mm (0.009 inch). This amount of out-of-flat is accept
able.
The cylinder head surface finish should be 1.78-
3.00 microns (70-125 microinches).
Inspect push rods. Replace worn or bent rods.
INSTALLATION
(1) Apply Perfect Sealant No.5, or equivalent, to Fig. 6 Cylinder Head Bolt Tightening Sequence
both sides of the gasket (Fig. 5). (7) Apply Mopar Silicone Rubber Adhesive Seal
ant, or equivalent, to the four corner joints. An ex
gasket. The sealant should be slightly higher t h a n

(2) Position the new cylinder head gaskets onto the
cylinder block.
and cylinder block.
bolts, in sequence, to 68 N»m (50 ft. lbs.) torque (Fig.
to 143 N®m (105 ft. lbs.) torque. Repeat procedure to
confirm t h a t all bolts are at 143 N-m (105 ft. lbs.)
torque.
REAR CROSS-OVER GASKET J9209-99
make sure the piston in that cylinder is N O T at
T D C . Contact between the valves and piston could (9) Install the flange gaskets. Be sure t h a t the ver
occur. tical port alignment tab is resting on the deck face of
(5) Install push rods and rocker arm assemblies in be in position with t h e mating cylinder head gasket
their original position. Tighten the bolts to 28 N»m tabs (Fig. 8). The words MANIFOLD SIDE should be
(21 ft. lbs.) torque. visible on the center of each flange gasket.
(6) Place the 4 plastic locator dowels into the holes (10) Carefully lower intake manifold into position
in the block Fig. 7). on the cylinder block and cylinder heads. Use the
FLANGE GASKET (15) Connect heat indicator sending unit wire.
X (16) Connect the heater hoses and bypass hose.
down cables.
(20) Install the fuel lines.
generator mounting bolt to 41 N-m (30 ft. lbs.)
torque. Tighten the adjusting strap bolt to 23 N-m
(200 in. lbs.) torque. Refer to Group 7, Cooling Sys
tem for adjusting the belt tension.
(22) Install the intake manifold-to-generator
bracket support rod. Tighten the bolts.
(23) Place the cylinder head cover gaskets in posi
Fig. 8 intake Manifold Flange Gasket Alignment tion and install cylinder head covers. Tighten the
alignment dowels in the cross-over gaskets to posi bolts to 11 N-m (95 in. lbs.) torque.
tion the intake manifold. After intake manifold is in (24) Install closed crankcase ventilation system.
place, inspect to make sure seals are in place. (25) Connect the evaporation control system.
(11) The following torque sequence duplicates the (26) Install the air cleaner.
expected results of the automated assembly system (27) Install the heat shields. Tighten the bolts to
(Fig. 9). 41 N-m (30 ft. lbs.) torque.
(28) Fill cooling system (refer to Group 7, Cooling
System for proper procedure).
VALVES / VALVE SPRINGS

head.
REMOVAL
J9209-60
Compressor Tool MD-998772A.
Fig. 9 Intake Manifold Bolt Tightening Sequence (3) Remove valve retaining locks, valve spring re
• Step 1—Tighten bolts 1 through 4, in sequence, to (4) Before removing valves, remove any burrs from
8 N-m (72 in. lbs.) torque. Tighten in alternating valve stem lock grooves to prevent damage to the
steps 1.4 N-m (12 in. lbs.) torque at a time. valve guides. Identify valves to ensure installation in
• Step 2—Tighten bolts 5 through 12, in sequence, original location.
to 8 N-m (72 in. lbs.) torque.
• Step 3—Check t h a t all bolts are tighten to 8 N-m VALVE CLEANING
(72 in. lbs.) torque. Clean valves thoroughly. Discard burned, warped
• Step 4—Tighten all bolts, in sequence, to 16 N-m and cracked valves.
(12 ft. lbs.) torque. Remove carbon and varnish deposits from inside of
• Step 5—Check t h a t all bolts are tighten to 16 N-m valve guides with a reliable guide cleaner.
(12) Install exhaust manifolds. Tighten the bolts VAL VE INSPECTION
and nuts to 34 N-m (25 ft. lbs.) torque. Measure valve stems for wear. If wear exceeds
(13) Adjust spark plugs to specifications (refer to 0.051 mm (0.002 inch), replace the valve.
Group 8D, Ignition System). Install the plugs and Measure valve stem guide clearance as follows:
tighten to 41 N-m (30 ft. lbs.) torque. (a) Install Valve Guide Sleeve Tool C-3973 over
(14) Install coil wires. valve stem and install valve (Fig. 10). The special
Slowly t u r n r e a m e r b y h a n d a n d clean g u i d e t h o r
o u g h l y before i n s t a l l i n g n e w v a l v e . R e a m t h e v a l v e
g u i d e s f r o m s t a n d a r d t o 0 , 3 8 1 m m (0.015 I n c h ) .
Use a 2 step p r o c e d u r e so t h e valve guides a r e
r e a m e d t r u e in relation to t h e valve seat:
• Step 1 - R e a m to 0.0763 mm (0.003 inch),
• Step 2—Ream, to 0.381 mm (0.015 inch).
REFACING VAL WES / WAL WE SEATS

(Fig. 13).
Fig. 10 Positioning Valve with Tool C-3973
sleeve places the valve at the correct height for CONTACT
checking with a dial indicator.
(b) Attach Dial Indicator Tool C-3339 to cylinder
head and set it at right angle of valve stem being
measured (Fig. 11).
A - SEAT WIDTH - INTAKE 1.016-1.524 mm (0.040 - 0.060 in.)

EXHAUST 1.524 - 2.032 mm (0.060 - 0.080 in.)
B - FACE ANGLE (INTAKE & EXHAUST) 437.° - 4 3 / / 3
C - SEAT ANGLE (INTAKE & EXHAUST) 447/ - 447/

D - CONTACT SURFACE
J9309-95
Fig. 11 Measuring Valve Guide Wear Fig. 13 Valve Face and Seat Angles
(c) Move valve to and from the indicator. The to VALVES
tal dial indicator reading should not exceed 0.432 Inspect the remaining margin after the valves are
mm (0.017 inch). Ream the guides for valves with refaced (Fig. 14). Valves with less t h a n 1.190 mm
oversize stems if dial indicator reading is excessive (0.047 inch) margin should be discarded.
Service valves with oversize stems are available VALVE SEATS
(Fig. 12).
C A U T I O N : D O N O T un-shroud valves during valve
Reamer O / S Valve Guide Size seat refacing (Fig. 15).
(1) When refacing valve seats, it is important t h a t

0.076 mm 8.026 - 8.052 mm
(0.316-0.317in.) the correct size valve guide pilot be used for reseat
(0.003 in.)
ing stones. A true and complete surface must be ob
0.381 mm 8.331 - 8.357 mm tained.
(0.015 In.) (0.328-0.329 In.) (2) Measure the concentricity of valve seat using a
dial indicator. Total runout should not exceed 0.051
m m (0.002 inch) total indicator reading.
(3) Inspect the valve seat with Prussian blue to de
J9309-30 termine where the valve contacts the seat. To do
Fig. 12 Reamer Sizes t h e n set valve in place. Rotate the valve with light
pressure. If the blue is transferred to the center of
9 - 56 5.2L ENGINE •
the spring load at test length. Fractional measure
ments are indicated on the table for finer adjust
ments. Refer to specifications to obtain specified
EXHAUST
VALVE height and allowable tensions. Discard the springs
t h a t do not meet specifications.
VALVE SPRING
RETAINER LOCK SPECIAL
GROOVE TOOL C-647
J9209-127
Fig. 14 Intake and Exhaust Valves
^ 9209-37
Fig. 16 Testing Valve Spring for Compressed

Length with Tool C-647
INSTALLATION
(1) Coat valve stems with lubrication oil and insert
(2) If valves or seats are reground, check valve
stem height. If valve is too long, replace cylinder
head.
(3) Install new seals on all valve guides. Install
valve springs and valve retainers.
(4) Compress valve springs with Valve Spring
Compressor Tool MD-998772A, install locks and re
lease tool. If valves and/or seats are ground, measure
Fig. 15 Refacing Valve Seats the installed height of springs. Make sure the mea
valve face, contact is satisfactory. If the blue is trans surement is taken from bottom of spring seat in cyl
ferred to the top edge of valve face, lower valve seat inder head to the bottom surface of spring retainer. If
with a 15° stone. If the blue is transferred to bottom spacers are installed, measure from the top of spacer.
edge of valve face raise valve seat with a 60° stone. If height is greater t h a n 42.86 mm (1-11/16 inches),
(4) When seat is properly positioned the width of install a 1.587 mm (1/16 inch) spacer in head coun-
intake seats should be 1.016-1.524 mm (0.040-0.060 terbore. This should bring spring height back to nor
inch). The width of the exhaust seats should be mal 41.27 to 42.86 mm (1-5/8 to 1-11/16 inch).
1.524-2.032 mm (0.060-0.080 inch).
VALVE STEM SHIELD / SPRING REPLACEMENT #
WALVE SPRING INSPECTION This procedure is done with the cylinder head in
Whenever valves have been removed for inspection, stalled.
reconditioning or replacement, valve springs should (1) Set engine basic timing to Top Dead Center
be tested. As an example the compression length of (TDC) and remove air cleaner.
the spring to be tested is 1-5/16 inch. Turn table of (2) Remove cylinder head covers and spark plugs.
Valve Spring Tester Tool C-647 until surface is in (3) Remove coil wire from distributor and secure to
line with the 1-5/16 inch mark on the threaded stud. good ground to prevent engine from starting.
Be sure the zero mark is to the front (Fig. 16). Place (4) Using suitable socket and flex handle at crank
spring over stud on the table and lift compressing le shaft retaining bolt, t u r n engine so the No.l piston is
ver to set tone device. Pull on torque wrench until at TDC on the compression stroke.
ping is heard. Take reading on torque wrench at this (5) Remove rocker arms.
• 5.2L ENGINE 9 - 57
(6) With air hose attached to an adapter installed termittent or constant, and usually more t h a n 1 tap
in No.l spark plug hole, apply 620-689 k P a (90-100 pet will be noisy. When oil level and leaks have been
psi) air pressure. corrected, operate the engine at fast idle. Run engine
(7) Using Valve Spring Compressor Tool for a sufficient time to allow all of the air inside the
MD-998772A, compress valve spring and remove re tappets to be bled out.
tainer valve locks and valve spring.
(8) Install seals on the exhaust valve stem and po TAPPET NOISE DIAGNOSIS
sition down against valve guides. (1) To determine source of tappet noise, operate en
(9) The intake valve stem seals should be pushed gine at idle with cylinder head covers removed.
firmly and squarely over the valve guide using the (2) Feel each valve spring or rocker arm to detect
valve stem as a guide. DO NOT force seal against noisy tappet. The noisy tappet will cause the affected
top of guide. When installing the valve retainer spring and/or rocker arm to vibrate or feel rough in
locks, compress the spring only enough to install the operation.
locks. Worn valve guides or c o c k e d springs are some
(10) Follow the same procedure on the remaining 7 times mistaken for noisy tappets. If s u c h is the
cylinders using the firing sequence 1-8-4-3-6-5-7-2. case, noise m a y be d a m p e n e d by applying side
Make sure piston in cylinder is at TDC on the valve thrust on the valve spring. If n o i s e is not appre
spring t h a t is being removed. ciably reduced, it c a n be a s s u m e d the noise is in
(11) Remove adapter from the No.l spark plug the tappet. Inspect the rocker arm p u s h rod
hole. sockets and push rod e n d s for wear.
(12) Install rocker arms. (3) Valve tappet noise ranges from light noise to a
(13) Install covers and coil wire to distributor. heavy click. A light noise is usually caused by exces
(14) Install air cleaner. sive leak-down around the unit plunger or by the
(15) Road test vehicle. plunger partially sticking in the tappet body cylin
der. The tappet should be replaced. A heavy click is
HYDRAULIC TAPPETS
caused by a tappet check valve not seating or by for
Before disassembling any part of the engine to cor
rect tappet noise, check the oil pressure. If vehicle eign particles becoming wedged between the plunger
has no oil pressure gauge, install a reliable gauge at and the tappet body. This will cause the plunger to
the pressure sending unit. The pressure should be be stick in the down position. This heavy click will be
tween 207-552 kPa (30-80 psi) at 3,000 RPM. accompanied by excessive clearance between the
Check the oil level after the engine reaches normal valve stem and rocker arm as valve closes. In either
operating temperature. Allow 5 minutes to stabilize case, tappet assembly should be removed for inspec
oil level, check dipstick. tion and cleaning.
The oil level in the pan should never be above the The valve train generates a noise very much like a
FULL mark or below the ADD OIL mark on dipstick. light tappet noise during normal operation. Care
Either of these 2 conditions could be responsible for must be taken to ensure that tappets are making the
noisy tappets. noise. In general, if more than one tappet seems to
be noisy, its probably not the tappets.
OIL LEWEL
REMOVAL
HIGH
If oil level is above the FULL mark, it is possible (2) Remove cylinder head cover.
for the connecting rods to dip into the oil. With the (3) Remove rocker assembly and push rods. Iden
engine running this condition could create foam in
tify push rods to ensure installation in original loca
tion.
draulic tappets by the oil pump causing them to lose
(4) Remove intake manifold.
length and allow valves to seat noisily.
(5) Remove yoke retainer and aligning yokes.
LOW (6) Slide Hydraulic Tappet Remover/Installer Tool
Low oil level may allow oil pump to take in air. C-4129-A through opening in cylinder head and seat
When air is fed to the tappets, they lose length tool firmly in the head of tappet.
which allows valves to seat noisily. Any leaks on in (7) Pull tappet out of bore with a twisting motion.
take side of oil pump through which air can be If all tappets are to be removed, identify tappets to
drawn will create the same tappet action. Check the ensure installation in original location.
lubrication system from the intake strainer to the (8) If the tappet or bore in cylinder block is scored,
pump cover, including the relief valve retainer cap. scuffed, or shows signs of sticking, ream the bore to
When tappet noise is due to aeration, it may be in next oversize. Replace with oversize tappet.
CAUTION: Th© plunger and tappet bodies are not VALVE TIMING
interchangeable. The plunger and valve must al (1) Turn crankshaft until the No.6 exhaust valve
ways be fitted to the original body. It is advisable to is closing and No.6 intake valve is opening.
work on one tappet at a time to avoid mixing of (2) Insert a 6.350 mm (1/4 inch) spacer between
parts. Mixed parts are not compatible. DO NOT dis rocker arm pad and stem tip of No.l intake valve.
assemble a tappet on a dirty work bench, Allow spring load to bleed tappet down giving in ef
fect a solid tappet.
(3) Install a dial indicator so plunger contacts
DISASSEMBLE
valve spring retainer as nearly perpendicular as pos
(1) Pry out plunger retainer spring clip (Fig. 17).
sible. Zero the indicator.
(2) Clean varnish deposits from inside of tappet
(4) Rotate the crankshaft clockwise (normal run
body above plunger cap.
ning direction) until the valve has lifted 0.254 mm
(3) Invert tappet body and remove plunger cap,
(0.010 inch). The timing of the crankshaft should
plunger, check valve, check valve spring, check valve
now read from 10° before top dead center to 2° after
retainer and plunger spring (Fig. 17). Check valve
top dead center. Remove spacer.
could be flat or ball.
CAUTION: DO NOT turn crankshaft any further
ASSEMBLE clockwise as valve spring might bottom and result
(1) Clean all tappet parts in a solvent t h a t will re in serious damage.
move all varnish and carbon.
(2) Replace tappets t h a t are unfit for further ser (5) If reading is not within specified limits:
vice with new assemblies. (a) Check sprocket index marks.
(3) If plunger shows signs of scoring or wear, in (b) Inspect timing chain for wear.
stall a new tappet assembly. If valve is pitted, or (c) Check accuracy of DC mark on timing indica
valve seat on end of plunger is prevented from seat tor.
ing, install a new tappet assembly.
(4) Assemble tappets (Fig. 17). VIBRATION DAMPER
PLUNGER PLUNGER
CHECK RETAINER REMOVAL
BALL SPRING CLIP (1) Disconnect the negative cable from the battery.
ROLLER
TAPPET
I PLUNGER (2) Remove fan shroud retainer bolts and set
shroud back over engine.
RETAINER (4) Remove the serpentine belt (refer to Group 7,
BODY
CHECK VALVE Cooling System).
PLUNGER
SPRING CAP J9109-220 (5) Remove the vibration damper pulley.
Fig. 17 Hydraulic Tappet Assembly end of crankshaft.
INSTALLATION (7) Install bar and screw from Puller Tool Set
(1) Lubricate tappets. C-3688. Install 2 bolts with washers through the
(2) Install tappets and push rods in their original puller tool and into the vibration damper (Fig. 1).
positions. Ensure t h a t the oil feed hole in the side of (8) Pull vibration damper off of the crankshaft.
the tappet body faces up (away from the crankshaft).
(3) Install aligning yokes with ARROW toward
camshaft.
(4) Install yoke retainer. Tighten the bolts to 23
N»m (200 in. lbs.) torque. Install intake manifold.
(5) Install push rods in original positions.
(6) Install rocker arm.
(8) Start and operate engine. Warm up to normal
operating temperature.
J9209-81
CAUTION: To prevent damage to valve mechanism,
engine must not be run above fast idle until all hy Fig. 1 Vibration Damper Assembly
draulic tappets have filled with oil and have become
quiet.
• 5.2L ENGINE 9 - 59
INSTALLATION
(1) Position the vibration damper onto the crank
shaft.

(1) Place a scale next to the timing chain so that
shaft sprocket attaching bolt. Apply torque in the di
Fig. 2 Installing Vibration Damper rection of crankshaft rotation to take up slack; 41
(3) Install the crankshaft bolt and washer. Tighten N»m (30 ft. lbs.) torque with cylinder head installed
the bolt to 183 N*m (135 ft. lbs.) torque. or 20 N»m (15 ft. lbs.) torque with cylinder head re
(4) Install the crankshaft pulley. Tighten the pul moved. With a torque applied to the camshaft
ley bolts to 23 N i n (200 in. lbs.) torque. sprocket bolt, crankshaft should not be permitted to
move. It may be necessary to block the crankshaft to
prevent rotation.
Cooling System).
(6) Install the cooling system fan. Tighten the (3) Hold a scale with dimensional reading even
bolts to 23 N*m (17 ft. lbs.) torque. with the edge of a chain link. With cylinder heads
(7) Position the fan shroud and install the bolts. installed, apply 14 Nnn (30 ft. lbs.) torque in the re
Tighten the retainer bolts to 11 N»m (95 in. lbs.) verse direction. With the cylinder heads removed, ap
torque. ply 20 N»m (15 ft. lbs.) torque in the reverse
direction. Note the amount of chain movement (Fig.
4).
TIMING CHAIN COVER
REMOVAL
System).
Cooling System).
(4) Remove water pump (refer to Group 7, Cooling
System).
(5) Remove power steering pump (refer to Group
19, Steering).
Fig. 4 Measuring Timing Chain Wear and Stretch
(7) Remove fuel lines (refer to Group 14, Fuel Sys (4) Install a new timing chain, if its movement ex
tem). ceeds 3.175 mm (1/8 inch).
(8) Loosen oil pan bolts and remove the front bolt (5) If chain is not satisfactory, remove camshaft
at each side. sprocket attaching bolt and remove timing chain
(9) Remove the cover bolts. with crankshaft and camshaft sprockets.
(10) Remove chain case cover and gasket using ex (6) Place both camshaft sprocket and crankshaft
treme caution to avoid damaging oil pan gasket. sprocket on the bench with timing marks on exact
(11) Place a suitable tool behind the lips of the oil imaginary center line through both camshaft and
seal to pry the oil seal outward. Be careful not to crankshaft bores.
damage the crankshaft seal surface of cover (Fig. 3). (7) Place timing chain around both sprockets.
9 - 60 5.2L ENGINE
(8) Turn crankshaft and camshaft to line up with CRANKSHAFT INSTALL THIS
k
keyway location in crankshaft sprocket and in cam FRONT OIL END INTO
shaft sprocket. SEAL SPECIAL TOOL
6635
(10) Slide both sprockets evenly over their respec
tive shafts and use a straightedge to check alignment
of timing marks (Fig. 5).
J9309-44
Fig. 6 Placing Oil Seal on Installation Tool 6635

TIMING
J9209-129 SPECIAL TOOL \ | OIL
MARKS SEAL

thrust plate and up to 0.254 mm (0.010 inch) with a
used thrust plate. If not within these limits install a
new thrust plate.
CLEANING
Be sure mating surfaces of chain case cover and
cylinder block are clean and free from burrs.
INSTALLATION
chain case cover to avoid damaging oil pan gasket. TIMING
Use a small amount of Mopar Silicone Rubber Adhe CHAIN
sive Sealant, or equivalent, at the joint between tim COVER J9309-45*-
Fig. 7 Position Tool and Seal onto Crankshaft
(2) Place the smaller diameter of the oil seal over (9) Install water pump and housing assembly us
Front Oil Seal Installation Tool 6635 (Fig. 6). Seat ing new gaskets (refer to Group 7, Cooling System).
the oil seal in the groove of the tool. Tighten bolts to 41 Nnn (30 ft. lbs.) torque.
(3) Position the seal and tool onto the crankshaft (10) Install power steering pump (refer to Group
(Fig. 7 ) . 19, Steering).
(4) Using the vibration damper bolt, tighten the (11) Install the serpentine belt (refer to Group 7,
bolt to draw the seal into position on the crankshaft Cooling System).
(Fig. 8). (12) Install the cooling system fan. Tighten the
(5) Tighten chain case cover bolts to 41 Nnn (30 ft. bolts to 23 Nnn (17 ft. lbs.) torque.
lbs.) torque. Tighten oil pan bolts to 24 Nnn (215 in. (13) Position the fan shroud and install the bolts.
lbs.) torque. Tighten the bolts to 11 Nnn (95 in. lbs.) torque.
(6) Remove the vibration damper bolt and seal in (14) Fill cooling system (refer to Group 7, Cooling
stallation tool. System for the proper procedure).
(7) Install vibration damper. (15) Connect the negative cable to the battery.
(8) Install fuel lines (refer to Group 14, Fuel Sys
tem).
• 5.2L ENGINE 9 - 61
J9309-71
Fig. 9 Camshaft and Sprocket Assembly

REMOVAL
(2) Remove cylinder head covers.
(3) Remove timing case cover and timing chain.
(4) Remove rocker arms.
(5) Remove push rods and tappets. Identify each
part so it can be installed in its original location.
(6) Remove distributor and lift out the oil pump
J9309-46
and distributor drive shaft.
Fig. 8 Installing Oil Seal (7) Remove camshaft thrust plate, note location of
oil tab (Fig. 10).
FRONT CRANKSHAFT OIL SEAL REPLACEMENT
The oil seal can be replaced without removing the
aligned.
(3) If front seal is suspected of leaking, check front
oil seal alignment to crankshaft. The seal installa
tion/alignment tool 6635, should fit with minimum
interference. If tool does not fit, t h e cover must be re
moved and installed properly.
(6) Position the seal and tool onto the crankshaft
(Fig. 7).
(Fig. 8).
(8) Remove the vibration damper bolt and seal in Fig. 10 Timing Chain Oil Tab Installation
stallation tool. (8) Install a long bolt into front of camshaft to fa
(9) Install the vibration damper. cilitate removal of the camshaft. Remove camshaft,
(10) Connect the negative cable to the battery. being careful not to damage cam bearings with the
cam lobes.
CAMSHAFT
This procedure requires t h a t the engine is removed REMOVAL-BEARING
from the vehicle. (1) With engine completely disassembled, drive out
The camshaft has an integral oil pump and distrib rear cam bearing core hole plug.
utor drive gear (Fig. 9). (2) Install proper size adapters and horseshoe
washers (part of Camshaft Bearing Remover/Installer
9 - 62 5.2L ENGINE • — — — — — •
(3) Hold tool in position with a distributor lock-
plate bolt. This tool will restrict camshaft from being
plug in rear of cylinder block Tool should remain
installed until the camshaft a n d crankshaft
sprockets and timing chain have b e e n installed.
plate. Tighten bolts to 24 N*m (210 in. lbs.) torque.
order to catch oil for chain lubrication.
Fig, 11 Camshaft Bearings Removal and installation (5) Place both camshaft sprocket and crankshaft
with Tool C-3132-A sprocket on the bench with timing marks on exact
Tool C-3132-A) at back of each bearing shell. Drive
crankshaft bores.
out bearing shells (Fig. 11).
INSTALL A TION- BEARING (7) Turn crankshaft and camshaft to line up with
(1) Install new camshaft bearings with Camshaft keyway location in
Bearing Remover/Installer Tool C-3132-A by sliding crankshaft sprocket and in camshaft sprocket.
the new camshaft bearing shell over proper adapter. (8) Lift sprockets and chain (keep sprockets tight
(2) Position rear bearing in the tool. Install horse against the chain in position as described).
shoe lock and by reversing removal procedure, care (9) Slide both sprockets evenly over their respec
fully drive bearing shell into place. tive shafts and use a straightedge to check alignment
(3) Install remaining bearings in the same man of timing marks (Fig. 13).
ner. Bearings must be carefully aligned to bring oil
holes into full register with oil passages from the
main bearing. If the camshaft bearing shell oil holes
are not in exact alignment, remove and install them
correctly. Install a new core hole plug at the rear of
camshaft. Be sure this plug d o e s not leak.
INSTALLATION
Whenever an engine h a s b e e n rebuilt, a n e w
camshaft and/or n e w tappets installed, add 1 Fig. 13 Alignment of Timing Marks
pint of Mopar Crankcase Conditioner, or equiv
alent. The oil mixture should be left in engine (10) Install the camshaft bolt/cup washer. Tighten
for a minimum of 805 k m (500 miles). Drain at bolt to 68 N«m (50 ft. lbs.) torque.
the next normal oil change. (11) Measure camshaft end play. Refer to Specifi
(2) Install Camshaft Gear Installer Tool C-3509 cations for proper clearance. If not within limits in
with tongue back of distributor drive gear (Fig. 12). stall a new thrust plate.
same position from which it was removed. When
camshaft is replaced, all of the tappets must be
replaced.
DISTRIBUTOR
REMOVAL
procedure.

(1) Insert Distributor Drive Shaft Bushing Puller
Fig. 12 Camshaft Holding Tool C-3509 (Installed Tool C-3052 into old bushing and thread down until
Position) a tight fit is obtained (Fig. 14).
(2) When in this position, the timing m a r k on vi

bration damper should be under "0" on the timing in
dicator.
(3) Coat shaft and drive gear with engine oil. In
stall the shaft so t h a t after the gear spirals into
place, it will index with the oil pump shaft. The slot
in top of drive gear should be aligned towards left
front intake manifold attaching bolt hole (Fig. 17).
Fig. 14 Distributor Driveshaft Bushing Removal

(2) Hold puller screw and tighten puller nut until
bushing is removed.
INSTALLA TION-DRIVE SHAFT BUSHING

(2) Drive bushing and tool into position, using a
Fig. 17 Position or Installed Distributor Drive Gear
hammer (Fig. 15).
INSTALLATION
procedure.
OIL PAN
REMOVAL
(3) Raise vehicle.
(5) Remove exhaust pipe.
Fig. 15 Distributor Driveshaft Bushing Installation (6) Remove left engine to transmission strut.
(7) Remove oil pan and one-piece gasket.
(3) As the burnisher is pulled through the bushing,
the bushing is expanded tight in the block and bur CLEANING
nished to correct size (Fig. 16). DO NOT ream this Clean the block and pan gasket surfaces.
bushing. Trim or remove excess sealant film in the rear
main cap oil pan gasket groove. DO NOT r e m o v e
the sealant inside the rear main cap slots.
If present, trim excess sealant from inside t h e en
gine.
cloth.
vent. Inspect condition of screen.
INSPECTION
Inspect oil drain plug and plug hole for stripped or
damaged threads. Repair as necessary.
Fig. 16 Burnishing Distributor Driveshaft Bushing
Inspect oil pan mounting flange for bends or distor
DISTRIBUTOR TIMING tion. Straighten flange, if necessary.
Before installing the distributor and oil pump drive
shaft, time engine as follows: INSTALLATION
(1) Rotate crankshaft until No.l cylinder is at top (1) Fabricate 4 alignment dowels from 1 1/2 x 5/16
dead center on the firing stroke. inch bolts. Cut the head off the bolts and cut a slot
9 - 64 5.2L ENGINE •
into the top of the dowel. This will allow easier in (11) Install dipstick.
stallation and removal with a screwdriver (Fig. 1). (12) Connect the negative cable to the battery.
(13) Fill crankcase with oil to proper level.
VI2' x 5/16" BOLT
OIL PUMP
REMOVAL
DOWEL
cap.
DISASSEMBLE
SLOT J9209-106 (1) Remove the relief valve as follows:
Fig. 1 Fabrication of Alignment Dowels inch) hole into the relief valve retainer cap and in
(2) Install the dowels in the cylinder block (Fig. 2). sert a self-threading sheet metal screw.
(3) Apply small amount of Mopar Silicone Rubber (b) Clamp screw into a vise and while supporting
oil pump, remove cap by tapping pump body using
DOWEL DOWEL a soft hammer. Discard retainer cap and remove
spring and relief valve (Fig. 3).
OIL PUMP ASSEMBLY
SPRING COTTER PIN
RELIEF VALVE
' RETAINER CAP RH174
Fig. 3 Oil Pressure Relief Valve

J9309-79
(2) Remove oil pump cover (Fig. 4).
(3) Remove pump outer rotor and inner rotor with
Fig. 2 Position of Dowels in Cylinder Block
shaft (Fig. 4).
Adhesive Sealant, or equivalent in the corner of the (4) Wash all parts in a suitable solvent and inspect
cap and the cylinder block. carefully for damage or wear.
(4) Slide the one-piece gasket over the dowels and
INNER ROTOR DISTRIBUTOR DRIVESHAFT
onto the block. AND SHAFT (REFERENCE)
m m
(5) Position the oil pan over the dowels and onto
the gasket.
(6) Install the oil pan bolts. Tighten the bolts to 24 COTTER PIN
(7) Remove the dowels. Install the remaining oil
pan bolts. Tighten these bolts to 24 N«m (215 in. lbs.)
torque. RETAINER
(8) Install the drain plug. Tighten drain plug to 34 CAP
N«m (25 ft. lbs.) torque. SPRING
LARGE CHAMFERED
(9) Install the engine to transmission strut. EDGE RY10B
(10) Install exhaust pipe.
(11) Lower vehicle. Fig. 4 Oil Pump
5.2L ENGINE S - 65
INSPECTION
Mating surface of the oil pump cover should be
smooth. Replace pump assembly if cover is scratched
or grooved.
Lay a straightedge across the pump cover surface
(Fig. 5). If a 0.038 mm (0.0015 inch) feeler gauge can
be inserted between cover and straightedge, pump
assembly should be replaced.
Fig. 7 Measuring Inner Rotor Thickness
Fig. 5 Checking Oil Pump Cover Flatness

Measure thickness and diameter of OUTER rotor.
If outer rotor thickness measures 20.9 mm (0.825
inch) or less or if the diameter is 62.7 mm (2.469
inches) or less, replace outer rotor (Fig. 6).
Fig. 8 Measuring Outer Rotor Clearance in Housing
OUTER
ROTOR
INNER
ROTOR

RH179
If inner rotor measures 20.9 mm (0.825 inch) or
less, replace inner rotor and shaft assembly (Fig. 7). Fig. 9 Measuring Clearance Between Rotors
Slide outer rotor into pump body. Press rotor to the
(0.004 inch) or more can be inserted between rotors
side with your fingers and measure clearance be
and the straightedge, replace pump assembly (Fig.
tween rotor and pump body (Fig. 8). If clearance is
10).
0.356 mm (0.014 inch) or more, replace oil pump as
Inspect oil pressure relief valve plunger for scoring
sembly.
and free operation in its bore. Small m a r k s may be
Install inner rotor and shaft into pump body. If
removed with 400-grit wet or dry sandpaper.
clearance between inner and outer rotors is 0.203
The relief valve spring has a free length of approx
mm (0.008 inch) or more, replace shaft and both ro
imately 49.5 mm (1.95 inches). The spring should
tors (Fig. 9).
test between 19.5 and 20.5 pounds when compressed
Place a straightedge across the face of the pump,
to 34 mm (1-11/32 inches). Replace spring t h a t fails
between bolt holes. If a feeler gauge of 0.102 mm
to meet these specifications (Fig. 11).
i - 68 5.2L ENGINE

The pistons are elliptically turned so t h a t the di
ameter at the pin boss is less than its diameter
across the thrust face. This allows for expansion un
der normal operating conditions. Under operating
temperatures, expansion forces the pin bosses away
from each other, causing the piston to assume a more
nearly round shape.
All pistons are machined to the same weight, re
gardless of size, to maintain piston balance.
The piston pin rotates in the piston only and is re
RH180
tained by the press interference fit of the piston pin
Fig. 10 Measuring Clearance Over Rotors in the connecting rod.
If oil pressure was low and pump is within specifi REMOVAL

cations, inspect for worn engine bearings or other (1) Remove the engine from the vehicle.
reasons for oil pressure loss. (2) Remove the cylinder head.
BV y%L RETAINER CAP
N
(4) Remove top ridge of cylinder bores with a reli
able ridge reamer before removing pistons from cyl
inder block. Re sure to keep tops of pistons covered
COTTER KEY during this operation.
(5) Be sure the connecting rod and connecting rod
CHAMFER cap are identified with the cylinder number. Remove
connecting rod cap. Install connecting rod bolt guide
set on connecting rod bolts.
(6) Pistons and connecting rods must be removed
from top of cylinder block. When removing piston
and connecting rod assemblies from the engine, ro
tate crankshaft so t h a t the connecting rod is centered
RN98 in cylinder bore and at BDC. Be careful n o t t o n i c k
crankshaft journals.
Fig. 11 Proper Installation of Retainer Cap (7) After removal, install bearing cap on the mat
ing rod.
ASSEMBLE
(1) Install pump rotors and shaft, using new parts INSPECTION
as required. Check the crankshaft connecting rod journal for ex
(2) Position the oil pump cover onto the pump cessive wear, taper and scoring.
body. Tighten cover bolts to 11 N»m (95 in. lbs.) Check the cylinder block bore for out-of-round,
torque. taper, scoring and scuffing.
(3) Install the relief valve and spring. Insert the Check the pistons for taper and elliptical shape be
cotter pin. fore they are fitted into the cylinder bore (Fig. 12).
(4) Tap on a new retainer cap.
(5) Prime oil pump before installation by filling ro FITTING PISTONS*
tor cavity with engine oil. Piston and cylinder wall must be clean and dry.
Specified clearance between the piston and the cylin
INSTALLATION der wall is 0.013-0.038 mm (0.0005-0.0015 inch).
(1) Install oil pump. During installation slowly ro Piston diameter should be measured at the top of
tate pump body to ensure driveshaft-to-pump rotor skirt, 90° to piston pin axis. Cylinder bores should be
shaft engagement. measured halfway down the cylinder bore and trans
(2) Hold the oil pump base flush against mating verse to the engine crankshaft center line.
Pistons and cylinder bores should be measured at
normal room temperature, 21°C (70°F).
pump attaching bolts. Tighten attaching bolts to 41
Nnn (30 ft. lbs.) torque. FITTING RINGS
(3) Install the oil pan. (1) Measurement of end gaps:
(a) Measure piston ring gap 2 inches from bot
tom of cylinder bore. An inverted piston can be
DIAMETER (D) FEELER GAUGE

SHOULD BE 98.704-98.831 mm
0.0000-0.0152 mm • (3.886-3.891 in.)-
(0.0000-0.0006 in.)
LARGER THAN (C).
26.543 mm
(1.045 in.)
62.230 mm ± c
(2.45 in.)
1
RING
GROOVE
J9209-136

Fig. 13 Measuring Piston Ring Side Clearance
SKIRT SHOULD BE 0.254-0.304 mm OIL R I N G
(0.010-0.012 in.) LESS AT DIAMETER SPACER GAP
J9309-9
SECOND
Fig. 12 Piston Measurements COMPRESSION
TOP
RING G A P
used to push the rings down to ensure positioning COMPRESSION
OIL RING RAIL
RING G A P
rings squarely in the cylinder bore before measur G A P (TOP)
ing.
(b) Insert feeler gauge in the gap. The top com
pression ring gap should be between 0.254-0.508
mm (0.010-0.020 inch). The second compression
ring gap should be between 0.508-0.762 mm (0.020- OIL R I N G RAIL
0.030 inch). The oil ring gap should be 0.254-1.270 G A P (BOTTOM) J9309-80
mm (0.010-0.050 inch).
(c) Rings with insufficient end gap may be prop Fig. 14 Proper Ring Installation
erly filled to the correct dimension. Rings with ex CONNECTING ROD BEARINGS
cess gaps should not be used. Fit all rods on a bank until completed. DO NOT al
(2) Install rings and confirm ring side clearance: ternate from one bank to another, because connect
(a) Install oil rings being careful not to nick or ing rods and pistons are not interchangeable from
scratch the piston. one bank to another.
(b) Install the compression rings using Installa The bearing caps are not interchangeable and
tion Tool C-4184. The top compression may be in should be marked at removal to ensure correct as
stalled with either side up. The second compression sembly.
ring must be installed with the identification m a r k Each bearing cap has a small V-groove across the
face up (toward top of piston) and the chamfer parting face. When installing the lower bearing
should face down. An identification mark on the shell, make certain t h a t the V-groove in the shell is
ring is a drill point, a stamped letter "O", an oval in line with the V-groove in the cap. This provides
depression or the word TOP. lubrication of the cylinder wall in the opposite bank.
The bearing shells must be installed so t h a t the
(c) Measure side clearance between piston ring
tangs are in the machined grooves in the rods and
and ring land (Fig. 13). Clearance should be 0.038-
caps.
0.076 mm (0.0015-0.0030 inch) for the compression
Limits of taper or out-of-round on any crankshaft
rings. The steel rail oil ring should be free in
journals should be held to 0.025 mm (0.001 inch).
groove, but should not exceed 0.203 mm (0.0080 Bearings are available in 0.025 mm (0.001 inch),
inch) side clearance. 0.051 mm (0.002 inch), 0.076 mm (0.003 inch), 0.254
(d) Pistons with insufficient or excessive side mm (0.010 inch) and 0.305 mm (0.012 inch) under
clearance should be replaced. size. Install the bearings in pairs. DO NOT use a
(3) Arrange ring gaps 90° apart as shown in Fig. n e w bearing half with a n old bearing half. DO
14. NOT file the rods or bearing caps.
9 - 68 5.2L ENGINE •
INSTALLATION Identification Stamp
Undersize Journal
(1) Be sure t h a t compression ring gaps are stag
gered so t h a t neither is in-line with oil ring rail gap. 0.025 mm (0.001 in.) (Rod) R1-R2-R3 or R4
(2) Before installing the ring compressor, make 0.025 mm (0.001 in.) (Main) M1-M2-M3-M4 or M5
rail gaps located properly (Fig. 14).
(3) Immerse the piston head and rings in clean en #8 CRANKSHAFT (ROD)
COUNTERWEIGHT (MAIN)
over the piston and tighten with the special wrench
(part of Tool C-385). Be sure position of rings d o e s
not c h a n g e during this operation. f\
bolts, the long protector should be installed on the
numbered side of the connecting rod.
(5) Rotate crankshaft so that the connecting rod J9209-138
Fig. 15 Location of Crankshaft Identification
same. Insert rod and piston into cylinder bore and (5) Remove and discard the crankshaft rear oil
guide rod over the crankshaft journal. seals.
(6) Tap the piston down in cylinder bore, using a (6) Remove and discard the front crankshaft oil
hammer handle. At the same time, guide connecting seal.
rod into position on crankshaft journal.
(7) The notch or groove on top of piston must be INSPECTION OF JOURNALS
pointing toward front of engine. The larger chamfer The crankshaft connecting rod and main journals
of the connecting rod bore must be installed toward should be checked for excessive wear, taper and scor
crankshaft journal fillet. ing. The maximum taper or out-of-round on any
(8) Install rod caps. Be sure connecting rod, con crankshaft journal is 0.025 mm (0.001 inch).
necting rod cap and cylinder bore number are the Journal grinding should not exceed 0.305 mm
same. Install nuts on cleaned and oiled rod bolts and (0.012 inch) under the standard journal diameter. DO
tighten nuts to 61 N®m (45 ft. lbs.) torque. NOT grind thrust faces of No.3 main bearing. DO
(9) Install the oil pan. NOT nick crank pin or bearing fillets. After grind
(10) Install the cylinder head. ing, remove rough edges from crankshaft oil holes
(11) Install the engine into the vehicle. and clean out all oil passages.
CRANKSHAFT C A U T I O N : After any journal grind, it is important
A crankshaft which has undersize journals will be that the final paper or cloth polish be in the s a m e
stamped with 1/4 inch letters on the milled flat on direction a s the engine rotates.
the No.8 crankshaft counterweight (Fig. 15).
F O R EXAMPLE: R2 stamped on the No.8 crank
shaft counterweight indicates t h a t the No.2 rod jour INSTALLATION
nal is 0.025 mm (0.001 in) undersize. M4 indicates (1) Lightly oil the new upper seal lips with engine
t h a t the No.4 main journal is 0.025 mm (0.001 in) oil.
undersize. R3 M2 indicates t h a t the No.3 rod journal (2) Install the new upper rear bearing oil seal with
and the No.2 main journal are 0.025 mm (0.Q01 in) the yellow paint facing towards the rear of the en
undersize. gine.
When a crankshaft is replaced, all main and con (3) Position the crankshaft into the cylinder block.
necting rod bearings should be replaced with new (4) Lightly oil the new lower seal lips with engine
bearings. Therefore, selective fitting of the bearings oil.
is not required when a crankshaft and bearings are
replaced.
REMOVAL the rear of the engine.
(1) Remove the oil pan. (6) Apply 5 mm (0.20 in) drop of Loctite 515, or
(2) Remove the oil pump from the rear main bear equivalent, on each side of the rear main bearing cap
ing cap. (Fig. 16). Do not over apply sealant or allow the seal
(3) Identify bearing caps before removal. Remove ant to contact the rubber seal. Assemble bearing cap
bearing caps and bearings one at a time. to cylinder block immediately after sealant applica
(4) Lift the crankshaft out of the block. tion.
5.2L ENGINE 9 - 69
Upper and lower No.3 bearing halves are flanged

to carry the crankshaft t h r u s t loads. They are NOT
interchangeable with any other bearing halves in the
engine (Fig. 18). Bearing shells are available in stan
dard and the following under sizes: 0.25 m m (0.001
inch), 0.051 m m (0.002 inch), 0.076 m m (0.003 inch),
0.254 m m (0.010 inch) and 0.305 m m (0.012 inch).
Never install an undersize bearing t h a t will reduce
clearance below specifications.
BEARING CAP J9309-72

ment dowel and cap bolts. Do not remove excess ma
bearing caps. Install all cap bolts and alternately
tighten to 115 Nnn (85 ft. lbs.) torque.
(9) Install oil pump.
(10) Apply Mopar Silicone Rubber Adhesive Seal Fig. 18 Main Bearing Identification
REMOVAL
provide cap to block and oil pan sealing (Fig. 17). Ap
ply enough sealant until a small amount is squeezed (1) Remove the oil pan.
out. Withdraw nozzle and wipe excess sealant off the (2) Remove the oil pump from the rear main bear
oil pan seal groove. ing cap.
(11) Install new front crankshaft oil seal. (3) Identify bearing caps before removal. Remove
(12) Immediately install the oil pan. bearing caps one at a time.
(4) Remove upper half of bearing by inserting
MOPAR SILICONE SEALANT Crankshaft Main Bearing Remover/Installer Tool
RUBBER ADHESIVE APPLIED C-3059 into the oil hole of crankshaft (Fig. 19).
(5) Slowly rotate crankshaft clockwise, forcing out
upper half of bearing shell.
Fig. 17 Apply Sealant to Bearing Cap to Block Joint

CRANKSHAFT MAIN BEARINGS
Bearing caps are not interchangeable and should
be marked at removal to ensure correct assembly.
Upper and lower bearing halves are NOT inter
changeable. Lower main bearing halves of No.2 and Fig. 19 Upper Main Bearing Removal and
4 are interchangeable. Installation with Tool C-3059
INSTALLATION ply enough sealant until a small amount is squeezed
Only one main bearing should be selectively fitted out. Withdraw nozzle and wipe excess sealant off the
while all other main bearing caps are properly tight oil pan seal groove.
ened. All bearing capbolts removed during service (12) Install new front crankshaft oil seal.
procedures are to be cleaned and oiled before instal (13) Immediately install the oil pan.
lation.
When installing a new upper bearing shell, slightly UPPER SEAL REPLACEMENT (CRANKSHAFT
chamfer the sharp edges from the plain side. INSTALLED)
(1) Start bearing in place, and insert Crankshaft (1) Remove the oil pan.
Main Bearing Remover/Installer Tool C-3059 into oil (2) Remove the oil pump from the rear main bear
hole of crankshaft (Fig. 19). ing cap.
(2) Slowly rotate crankshaft counterclockwise slid (3) Remove the rear main bearing cap. Remove
ing the bearing into position. Remove Tool C-3059. and discard the old lower oil seal.
(3) Install the bearing cap. Clean and oil the bolts. ( 4 ) Carefully remove and discard the old upper oil
Tighten the capbolts to 115 N»m (85 ft. lbs.) torque. seal.
(4) Install the oil pump. (5) Lightly oil the new upper seal lips with engine
(5) Install the oil pan. oil. To allow ease of installation of the seal, loosen at
least the 2 main bearing caps forward of the rear
CRANKSHAFT REAR OIL SEALS bearing cap.
The service seal is a 2 piece, viton seal. The upper (6) Rotate the new upper seal into the cylinder
seal half can be installed with crankshaft removed block being careful not to shave or cut the outer sur
from engine or with crankshaft installed. When a face of the seal. To assure proper installation, use the
new upper seal is installed, install a new lower seal. installation tool provided with the kit. Install the
The lower seal half can only be installed with the new seal with the yellow paint facing towards the
rear main bearing cap removed. rear of the engine.
UPPER SEAL REPLACEMENT (CRANKSHAFT the bearing cap with the yellow paint facing towards
REMOVED) the rear of the engine.
(1) Remove the crankshaft. (8) Apply 5 mm (0.20 in) drop of Loctite 515, or
(2) Lightly oil the new upper seal lips with engine equivalent, on each side of the rear main bearing cap
oil. (Fig. 16). Do not over apply sealant or allow the seal
(3) Install the new upper rear bearing oil seal with ant to contact the rubber seal. Assemble bearing cap
the yellow paint facing towards the rear of the en to cylinder block immediately after sealant applica
gine. tion. Be sure the yellow paint faces toward the rear
(4) Position the crankshaft into the cylinder block. of the engine.
(5) Lightly oil the new lower seal lips with engine (9) To align the bearing cap, use cap slot, align
oil. ment dowel and cap bolts. Do not remove excess ma
(6) Install the new lower rear bearing oil seal into terial after assembly. Do not strike rear cap more
the bearing cap with the yellow paint facing towards t h a n 2 times for proper engagement.
the rear of the engine. (10) Install the rear main bearing cap with cleaned
(7) Apply 5 mm (0.20 in) drop of Loctite 515, or and oiled cap bolts. Alternately tighten ALL cap
equivalent, on each side of the rear main bearing cap bolts to 115 N*m (85 ft. lbs.) torque.
(Fig. 16). Do not over apply sealant or allow the seal (11) Install oil pump.
ant to contact the rubber seal. Assemble bearing cap (12) Apply Mopar Silicone Rubber Adhesive Seal
to cylinder block immediately after sealant applica ant, or equivalent, at bearing cap to block joint to
tion. provide cap to block and oil pan sealing (Fig. 17). Ap
(8) To align the bearing cap, use cap slot, align ply enough sealant until a small amount is squeezed
ment dowel and cap bolts. Do not remove excess ma out. Withdraw nozzle and wipe excess sealant off the
oil pan seal groove.
bearing caps. Install all cap bolts and alternately LOWER SEAL REPLACEMENT
tighten to 115 N*m (85 ft. lbs.) torque. (1) Remove the oil pan.
(10) Install oil pump. (2) Remove the oil pump from the rear main bear
(11) Apply Mopar Silicone Rubber Adhesive Seal ing cap.
ant, or equivalent, at bearing cap to block joint to (3) Remove the rear main bearing cap and discard
provide cap to block and oil pan sealing (Fig. 17). Ap the old lower seal.
• 5.2L ENGINE 9 - 71
(4) Carefully install a n e w upper seal (refer to Up OIL LINE PLUG
per Seal Replacement - Crankshaft I n s t a l l e d proce The oil line plug is located i n t h e vertical passage
dure above). at t h e r e a r of the b l o c k b e t w e e n t h e Oil-To-Filter a n d
(5) Lightly oil the n e w lower seal lips w i t h engine Oil-From-Filter passages (Fig, 20). Improper installa
oil. tion or plug missing could cause erratic, low or no oil
(6) Install a new lower seal in bearing cap with pressure.
yellow paint facing t h e rear of engine. (1) Remove oil pressure sending unit from back of
(7) Apply 5 m m (0.20 in) drop of Loctite 5 1 5 , or block.
equivalent, on each side of the rear main bearing cap (2) Insert a 3.175 m m (1/8 inch) finish wire or
(Fig. 16). Do not over apply sealant or allow the seal equivalent into passage.
ant to contact the rubber seal. Assemble bearing cap (3) Plug should be 192.0 to 195.2 m m (7-1/2 to
to cylinder block immediately after sealant applica 7-11/16 inches) from machined surface of block (Fig.
tion. 20). If plug is too high, use a suitable flat dowel drift
(8) T o align t h e bearing cap, use c a p slot, align to position properly.
ment dowel and cap bolts. D o not remove excess ma RIGHT OIL GALLERY
terial after assembly. D o not strike rear cap more
(9) Install t h e rear main bearing cap w i t h cleaned
and oiled cap bolts. Alternately tighten the cap bolts
to 115 N-m (85 ft. lbs.) torque*.
(11) Apply M o p a r Silicone Rubber Adhesive S e a l
ant, or equivalent, a t bearing cap to block joint to
ply enough sealant until a small amount is squeezed
out. Withdraw nozzle and wipe excess sealant off the
oil p a n seal groove.
(12) Immediately install t h e oil pan.
CYLINDER BLOCK
Remove t h e engine assembly from t h e vehicle.
DISASSEMBLE
(1) Remove t h e cylinder head.
(2) Remove t h e oil pan. CRANKSHAFT FROM OIL PUMP J9209-147
(3) R e m o v e t h e piston/connecting rod assembly.
Fig, 20 Oil Line Plug
CLEANING (4) If plug is off location, remove oil pan and rear
Clean cylinder block thoroughly and check ail core main bearing cap. Use suitable flat dowel to remove
hole plugs for evidence of leaking. plug. Coat outside diameter of plug with Mopar (stud
INSPECTION and bearing mount adhesive), or equivalent. Plug
Examine block for cracks or fractures. should be 54.0 to 57.7 m m (2-1/8 to 2-5/16 inches)
The cylinder walls s h o u l d be checked for out-of- from bottom of the block.
bound a n d taper with C y l i n d e r Bore Indicator Tool (5) Assemble engine and check oil pressure.
C-119. T h e cylinder block should be bored a n d honed
with new pistons a n d rings fitted if: ENGINE CORE, OIL AND CAMSHAFT PLUGS
• T h e cylinder bores show more t h a n 0.127 m m Engine core plugs have been pressed into the oil
(0.005 inch) out-of-round. galleries behind t h e camshaft t h r u s t plate (Fig. 21).
• The cylinder bores show a taper of more t h a n This w i l l reduce internal leakage a n d help maintain
0.254 m m (0.010 inch). higher oil pressure a t idle.
• The cylinder walls are badly scuffed or scored.
Boring a n d h o n i n g operation should be closely co REMOVAL
ordinated with t h e fitting o f pistons and rings so (1) Using a blunt tool such as a drift or a screw
specified clearances m a y be m a i n t a i n e d . driver a n d a hammer, strike t h e bottom edge of t h e
Refer to Standard Service Procedures in t h e begin cup plug (Fig. 22).
ning of this G r o u p for t h e proper h o n i n g of cylinder
bores.
9 - 72 5.2L ENGINE
CYLINDER
" BLOCK ' /
DRIFT 9209-41

INSTALLATION
Fig. 21 Location of Cup Plugs in Oil Galleries (1) Coat edges of plug and core hole with Mopar
Gasket Maker, or equivalent.
(2) With the cup plug rotated, grasp firmly with
pliers or other suitable tool and remove plug (Fig. C A U T I O N : DO NOT drive cup plug into the casting
22). as restricted coolant flow can result and cause se
rious engine problems.
CLEANING
Thoroughly clean inside of cup plug hole in cylin (2) Using proper drive plug, drive plug into hole.
der block or head. Be sure to remove old sealer. The sharp edge of the plug should be at least 0.50
mm (0.020 inch) inside the lead-in chamfer.
Make certain the new plug is cleaned of all oil or
It is not necessary to wait for curing of the sealant.
grease.
The cooling system can be filled and the vehicle
placed in service immediately.
ASSEMBLE
(1) Install the piston/connecting rod assembly.
(3) Install the cylinder head.
Camshaft
Bearing Diameter End Play 0.051-0.178 mm
No. 1 . . . . . . . . . . . . . . . . . . . . . . . . 50.800-50.825 mm (0.002-0.007 in)
(2.000-2.001 in) Max. Allowable 0.254 mm
No. 2 . . . 50.394-50.419 mm (0.010 in)
(1.984-1.985 in) Main Bearing Journals
No. 3 . . 50.013-50.038 mm Diameter . . . . . . . . . . . . . . . . . . . . . 63.487-63.513 mm
(1.969-1.970 in) (2.4995-2.5005 in)
No. 4 . . . . . . . . . . . . . . . . . . . . 49.606-49.632 mm Out-of-Round (Max.) 0.0254 mm
(1.953-1.954 in) (0.001 in)
No. 5 39.688-39.713 mm Taper (Max.) 0.0254 mm
(1.5625-1.5635 in) (0.001 in)
Diametrical Clearance 0.0254-0.0762 mm
(0.001-0.003 in) C y l i n d e r Block
Max. Allowable 0.127 mm Cylinder Bore
(0.005 in) Diameter 99.314-99.365 mm
End Play. . . . . . 0.051-0.254 mm (3.910-3.912 in)
(0.002-0.010 in) Out-of-Round (Max.) . . . . . . . . . . . . 0.127 mm
Bearing Journal Diameter (0.005 in)
No. 1 . . . . . . . . . . . . . . . . . . . . . . . . 50.749-50.775 mm Taper (Max.) 0.254 mm
(1.998-1.999 in) (0.010 in)
No. 2 50.343-50.368 mm Oversize (Max.) . . . . . . . . . . . . . . . . 1.016 mm
(1.982-1.983 in) (0.040 in)
No. 3 . . . 49.962-49.987 mm Distributor Lower Drive Shaft
(1.967-1.968 in) Bushing (Press Fit in Block) 0.0127-0.3556 mm
No. 4 . . . . . . . . . . . . . . . . . . . . 49.555-49.581 mm (0.0005-0.0140 in)
(1.951-1.952 in) Shaft-to-Bushing Clearance . . . . . . . . 0.0178-0.0686 mm
No. 5 39.637-39.662 mm (0.0007-0.0027 in)
(1.5605-1.5615 in) Tappet Bore Diameter . . . . . . . . . 22.99-23.01 mm
(0.9051-0.9059 in)
Connecting Rods
Bearing Clearance 0.0127-0.0559 mm Cylinder H e a d
(0.0005-0.0022 in) Compression Pressure 689 kPa
Piston Pin Bore Diameter . 24.966-24.978 mm (100 psi)
(0.9829-0.9834 in) Gasket Thickness (Compressed) . . . . . . 1.2065 mm
Side Clearance (Two Rods) . . . . . . . . . 0.152-0.356 mm (0.0475 in)
(0.006-0.014 in) Valve Seat
Total Weight (Less Bearing) . . . . . . . . . 726 grams Angle. . . . . 44.25° - 44.75°
(25.61 oz) Runout (Max.) . . . . . . . . . . . . . 0.0762 mm
(0.003 in)
Crankshaft Width (Finish) - Intake 1.016-1.524 mm
Connect Rod Journal (0.040-0.060 in)
Diameter . . . . . . . 53.950-53.975 mm Width (Finish) - Exhaust. . . . . . . . . . 1.524-2.032 mm
(2.124-2.125 in) (0.060-0.080 in)
Out-of-Round (Max.) . . . . . . . . . . . . 0.0254 mm
(0.001 in) H y d r a u l i c Tappets
Taper (Max.) .... . . . . . . 0.0254 mm Body Diameter 22.949-22.962 mm
(0.001 in) (0.9035-0.9040 in)
Clearance in Block . 0.0279-0.0610 mm
Diametrical Clearance (0.0011-0.0024 in)
No. 1 0.0127-0.0381 mm Dry Lash 1.524-5.334 mm
(0.0005-0.0015 in) (0.060-0.210 in)
Nos. 2, 3, 4 and 5 . . . . . . . . . . . . . 0.0127-0.0508 mm Push Rod Length . . . . . . . . . . . . . 172.57-173.08 mm
(0.0005-0.0020 in) (6.794-6.814 in)
Max. Allowable (Nos. 2, 3,4&5) 0.0635 mm
(0.0025 in)
J9309-97
ENGINE SPECIFICATIONS (CONT*)
Oil P u m p Piston Pins

Clearance Over Rotors ( M a x . ) . . . . . 0.1016 mm Clearance
(0.004 in) In Piston . 0.00635-0.01905 mm
Cover Out-of-Flat ( M a x . ) . . . . . 0.0381 mm (0.00025-0.00075 in)
(0.0015 in) In Rod (interference) . . . . . . . . . . 0.0178-0.0356 mm
Inner Rotor Thickness (Min.) 20.955 mm (0.0007-0.0014 in)
(0.825 in) Diameter. 24.996-25.001 mm
Clearance ( M a x . ) . . . . . . . . . . . . . 0.3556 mm End Play NONE
(0.014 in) Length 75.946-76.454 mm
(2.469 in)
Thickness (Min.) 20.955 mm Piston Rings
(0.825 in) Ring Gap
Tip Clearance Between Rotors (Max). . 0.2032 mm Compression Rings . 0.254-0.508 mm
(0.008 in) (0.010-0.020 in)
Oil Control (Steel Rails) . 0.254-1.270 mm
At Curb Idle Speed* 41.4 kPa Ring Side Clearance
(6 psi) Compression Rings 0.038-0.076 mm
At 3000 rpm 207-552 kPa (0.0015-0.0030 in)
(30-80 psi) Oil Ring (Steel Rails) . . . . . . . . . . 0.06-0.21 mm
Oil Pressure Switch (0.002-0.008 in)
Actuating Pressure (Min.) . 34.5-48.3 kPa Ring Width
(5-7 psi) Compression Rings 1.971-1.989 mm
(0.0776-0.0783 in)
* C A U T I O N : If pressure is ZERO at curb idle, Oil Ring (Steel Rails) 3.848-3.975 mm
D O NOT run engine at 3,000 rpm. (0.1515-0.1565 in)
O i l Filter V®hr©s
Bypass Valve Setting . . . . . . . . . . . . 62-103 kPa Face Angle 43.25° - 43.75°
(9-15 psi) Head Diameter
Intake . . . . . . . . . . . . . . . . . . . . . 48.666 mm
Pistons (1.916 in)
Clearance at Top of Skirt . . . . 0.0127-0.0381 mm Exhaust 41.250 mm
(0.0005-0.0015 in) (1.624 in)
Land Clearance (Diametrical) . . . . . 0.635-1.016 mm Length (Overall)
(0.025-0.040 in) Intake . 124.28-125.92 mm
Piston Length . . . . . . . . . . . . . . . . . 86.360 mm (4.893-4.918 in)
(3.40 in) Exhaust . 124.64-125.27 mm
Piston Ring Groove Depth (4.907-4.932 in)
Nos. 1 and 2 4.572-4.826 mm Lift (Zero Lash) 10.973 mm
(0.180-0.190 in) (0.432 in)
No. 3 3.810-4.064 mm Stem Diameter 7.899-7.925 mm
(0.150-0.160 in) (0.311-0.312 in)
Weight 592.6-596.6 grams Stem-to-Guide C l e a r a n c e . . . . . . . . . 0.0254-0.0762 mm
(20.90-21.04 oz) (0.001-0.003 in)
Max. Allowable (Rocking Method). . 0.4318 mm
(0.017 in)
Guide Bore Diameter (Std) 7.950-7.976 mm
(0.313-0.314 in)
J9309-32
ENGINE SPECIFICATIONS (CONT,)
Valve S p r i n g s Valve Timing

Free Length (Approx.) 49.962 mm Exhaust Valve
(1.967 in) Closes (ATC) 16°
Spring Tension . @ 41.66 mm = 378 N Opens (BBC) 52°
(Valve Closed) (@ 1.64 in . 85 lbs) Duration 248°
Spring Tension . @ 30.89 mm = 890 N Intake Valve
(Valve Open) (@ 1.212 in = 200 lbs) Closes (ABC) 50°
Number of Coils . . . . . . . . . . . . . . . 6.8 Opens (BTC) . 10°
Installed Height 41.66 mm Duration . 240°
(Spring Seat to Retainer) (1.64 in) Valve Overlap . . . 26°
Wire Diameter . 4.50 mm
(0.177 in)
J9309-33
CONDITION IDENTIFICATION L O C A T I O N O F IDENTIFICATION
CRANKSHAFT JOURNALS RorM Milled flat on no. 8 crankshaft counterweight.

(UNDERSIZE) M-2-3 etc. (indicating no. 2 and 3 main bearing
0.0254 mm (0.001 in.) journal)
and/or
R-l-4 etc. (indicating no. 1 and 4 connecting rod
journal)
HYDRAULIC TAPPETS • Diamond-shaped stamp top pad - front of

(OVERSIZE) engine and flat ground on outside surface of
0.2032 mm (0.008 in.) each O/S tappet bore.
VALVE STEMS (OVERSIZE) X Milled pad adjacent to two tapped holes

0.127 mm (0.005 in.) (3/8 in.) on each end of cylinder head.
J9309-82

Adjusting Strap Bolt... 23 N-m (200 in. lbs.) Rear Insulator-to-Bracket
Camshaft Bolt 68 N-m (50 ft. lbs.) Through-Bolt (2WD)................................. 68 N-m (50 ft. lbs.
Camshaft Thrust Plate Bolts........................ 24 N-m (210 in. lbs.) Rear Insulator-to-Crossmember
Chain Case Cover Bolts 41 N-m (30 ft. lbs.) Support Bracket Nut (2WD) 41 N-m (30 ft. lbs.
Rear Insulator Mounting Plate-to-
Connecting Rod Cap Bolts 61 N-m (45 ft. lbs.)
Rail Assembly Nuts (4WD) 41 N-m (30 ft. lbs.
Crankshaft Main Bearing Cap Bolts 115 N-m (85 ft. lbs.) Rear Support Bracket-to-Crossmember
Cylinder Head Bolts Flange Nuts 41 N-m (30ft.lbs.
1st Step 68 N-m (50 ft. lbs.) Rear Support Plate-to-lnsulator
2nd Step 143 N-m (105 ft. lbs.) Mounting Plate Bolts (4WD) 41 N-m (30ft.lbs.
Cylinder Head Cover Bolts 11 N-m (95 in. lbs.) Rear Support Plate-to-Transfer
Exhaust Manifold-to-Cylinder Case Bolts 41 N-m (30ft.lbs.
Front Insulator Attaching Spark Plugs.... 41 N-m (30 ft. lbs.
Bolts (2WD).. 41 N-m (30 ft. lbs.) Starter Mounting Bolts 68 N-m (50 ft. lbs.
Front Insulator Stud Nuts 102 N-m (75 ft. lbs.) Throttle Body Bolts (MPI)... 23 N-m (200 in. lbs.
Front Mount Adaptor-to-Block Bolts 41 N-m (30 ft. lbs.) Torque Converter Drive Plate Bolts 31 N-m (270 in. lbs.
Front Mount Bracket-to- Transfer Case-to-Insulator
Crossmember Bolts (4WD) 41 N-m (30 ft. lbs.) Mounting Plate Nuts.... 204 N-m (150 ft. lbs.
Bolts (2WD).... 68 N-m (50 ft. lbs.
Service Manual. Bolts (4WD) 68 N-m (50ft.lbs.
Oil Pan Drain Plug 34 N-m (25 ft. lbs.) Insulator Mounting Plate Nuts (4WD) .... 204 N-m (150 ft. lbs.
Oil Pump Attaching Bolts 41 N-m (30 ft. lbs.) Vibration Damper Retainer Bolt 183 N-m (135ft.lbs.
Oil Pump Cover Bolts.. 11 N-m (95 in. lbs.)
Cover Bolt 41 N-m (30ft.Ibs.j
J9309-98
5 . 9 L ENGINE SERVICE P R O C E D U R E S
INDEX
page page
Camshaft 91 General Information 77
Crankshaft Main Bearings 99 Oil P a n 93
Crankshaft Rear Oil Seals 100 Oil Pump . 94
Cylinder Block 101 Piston / Connecting Rod Assembly 96
Cylinder Head Cover 81 Rocker Arms 81
Cylinder Heads 82 Specifications—5.9L Engine 103
Distributor 92 Timing Chain Cover 89
Engine Assembly 80 Valve Stem Shield / Spring Replacement 86
Engine Front Mounts 77 Valve Timing . 88
Engine Rear Mount 78 Valves / Valve Springs 84
Front Crankshaft Oil Seal Replacement 91 Vibration Damper 88
GENERAL INFORMATION
The 5.9 Liter (360 CID) eight-cylinder engine is a
V-Type lightweight, single cam, overhead valve en
gine with hydraulic roller tappets (Fig. 1).
Engine Type .90° V-8 OHV

Bore and Stroke
Displacement
Compression Ratio
101.6 x 90.9 mm (4.00 x 3.58 in.)
5.9L (360 cu. in.)
9.1:1
o FRONT
CLOCKWISE ROTATION
1-8-4-3-6-5-7-2
Torque 441 N-m (325 ft. lbs.) @ 3,200 rpm OF

(Heavy Duty). 448 N-m (330 ft. lbs.) @ 2,800 rpm ENGINE
Firing Order 1-8-4-3-6-5-7-2
Lubrication . . . . . . Pressure Feed - Full Flow Filtration
Engine Oil Capacity .4.7L (5.0 Qts) w/filter
Cooling System . . . Liquid Cooled - Forced Circulation
J908D-49
Cooling Capacity . . . . . . . 14.7L (15.5 Qts)
Ramcharger (4WD) 14.2L (15.0 Qts) Fig. 2 Firing Order
Cylinder Block Cast Iron
Crankshaft - Nodular Iron
Cylinder Head • . Cast Iron X M 5.9L T XXXX XXXXXXXX
Combustion Chambers Wedge-High Swirl Valve
Shrouding
Camshaft Nodular Cast Iron X = Last Digit of Model Year
Pistons Cast Aluminum Alloy M = Plant - M Mound Road
Connecting Rods Forged Steel S Saltillo
T Trenton
J9309-99 K Toluca
5.9L = Engine Displacement
Fig. 1 Engine Description T = Usage - T Truck
This engine is designed for unleaded fuel. XXXX = Month/Day
XXXXXXXX = Serial Code - Last 8 Digits of VIN No.
Engine lubrication system consists of a rotor type
The cylinders are numbered from front to rear; 1, J9209-74
3, 5, 7 on the left bank and 2, 4, 6, 8 on the right
bank. The firing order is 1-8-4-3-6-5-7-2 (Fig. 2). Fig. 3 Engine identification Number
The engine serial number is stamped into a ma ENGINE FRONT MOUNTS
chined pad located on the left, front corner of the cyl
inder block. When component part replacement is REMOVAL
necessary, use the engine type and serial number for (1) Raise hood and position fan to assure clearance
reference (Fig. 3). for radiator top tank and hose.
9 - 78 5.9L ENGINE •
CAUTION: DO NOT lift the engine by the intake (6) Lower the vehicle.
manifold. (7) Remove lifting fixture.
(2) Install an engine lifting fixture. engine r e a r MOUNT

(4) Remove nuts from brackets and insulators (Fig, REMCYAL-2WD
4). (1) Raise vehicle on a hoist.
(5) Raise engine with lifting fixture only far (2) Position a transmission jack under the trans
enough to remove insulators. mission and raise rear of transmission and engine
SLIGHTLY.
SCREW <£> SCREW <B> (3) Remove rear mount through-bolt from frame
crossmember (sport utility) or from the transmission
support bracket (Fig. 5).
FRONT (4) Remove the flange nuts from the crossmember
#C3p LOCATING PIN support bracket (Fig. 5).
- -•- — SIDE
ONLY (5) Raise rear of transmission enough to provide
USE FRONT HOLES insulator to crossmember clearance. Remove the in
FOR INSULATOR MTG.
sulator flange nuts and remove the insulator (Fig. 5).
2-WHEEL DRIVE
(6) If necessary, remove the attaching bolts hold
TIGHTENING TORQUE INSULATORS ^ ing the transmission support bracket to the transmis
75 FT. LBS.(102 N-m) sion (Fig. 5).
65 FT. LBS. (38 Hw) 4-WHEEL DRIVE
FRAME SHOWN INSTALLATION-2WD
<£) 30 FT. LBS. (41 N-m) INSULATOR
BRACKET bracket to the transmission (Fig. 5). Install the at
(FRONT ENG
SUPPORT) taching bolts and tighten to 68 N-m (50 ft. lbs.)
torque.
(2) Position insulator in transmission support
tion relative to transmission rear support bracket.
Tighten the through-bolt nut to 68 N-m (50 ft. lbs.)
torque.
RIGHT SIDE LEFT SIDE
4-WHEEL 2-WHEEL the insulator (Fig. 5). Install the flange nut(s) and
RR09B145
DRIVE DRIVE tighten to 41 N-m (30 ft. lbs.) torque.
(5) Using the transmission jack, lower the insula
Fig. 4 Engine Front Mounts
tor and crossmember support bracket onto the cross-
(6) If necessary, remove the bracket from the block member (Fig. 5).
(Fig. 4). (6) Tighten the crossmember flange nuts to 41 N-
(7) If necessary, remove the front engine support m (30 ft. lbs.) torque.
bracket (Fig. 4). (7) Remove the transmission jack.
INSTALLATION
(1) If removed, install the front engine support REMOVAL-4WD
bracket. Tighten the bolts to 41 N-m (30 ft. lbs.) (1) Raise the vehicle on a hoist.
torque. (2) Remove the skid plate (if equipped) from the
(2) If removed, position the bracket to the block. rear crossmember and transmission crossmember
Install the screws and tighten screw A to 102 N r n (Fig. 6).
(75 ft. lbs.) torque. Tighten screw B to 88 N-m (65 ft. (3) Position transmission jack under transmission
lbs.) torque. and raise rear of transmission and engine
(3) With engine raised slightly, install insulators. SLIGHTLY.
(4) Lower engine with lifting fixture while guiding (4) AUTOMATIC TRANSMISSION-Remove
insulator studs into attaching holes in crossmember the nuts and bolts holding the transmission support
and brackets (Fig. 4). spacer to the insulator mounting plate (Fig. 7). Re
(5) Tighten attaching insulator nuts to 102 N-m move the bolts and nuts holding the engine rear sup
(75 ft. lbs.) torque. port plate to the insulator mounting plate (Fig. 7).
TRANSMISSION
SUPPORT
BRACKET
TRANSMISSION
TRANSMISSION
SUPPORT
BRACKET
INSULATOR
CROSSMEMBER
(SPORT UTILITY) J9109-240
FIG, 5 REAR ENGINE Supporis-2WD
SNSTALLA TION-4 WD
j TRANSFER CASE f||
iSKID PLATE (1) If removed, position the engine rear support
SKID PLATE llllpifci^—^
ATTACHING BOLTS p t l l l l S K i P PLATE f
I ATTACHING BOLTSlt bracket (automatic transmission) to the transfer case
(Fig. 7). Install t h e bolts and tighten to 41 N«m (30
ft. lbs.) torque.
spacer (automatic transmission) to t h e extension as
sembly (Fig. 1). Install t h e bolts and tighten to 68
PU873 N*m (50 ft. lbs.) torque.
(3) Install insulator mounting plate, mounting
FIG. 6 SKID PLATE bolts, spacers, washers and upper/lower insulators to
(5) M A N U A L TRANSMISSION—Remove t h e the rail assembly (Figs. 7 and 8). Tighten the mount
nuts and bolts holding the insulator mounting plate ing bolt nuts to 204 N*m (150 ft. lbs.) torque.
to t h e transfer case (Fig. 8). ( 4 ) AUTOMATIC TRANSMISSION—Align the
(6) Remove insulator mounting bolts, spacers, engine rear support plate and t h e transmission sup
washers and upper/lower insulators (Figs. 7 and 8). port spacer to the insulator mounting plate (Fig. 7).
(7) Remove t h e insulator mounting plate (Figs. 7 Lower the engine and transmission onto the insula
and 8). tor mounting plate and install t h e bolts. Tighten the
(8) If necessary, remove t h e transmission support transmission support spacer nuts to 204 N*m (150 ft.
spacer (automatic transmission) from the extension lbs.) torque. Tighten the engine rear support plate to
assembly (Fig. 7). 41 Nnn (30 ft. lbs.) torque.
(9) If necessary, remove t h e engine rear support (5) MANUAL TRANSMISSION—Align the
bracket (automatic transmission) from the transfer transfer case to t h e insulator mounting plate and
case (Fig. 7). lower t h e engine and transmission. Install t h e bolts
and tighten the nuts (Fig. 8 - n u t A) to 204 N-m (150
ft. lbs.) torque. Install t h e bolts and tighten t h e nuts
(Fig. 8 - n u t B) to 41 N-m (30 ft. lbs.) torque
9 - 80 5.9L ENGINE •
TRANSFER TRANSFER
CASE CASE
SPACER
UPPER
INSULATOR INSULATOR
MOUNTING
PLATE
ENGINE REAR
SUPPORT NUT®
PLATE INSULATOR
MOUNTING
PLATE
LOWER LOWER
INSULATOR INSULATOR
\7" RAIL 1 J9109-244 J9109-245
Fig. 7 Rear Engine Support—4WD with Automatic Fig. 8 Rear Engine Support—4WD with Manual
Transmission Transmission
(7) Lower the vehicle. (17) Remove starter motor (refer to Group 8B, Bat
ENGINE ASSEMBLY (18) Remove the generator (refer to Group 8B, Bat
REMOVAL (19) Raise and support the vehicle on a hoist.
(1) Scribe hood hinge outlines on hood. Remove the (20) Disconnect exhaust pipe at manifold.
hood. (21) A U T O M A T I C T R A N S M I S S I O N :
(2) Remove the battery. (a) Support transmission. This will assure t h a t
(3) Drain cooling system (refer to Group 7, Cooling the torque converter will remain in proper position
System for the proper procedure). in the transmission housing.
(4) Remove the air cleaner. (b) Remove bell housing bolts and inspection
(5) Disconnect the radiator and heater hoses. Re plate.
move radiator (refer to Group 7, Cooling System). (c) Attach a C-clamp on front bottom of trans
(6) Set fan shroud aside. mission torque converter housing to prevent torque
(7) Remove the vacuum lines. converter from falling out.
(8) Remove the distributor cap and wiring. (d) Remove torque converter drive plate bolts
(9) Disconnect the accelerator linkage. from torque converter drive plate. Mark converter
(10) Remove MPI throttle body. and drive plate to aid in assembly.
(11) Disconnect the fuel lines. (22) M A N U A L T R A N S M I S S I O N ;
(12) Disconnect the starter wires. (a) Support transmission.
(13) Disconnect the oil pressure wire. (b) Disconnect clutch release mechanism and re
(14) Discharge the air conditioning system, if move transmission to clutch housing bolts.
equipped (refer to Group 24, Heating and Air Condi
C A U T I O N : D O N O T lift the engine by the intake
tioning for service procedures).
manifold.
(15) Disconnect the air conditioning hoses.
(16) Disconnect the power steering hoses, if (23) Install an engine lifting fixture.
equipped. (24) Remove engine front mount bolts.
• 5.9L ENGINE 9-81

nect the engine from the torque converter drive (27) Warm engine and adjust.
stand. CYLINDER HEAD COVER
(1) Remove engine from the repair stand and posi again.
(2) Install an engine support fixture. CYLINDER HEAD
(4) AUTOMATIC TRANSMISSION:
the bolts to 31 Nnn (270 in. lbs.) torque.
(5) MANUAL TRANSMISSION: Fig. 1 Cylinder Head Cover Gasket
(a) Position the drive pinion shaft to the clutch
disc. REMOVAL
(b) Connect the clutch release mechanism and (1) Disconnect the negative cable from the battery.
install the transmission to clutch bolts. Tighten the (2) Disconnect closed ventilation system and evap
bolts to 68 Nnn (50 ft. lbs.) torque. oration control system from cylinder head cover.
(c) Install the engine front mounts. (3) Remove cylinder head cover and gasket. The
(6) Remove transmission support. gasket may be used again.
(8) Lower the vehicle. CLEANING
(9) Remove engine lifting fixture. Clean cylinder head cover gasket surface.
(10) Install the generator (refer to Group 8B, Bat Clean head rail, if necessary.
(11) Install the starter motor (refer to Group 8B, INSPECTION
Battery/Starter/Generator Service). Inspect cover for distortion and straighten, if nec
(12) Connect power steering hoses, if so equipped. essary.
(13) Connect air conditioning hoses. Check the gasket for use in head cover installation.
(14) Evacuate and charge the air conditioning sys If damaged, use a new gasket.
tem, if equipped (refer to Group 24, Heater and Air
Conditioning for service procedures). INSTALLATION
(15) Using a new gasket, install MPI throttle body. (1) The cylinder head cover gasket can be used
Tighten the throttle body bolts to 23 Nnn (200 in. again. Install the gasket onto the head rail.
lbs.) torque. (2) Position the cylinder head cover onto the gas
(16) Connect the accelerator linkage. ket. Tighten the bolts to 11 Nnn (95 in. lbs.) torque.
(21) Connect the fuel lines. ROCKER ARMS
System). Connect the radiator hoses and heater REMOVAL
hoses. (1) Disconnect spark plug wires by pulling on the
(23) Install fan shroud in position. boot straight out in line with plug.
9 - 82 5.9L ENGINE •
(3) Remove the rocker arm bolts and pivots (Fig. EXHAUST SPARK EXHAUST SPARK EXHAUST
2). Place them on a bench in the same order as re VALVE PLUGS VALVES PLUGS VALVE
moved.
ROCKER CYLINDER
INTAKE INTAKE
VALVES VALVES J9309-37
J9209-65
Fig. 2 Rocker Arms
INSTALLATION
(1) Rotate the crankshaft until the "V8" mark
lines up with the TDC m a r k on the timing chain
C A U T I O N : D O N O T rotate or crank the engine dur

ing or immediately after rocker arm installation. A l
(2) Install the push rods in the same order as re

moved.
(3) Install rocker arm and pivot assemblies in the
same order as removed. Tighten the rocker a r m bolts
to 28 N*m (21 ft. lbs.) torque. Fig. 4 Exhaust Manifold Heat Shields
(5) Connect spark plug wires.
(11) Remove distributor cap and wires.
CYLINDER HEADS (12) Disconnect the coil wires.
The alloy cast iron cylinder heads (Fig. 3) are held (13) Disconnect heat indicator sending unit wire.
in place by 10 bolts. The spark plugs are located in (14) Disconnect heater hoses and bypass hose.
the peak of the wedge between the valves. (15) Remove cylinder head covers and gaskets.
The 5.9L cylinder head is identified by the foundry (16) Remove intake manifold and throttle body as
m a r k CF. an assembly. Discard the flange side gaskets and the
front and rear cross-over gaskets.
REMOVAL (17) Remove exhaust manifolds.
(1) Disconnect the negative cable from the battery. (18) Remove rocker arm assemblies and push rods.
(2) Drain cooling system (refer to Group 7, Cooling Identify to ensure installation in original locations.
System for the proper procedures). (19) Remove the head bolts from each cylinder
(3) Remove the heat shields (Fig. 4). head and remove cylinder heads. Discard the cylin
der head gasket.
(6) Disconnect the evaporation control system. CLEANING
heads.
(9) Disconnect accelerator linkage and if so
down cables.
• I J L ENGINE 9 - 83
INSPECTION
span length in inches in any direction, either replace
head or lightly machine the head surface.
FOR EXAMPLE: A 305 mm (12 inch) span is
0.102 mm (0.004 inch) out-of-flat. The allowable out-
of-flat is 305 x 0.00075 (12 x 0.00075) equals 0.23
mm (0.009 inch). This amount of out-of-flat is accept
able.
The cylinder head surface finish should be 1.78-
4.57 microns (70-180 microinches).
Inspect push rods. Replace worn or bent rods.
INSTALLATION
(1) Apply Perfect Sealant No.5, or equivalent, to Fig. 6 Cylinder Head Bolt Tightening Sequence
both sides of the gasket (Fig. 5). (7) Apply Mopar Silicone Rubber Adhesive Seal
gasket. The sealant should be slightly highe^ t h a n

(2) Position the new cylinder head gaskets onto the
cylinder block.
and cylinder block.
bolts, in sequence, to 68 N-m (50 ft. lbs.) torque (Fig.
to 143 N-m (105 ft. lbs.) torque. Repeat procedure to
confirm t h a t all bolts are at 143 N-m (105 ft. lbs.)
torque.
make sure the piston in that cylinder is NOT at
T D C . Contact between the valves and piston could (9) Install the flange gaskets. Be sure t h a t the ver
occur. tical port alignment tab is resting on the deck face of
(5) Install push rods and rocker arm assemblies in be in position with the mating cylinder head gasket
their original position. Tighten the bolts to 28 N-m tabs (Fig. 8). The words MANIFOLD SIDE should be
(21 ft. lbs.) torque. visible on the center of each flange gasket.
(6) Place the 4 plastic locator dowels into the holes (10) Carefully lower intake manifold into position
in the block Fig. 7). on the cylinder block and cylinder heads. Use the
FLANGE GASKET (15) Connect heat indicator sending unit wire.
(16) Connect the heater hoses and bypass hose.
down cables.
(20) Install the fuel lines.
generator mounting bolt to 41 N-m (30 ft. lbs.)
torque. Tighten the adjusting strap bolt to 23 N-m
(200 In. lbs.) torque. Refer to Group 7, Cooling Sys
tem for adjusting the belt tension.
(22) Install the intake manifold-to-generator
bracket support rod. Tighten the bolts.
(23) Place the cylinder head cover gaskets in posi
Fig. 8 Intake Manifold Flange Gasket Alignment tion and install cylinder head covers. Tighten the
alignment dowels in the cross-over gaskets to posi bolts to 11 N-m (95 in. lbs.) torque.
tion the intake manifold. After intake manifold is in (24) Install closed crankcase ventilation system.
place, inspect to make sure seals are in place. (25) Connect the evaporation control system.
(11) The following torque sequence duplicates the (26) Install the air cleaner.
expected results of the automated assembly system (27) Install the heat shields. Tighten the bolts to
(Fig. 9). 41 N-m (30 ft. lbs.) torque.
System for proper procedure).
¥AL¥ES / WALWE S P R I l i S
head.
REMOVAL
J9209-60 Compressor Tool MD-998772A.
Fig. 9 Intake Manifold Bolt Tightening Sequence (3) Remove valve retaining locks, valve spring re
• Step 1—Tighten bolts 1 through 4, in sequence, to (4) Before removing valves, remove any burrs from
8 N-m (72 in. lbs.) torque. Tighten in alternating valve stem lock grooves to prevent damage to the
steps 1.4 N-m (12 in. lbs.) torque at a time. valve guides. Identify valves to ensure Installation in
• Step 2—Tighten bolts 5 through 12, in sequence, original location,
• Step 3—-Check t h a t all bolts are tighten to 8 N-m VALVE CLEANING
(72 in. lbs.) torque. Clean valves thoroughly. Discard burned, warped
• Step 4—Tighten all bolts, in sequence, to 16 N-m and cracked valves.
(12 ft. lbs.) torque. Remove carbon and varnish deposits from Inside of
• Step 5—Check t h a t all bolts are tighten to 16 N-m valve guides with a reliable guide cleaner.
(12) Install exhaust manifolds. Tighten the bolts VALVE INSPECTION
and nuts to 34 N-m (25 ft. lbs.) torque. Measure valve stems for wear. If wear exceeds
(13) Adjust spark plugs to specifications (refer to 0.051 mm (0.002 Inch), replace the valve.
Group 8D, Ignition System). Install the plugs and Measure valve stem guide clearance as follows:
tighten to 41 N-m (30 ft. lbs.) torque. (a) Install Valve Guide Sleeve Tool C-3973 over
(14) Install coil wires. valve stem and install valve (Fig. 10). The special
• 5.9L ENGINE 9 - 85
sleeve places the valve at the correct height for Slowly t u r n reamer by hand and clean guide thor
checking with a dial indicator. oughly before installing new valve. R e a m the valve
g u i d e s from standard to 0.381 m m (0.015 inch).
U s e a 2 step procedure so the v a l v e guides are
r e a m e d true in relation to the v a l v e seat:
REFACING VALVES / VALVE SEATS

(Fig. 13).
CONTACT
A - SEAT WIDTH - INTAKE 1.016-1.524 mm (0.040 - 0.060 in.)

EXHAUST 1.524 - 2.032 mm (0.060 - 0.080 in.)
3
B - FACE ANGLE (INTAKE & EXHAUST) 4374°-43 / ° 4
3
C - SEAT ANGLE (INTAKE & EXHAUST) 447/ - 44 A°
D - CONTACT SURFACE
J9309-95
Fig. 11 Measuring Valve Guide Wear Fig. 13 Valve Face and Seat Angles
(c) Move valve to and from the indicator. The to VALVES
tal dial indicator reading should not exceed 0.432 Inspect the remaining margin after the valves are
mm (0.017 inch). Ream the guides for valves with refaced (Fig. 14). Valves with less t h a n 1.190 mm
oversize stems if dial indicator reading is excessive (0.047 inch) margin should be discarded.
VALVE SEATS
Service valves with oversize stems are available
(Fig. 12). C A U T I O N : D O NOT un-shroud valves during valve
seat refacing (Fig. 15).
Reamer O / S Valve Guide Size
(1) When refacing valve seats, it is important t h a t
0.076 mm 8.026 - 8.052 mm the correct size valve guide pilot be used for reseat
(0.003 in.) (0.316-0.317 in.) ing stones. A true and complete surface must be ob
tained.
0.381 mm 8.331 - 8.357 mm
(0.328-0.329 in.) (2) Measure the concentricity of valve seat using a
(0.015 in.)
dial indicator. Total runout should not exceed 0.051
mm (0.002 inch) total indicator reading.
(3) Inspect the valve seat with Prussian blue to de
J9309-30 termine where the valve contacts the seat. To do
Fig. 12 Reamer Sizes then set valve in place. Rotate the valve with light
pressure. If the blue is transferred to the center of
9 • 86 5.9L ENGINE •
the spring load at test length. Fractional measure
ments are indicated on the table for finer adjust
>
\ MARGIN / ments. Refer to specifications to obtain specified
INTAKE EXHAUST
VALVE VALVE height and allowable tensions. Discard the springs
\ A C E ^ t h a t do not meet specifications.
* STEM *
VALVE SPRING
RETAINER LOCK SPECIAL
GROOVE TOOL C-647
J9209-127
Fig. 14 intake and Exhaust Waives
9209-37
REFACING STONE
MUST NOT CUT
VALVE SHROUD Fig. 16 Testing Waive Spring for Compressed
Length with Tool C-647
INSTALLATION
(1) Coat valve stems with lubrication oil and insert
(2) If valves or seats are reground, check valve
stem height. If valve is too long, replace cylinder
head.
(3) Install new seals on all valve guides. Install
valve springs and valve retainers.
(4) Compress valve springs with Valve Spring
Compressor Tool MD-998772A, install locks and re
lease tool. If valves and/or seats are ground, measure
Fig. 15 Refacing Waive Seats the installed height of springs. Make sure the mea
valve face, contact is satisfactory. If the blue is trans surement is taken from bottom of spring seat in cyl
ferred to the top edge of valve face, lower valve seat inder head to the bottom surface of spring retainer. If
with a 15° stone. If the blue is transferred to bottom spacers are installed, measure from the top of spacer.
edge of valve face raise valve seat with a 60° stone. If height is greater t h a n 42.86 mm (1-11/16 inches),
(4) When seat is properly positioned the width of install a 1.587 mm (1/16 inch) spacer in head coun-
intake seats should be 1.016-1.524 mm (0.040-0.060 terbore. This should bring spring height back to nor
inch). The width of the exhaust seats should be mal 41.27 to 42.86 mm (1-5/8 to 1-11/16 inch).
1.524-2.032 mm (0.060-0.080 inch).
¥AL¥E STEM SHIELD / SPRING REPLACEMENT
VALVE SPRING INSPECTION This procedure is done with the cylinder head in
Whenever valves have been removed for inspection, stalled.
reconditioning or replacement, valve springs should (1) Set engine basic timing to Top Dead Center
be tested. As an example the compression length of (TDC) and remove air cleaner.
the spring to be tested is 1-5/16 inch. Turn table of (2) Remove cylinder head covers and spark plugs.
Valve Spring Tester Tool C-647 until surface is in (3) Remove coil wire from distributor and secure to
line with the 1-5/16 inch mark on the threaded stud. good ground to prevent engine from starting.
Be sure the zero mark is to the front (Fig. 16). Place (4) Using suitable socket and flex handle at crank
spring over stud on the table and lift compressing le shaft retaining bolt, t u r n engine so the No.l piston is
ver to set tone device. Pull on torque wrench until at TDC on the compression stroke.
ping is heard. Take reading on torque wrench at this (5) Remove rocker arms.
• 5.9L ENGINE 9 - 87
(6) With air hose attached to an adapter installed engine should be operated at fast idle for sufficient
in No.l spark plug hole, apply 620-689 k P a (90-100 time. This allows all of the air inside of the tappets
psi) air pressure. to be bled out.
(7) Using Valve Spring Compressor Tool
MD-998772A, compress valve spring and remove re TAPPET NOISE DIAGNOSIS
tainer valve locks and valve spring. (1) To determine source of tappet noise, operate en
(8) Install seals on the exhaust valve stem and po gine at idle with cylinder head covers removed.
sition down against valve guides. (2) Feel each valve spring or rocker arm to detect
(9) The intake valve stem seals should be pushed noisy tappet. The noisy tappet will cause the affected
firmly and squarely over the valve guide using the spring and/or rocker arm to vibrate or feel rough in
valve stem as a guide. DO NOT force seal against operation.
top of guide. When installing the valve retainer W o r n v a l v e g u i d e s o r c o c k e d s p r i n g s a r e some
locks, compress the spring only enough to install the t i m e s m i s t a k e n for n o i s y t a p p e t s . If s u c h is t h e
locks. c a s e , n o i s e m a y b e d a m p e n e d b y a p p l y i n g side
(10) Follow the same procedure on the remaining 7 t h r u s t o n t h e v a l v e s p r i n g . If n o i s e is n o t a p p r e
cylinders using the firing sequence 1-8-4-3-6-5-7-2. c i a b l y r e d u c e d , it c a n b e a s s u m e d t h e n o i s e Is in
Make sure piston in cylinder is at TDC on the valve the tappet. Inspect t h e rocker arm push rod
spring t h a t is being removed. s o c k e t s a n d p u s h r o d e n d s for w e a r .
(11) Remove adapter from the No.l spark plug (3) Valve tappet noise ranges from light noise to a
hole. heavy click. A light noise is usually caused by exces
(12) Install rocker arms. sive leak-down around the unit plunger or by the
(13) Install covers and coil wire to distributor. plunger partially sticking in the tappet body cylin
(14) Install air cleaner. der. The tappet should be replaced. A heavy click is
(15) Road test vehicle. caused by a tappet check valve not seating or by for
eign particles becoming wedged between the plunger
HYDRAULIC TAPPETS
and the tappet body. This will cause the plunger to
Before disassembling any part of the engine to cor
stick in the down position. This heavy click will be
rect tappet noise, check the oil pressure. If vehicle
has no oil pressure gauge, Install a reliable gauge at accompanied by excessive clearance between the
the pressure sending unit. The pressure should be be valve stem and rocker arm as valve closes. In either
tween 207-552 kPa (30-80 psi) at 3,000 RPM. case, tappet assembly should be removed for inspec
Check the oil level after the engine reaches normal tion and cleaning.
operating temperature. Allow 5 minutes to stabilize The valve train generates a noise very much like a
oil level, check dipstick. light tappet noise during normal operation. Care
The oil level in the pan should never be above the must be taken to ensure t h a t tappets are making the
FULL mark or below the ADD OIL m a r k on dipstick. noise. In general, if more t h a n one tappet seems to
Either of these 2 conditions could be responsible for be noisy, its probably not the tappets.
noisy tappets.
REMOVAL
OIL LEVEL (1) Remove the air cleaner.
(2) Remove cylinder head cover.
HIGH
(3) Remove rocker assembly and push rods. Iden
If oil level Is above the FULL mark, It is possible tify push rods to ensure Installation in original loca
for the connecting rods to dip into the oil. With the tion.
engine running this condition could create foam in
(4) Remove Intake manifold.
(5) Remove yoke retainer and aligning yokes.
draulic tappets by the oil pump causing them to lose
(6) Slide Hydraulic Tappet Remover/Installer Tool
length and allow valves to seat noisily.
C-4129-A through opening in cylinder head and seat
LOW tool firmly in the head of tappet.
Low oil level may allow oil pump to take in air. (7) Pull tappet out of bore with a twisting motion.
When air is fed to the tappets, causes them to lose If all tappets are to be removed, identify tappets to
length and allows valves to seat noisily. Any leaks ensure installation in original location.
on intake side of oil pump through which air can be (8) If the tappet or bore in cylinder block is scored,
drawn will create the same tappet action. When tap scuffed, or shows signs of sticking, ream the bore to
pet noise is due to aeration, it may be intermittent or next oversize. Replace with oversize tappet.
constant, and usually more t h a n 1 tappet will be
noisy. When oil level and leaks have been corrected,
9 - 88 5.9L ENGINE •
C A U T I O N : T h e plunger a n d tappet bodies are not (2) Insert a 6.350 mm (1/4 inch) spacer between
interchangeable,. T h e plunger a n d valve must al rocker arm pad and stem tip of No.l intake valve.
ways be fitted to the original body, It is advisable to Allow spring load to bleed tappet down giving in ef
work o n o n e tappet at a time to avoid mixing of fect a solid tappet.
parts. Mixed parts are not compatible. D O N O T dis (3) Install a dial indicator so plunger contacts
a s s e m b l e a tappet o n a dirty work b e n c h . valve spring retainer as nearly perpendicular as pos
sible. Zero the Indicator.
(4) Rotate the crankshaft clockwise (normal run
DISASSEMBLE ning direction) until the valve has lifted 0.863 mm
(1) Pry out plunger retainer spring clip (Fig. 17). (0.034 inch). The timing of the crankshaft should
(2) Clean varnish deposits from inside of tappet now read from 10° before top dead center to 2° after
body above plunger cap. top dead center. Remove spacer.
(3) Invert tappet body and remove plunger cap,
plunger, check valve, check valve spring, check valve C A U T I O N : D O N O T turn crankshaft a n y further
retainer and plunger spring (Fig, 17). Check valve clockwise a s valve spring might bottom a n d result
could be flat or ball. in serious damage.
ASSEMBLE (5) If reading is not within specified limits:
(1) Clean all tappet parts in a solvent t h a t will re (a) Check sprocket index marks.
move all varnish and carbon. (b) Inspect timing chain for wear.
(2) Replace tappets t h a t are unfit for further ser (c) Check accuracy of DC m a r k on timing indica
vice with new assemblies. tor. -
(3) If plunger shows signs of scoring or wear, in
stall a new tappet assembly. If valve is pitted, or ¥IBRATI0N PAMPER
valve seat on end of plunger is prevented from seat
ing, install a new tappet assembly. REMOVAL
(4) Assemble tappets (Fig. 17). (1) Disconnect the negative cable from the battery.
(2) Remove fan shroud retainer bolts and set
shroud back over engine.
Cooling System).
(5) Remove the vibration damper pulley.
end of crankshaft.
SPiING CAP J9109-220 (7) Install bar and screw from Puller Tool Set
C-3688. Install 2 bolts with washers through the
Fig. 17 Hydraulic Tappet Assembly puller tool and into the vibration damper (Fig. 1).
INSTALLATION
(1) Lubricate tappets.
(2) Install tappets and push rods in their original
positions. Ensure t h a t the oil feed hole In the side of
the tappet body faces up (away from the crankshaft).
(3) Install rocker arm and shaft assembly.
(4) Install vent cover.
(5) Install distributor, start engine and reset tim
ing.
C A U T I O N : T o prevent d a m a g e to valve m e c h a n i s m , J
920
9-
81
engine must not be run above fast idle until all hy Fig. 1 Vibration Damper Assembly
draulic tappets have filled with oil a n d have b e c o m e
quiet. (8) Pull vibration damper off of the crankshaft.
INSTALLATION
¥AL¥E TIMING (1) Position the vibration damper onto the crank
(1) Turn crankshaft until the No.6 exhaust valve shaft.
is closing and No.6 intake valve Is opening.
• 5.9L ENGINE 9 - 89


rection of crankshaft rotation to take up slack; 41
N-m (30 ft, lbs.) torque with cylinder head installed
Fig. 2 Installing Vibration Damper or 20 N-m (15 ft. lbs.) torque with cylinder head re
(3) Install the crankshaft bolt and washer. Tighten moved. With a torque applied to the camshaft
the bolt to 183 N-m (135 ft. lbs.) torque. sprocket bolt, crankshaft should not be permitted to
(4) Install the crankshaft pulley. Tighten the pul move. It may be necessary to block the crankshaft to
ley bolts to 23 N-m (200 In. lbs.) torque. prevent rotation.
(5) Install the serpentine belt (refer to Group 7, (3) Hold a scale with dimensional reading even
Cooling System). with the edge of a chain link. With cylinder heads
(6) Install the cooling system fan. Tighten the installed, apply 14 N-m (30 ft. lbs.) torque In the re
bolts to 23 N-m (17 ft. lbs.) torque. verse direction. With the cylinder heads removed, ap
(7) Position the fan shroud and install the bolts. ply 20 N-m (15 ft. lbs.) torque In the reverse
Tighten the retainer bolts to 11 N-m (95 in. lbs.) direction. Note the amount of chain movement (Fig.
torque. 4).
TIMING CHAIN COWER

REMOVAL
System).
Cooling System).
(4) Remove water pump (refer to Group 7, Cooling
System).
(5) Remove power steering pump (refer to Group Fig. 4 Measuring Timing Chain Wear and Stretch
19, Steering).
(6) Remove vibration damper. (4) Install a new timing chain, if its movement ex
(7) Remove fuel lines (refer to Group 14, Fuel Sys ceeds 3.175 mm (1/8 inch).
tem). (5) If chain is not satisfactory, remove camshaft
(8) Loosen oil pan bolts and remove the front bolt sprocket attaching bolt and remove timing chain
at each side. with crankshaft and camshaft sprockets,
(9) Remove the cover bolts. (6) Place both camshaft sprocket and crankshaft
(10) Remove chain case cover and gasket using ex sprocket on the bench with timing marks on exact
treme caution to avoid damaging oil pan gasket. imaginary center line through both camshaft and
(11) Place a suitable tool behind the lips of the oil crankshaft bores.
seal to pry the oil seal outward. Be careful not to (7) Place timing chain around both sprockets.
damage the crankshaft seal surface of cover (Fig. 3). (8) Turn crankshaft and camshaft to line up with
shaft sprocket.
(1) Place a scale next to the timing chain so t h a t
shaft sprocket attaching bolt. Apply torque in the di-
9 - 90 5.9L ENGINE •
(10) Slide both sprockets evenly over their respec (3) Position the seal and tool onto the crankshaft
tive shafts and use a straightedge to check alignment (Fig. 7).
of timing m a r k s (Fig. 5).
SPECIAL TOOL OIL
SEAL
TIMING
J9209-129
MARKS

thrust plate and up to 0.254 mm (0.010 inch) with a TIMING'
used thrust plate. If not within these limits install a CHAIN
new thrust plate. COVER J9309-45-
CLEANING Fig. 7 Position Tool and Seal onto Crankshaft

Be sure mating surfaces of chain case cover and (4) Using the vibration damper bolt, tighten the
cylinder block are clean and free from burrs. bolt to draw the seal into position on the crankshaft
(Fig. 8).
INSTALLATION
chain case cover to avoid damaging oil pan gasket.
Use a small amount of Mopar Silicone Rubber Adhe
sive Sealant, or equivalent, at the joint between tim
CRANKSHAFT. INSTALL THIS

FRONT OIL END INTO
SEAL SPECIAL TOOL
6635
J9309-46
Fig. 8 Installing Oil Seal

(5) Tighten chain case cover bolts to 41 N-m (30 ft.
J9309-44 lbs.) torque. Tighten oil pan bolts to 24 N»m (215 in.
lbs.) torque.
Fig. 6 Placing Oil Seal on Installation Tool 6635 (6) Remove the vibration damper bolt and seal in
stallation tool.
(7) Install vibration damper.
(8) Install fuel lines (refer to Group 14, Fuel Sys THRUST
tem). PLATE
(9) Install water pump and housing assembly us
ing new gaskets (refer to Group 7, Cooling System). OIL PUMP A N D
DISTRIBUTOR DRIVE
Tighten bolts to 41 N-m (30 ft. lbs.) torque. GEAR INTEGRAL
(10) Install power steering pump (refer to Group WITH CAMSHAFT
19, Steering). •CAMSHAFT SPROCKET
Cooling System). J8309-71
(12) Install the cooling system fan. Tighten the
bolts to 23 N-m (17 ft. lbs.) torque. Fig. 9 Camshaft and Sprocket Assembly
(13) Position the fan shroud and install the bolts. (6) Remove distributor and lift out the oil pump
Tighten the bolts to 11 N-m (95 in. lbs.) torque. and distributor drive shaft.
(14) Fill cooling system (refer to Group 7, Cooling (7) Remove camshaft thrust plate, note location of
System for the proper procedure). oil tab (Fig. 10).
FRONT CRANKSHAFT OIL SEAL REPLACEMENT

The oil seal can be replaced without removing the
aligned.
(3) If front seal is suspected of leaking, check front
oil seal alignment to crankshaft. The seal installa
tion/alignment tool 6635, should fit with minimum
interference. If tool does not fit, the cover must be re
moved and installed properly.
the oil seal in the groove of the tool. THRUST PLATE
(6) Position the seal and tool onto the crankshaft REAR SIDE
(Fig. 7).
J9209-132
Fig. 10 Timing Chain Oil Tab Installation
(Fig. 8).
(8) Remove the vibration damper bolt and seal in (8) Install a long bolt into front of camshaft to fa
stallation tool. cilitate removal of the camshaft. Remove camshaft,
(9) Install the vibration damper. being careful not to damage cam bearings with the
(10) Connect the negative cable to the battery. cam lobes.
CAMSHAFT REMOVAL-BEARING
This procedure requires t h a t the engine is removed (1) With engine completely disassembled, drive out
from the vehicle. rear cam bearing core hole plug.
The camshaft has an integral oil pump and distrib (2) Install proper size adapters and horseshoe
utor drive gear (Fig. 9). washers (part of Camshaft Bearing Remover/Installer
Tool C-3132-A) at back of each bearing shell. Drive
REMOVAL out bearing shells (Fig. 11).
(2) Remove cylinder head covers. INSTALLATION-BEARING
(3) Remove timing case cover and timing chain. (1) Install new camshaft bearings with Camshaft
(4) Remove rocker arms. Bearing Remover/Installer Tool C-3132-A by sliding
(5) Remove push rods and tappets. Identify each the new camshaft bearing shell over proper adapter.
part so it can be installed in its original location. (2) Position rear bearing in the tool. Install horse-
9 - 92 5.9L ENGINE •
plate. Tighten bolts to 24 N-m (210 in. lbs.) torque.
order to catch oil for chain lubrication.
(5) Place both camshaft sprocket and crankshaft
sprocket on the bench with timing marks on exact
crankshaft bores.
(7) Turn crankshaft and camshaft to line up with
Fig. 11 Camshaft Bearings Removal and Installation
shaft sprocket.
with Tool C-3132-A
shoe lock and by reversing removal procedure, care against the chain in position as described).
fully drive bearing shell into place. (9) Slide both sprockets evenly over their respec
(3) Install remaining bearings in the same man tive shafts and use a straightedge to check alignment
ner. Bearings must be carefully aligned to bring oil of timing marks (Fig. 13).
holes into full register with oil passages from the
main bearing. If the camshaft bearing shell oil holes
are not in exact alignment, remove and install them
correctly. Install a new core hole plug at the rear of
camshaft. B e sure this plug d o e s not leak.
INSTALLATION
Whenever an engine h a s b e e n rebuilt, a n e w
camshaft and/or n e w tappets installed, add 1
pint of Mopar Crankcase Conditioner, or equiv Fig. 13 Alignment of Timing Marks
alent. The oil mixture should b e left in engine (10) Install the camshaft bolt/cup washer. Tighten
for a minimum of 805 k m (500 miles). Drain at bolt to 68 N-m (50 ft. lbs.) torque.
the next normal oil change. (11) Measure camshaft end play. Refer to Specifi
(2) Install Camshaft Gear Installer Tool C-3509 cations for proper clearance. If not within limits, in
with tongue back of distributor drive gear (Fig. 12). stall a new thrust plate.
same position from which it was removed. When
camshaft is replaced, all of the tappets must be
replaced.
DISTRIBUTOR
REMOVAL
procedure.

(1) Insert Distributor Drive Shaft Bushing Puller
Fig. 12 Camshaft Holding Tool C-3509 (Installed Tool C-3052 into old bushing and thread down until
Position) a tight fit is obtained (Fig. 14).
(3) Hold tool in position with a distributor lock- (2) Hold puller screw and tighten puller nut until
plate bolt. This tool will restrict camshaft from being bushing is removed.
INSTALLATION-DRIVE SHAFT BUSHING
plug in rear of cylinder block. Tool should remain
installed until the camshaft a n d crankshaft
sprockets and timing chain h a v e b e e n installed.
• 5.9L ENGINE 9 - 93
Fig. 14 Removing Distributor Driveshaft Bushing Fig. 17 Position of Installed Distributor Drive Gear
(2) Drive bushing and tool into position, using a on top of drive gear should be aligned towards left
hammer (Fig. 15). front intake manifold attaching bolt hole (Fig. 17).
INSTALLATION
procedure.
OIL PAN
REMOVAL
(3) Raise vehicle.
Fig. 15 Distributor Driveshaft Bushing Installation (5) Remove exhaust pipe.
(3) As the burnisher is pulled through the bushing, (6) Remove left engine to transmission strut.
the bushing is expanded tight in the block and bur (7) Remove oil pan and one-piece gasket.
nished to correct size (Fig. 16). DO NOT ream this
bushing. CLEANING
Clean the block and pan gasket surfaces.
Trim or remove excess sealant film in the rear
main cap oil pan gasket groove. DO NOT remove
the sealant inside the rear main c a p slots.
If present, trim excess sealant from inside the en
gine.
cloth.
vent. Inspect condition of screen.
INSPECTION
Fig. 16 Burnishing Distributor Driveshaft Bushing Inspect oil drain plug and plug hole for stripped or
damaged threads. Repair as necessary.
DISTRIBUTOR TIMING Inspect oil pan mounting flange for bends or distor
Before installing the distributor and oil pump drive tion. Straighten flange, if necessary.
shaft, time engine as follows:
(1) Rotate crankshaft until No.l cylinder is at top INSTALLATION
dead center on the firing stroke. (1) Fabricate 4 alignment dowels from 1 1/2 x 5/16
(2) When in this position, the timing mark on vi inch bolts. Cut the head off the bolts and cut a slot
bration damper should be under "0" on the timing in into the top of the dowel. This will allow easier in
dicator. stallation and removal with a screwdriver (Fig. 1).
(3) Coat shaft and drive gear with engine oil. In (2) Install the dowels in the cylinder block (Fig. 2).
stall the shaft so t h a t after the gear spirals into (3) Apply small amount of Mopar Silicone Rubber
place, it will index with the oil pump shaft. The slot Adhesive Sealant, or equivalent in the corner of the
cap and the cylinder block.
-17 " x 5 / 1 6 " BOLT OIL P U 1 P
REMOVAL
cap.
DOWEL
DISASSEMBLE
SLOT
E J9209-106
(1) Remove the relief valve as follows:
inch) hole into the relief valve retainer cap and in
sert a self-threading sheet metal screw.
Fig. 1 Fabrication of Alignment Dowels
(b) Clamp screw into a vise and while supporting
DOWEL ^ ^ ^ ^ DOWEL oil pump, remove cap by tapping pump body using
a soft hammer. Discard retainer cap and remove
spring and relief valve (Fig. 3).
OIL PUMP ASSEMBLY
SPRING COTTER PIN
RELIEF VALVE
RH174
' RETAINER CAP
J9309-79 Fig. 3 Oil Pressure Relief Valve

(2) Remove oil pump cover (Fig. 4).
F/g. 2 Position of Dowels in Cylinder Block (3) Discard oil seal ring.
(4) Slide the one-piece gasket over the dowels and (4) Remove pump rotors and shaft (Fig. 4).
onto the block. (5) Wash all parts in a suitable solvent and inspect
(5) Position the oil pan over the dowels and onto carefully for damage or wear.
the gasket. INNER ROTOR DISTRIBUTOR DRIVESHAFT
(6) Install the oil pan bolts. Tighten the bolts to 24 AND SHAFT BODY (REFERENCE)
(7) Remove the dowels. Install the remaining oil
pan bolts. Tighten these bolts to 24 Nmi (215 in. lbs.) COTTER PIN
torque.
(8) Install the drain plug. Tighten drain plug to 34
(9) Install the engine to transmission strut. RETAINER
CAP
(10) Install exhaust pipe.
SPRING
(11) Lower vehicle. LARGE CHAMFERED
(11) Install dipstick. EDGE R
Y1
0B
Fig. 4 Oil Pump
(13) Fill crankcase with oil to proper level.
INSPECTION
Mating surface of the oil pump cover should be
smooth. Replace pump assembly If cover is scratched
or grooved.
• 5.9L ENGINE 9 - 95
Lay a straightedge across the pump cover surface Slide outer rotor into pump body. Press rotor to t h e
(Fig. 5). If a 0.038 mm (0.0015 inch) feeler gauge can side with your fingers and measure clearance be
be inserted between cover and straightedge, pump tween rotor and pump body (Fig. 8). If clearance is
assembly should be replaced. 0.356 mm (0.014 inch) or more, replace oil pump as
sembly.
Fig. 5 Checking Oil Pump Cover Flatness

Fig. 8 Measuring Outer Rotor Clearance in Housing
Measure thickness and diameter of OUTER rotor.
If outer rotor thickness measures 20.9 m m (0.825 Install inner rotor and shaft into pump body. If
inch) or less or if the diameter is 62.7 m m (2.469 clearance between inner and outer rotors is 0.203
inches) or less, replace outer rotor (Fig. 6). mm (0.008 inch) or more, replace shaft and both ro
tors (Fig. 9).
OUTER
ROTOR
INNER
ROTOR
RH179
Fig. 9 Measuring Clearance Between Rotors
If inner rotor measures 20.9 mm (0.825 inch) or
less, replace inner rotor and shaft assembly (Fig. 7). Place a straightedge across the face of the pump,
between bolt holes. If a feeler gauge of 0.102 mm
(0.004 inch) or more can be inserted between rotors
and the straightedge, replace pump assembly (Fig.
10).
Inspect oil pressure relief valve plunger for scoring
and free operation in its bore. Small marks may be
removed with 400-grit wet or dry sandpaper.
The relief valve spring has a free length of approx
imately 49.5 mm (1.95 inches). The spring should
test between 19.5 and 20.5 pounds when compressed
to 34 mm (1-11/32 inches). Replace spring t h a t fails
to meet these specifications (Fig. 11).
If oil pressure was low and pump is within specifi
cations, inspect for worn engine bearings or other
reasons for oil pressure loss.
Fig. 7 Measuring Inner Rotor Thickness
9 - 96 5.9L ENGINE •
temperatures, expansion forces the pin bosses away
from each other, causing the piston to assume a more
nearly round shape.
All pistons are machined to the same weight, re
gardless of size, to maintain piston balance.
The piston pin rotates in the piston only and is re
tained by the press interference fit of the piston pin
in the connecting rod.
REMOVAL
(1) Remove the engine from the vehicle.
(4) Remove top ridge of cylinder bores with are li
able ridge reamer before removing pistons from cyl
inder block. Be sure to keep tops of pistons covered
during this operation.
(5) Be sure the connecting rod and connecting rod
cap are identified with the cylinder number. Remove
connecting rod cap. Install connecting rod bolt guide
set on connecting rod bolts.
(6) Pistons and connecting rods must be removed
from top of cylinder block. When removing piston
and connecting rod assemblies from the engine, ro
tate crankshaft so t h a t the connecting rod is centered
in cylinder bore and at BDC. Be careful n o t t o nick
crankshaft journals.
(7) After removal, install bearing cap on the mat
ing rod.
Fig. 11 Proper installation of Retainer Cap
ASSEMBLE INSPECTION
(1) Install pump rotors and shaft, using new parts Check the crankshaft connecting rod journal for ex
as required. cessive wear, taper and scoring.
Check the cylinder block bore for out-of-round,
(2) Position the oil pump cover onto the pump
taper, scoring and scuffing.
body. Tighten cover bolts to 11 N-m (95 in. lbs.)
Check the pistons for taper and elliptical shape be
torque.
fore they are fitted into the cylinder bore (Fig. 12).
(3) Install the relief valve and spring. Insert the
cotter pin. FITTING PISTONS
(4) Tap on a new retainer cap. Piston and cylinder wall must be clean and dry.
(5) Prime oil pump before installation by filling ro Specified clearance between the piston and the cylin
tor cavity with engine oil. der wall is 0.013-0.038 mm (0.0005-0.0015 inch).
Piston diameter should be measured at the top of
INSTALLATION skirt, 90° to piston pin axis. Cylinder bores should be
(1) Install oil pump. During installation slowly ro measured halfway down the cylinder bore and trans
tate pump body to ensure driveshaft-to-pump rotor verse to the engine crankshaft center line.
shaft engagement. Pistons and cylinder bores should be measured at
(2) Hold the oil pump base flush against mating normal room temperature, 21°C (70°F).
pump attaching bolts. Tighten attaching bolts to 4 1 FITTING RINGS
N-m (30 ft. lbs.) torque. (1) Measurement of end gaps:
(3) Install the oil pan. (a) Measure piston ring gap 2 inches from bot
tom of cylinder bore. An inverted piston can be
PISTON / CONNECTING ROD ASSEMBLY used to push the rings down to ensure positioning
The pistons are elliptically turned so t h a t the di rings squarely in the cylinder bore before measur
ameter at the pin boss Is less t h a n its diameter ing.
across the t h r u s t face. This allows for expansion un (b) Insert feeler stock in the gap. The compres
der normal operating conditions. Under operating sion ring gap should be between 0.254-0.508 mm
• 5.9L ENGINE 9 - 97
DIAMETER (D) FEELER GAUGE

SHOULD BE 98.704-98.831 mm
0.0000-0.0152 mm (3.886-3.891 in.]
(0.0000-0.0006 in.
LARGER THAN (C)
H-c
-#-D
GROOVE
J9209-136

Fig. 13 Measuring Piston Ring Side Clearance
SKIRT SHOULD BE 0.254-0.304 mm OIL R I N G
(0.010-0.012 in.) LESS AT DIAMETER SPACER GAP
J9309-9
SECOND
Fig. 12 Piston Measurements COMPRESSION
TOP
R I N G GAP
(0.010-0.020 inch). The second compression ring COMPRESSION
OIL R I N G RAIL
RING G A P
gap should be between 0.508-0.762 mm (0.020- G A P (TOP)
0.030 inch). The oil ring gap should be 0.254-1.270
mm (0.010-0.050 inch).
(c) Rings with insufficient end gap may be prop
erly filled to the correct dimension. Rings with ex
cess gaps should not be used.
OIL RING RAIL
(2) Install rings and confirm ring side clearance: GAP (BOTTOM) J9309-80
(a) Install oil rings being careful not to nick or
scratch the piston. Fig. 14 Proper Ring Installation
(b) Install the compression rings using Installa The bearing caps are not interchangeable and
tion Tool C-4184. The top compression may be in should be marked at removal to ensure correct as
stalled with either side up. The second compression sembly.
ring must be installed with the identification mark Each bearing cap has a small V-groove across the
face up (toward top of piston) and the chamfer parting face. When installing the lower bearing
should face down. An identification m a r k on the shell, make certain t h a t the V-groove in the shell is
ring is a drill point, a stamped letter "O", an oval in line with the V-groove in the cap. This provides
depression or the word TOP. lubrication of the cylinder wall in the opposite bank.
(c) Measure side clearance between piston ring The bearing shells must be installed so t h a t the
and ring land (Fig. 13). Clearance should be 0.038- tangs are in the machined grooves in the rods and
0.076 mm (0.0015-0.0030 inch) for the compression caps.
rings. The steel rail oil ring should be free in Limits of taper or out-of-round on any crankshaft
groove, but should not exceed 0.203 mm (0.0080 journals should be held to 0.025 mm (0.001 inch).
inch) side clearance. Bearings are available in 0.025 mm (0.001 inch),
(d) Pistons with insufficient or excessive side 0.051 mm (0.002 inch), 0.076 m m (0.003 inch), 0.254
clearance should be replaced. mm (0.010 inch) and 0.305 m m (0.012 inch) under
(3) Arrange ring gaps 90° apart as shown in Fig. size. Install the bearings in pairs. DO NOT use a
14.
n e w bearing half with an old bearing half. DO
CONNECTING ROD BEARINGS NOT file the rods or bearing caps.
Fit all rods on a bank until completed. DO NOT al
ternate from one bank to another, because connect INSTALLATION
ing rods and pistons are not interchangeable from (1) Be sure t h a t compression ring gaps are stag
one bank to another. gered so t h a t neither is in line with oil ring rail gap.
(2) Before installing the ring compressor, make
Undersize Journal Identification Stamp
rail gaps located properly (Fig. 14).
0.025 mm (0.001 inch) (Rod) R1-R2-R3 or R4
(3) Immerse the piston head and rings in clean en
0.025 mm (0.001 inch) (Main) M1-AA2-M3-AA4 or AA5
over the piston and tighten with t h e special wrench
(part of Tool C-385). B e s u r e p o s i t i o n of r i n g s d o e s V/ L E T T E R S — / R - l - 2 > (ROD)
not change d u r i n g this operation. VM-WHMAIN)
bolts, the long protector should be installed on the
numbered side of the connecting rod.
(5) Rotate crankshaft so t h a t the connecting rod
same. Insert rod and piston into cylinder bore and J9309-52
guide rod over the crankshaft journal.
(6) Tap the piston down in cylinder bore, using a Fig. 15 Location of Crankshaft identification
hammer handle. At the same time, guide connecting INSPECTION OF JOURNALS
rod into position on crankshaft journal. The crankshaft connecting rod and main journals
(7) The notch or groove on top of piston must be should be checked for excessive wear, taper and scor
pointing toward front of engine. The larger chamfer ing. The maximum taper or out-of-round on any
of the connecting rod bore must be Installed toward crankshaft journal is 0.025 mm (0.001 inch).
crankshaft journal fillet. Journal grinding should not exceed 0.305 mm
(8) Install rod caps. Install nuts on cleaned and (0.012 inch) under the standard journal diameter. DO
oiled rod bolts and tighten nuts to 61 N*m (45 ft. lbs.) NOT grind thrust faces of No.3 main bearing. DO
torque. NOT nick crank pin or bearing fillets. After grind
(9) Install the oil pan. ing, remove rough edges from crankshaft oil holes
(10) Install the cylinder head. and clean out all oil passages.
(11) Install the engine Into the vehicle.
C A U T I O N : After any journal grind, it is important
CRANKSHAFT that the final paper or cloth polish be in the same
A crankshaft which has undersize journals will be direction a s the engine rotates.
stamped with 1/4 inch letters on the milled flat on
the No.3 crankshaft counterweight (Fig. 15).
F O R EXAMPLE: R2 stamped on the No.3 crank INSTALLATION
shaft counterweight indicates t h a t the No.2 rod jour (1) Lightly oil the new upper seal lips with engine
nal is 0.025 m m (0.001 in) undersize. M4 indicates oil.
t h a t the No.4 main journal is 0.025 mm (0.001 in) (2) Install the new upper rear bearing oil seal with
undersize. R3 M2 indicates t h a t the No.3 rod journal the yellow paint facing towards the rear of the en
and the No.2 main journal are 0.025 mm (0.001 In) gine.
undersize. (3) Position the crankshaft into the cylinder block.
When a crankshaft is replaced, all main and con (4) Lightly oil the new lower seal lips with engine
necting rod bearings should be replaced with new oil.
bearings. Therefore, selective fitting of the bearings (5) Install the new lower rear bearing oil seal into
is not required when a crankshaft and bearings are the bearing cap with the yellow paint facing towards
replaced. the rear of the engine.
(6) Apply 5 mm (0.20 in) drop of Loctite 515, or
REMOVAL equivalent, on each side of the rear main bearing cap
(1) Remove the oil pan. (Fig. 16). Do not over apply sealant or allow the seal
(2) Remove the oil pump from the rear main bear ant to contact the rubber seal. Assemble bearing cap
ing cap. to cylinder block immediately after sealant applica
(3) Identify bearing caps before removal. Remove tion.
bearing caps and bearings one at a time. (7) To align the bearing cap, use cap slot, align
(4) Lift the crankshaft out of the block. ment dowel and cap bolts. Do not remove excess ma
(5) Remove and discard the crankshaft rear oil terial after assembly. Do not strike rear cap more
seals. t h a n 2 times for proper engagement.
(6) Remove and discard the front crankshaft oil (8) Clean and oil all cap bolts. Install all main
seal. bearing caps. Install all cap bolts and alternately
• 5.9L ENGINE 9 - 99
Never install an undersize bearing t h a t will reduce

clearance below specifications.
BEARING CAP J9309-72

(9) Install oil pump. Fig. 18 Main Bearing Identification
(10) Apply Mopar Silicone Rubber Adhesive Seal
ant, or equivalent, at bearing cap to block joint to REMOVAL
provide cap to block and oil pan sealing (Fig. 17). Ap (1) Remove the oil pan.
ply enough sealant until a small amount is squeezed (2) Remove the oil pump from the rear main bear
out. Withdraw nozzle and wipe excess sealant off t h e ing cap.
oil pan seal groove. (3) Identify bearing caps before removal. Remove
(11) Install new front crankshaft oil seal. bearing caps one at a time.
(12) Immediately install the oil pan. (4) Remove upper half of bearing by inserting
Crankshaft Main Bearing Remover/Installer Tool
MOPAR SILICONE SEALANT C-3059 into the oil hole of crankshaft (Fig. 19).
RUBBER ADHESIVE APPLIED
(5) Slowly rotate crankshaft clockwise, forcing out
upper half of bearing shell.
Fig. 17 Apply Sealant to Bearing Cap to Block Joint

CRANKSHAFT MAIN BEARINGS
Bearing caps are not interchangeable and should
be marked at removal to ensure correct assembly.
Upper and lower bearing halves are NOT inter Fig. 19 Upper Main Bearing Removal and
changeable. Lower main bearing halves of No.2 and Installation with Tool C-3059
4 are interchangeable.
Upper and lower No.3 bearing halves are flanged INSTALLATION
to carry the crankshaft thrust loads. They are NOT Only one main bearing should be selectively fitted
interchangeable with any other bearing halves in the while all other main bearing caps are properly tight
engine (Fig. 18). Bearing shells are available in stan ened. All bearing capbolts removed during service
dard and the following undersizes: 0.25 mm (0.001 procedures are to be cleaned and oiled before instal
inch), 0.051 mm (0.002 inch), 0.076 mm (0.003 inch), lation.
0.254 mm (0.010 inch) and 0.305 mm (0.012 inch).
9 - 100 5.9L ENGINE •
When installing a new upper bearing shell, slightly UPPER SEAL REPLACEMENT (CRANKSHAFT
chamfer the sharp edges from the plain side. INSTALLED)
(1) Start bearing in place, and insert Crankshaft (1) Remove the oil pan.
Main Bearing Remover/Installer Tool C-3059 into oil (2) Remove the oil pump from the rear main bear
hole of crankshaft (Fig. 16). ing cap.
(2) Slowly rotate crankshaft counterclockwise slid (3) Remove the rear main bearing cap. Remove
ing the bearing into position. Remove Tool C-3059. and discard the old lower oil seal.
(3) Install the bearing cap. Clean and oil the bolts. (4) Carefully remove and discard the old upper oil
Tighten the capbolts to 115 N » m (85 ft. lbs.) torque. seal.
(4) Install the oil pump. (5) Lightly oil the new upper seal lips with engine
(5) Install the oil pan. oil. To allow ease of installation of the seal, loosen at
least the 2 main bearing caps forward of the rear
CRANKSHAFT REAR OIL SEALS bearing cap.
The service seal is a 2 piece, viton seal. The upper (6) Rotate the new upper seal into the cylinder
block being careful not to shave or cut the outer sur
seal half can be installed with crankshaft removed
face of the seal. To assure proper installation, use the
from engine or with crankshaft installed. When a
installation tool provided with the kit. Install the
new upper seal is installed, install a new lower seal.
new seal with the yellow paint facing towards the
The lower seal half can only be installed with the
rear of the engine.
rear main bearing cap removed. (7) Install the new lower rear bearing oil seal into
UPPER SEAL REPLACEMENT (CRANKSHAFT the bearing cap with the yellow paint facing towards
the rear of the engine.
REMOVED)
(8) Apply 5 m m (0.20 in) drop of Loctite 515, or
(1) Remove the crankshaft.
(2) Lightly oil the new upper seal lips with engine
(Fig. 16). Do not over apply sealant or allow the seal
oil.
ant to contact the rubber seal. Assemble bearing cap
(3) Install the new upper rear bearing oil seal with to cylinder block immediately after sealant applica
the yellow paint facing towards the rear of the en tion. Be sure the yellow paint faces toward the rear
gine. of the engine.
(4) Position the crankshaft into the cylinder block. (9) To align the bearing cap, use cap slot, align
(5) Lightly oil the new lower seal lips with engine ment dowel and cap bolts. Do not remove excess ma
oil. terial after assembly. Do not strike rear cap more
(6) Install the new lower rear bearing oil seal into t h a n 2 times for proper engagement.
the bearing cap with the yellow paint facing towards (10) Install the rear main bearing cap with cleaned
the rear of the engine. and oiled cap bolts. Alternately tighten ALL cap
(7) Apply 5 mm (0.20 in) drop of Loctite 515, or bolts to 115 N*m (85 ft. lbs.) torque.
equivalent, on each side of the rear main bearing cap (11) Install oil pump.
(Fig. 16). Do not over apply sealant or allow the seal (12) Apply Mopar Silicone Rubber Adhesive Seal
ant to contact the rubber seal. Assemble bearing cap ant, or equivalent, at bearing cap to block joint to
to cylinder block immediately after sealant applica provide cap to block and oil pan sealing (Fig. 17). Ap
tion. ply enough sealant until a small amount is squeezed
(8) To align the bearing cap, use cap slot, align out. Withdraw nozzle and wipe excess sealant off the
ment dowel and cap bolts. Do not remove excess ma oil pan seal groove.
terial after assembly. Do not strike rear cap more (13) Immediately install the oil pan.
LOWER SEAL REPLACEMENT
bearing caps. Install all cap bolts and alternately (2) Remove the oil pump from the rear main bear
tighten to 115 N t h (85 ft. lbs.) torque. ing cap.
(10) Install oil pump. (3) Remove the rear main bearing cap and discard
(11) Apply Mopar Silicone Rubber Adhesive Seal the old lower seal.
ant, or equivalent, at bearing cap to block joint to (4) Carefully install a new upper seal (refer to Up
provide cap to block and oil pan sealing (Fig. 17). Ap per Seal Replacement - Crankshaft Installed proce
ply enough sealant until a small amount is squeezed dure above).
out. Withdraw nozzle and wipe excess sealant off the (5) Lightly oil the new lower seal lips with engine
oil pan seal groove. oil.
(12) Install new front crankshaft oil seal. (6) Install a new lower seal in bearing cap with
(13) Immediately install the oil pan. yellow paint facing the rear of engine.
• 5.9L ENGINE 9 - 101
(7) Apply 5 mm (0.20 in) drop of Loctite 515, or (1) Remove oil pressure sending unit from back of
equivalent, on each side of the rear main bearing cap block.
(Fig. 16). Do not over apply sealant or allow the seal (2) Insert a 3.175 mm (1/8 inch) finish wire or
ant to contact the rubber seal. Assemble bearing cap equivalent into passage.
to cylinder block immediately after sealant applica (3) Plug should be 190.0 to 195.2 mm (7-1/2 to
tion. 7-11/16 inches) from machined surface of block (Fig.
(8) To align the bearing cap, use cap slot, align 20). If plug is too high, use a suitable flat dowel drift
ment dowel and cap bolts. Do not remove excess ma to position properly.
than 2 times for proper engagement. RIGHT OIL GALLERY
(9) Install the rear main bearing cap with cleaned

and oiled cap bolts. Alternately tighten the cap bolts
(11) Apply Mopar Silicone Rubber Adhesive Seal
ply enough sealant until a small amount is squeezed
out. Withdraw nozzle and wipe excess sealant off the
oil pan seal groove.
CYLINDER BLOCK J9109-229

Remove t h e engine assembly from the vehicle.
Fig. 20 Oil Line Plug
DISASSEMBLE
(1) Remove the cylinder head. (4) If plug is off position, remove oil pan and rear
(2) Remove the oil pan. main bearing cap. Use suitable flat dowel to remove
(3) Remove the piston/connecting rod assembly. plug. Coat outside diameter of plug, with Mopar (stud
and bearing mount adhesive), or equivalent. Plug
CLEANING should be 54.0 to 57.7 mm (2-1/8 to 2-5/16 inches)
Clean cylinder block thoroughly and check all core from bottom of the block.
hole plugs for evidence of leaking. (5) Assemble engine and check oil pressure.
INSPECTION ENGINE CORE, OIL AND CAMSHAFT PLUGS
Examine block for cracks or fractures. Engine core plugs have been pressed into the oil
The cylinder walls should be checked for out-of- galleries behind the camshaft t h r u s t plate (Fig. 21).
round and taper with Cylinder Bore Indicator Tool This will reduce internal leakage and help maintain
C-119. The cylinder block should be bored and honed higher oil pressure at idle.
with new pistons and rings fitted if:
• The cylinder bores show more t h a n 0.127 mm RE10¥AL
(0.005 inch) out-of-round. (1) Using a blunt tool such as a drift or a screw
• The cylinder bores show a taper of more t h a n
driver and a hammer, strike the bottom edge of the
0.254 mm (0.010 inch).
cup plug (Fig. 22).
• The cylinder walls are badly scuffed or scored.
(2) With the cup plug rotated, grasp firmly with
Boring and honing operation should be closely co
pliers or other suitable tool and remove plug (Fig.
ordinated with the fitting of pistons and rings so
specified clearances may be maintained. 22).
Refer to Standard Service Procedures in the begin
CLEANING
ning of this Group for the proper honing of cylinder
bores. Thoroughly clean inside of cup plug hole in cylin
der block or head. Be sure to remove old sealer.
OIL LINE PLUG Make certain the new plug is cleaned of all oil or
The oil line plug is located in the vertical passage grease.
at the rear of the block between the Oil-To-Filter and
Oil-From-Filter passages (Fig. 20). Improper installa INSTALLATION
tion or plug missing could cause erratic, low or no oil (1) Coat edges of plug and core hole with Mopar
pressure. Gasket Maker, or equivalent.
9 - 102 5.9L ENGINE — ^ ^ — — ^ — •
CYLINDER

(2) Using proper drive plug, drive plug into hole.
The sharp edge of the plug should be at least 0.50
Fig. 21 Location of Cup Plugs in Oil Galleries
mm (0.020 inch) inside the lead-in chamfer.
CAUTION: DO NOT drive cup p l u g into the casting It is not necessary to wait for curing of the sealant.
a s restricted coolant flow c a n result and cause s e The cooling system can be filled and the vehicle
rious engine problems. placed in service immediately.
ASSEMBLE
(1) Install the piston/connecting rod assembly.
— 5.9L ENGINE 9 - 103
EmmmE SPECIFICATIONS
Camshaft
Bearing Diameter End Play 0.051 -0.178 mm

Ni o 50.800 - 50.825 mm (0.002 - 0.007 in)
" " (2.000 - 2.001 in) Max. Allowable 0.254 mm
2N o 50.394-50.419 mm (0.010 in)
' (1.984- 1.985 in) Main Bearing Journals
N o 3 50.013 - 50.038 mm Diameter 71.361 - 71.387 mm
(1.969- 1 970 in) (2.8095- 2.8105 in)
No 4 49.606 - 49.632 mm Out-of-Round (Max.) 0.0254 mm
(1.953 - 1.954 in) (0.001 in)
No 5 ................ 39.683 -39.713 mm Taper (Max.) .., 0.0254 mm
(1.5625- 1.5635 in) (0.001 in)
Diametrical Clearance 0.0254 - 0.0762 mm
(0.001 - 0.003 in) Cylinder Block
Max. Allowable . 0.127 mm
(0.005 in) Cylinder Bore
End p | ay 0.051 - 0.254 mm Diameter , 101.60 - 101.65 mm
(0.002-0.010 in) (4.000 - 4.002 in)
Bearinq Journal Diameter Out-of-Round (Max.) ........... 0.127 mm
N i o 50.749 - 50.775 mm (0.005 in)
(1.998- 1.999 in) Taper (Max.) 0.254 mm
No 2 50.343 - 50.368 mm (0.010 in)
(1.982- 1.983 in) Distributor Lower Drive Shaft
No 3 . .............. 49.962 - 49.987 mm Bushing (Press Fit in Block) 0.0127 - 0.3556 mm
(1.967- 1.968 in) (0.0005-0.0140 in)
No 4 . 49.555-49.581 mm Shaft-to-Bushing Clearance 0.0178 - 0.0686 mm
(1.951 - 1 952 in) (0.0007 - 0,0027 in)
No 5 39.637 - 39.662 mm Tappet Bore Diameter .............. 22.99 - 23.01 mm
(1.5605- 1.5615 in) (0.9051 - 0.9059 in)
Connecting Rods Cylinder Head
Bearing Clearance 0.0127 - 0.0559 mm Compression Pressure 689 kPa

(0.0005 - 0.0022 in) (100 psi)
Piston Pin Bore Diameter 24.966 - 24.978 mm Gasket Thickness (Compressed) 1.2065 mm
(0.9829 - 0.9834 in) (0.0475 In)
Side Clearance (Two Rods) ......................... 0.152 - 0.356 mm Valve Seat
(0.006-0.014 in) Angle . 44.25° - 44.75°
Total Weight (Less Bearing) . ... • 758 grams Runout (Max.) ....................... 0.0762 mm
(25.74 oz) (0.003 in)
Crankshaft Width (Finish) - Intake 1.016-1.524 mm
Connecting Rod Journal (0,040-0.060 in)
Diameter . 53.950 - 53.975 mm Width (Finish) - Exhaust 1.524-2.032 mm
(2.124 - 2.125 in) (0.060-0.080 in)
Out-of-Round (Max.) 0.0254 mm Hydraulic Tappets
(0.001 in)
Taper (Max.) ... 0.0254 mm Body Diameter 22.949 - 22.962 mm
(0.001 in)
(0.9035 - 0.9040 in)
Diametrical Clearance
Clearance in Block 0.0279 - 0.0610 mm
No 1 ... ........ 0.0127 - 0.0381 mm
(0.0011 - 0.0024 in)
(0.0005-0.0015 in)
Dry Lash . 1.524 - 5.334 mm
Max Allowable (No.l) - 0.0381 mm
( 0 . 0 6 0 - 0 2 1 0 in)
(0.0015 in)
Push Rod Length 190.63 - 191.14mm
Nos.2, 3, 4 and 5 0.0127 - 0.0508 mm
(7.505 - 7.525 in)
(0.0005 - 0.0020 in)
Max. Allowable (Nos.2, 3, 4 & 5) ...... - 0.0635 mm
J9309-102
(0.0025 in)
9 - 104 5.9L ENGINE
•
ENGINE SPECIFICATIONS (CONT„)
Oil Pump Piston Rings

Clearance over Rotors (Max.) 0.1016 mm Ring Gap
(0.004 in) Compression Ring (Top) 0.30 - 0.55 mm
Cover Out-of-Flat (Max.) 0.0381 mm (0.012-0.022 in)
(0.0015 in) Compression Rings (2nd) 0.55 - 0.80 mm
Inner Rotor Thickness (Min.) 20.955 mm (0.022 - 0.031 in)
(0.825 in) Oil Control (Steel Rails) 0.381 - 1.397 mm
Clearance (Max.) 0.3556 mm Ring Side Clearance
(0.014 in) Compression Rings 0.040 - 0.085 mm
(2.469 in) Oil Ring (Steel Rails) 0.05 - 0.21 mm
Thickness (Min.) 20.955 mm (0.002 - 0.008 in)
(0.825 in) Ring Width
Tip Clearance between Rotors (Max.) 0.2032 mm Compression Rings 1.530 - 1.555 mm
(0.008 in) (0.060 - 0.061 in)
Oil Ring (Steel Rails) - Max 0.447 - 0.473 mm
At Curb Idle Speed * 41.4 kPa Valves
(6 psi)
At 3000 rpm 207 - 552 kPa Face Angle 43.25° - 43.75°
(30 - 80 psi) Head Diameter
Switch Actuating Pressure (Min.) 34.5 - 48.3 kPa Intake 47.752 mm
(5-7 psi) (1.88 in)
* CAUTION: If pressure is ZERO at curb idle, DO NOT Exhaust 41.072 mm
run engine at 3,000 rpm. (1.617 in)
Length (Overall)
Oil Filter Intake 126.21 - 126.85 mm
Bypass Valve Setting 62 -103 kPa (4.969 - 4.994 in)
(9-15 psi) Exhaust 126.44 - 127.30 mm
(4.978-5.012 in)
Pistons Lift (Zero Lash) 10.414 mm
(0.410 in)
Clearance at Top of Skirt 0.0127 - 0.0381 mm Stem Diameter
(0.0005-0.0015 in) Intake 9.449 - 9.474 mm
Land Clearance (Diametrical) 0.508 - 0.660 mm (0.372 - 0.373 in)
(0.020 - 0.026 in) Exhaust 9.423 - 9.449 mm
Piston Length 81.03 mm (0.371 - 0.372 in)
(3.19 in) Stem-to-Guide Clearance
Piston Ring Groove Depth Intake 0.0254 - 0.0762 mm
Nos.l and 2 4.761 -4.912 mm (0.001 - 0.003 in)
Exhaust 0.0508-0.1016 mm
(0.187-0.193 in)
(0.002 - 0.004 in)
No.3 3.996-4.177 mm
Max. Allowable (Rocking Method) 0.4318 mm
(0.157-0.164 in)
(0.017 in)
Weight 582 - 586 grams
Guide Bore Diameter (Std) 9.500 - 9.525 mm
(20.53 - 20.67 oz)
(0.374 - 0.375 in)
Piston Pins
Clearance In Piston 0.006 - 0.019 mm

(0.00023 - 0.00074 in)
Diameter 25.007 - 25.015 mm
(0.9845 - 0.9848 in)
End Play NONE
Length 67.8 - 68.3 mm
(2.67 - 2.69 in) J9309-103
5.9L ENGINE 9 - 105
ENGINE SPECIFICATIONS (CONT.J
Valve Springs V a l v e Timing

Free Length ( A p p r o x . ) . . . . . . . . . . . 49.962 mm Exhaust Valve
f1.967 in) Closes (ATC) ............. 16°
Spring Tension . . . . . . . . . . . . . . . . @ 41.66 mm = 378 N Opens (BBC) . . . . . . . . . . . . . . . . . . ....... 52°
(Valve Closed) (@ 1.64 in « 85 lbs) Duration 248°
Spring Tension @ 30.89 mm = 890 N Intake Valve
(Valve Open) (@ 1.212 in = 200 lbs) Closes (ABC) 50°
Number of Coils . . . . . . . . . . . . . . . 6.8 Opens (BTC) 10°
Installed Height 41.66 mm Duration . . . . . . . . . . . . . . . . . 240°
(Spring Seat to Retainer) (1.64 in) Valve O v e r l a p . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26°
Wire Diameter . . . . . . . . . . . . . . . . 4.50 mm
(0.177 in)
J9309-33
CONDITION IDENTIFICATION LOCATION OF IDENTIFICATION
0.025 mm (0.001 inch) RorM Milled flat on number three crankshaft

U/S Crankshaft M-2-3 etc. (Indicating No. 2 & 3 main counterweight
bearing journal)
and/or
R-l-4 etc. (Indicating No. 1 & 4 connecting
rod journal)
0.508 mm (0.020 inch) A Following engine serial number.

O / S Cylinder Bores
0.203 mm (0.008 inch) 3/8" diamond-shaped stamp Top pad — Front

O / S Tappets • of engine and flat ground on outside surface of
each O / S tappet bore.
0.127 mm (0.005 inch) X Milled pad adjacent to two 3/8" tapped holes
O / S Valve Stems on each end of cylinder head.
J9209-120
Adjusting Strap Bolt 23 N-m (200 in. lbs.) Rear Insulator-to-Bracket

Camshaft Bolt 68 N-m (50ft.lbs.) Through-Bolt (2WD) 68 N-m (50 ft. lbs.
Camshaft Thrust Plate Bolts 24 N-m (210 in. lbs.) Rear Insulator-to-Crossmember
Chain Case Cover Bolts 41 N-m (30 ft. lbs.) Support Bracket Nut (2WD) 41 N-m (30ft.lbs.
Rear Insulator Mounting Plate-fo-
Connecting Rod Cap Bolts.. 61 N-m (45 ft. lbs.)
Rail Assembly Nuts (4WD) 41 N-m (30ft.lbs.
Crankshaft Main Bearing Cap Bolts 115 N-m (85 ft. lbs.) Rear Support Bracket-to-Crossmember
Cylinder Head Bolts Flange Nuts 41 N-m (30ft.lbs.
1st Step 68 N-m (50 ft. lbs.) Rear Support Plate-to-lnsulator
2nd Step 143 N-m (105 ft. lbs.) Mounting Plate Bolts (4WD) 41 N-m (30ft.lbs.
Cylinder Head Cover Bolts .......................... 11 N-m (95 in. lbs.) Rear Support Plate-to-Transfer
Exhaust Manifold-to-Cylinder Case Bolts 41 N-m (30ft.lbs.
Front Insulator Attaching Spark Plugs....... 41 N-m (30ft.lbs.
Bolts (2WD) 41 N-m (30 ft. lbs.) Starter Mounting Bolts. 68 N-m (50ft.lbs.
Front Insulator Stud Nuts 102 N-m (75 ft. lbs.) Throttle Body Bolts (MPI) 23 N-m (200 in. lbs.
Front Mount Adaptor-to-Block Bolts 41 N-m (30 ft. lbs.) Torque Converter Drive Plate Bolts 31 N-m (270 in. lbs.
Front Mount Bracket-to- Transfer Case-to-lnsulator
Crossmember Bolts (4WD) 41 N-m (30 ft. lbs.) Mounting Plate Nuts... 204 N-m (150ft.lbs.
Bolts (2WD) 68 N-m (50ft.lbs.
Service Manual. Bolts (4WD) 68 N-m (50 ft. lbs.
Oil Pan Drain Plug 34 N-m (25 ft. lbs.) insulator Mounting Plate Nuts (4WD) .... 204 N-m (150 ft. lbs.
Oil Pump Attaching Bolts 41 N-m (30 ft. lbs.) Vibration Damper Retainer Bolt 183 N-m (135 ft. lbs.
Oil Pump Cover Bolts 11 N-m (95 in. lbs.)
Cover Bolt 41 N-m (30 ft. lbs.)
J9309-98
• 5.9L (DIESEL) ENGINE 9 - 107
5.9L (DIESEL) E N G I N E SERVICE P R O C E D U R E S
INDEX
page page
Camshaft 127 Oil Filter B y p a s s Valve . 148
Crankshaft 138 Oil Pan / Suction Tube 146
Cylinder Block 129 Oil Pressure Regulator Valve / Spring 148
Cylinder Head 113 Oil Pump 146
Engine Assembly . 109 Piston / Connecting R o d Assembly 134
Engine Front Mounts (Insulators / Brackets) . . . 107 Rocker Levers / Push Rods 112
Engine Rear Support 108 Specifications—5.9L Diesel Engines 151
Gear Housing / Cover 122 Tappet 125
General Information 107 Timing Pin 123
Oil Cooler Element / Gasket . 149 Valve Clearance Adjustment . . . . . . . . . . . . . . . 121
Oil Filter 148 Valves and Valve Springs 116
GENERAL INFORMATION
The 5.9 Liter (359 CID) six-cylinder diesel engine
is an In-line valve-in head type (Fig. 1).
Engine Type In-line 6 (Diesel-Turbo)

Bore and Stroke 102.0 x 120.0 mm
(4.02x4.72 in.)
Displacement 5.9L (359 cu. in.)
Compression Ratio 17.5:1
Torque 542 N-m (400 ft. lbs.)
@ 1,750 rpm
Firing Order 1-5-3-6-2-4
Lubrication Pressure Feed - Full Flow
Filtration w/Bypass Filter
Engine Oil Capacity 11.4L (12.0 Qts) w/Filter
Cooling System Liquid Cooled - Forced
Circulation
Cooling Capacity
Manual Trans 15.2L (16.0 Qts)
Automatic Trans 16.2L (17.0 Qts)
Recovery Bottle 0.95L(1.0Qts)
Cylinder Block.... Cast Iron J898D-10
Crankshaft Induction Hardened
Forged Steel Fig. 2 Firing Order
Cylinder Head Cast Iron The engine data plate is located on t h e driver side
Combustion Chambers High Swirl Bowl of the engine forward of the fuel injection pump.
Camshaft.... Chilled Cast Iron
Pistons Cast Aluminum
Connecting Rods Forged Steel ENGINE FRONT MOUNTS (INSULATORS /
BRACKETS)
J9209-48 REMOVAL
Fig. 1 Diesel Engine Description (1) Raise hood and position fan to assure clearance
for radiator top tank and hose.
This engine is designed for No.2 Diesel Fuel. Only (2) Raise vehicle on a hoist. Support t h e engine.
use No.l Diesel Fuel where extended arctic condi (3) Remove the through-bolts and nuts from the
tions exist (below -23°C or -10°F). bracket (Fig. 3).
Engine lubrication system consists of a gerotor (4) Remove t h e nuts from insulator studs (Fig. 3).
type oil pump and a full flow oil filter with a bypass (5) Raise engine with a lifting fixture only far
valve. enough to remove the insulators and brackets. Mark
The cylinders are numbered from front to rear; 1, the locating pin position.
2, 3, 4, 5 and 6. The firing order is 1-5-3-6-2-4 (Fig. (6) Remove t h e engine mounting brackets from t h e
2). engine block.
9 - 108 §.9L (DIESEL) ENGINE •
TRANSMISSION
SUPPORT
BRACKET
INSULATOR
TRANSMISSION
BLOCKER
BRACKET
INSULATOR/
CROSSMEMBER
BRACKET
CROSSMEMBER
J9109-149
Fig. 4 Rear Engine Support—2WD

INSTALLA TION-2WD
(1) Install the insulator/crossmember bracket to
the crossmember. Tighten the nuts to 41 N-m (30 ft.
J9109-12
lbs.) torque.
Fig. 3 Engine Front Mount (2) Install the transmission blocker bracket to the
crossmember and the insulator/crossmember bracket
INSTALLATION
(Fig. 4). Tighten the nuts to 41 N-m (30 ft. lbs.)
(1) Install the engine mounting brackets to the torque.
block, if removed (Fig. 3). Tighten the bolts to 60 (3) Install the insulator to the crossmember and
N-m (44 ft. lbs.) torque. the insulator/crossmember bracket (Fig. 4). Tighten
(2) With the engine raised slightly, install the in the nuts to 41 N-m (30 ft. lbs.) torque.
sulators using the locating pin. Tighten the n u t s to (4) Lower the transmission until the insulator is
109 N-m (80 ft. lbs.) torque. lined up with the transmission support bracket.
(3) Install the bracket onto the insulator and (5) Install the through-bolt and tighten the n u t to
tighten the n u t to 109 Nnn (80 ft. lbs.) torque. 68 N-m (50 ft. lbs.) torque.
(4) Lower engine with lifting fixture while guiding (6) Remove the transmission jack.
insulator studs into attaching holes in crossmember (7) Lower the vehicle.
and brackets.
(5) Tighten attaching nuts and bolts to specified REMOVAL-4WD
torques (Fig. 3). (1) Raise the vehicle on a hoist.
(6) Lower the vehicle. (2) Remove the skid plate (if equipped) from the
(7) Remove lifting fixture. rear crossmember and transmission crossmember
(Fig. 5).
ENGINE REAR SUPPORT
REMOVAL-2WD SKID PLATE ^ M A T T A C H I N G BOLTSl
(1) Raise the vehicle on a hoist. .MIMING
(2) Position a transmission jack under the trans
mission.
(3) Remove the through-bolt from the transmission
support bracket/insulator (Fig. 4).
(4) Raise the transmission SLIGHTLY.
PU873
(5) Remove the insulator nuts (Fig. 4).
(6) Remove the transmission blocker bracket n u t s Fig. 5 Skid Plate
and remove the bracket (Fig. 4).
(3) Position a transmission jack under the trans
(7) Remove the insulator/crossmember bracket
mission.
nuts and remove the bracket (Fig. 4).
(4) Remove the nuts from the transfer case to plate
bolts and from the transfer case to strut bolts (Fig.
6).
(5) Raise the rear of the transmission and engine

SLIGHTLY.
(6) Remove the mounting bolts and nuts. Remove
the washers, sleeves and insulators (Fig. 6).
(7) The plate and strut will be removed as a unit.
Remove t h e bolts, washers and nuts (Fig. 6).
Fig. 7 Scribe Hood Hinge

dures). DO NOT waste reusable coolant. If the
solution is clean, drain the coolant into a clean con
tainer for reuse.
J9109-150 (4) Disconnect the radiator hoses. Remove the fan
shroud, fan/fan clutch assembly and radiator (refer to
Fig. 6 Rear Engine Mount—4WD Group 7, Cooling Systems for the proper procedures).
INSTALL A TION—4 WD (5) Disconnect the heater hoses at the dash panel
(1) Assemble the plate and the strut (Fig. 6). and at the water valve (Fig. 8).
Tighten the nuts to 240 N-m (150 ft. lbs.) torque.
(2) Install the plate and strut assembly to the rail
with the insulators, sleeves, washers and mounting
bolts (Fig. 6). Tighten the nuts to 240 N-m (150 ft.
lbs.) torque.
(3) Lower the rear of the engine and transmission
until the transfer case aligns with the holes in t h e
plate and the strut.
(4) Install the nuts to the transfer case to plate
bolts and to the transfer case to strut bolts (Fig. 6).
Tighten the nuts to 240 N-m (150 ft. lbs.) torque.
(5) Remove the transmission jack. Fig. 8 Heater Hoses
(7) Lower the vehicle. (6) Disconnect the air inlet tube from the turbo
charger (Fig. 9) and the air intake housing. Remove
ENGINE ASSEMBLY the tube.
(7) Remove the exhaust pipe from the turbocharger
REMOVAL outlet flange (Fig. 9).
(1) Disconnect the electrical connection into the (8) Disconnect the intercooler inlet duct from the
hood. Scribe the hood hinge bolt locations and re turbocharger and the intercooler (Fig. 10). Remove
move the hood (Fig. 7). the inlet duct.
(2) Disconnect the battery cables and remove the (9) Disconnect the intercooler outlet duct from the
battery. air inlet housing and the intercooler (Fig. 10). Re
(3) Drain the coolant from the cooling system (re move the outlet duct.
fer to Group 7, Cooling System for the proper proce-
9 - 119 5.9L (DIESEL) ENGINE •
Fig, 11 Generator Removal
Fig. 10 intercooler Ducts Fig. 12 Accelerator/Speed Control/Throttle Valve

Linkage
(10) Remove the drive belt. Disconnect the genera
tor ground wire. Remove the generator and set aside (b) M a r k torque converter and drive plate for as
(Fig. 11). sembly alignment. Note t h a t bolt holes in crank
(11) Remove the A/0 compressor and set aside. The shaft flange, drive plate and torque converter all
A/C compressor is located below the generator. have one offset hole.
(12) Disconnect the accelerator linkage, the speed (c) Rotate crankshaft in clockwise direction until
control linkage and the throttle valve linkage (Fig. converter bolts are accessible. Then remove bolts
12). one at a time. Rotate crankshaft with socket
(13) Raise and support the vehicle on a hoist. wrench on damper pulley bolt.
(14) Drain the engine lubricating oil. Dispose of (d) Support the transmission.
the oil according to all applicable regulations. (e) Remove bell housing bolts and inspection
(15) Disconnect the exhaust pipe steady rest clamp plate.
and remove. (19) M A N U A L TRANSMISSION:
(16) Disconnect the starter connections (Fig. 13). Refer to Group 21, Transmissions for the G360
(17) Disconnect the transmission cooler lines. Manual Transmission Removal procedure.
(18) AUTOMATIC TRANSMISSION: (20) Lower the vehicle.
(a) Remove torque converter bolt access cover. (21) Disconnect the power steering lines.
- 5.9L (DIESEL) ENGINE 9 - 111
J9109-1 1 3
Fig. 15 Wiper Motor/Voltage Regulator
Fig. 13 Starter Connections
ENGINE
(22) Disconnect the vacuum pump lines. / HOIST
(23) Disconnect all electrical connections from the
engine. P u t tags on the connections to identify their
locations.
(24) Disconnect the fuel lines to the lift pump and
fuel return. Use tags to identify the lines (Fig. 14).
Fig. 14 Lift Pump and Fuel Lines

(25) Put a cover or tape over all engine openings. Ml
(26) Make sure that the lifting brackets are J9109-H
mounted with the eye up. If not, remove the bracket
and install in the proper position. Tighten the lifting Fig. 16 Lifting Engine from Vehicle
bracket bolts to 77 N«m (57 ft. lbs.) torque. INSTALLATION
(27) Use the lifting brackets to apply tension to (1) If removed, install and tighten the rear engine
the engine. Remove the engine mount through-bolts lifting bracket to 77 N-m (57 ft. lbs.) torque. DO
from the cylinder block mounting bracket. NOT exceed this torque valve.
(2) Check the data plate to verify that the replace
C A U T I O N : When removing the engine, take care not
ment engine is the same model and rating as the en
to d a m a g e the wiper motor and voltage regulator
gine t h a t was removed.
mounted on the d a s h panel (Fig. 15).
(3) Install all accessories and brackets that had
(28) Lift the engine out of the vehicle (Fig. 16). been removed from the previous engine.
(29) Install the engine on a suitable stand. (4) Use the lifting brackets to lift the engine off of
(30) Remove all accessories and brackets not previ the stand.
ously removed for use with the replacement engine.
(5) Position the engine in the chassis and install (22) Position the intercooler outlet duct to the air
the through bolt. Tighten the through bolt nut to 41 inlet housing and the intercooler. With the clamps in
N-m (30 ft. lbs.) torque. position, tighten the clamp n u t to 8 N-m (72 in. lbs.)
(6) M a k e s u r e t h e lifting b r a c k e t s a r e m o u n t e d torque.
w i t h t h e eye d o w n . (23) Connect the air intake tube to the turbo
(7) Remove the covers or tape covering the engine charger inlet flange and the air cleaner housing.
openings. Tighten the clamps to 8 N-m (72 in. lbs.) torque.
(8) Connect the fuel lines to the lift pump and fuel (24) Install the exhaust pipe to the turbocharger.
return. Tighten the steady rest clamp to 8 N-m (72 in. lbs.)
(9) Connect all electrical connections. torque.
(10) Connect the power steering lines. (25) Make sure the air intake and exhaust pipe
(11) Raise and support the vehicle on a hoist. connections are tight and free of leaks.
(12) A U T O M A T I C T R A N S M I S S I O N : (26) Fill the engine with the required amount of
clean engine lubricating oil (refer to Group 0, Lubri
C A U T I O N : If new flex plate is installed, remove cation and Maintenance).
flashing from the engine back plate at the 5 and 7 (27) Fill the cooling system with a mixture of 50%
o'clock positions. water and 50% ethylene-glycol base antifreeze (refer
Group 7, Cooling System for the proper procedure).
(a) Rotate converter until alignment mark on the (28) Install the battery and connect the battery ca
converter is aligned with m a r k on drive plate. Off bles.
set holes in plate are next to 1/8 inch hole in inner (29) Check the oil level after the engine has r u n
circle of drive plate. for 2 or 3 minutes. Oil held in the oil filter and oil
(b) Install bell housing bolts. Tighten the bolts to passages will cause the oil level in the pan to be
41 N-m (30 ft. lbs.) torque. lower.
(c) With the torque converter plate aligned to the (30) Operate the engine at idle for 5 to 10 minutes
torque converter, install and tighten the bolts to 31 and check for leaks and loose parts.
(d) Install the converter housing access plate. ROCKER LEVERS / POSH RODS
(e) Remove the transmission support.
(13) M A N U A L T R A N S M I S S I O N : REMOVAL
Refer to Group 21, Transmissions for the G360 (1) Remove the valve covers (Fig. 1).
Manual Transmission Installation procedure. (2) Loosen the adjusting screw locknuts. Loosen
(14) Connect the ground cable and tighten the nut the adjusting screws until they stop (Fig. 2).
to 22 N-m (16 ft. lbs.) torque. Connect the solenoid
cable and tighten the n u t to 5 N-m (44 in. lbs.)
torque.
(15) Connect the transmission cooler lines.
(16) Install the exhaust pipe to the exhaust sys
tem.
(18) Install the A/C compressor and tighten the
bolts to 47 N-m (35 ft. lbs.) torque. If removed, con
nect the clutch electrical wire.
(19) Install the generator. Tighten the upper
mounting bolts to 24 N-m (18 ft. lbs.) torque. Now
tighten the lower mounting bolts to 43 N-m (32 ft.
lbs.) torque. Connect all wires.
(20) Install the radiator, fan/fan clutch assembly
and fan shroud (refer to Group 7, Cooling Systems
for the proper procedures). Connect the radiator
hoses.
(21) Position the intercooler inlet duct to the tur
bocharger and the intercooler. With the clamps in po
sition, tighten the clamp n u t to 8 N-m (72 in. lbs.)
torque.
(3) Remove the bolts from the rocker lever pedes (6) Check the push rods for roundness and
tals. Remove the pedestals and rocker lever assem straightness.
blies (Fig. 2). (7) Install t h e push rods into the sockets of the
(4) Remove the push rods. valve tappets. Lubricate the push rod sockets with
clean engine oil.
LOCKNUT ADJUSTING (8) Make sure the rocker lever adjusting screws
are completely backed out.
INSTALLATION
(1) Make sure the dowel rings in the pedestals are
installed into the dowel bores in the cylinder head.
(2) If the push rod is holding pedestal off head, bar
the engine until the pedestal will set on the head
surface without interference.
(3) Use clean engine oil to lubricate the cylinder
head bolt threads and under the bolt heads.
(4) Install t h e long bolts (12 mm) into the rocker
lever pedestals. Tighten the bolts as follows:
J9109-31 • Step 1—Tighten the bolts, in sequence (Fig. 3), to
90 N»m (66 ft. lbs.) torque. Check the torque. If lower
Fig. 2 Location of Rocker Lever Components t h a n 90 N»m (66 ft. lbs.), tighten to this torque.
DISASSEMBLE—ROCKER LEVERS • Step 2—Tighten the bolts, in sequence (Fig. 3), to
(1) Remove the retaining rings and thrust washers 120 N-m (89 ft. lbs.) torque. Check the torque. If
(Fig. 2). lower t h a n 120 N-m (89 ft. lbs.), tighten to this
(2) Remove the rocker levers (Fig. 2). DO NOT dis torque.
assemble the rocker lever shaft and pedestal. The • Step 3—Tighten the bolts, in sequence (Fig. 3), a n
pedestal and shaft must be replaced as an assembly. additional 90°.
(3) Remove the locknut and adjusting screw (Fig.
2).
C=J FRONT
(4) Clean all parts in a strong solution of laundry
detergent in hot water.
(5) Use compressed air to dry the parts after rins
ing in clean hot water. The pedestals are made from
powdered metal and may continue to show wetness
after they have been cleaned and dried.
(6) Inspect for excessive wear in the bore and the
contact surface for the valve stem. J9109-32
(7) Measure the rocker lever bore diameter. The
maximum diameter is 19.05 mm (0.75 inch). Replace Fig. 3 Rocker Lever (Head Boits) Tightening
if out of limits. Sequence
(8) Inspect the pedestal and shaft. (5) Tighten t h e 8 mm bolts to 24 Nnn (18 ft. lbs.)
(9) Measure the shaft diameter. The minimum di torque.
ameter is 18.94 mm (0.746 inch). Replace if out of (6) Install t h e valve cover. Tighten the valve cover
limits. bolt to 24 Nnn (18 ft. lbs.) torque.
ASSEMBLE-ROCKER LEVERS CYLINDER HEAD
(1) Install the adjusting screw and locknut. These cylinder heads can only be used on engines
(2) Lubricate the shaft with clean engine oil. Be with an intercooler. DO NOT interchange with ear
sure to assemble the intake and exhaust rocker le lier models.
vers in the correct location.
(3) Position the levers on the rocker shaft. Install REMOVAL
the thrust washers. (1) Drain the coolant. DO NOT waste reusable
(4) Clean the push rods in the hot soapy water. coolant. If the solution is clean, drain the coolant
(5) Inspect the push rod ball and socket for signs of into a clean container for reuse.
scoring or cracks where the ball and the socket are (2) Drain the engine oil. Dispose of the used oil
pressed into the tube. properly.
9 - 114 5.9L (DIESEL) ENGINE — •
(3) Disconnect the radiator and heater hoses (refer
to Group 7, Cooling System).
(4) Remove the turbocharger.
(5) Remove the exhaust manifold (Fig. 4).
Fig. 6 Fuel/Water Separator Filter
Fig. 4 Exhaust Manifold

(6) Remove the fuel lines and injector nozzles (re
fer to Group 14, Fuel System).
(7) Remove the valve covers (Fig. 5).
J9109-36
Fig. 7 Cylinder Head Bolt Removal

Sequence—Cylinder Head Hot
INSPECTION
Remove the cup plugs and inspect the coolant pas
sages. A large build up of rust and lime will require
removal of the cylinder block for cleaning in a hot
tank.
Inspect the cylinder bores for damage or excessive
wear. Rotate the crankshaft so the piston is at Bot
Fig. 5 Valve Cover tom Dead Center (BDC) to inspect the bores.
(8) Remove t h e rocker levers and push rods. Measure the cylinder bores (Fig. 8). DO NOT pro
(9) Remove the fuel/water separator filter (Fig. 6). ceed with in-chassis repair if the bores are damaged
Refer to Group 14, Fuel System, for the proper pro or worn beyond the limits (refer to Cylinder Bore Re
cedures. pair - Cylinder Block).
(10) If the engine is hot, remove the cylinder head Check the top surface for damage caused by the
bolts in the sequence shown in Fig. 7..The removal cylinder head gasket leaking between cylinders.
sequence is not important if t h e engine is cold. There Inspect the block and head surface for nicks, ero
are 3 sizes of head bolts. Note the position of each sion, etc.
bolt for future installation. Check the head distortion (Fig. 9). The distortion of
(11) Remove the cylinder head and gasket from the the combustion deck face is not to exceed 0.010 m m
cylinder block. (0.0004 inch) in any 50.8 m m (2.00 inch) diameter.
Overall variation end to end or side to side 0.30 mm
(0.012 inch).
* ^ ^ ^ — 5 . I L (DIESEL) ENGINE 9 - 115
REFERENCE
MIN. 102.0 mm (4.0157 inch) STOCK TOTAL (MAX.)

MAX. 102.1 16 mm (4.0203 inch) 1.00 mm (0.03937 inch)
Out-of-Round 0.038 mm (0.0015 inch) REFERENCE HEIGHT (MIN.)
Taper 0.76 mm (0.003 inch) 94.00 ±0.25 mm
(3.7008 ±0.0010 inch)
Oversize pistons and rings are SURFACE FINISH
available for bored cylinder blocks. 1.5 to 3.2 micrometers
(60 to 128 microinches)
J9109-75
J9109-134
Fig. 8 Cylinder Bore Diameter
Fig. 10 Cylinder Head Stock Removal
DO NOT proceed with the in-chassis overhaul if
Wash the cylinder head in hot soapy water solution
the cylinder head or block surface is damaged or not
(88°C or 140°F).
flat (within specifications).
After rinsing, use compressed air to dry the cylin
der head.
Polish the gasket surface with 400 grid paper. Use
an orbital sander or sanding block to maintain a flat
surface.
INSTALLATION
(1) The cylinder block and head must be clean and
dry.
(2) Position the gasket onto the dowels (Fig. 11).
Make sure the gasket is correctly aligned with the
holes in the cylinder block.
Fig. 9 Cylinder Head Combustion Deck Face (3) Carefully put the cylinder head onto the gasket
Measurement and cylinder block. Make sure the cylinder head is
REFACING HEAD SURFACE installed onto the dowels in the cylinder block (Fig.
The cylinder head combustion deck may be refaced 11).
in whatever increments necessary to clean up the (4) Install the push rods and rocker levers.
surface and maintain the surface finish and flatness (5) Use clean engine oil to lubricate the cylinder
tolerances. The combined total of stock removed must head bolt threads and under the bolt heads.
not exceed 1.00 mm (0.03937 inch). The amount of (6) The cylinder head bolts are 3 different sizes. In
stock removed each time must be steel stamped stall the bolts in the proper hole. Tighten the bolts as
above combustion deck edge, on the lower right hand follows:
corner of the rear face (Fig. 10). Check valve protru • Step 1—Tighten all bolts, in sequence (Fig. 12), to
#
sion after head surface refacing. 90 N m (66 ft. lbs.) torque. Check the torque. If lower
t h a n 90 N*m (66 ft. lbs.), tighten to this torque.
Surface finish requirements are 1.5-3.2 microme
• Step 2—Tighten all long 12 mm bolts (Nos. 4, 5,
ters (60-126 microinch).
12, 13, 20 and 21), in sequence (Fig. 12), to 120 N*m
CLEANING (89 ft. lbs.) torque. Check the torque. If lower t h a n
Clean the carbon from the injector nozzle seat with 120 N«m (89 ft. lbs.), tighten to this torque.
a nylon or brass brush. • Step 3 —Tighten all bolts, in sequence (Fig. 12), an
Scrape the gasket residue from all gasket surfaces. additional 90°.
CYLINDER HEAD VALVES AND VALVE SPRINGS
REMOWAL
(2) Mark the valves to identify their position.
(3) Compress the valve spring and remove the
valve stem collets (Fig. 1).
(4) Release valve spring and remove the retainer
and spring (Fig. 1).
(5) Remove the remaining collets, retainers,
springs and valves. Keep the valves in a labeled
rack.
(6) Remove the valve stem seals (Fig. 1).
Fig. 11 Cylinder Head/Gasket Alignment
-38
J9109-36 Fig. 1 Valve Removal

WALVES
Fig. 12 Cylinder Head Tightening Sequence
(7) Be sure to lubricate the push rod sockets with CLEANING AND INSPECTION
clean engine oil. Before cleaning, note the valve number. Clean the
(8) Install the rocker lever pedestal bolts and valve heads with a soft wire wheel. Mark the valve
tighten to 24 N*m (18 ft. lbs.) torque. with the numbet* noted above.
(9) Adjust the valve clearance. Polish the valve stems with crocus cloth.
(10) Install the valve covers. Tighten the bolts to Inspect for abnormal wear on the valve heads and
24 N*m (18 ft. lbs.) torque. stems. Replace badly worn valves.
(11) Install the injector nozzles and fuel lines (refer Check for bent valves. Replace bent valves.
to Group 14, Fuel System). Measure the valve stem diameter (Fig. 2). The
(12) Install the fuel filter (refer to Group 14, Fuel valve stem diameter should be 7.935-7.960 mm
System for the proper procedures). (0.3126-0.3134 inch). If out of limits, replace the
(13) Install the exhaust manifold (refer to Group valve. Mark the new valves with the replacement lo
11, Exhaust System and Intake Manifold). cation.
(14) Install the turbocharger.
(15) Connect the radiator and heater hoses.
(16) Fill the engine with new coolant or the clean
drained coolant (refer to Group 7, Cooling System for
Ik 1
the proper procedure).
(17) Fill the engine with clean lubricating oil (re
fer to Group 0, Lubrication and Maintenance).
MEASURE AT THESE POINTS
Fig. 2 Measure Valve Stem Diameter

Inspect the end of the valve stem for flatness.

If required, resurface the valve end.
VALVE GRINDING
The valve seat angle should be 30° (Intake Valve)
and 45° (Exhaust Valve) - (Fig. 3).
INTAKE EXHAUST
N E W DIAMETER LIMITS
8.019-8.029 mm (0.3157-0.3165 inch)
W O R N LIMIT
^ 00 ^ 8.090 mm (0.3185 inch)
J9109-135
J9109-41
Fig. 5 Valve Guide Bore
Fig. 3 Valve Seat Angle
INSTALLATION
Measure the rim thickness (Fig. 4). The minimum
THIN W A L L - S E R V I C E GUIDES
valve rim thickness is 0.79 mm (0.031 inch).
Machine the cylinder head valve guide bores to
VALVE RIM 11.125 ±0.013 mm (0.4380 ±0.0005 inch) in diame
THICKNESS ter (Fig. 6).
Service valve guides must be centered with valve
seats within 0.35 mm (0.01378 inch) diameter. They
must also be square with the combustion face within
0.10 m m (0.004 inch) at 50.0 mm (1.9685 inch) ra
dius.
Lubricate the valve guides with oil and press the
guides flush to the bottom of the bosses.
J9109-146 Trim off the top of the valve guides flush to top of
guide bosses, if necessary.
Fig. 4 Valve Rim Thickness Machine the valve guide bores to 8.029 ±0.010 mm
Grind the face of valves to be reused. (0.3161 ±0.0004 inch) - (Fig. 6).
The valve guide bore must be centered with the
Check the valve stem tip for flatness. If required,
valve seat within 0.35 mm (0.0138 inch) diameter. It
re-surface the tip.
also must be square with the combustion face within
VALWE GUIDES 0.010 mm (0.0004 inch) at 50.0 mm (2.0 inch) radius.
THICK W A L L - S E R V I C E GUIDES
INSPECTION Machine the cylinder head valve guide bores to
Inspect the valve guides for scuffing or scoring. 14.000 ±0.013 mm (0.5512 ±0.0005 inch) diameter
Measure the valve guide bore (Fig. 5). The bore di (Fig. 7).
ameter should be 8.019-8.089 mm (0.3157-0.3185 Valve guides must be centered with valve seats
within 0.35 mm (0.01378 inch) diameter. Valve
inch).
guides must also be square with the combustion face
If the valve guide bores are larger than the worn
within 0.10 mm (0.004 inch) at 50.0 mm (2.0 inch)
limit, the cylinder head must be machined for service
radius.
valve guides. New valve guides must be reamed to
Lubricate the valve guides with oil and press in
size after they are installed.
the guides to 12.25 ±0.50 mm (0.4823 ±0.020 inch)
If the cylinder head needs service valve guides and protrusion above the cylinder head.
valve seat inserts, the valve guides should be in Ream the bores to 8.029 ±0.010 mm (0.3161
stalled first. ±0.0004 inch) - (Fig. 7).
i - 118 5.9L (DIESEL) ENGINE
VALVE GUIDE BORES CYLINDER VALVE SEATS

HEAD
INSPECTION
Cylinder head with integral valve seats can be
ground only once. Previously ground integral seats
must be replaced with service seats.
One X stamped into the head casting identify seats
t h a t have been ground previously (Fig. 8).
EXHAUST Two X's stamped on the head indicate service seats
have been installed (Fig. 8). Service seats can be
ground.
INTAKE
SERVICE SEATS
INSTALLED
CYLINDER HEAD VALVE GUIDE BORES

11.125 ±0.013 mm (0.438 ± 0.0005 in)
VALVE GUIDE BORES
REGROUND
n o
8.029 ±0.010 mm (0.3161 ±0.0004 in)
INTEGRAL
VALVE SEAT
J9109-136
Fig. 6 Service Valve Guides—Thin Wall

VALVE GUIDE BORES
CYLINDER
HEAD
J9109-138
Fig. 8 Reworked Cylinder Head Seats—Stamped

Identification
On t h e integral seat head, if 0.254 m m (0.010 inch)
or more has been removed from the head combustion
surface, service seats must be installed.
EXHAUST INTAKE To determine if the head has been previously re
surfaced, before calculating valve depth, process as
follows:
(1) Check the rear lower right corner of the head
for a stamping t h a t would indicate previous resurfac
CYLINDER HEAD VALVE GUIDE BORES ing (e.g. .003).
14.000 ±0.013 mm (0.5512 ± 0.0005 in) (2) To verify the information, or if no amount is in
VALVE GUIDE BORES
dicated, measure the head height (Fig. 9).
8.029 ±0.010 mm (0.3161 ±0.0004 in)
(3) If the head height is 94.75 m m (3.730 inch) or
greater, the valve seats may be ground, if they have
J9109-137
not been ground previously.
Fig. 7 Service Valve Guides—Thick Wall CYLINDER
HEAD
VALVE SPRINGS HEIGHT
Measure t h e valve spring length. The approximate
free length is 55.63 m m (2.190 inch) with t h e maxi
m u m inclination of 1.0 m m (0.039 inch).
Measure t h e valve spring force. 289.32 N (65 lbs.)
is t h e minimum acceptable load required to compress
the spring to a height of 49.25 m m (1.94 inch).
If t h e valve spring does not meet the limits above,
replace the spring. J9109-139
Fig. 9 Cylinder Head Height

INTEGRAL VALWE SEAT GRINDING GRIND TO 15°

After resurfacing the valves and determining t h a t
all valves meet specifications, install the valves in
their designated locations and measure valve depth
(Fig. 10). The valve depth is the distance from the
valve face to the head deck. Record the depth of each
valve.
CYLINDER
HEAD DECK
J9109-141
Fig. 11 Grind Valve Seat

Replacement valve seat inserts must be installed if
VALVE the valve seats have been ground previously. The il
J9109-140 lustrated marks indicate valve seats have been
DEPTH
ground previously.
Fig. 10 Valve Depth Machine the cylinder head to install the service
Grind the valve seats to remove scores, scratches valve seats (Figs. 12 and 13).
and burns. The seat angle should be—Intake 30° and
COMBUSTION
Exhaust 45°. FACE
Install the valves in their respective bores and
measure the depth again (Fig. 10). Record t h e depth
of each valve.
The grinding depth is the difference between the
measurement before grinding and the measurement
after grinding. The grinding depth maximum limit
(integral seats only) is 0.254 mm (0.010 inch). Ser
vice valve seats are available for over limit integral
valve seats.
VALVE
Identify ground valve seats by stamping t h e cylin SEAT
der head. DEPTH
Install the valves in their designated locations and
measure the depth of each. The valve depth limit (In
tegral and Inserted Seats) is 0.99 mm to 1.52 mm
(0.039 inch to 0.060 inch). Replace the valve if the VALVE SEAT DEPTH
depth is over this limit. 10.40 ±0.10 mm (0.4094 ±0.004 inch)
Apply a light coat of valve lapping compound to VALVE SEAT WIDTH
each valve and lap each valve to its mating seat.
47.0 ±0.013 mm (1.8504 ± 0.0005 in)
Remove the valves and clean lapping compound
from the valves and seats. MAXIMUM RADIUS
Measure the valve seat width indicated by the lap 0.40 mm (0.0157 inch) MAX.
ping surface. The valve seat width limit is 1.50-2.00
SURFACE FINISH
mm (0.060-0.080 inch).
If required, grind the areas with a 60° stone and a 3.2 micrometers (128.0 microinch)
15° stone to center the seat on the valve face. Main J9109-142
tain the valve seat width limits (Fig. 11).
Fig. 12 Machining for Service Valve Seats—Intake
SERVICE VALVE SEAT INSTALLATION Valve
Inspect the valve guide bores as described in the Press service seats into the machined pockets.
valve guide section of this manual. If it is necessary Stake the valve seats into the pockets.
to install valve guides, install the guides before in
stalling the service seats.
COMBUSTION
FACE
VALVE
SEAT
DEPTH
M I N . - 0.990 mm (0.039 inch)
M A X . - 1.520 mm (0.060 inch)
'/// A
I
V
1 J9109-44
VALVE SEAT DEPTH Fig. 14 Valve Depth with Seat Insert

10.20 ±0.10 mm (0.4015 ±0.004 inch)
MAXIMUM
VALVE SEAT WIDTH MINIMUM 2.0 mm
1.5 mm (0.080 inch)
43.65 ±0.013 mm (1.7185 ±0.0005 in)
(0.060 inch)
MAXIMUM RADIUS
0.40 mm (0.0157 inch) MAX.
SURFACE FINISH
3.2 micrometers (128.0 microinch)
J9109-143
Fig. 13 Machining for Service Valve Seats—Exhaust

Valve
SERVICE VALVE SEAT GRINDING J9109-45
Install the valves in their designated location and
measure the valve depth. The valve depth is the dis Fig. 15 Valve Seat Width
tance from the valve face to the head deck. SERVICE VALVE SEAT REPLACEMENT
Record the depth of each valve (Fig. 14). The depth To replace service seat inserts, machine the insert
is 0.99-1.52 m m (0.039-0.060 inch). in the same manner as if machining out the internal
Grind the valve seats to remove scores, scratches seat. Hold the same tolerances and follow the same
and burns. The valve seat angle is 30° (Intake) and installation procedures.
45° (Exhaust).
Install the valves in their respective bores and INSTALLATION
measure the depth again (Fig. 14). The valve depth (1) Clean all cylinder head components before as
limit is 0.99-1.52 mm (0.039-0.060 inch). Replace the sembling.
valve if the depth is over the limit. (2) Install the valve stem seals (Fig. 16). The in
Apply a light coat of valve lapping compound to take and exhaust valve seals are the same.
each valve and lap each valve to its companion seat. (3) Lubricate the stems with SAE 90W oil before
Remove the valves and clean the lapping compound installing the valves. Install the valves in the same
from the valve and seats. positions as removed.
Measure the valve seat width indicated by the (4) Compress the valve spring after installing the
lapped surface (Fig. 15). The width limits are 1.5-2.0 spring and retainer (Fig. 17).
mm (0.060-0.080 inch). If required, grind lower area (5) Install new valve collets and release the spring
with 60° stone and upper area with 15° stone (Fig. tension (Fig. 17).
15). Be sure to center the seat on the valve face.
Maintain the valve seat within limits. WARNING: WEAR PROTECTIVE EQUIPMENT A N D
D O N O T S T A N D IN L I N E W I T H T H E VALVE STEM
WHEN TAPPING THE VALVES.
• 5 J L (DIESEL) ENGINE 9 - 121
Fig. 18 Locating TDC using Timing Pin
I = INTAKE E = EXHAUST
E I E I E I
© © © © © ©
Fig. 17 Valve, Valve Spring and Collet Installation
(6) Tap the ends of the valve stems with a mallet J9109-34 FRONT mz£>
to verify the collets are seated. Fig. 19 Adjust Valve Clearance—Step 1
(8) Check the valve clearance adjustment. STEP 2
Adjust the clearance for the valves shown in Fig.
VALVE CLEARANCE ADJUSTMENT 20. The valve lash adjustment is 0.254 mm (0.010
Use the timing pin to locate Top Dead Center inch) for the intake valve. The valve lash adjustment
(TDC) for cylinder No.l (Fig. 18). The timing pin is is 0.508 mm (0.020 inch) for the exhaust valve.
located at the back of the gear housing and below the Tighten the bolts to 24 N*m (18 ft. lbs.) torque.
injection pump. Be sure to disengage the timing pin I = INTAKE E = EXHAUST
after locating top dead center.
Adjust the valves when the engine is cold, below
60°C (140°F).
El I E I E
STEP 1
Adjust the clearance for the valves shown in Fig.
19. The valve lash adjustment is 0.254 mm (0.010
inch) for the intake valve. The valve lash adjustment
is 0.508 mm (0.020 inch) for the exhaust valve.
Tighten the valve adjusting nuts to 24 N*m (18 ft.
lbs.) torque.
Be sure timing pin is disengaged before rotating © © © © © ©
the crankshaft. Mark the pulley and rotate the J9109-35 FRONT
crankshaft 360°.
Fig. 20 Adjust Valve Clearance—Step 2
GEAR HOUSING / COVER
GEAR HOUSING
REMOVAL
(1) Remove the engine assembly from the vehicle.
(2) Remove the front end components and the gear
housing cover (refer to Gear Housing Cover Removal
for the proper procedures).
(3) Remove the following:
• Camshaft
• Gear driven accessories
• Fuel injection pump (refer to Group 14, Fuel Sys
tem)
• F a n hub assembly (refer to Group 7, Cooling Sys J9109-104
tem) Fig. 2 Camshaft/Crankshaft Gear Alignment
(4) Remove the gear housing and gasket (Fig. 1).
(5) Clean the gasket material from the cylinder GEAR HOUSING COVER
block.
REMOVAL
(1) Remove fan drive assembly.
(2) Remove the fan belt (Fig. 3).
(3) Remove belt tensioner (Fig. 3).
Fig. 1 Gear Housing/Gasket

INSTALLATION
(1) Install a new gasket and the gear housing.
Tighten the bolts to 24 N*m (18 ft. lbs.) torque. Fig. 3 Drive Belt Installation
(2) Install the camshaft. Make sure the alignment
(4) Remove oil fill tube and adaptor (Fig. 4).
marks on the camshaft and crankshaft gears are
aligned (Fig. 2),
(3) If a new housing is installed, the timing pin as
sembly must be accurately located.
(4) Install the following:
• F a n hub assembly (refer to Group 7, Cooling Sys
tem)
• Fuel injection pump (refer to Group 14, Fuel Sys
tem)
• Gear driven accessories
(5) Install the gear housing cover (refer to Gear
Housing Cover Installation for the proper proce -158
dures).
(6) Install the front end components. Fig. 4 Oil Fill Tube
(7) Install the engine assembly into t h e vehicle.
(6) Remove the bolts that hold the gear cover to onto the crankshaft. Install the seal onto the pilot
the gear housing. and start into the gear housing cover. Remove the pi
(7) Gently pry the cover away from the housing, lot.
taking care not to m a r the gasket surfaces (Fig. 5). (9) Use the alignment/installation tool and a plas
(8) Clean the old gasket residue from the back of tic h a m m e r to install the seal to the correct depth.
the gear cover and front of the gear housing. To prevent damage to the seal carrier, hit the align
ment/installation tool alternately at t h e 12, 3, 6 and
9 o'clock positions.
(10) Install the oil fill tube and mounting bolts.
Tighten the bolts to 43 N*m (32 ft. lbs.) torque.
(11) Install the vibration damper. DO NOT tighten
the bolts to the correct torque valve a t this time.
(12) Install the belt tensioner. Tighten the mount
ing bolts to 43 Nnn (32 ft. lbs.) torque.
(13) Raise the belt tensioner to install the belt.
(14) Tighten the vibration damper bolts to 125
N*m (92 ft. lbs.) torque. Use an engine barring tool to
keep the engine from rotating during tightening op
eration.
TIMING PIN
TIMING PIN REPLACEMENT
Fig. 5 Gear Housing and Cover The timing pin can be replaced without removing
INSTALLATION the assembly from the gear housing.
(1) Remove the timing pin by prying the retaining
(1) Lubricate the front gear train with clean en
ring out with a small screwdriver. Replace the re
gine oil. taining ring if it is damaged during removal.
(2) Thoroughly clean the front seal area of the (2) If timing pin assembly is removed from gear
crankshaft. The seal lip and the sealing surface on housing, it must be precisely reset to obtain exact
the crankshaft must be free from all oil residue to TDC.
prevent seal leaks. (3) Install a new O-Ring, lubricate t h e pin and po
(3) Install the gear housing cover and a new gas sition in the housing (Fig. 7). Install t h e new retain
ket. ing ring to 1.5 mm (0.059 inch).
(4) Install t h e bolts but DO NOT tighten them at
this time.
(5) Use the alignment/installation tool from the
seal kit to align the cover to the crankshaft (Fig. 6).
(6) Tighten the gear housing cover bolts to 24 N*m
Fig. 7 Engine Timing Pin Location

TIMING PIN HOUSING ASSEMBLY/ GASKET
Fig. 6 Alignment/Installation Tool
(7) Remove the alignment/installation tool. Always REMOVAL
use a seal pilot when you install a seal. (1) Locate TDC for cylinder No.l.
(8) Apply a bead of Loctite 277 to the outside di (2) Remove the timing pin housing assembly and
ameter of the seal. Install the pilot from the seal kit gasket.
(3) Clean any gasket material from the gear hous-
ing and from the timing pin housing assembly.
INSTALLATION (CYLINDER HEAD ON)

The location of the timing pin assembly on the
gear housing is critical for correct engine adjustment.
Follow this procedure to install the assembly so t h a t
it corresponds to TDC for cylinder No.l.
(1) Look through the hole in the gear housing and
rotate the engine until the hole in the cam gear can
be seen.
(2) Adjust the No.l cylinder exhaust rocker lever
to have zero (0) valve clearance.
(3) Remove the injector nozzles from all of the cyl
inders. This step is important to vent the cylinders so
the crankshaft can be rotated smoothly to locate TDC
for cylinder No.l.
Fig. 9 Locate and Mark Vibration Damper—First
(4) Temporarily install the vibration damper. Fab
Mark
ricate and install a wire pointer (Fig. 8).
Fig. 10 Mark Vibration Damper—Second Mark

Fig. 8 Fabricated Wire Pointer
(5) Rotate the crankshaft one-quarter rotation in
the opposite direction of engine rotation (counter
clockwise).
(6) Tighten the No.l cylinder exhaust valve adjust
ing screw two complete turns. Tighten the locknut.
CAUTION; U s e extreme care that the piston does

not p u s h against the exhaust valve with s o much
force that it bends the push rod (Fig. 9).
(7) Rotate t h e crankshaft slowly in the direction of

engine rotation until the piston touches the exhaust
valve (Fig. 9). Fig. 11 Location of Top Dead Center (TDC)
(8) Mark the vibration damper corresponding to m a r k is the TDC mark (Fig. 11).
the wire pointer (Fig. 9). (12) Completely loosen the No.l cylinder exhaust
(9) Rotate the crankshaft in the opposite direction valve adjusting screw.
until the piston touches the valve (Fig. 10). Make (13) Rotate the crankshaft with Cummins Barring
sure t h a t the piston touches the valve with approxi Tool 3377371 approximately 180° in the direction of
mately the same amount of force as in the previous engine rotation until the pointer is aligned with the
step (Fig. 10). TDC mark. Look through the back side of the gear
(10) Mark the vibration damper again (Fig. 10). housing for the timing pin hole in the camshaft gear.
(11) Measure the distance and m a r k the pulley at
one-half t h a t distance between the two marks. This
• 5 J L (DIESEL) ENGINE 9 - 125
(14) Reset the valves on No.l cylinder and install (3) Use two flywheel housing bolts to assemble the
valve cover. plate over No.l cylinder (Fig. 14).
(15) Install timing pin housing assembly and a
new gasket.
(16) Apply a coat of Loctite 59241 Liquid Teflon, or
equivalent to the threads of the Torx head bolts.
(17) Hold the timing pin in the hole to align the
housing and install the Torx head bolts. Tighten the
Torx bolts to 5 N»m (44 in. lbs.) torque.
(18) Install the injectors and bleed the fuel system
(refer to Group 14, Fuel System).
INSTALLATION (CYLINDER HEAD OFF)

The timing pin assembly is precisely located on the
gear housing to correspond to TDC for Cylinder No.l. Fig. 14 Fabricated Plate Location on No.1 Cylinder
The timing pin assembly must be relocated if the (4) Rotate the crankshaft in the direction of rota
gear housing is interchanged. tion until the piston contacts the plate.
(1) Temporarily install the vibration damper and a (5) Mark the vibration damper (Fig. 11).
fabricated wire pointer (Fig. 12). Put a flat washer (6) Rotate the engine in the opposite direction un
between the pointer and gear housing to prevent til the piston contacts the plate.
damage to the gear housing. (7) Mark the vibration damper (Fig. 11).
(2) Fabricate a steel plate (Fig. 13). (8) Mark the vibration damper for TDC. TDC will
be one-half the distance between the first two marks
(Fig. 11).
(9) Remove the plate and rotate the engine in the
direction of rotation until the pointer aligns with the
TDC mark.
(10) Look for the timing pin hole in the camshaft
gear. If it is not visible, rotate the crankshaft one
complete rotation. Align the pointer with the TDC
mark.
(11) Install the timing pin housing assembly with
a new gasket.
(12) Apply a coat of Loctite 59241 liquid teflon, or
equivalent to the threads of the torx head bolts.
(13) Push the pin into the hole in the cam gear to
align the timing pin housing.
Fig. 12 Fabricated Wire Pointer (14) Hold the pin in while tightening the torx head
bolts to 5 Nnn (44 in. lbs.) torque. Be sure timing pin
is disengaged before rotating the engine.
(15) Remove the vibration damper and wire
pointer.
TAPPET
REMOVAL
(1) Remove the camshaft.
(2) Insert a trough the full length of the cam bore
(Fig. 1). Cummins Tappet Changing Tool 3822513 is
available for this job.
(3) Make sure the trough is positioned so it will
catch the tappet when the wooden dowel is removed.
(4) Identify the location of each tappet as it is re
moved. The tappets must be installed in their origi
Fig. 13 Fabricated Steel Plate nal locations.
(5) Only remove one tappet at a time. Remove the INSTALLATION
rubber band from the two companion tappets, secur (1) Insert the trough the full length of the cam
ing the tappet not to be removed with the rubber bore.
band. (2) Feed the installation tool down the tappet bore
(6) Pull the wooden dowel from the tappet bore al and into the trough (Fig. 3).
lowing the tappet to fall into the trough (Fig. 1).
(7) Normally the tappet will fall over when it
drops into the trough. Use a flashlight to determine
this. If the tappet does not fall over, shake the
trough gently to get it to do so.
(8) Special care should be taken, when removing
the No.6 cylinder tappets. DO NOT knock or shake
the tappet over the end barrier of the trough.
(9) Carefully pull the trough and tappet from the
cam bore and remove the tappet. Repeat the process
until all tappets are removed.
J9109-153
Fig. 3 Tappet Installation Tool

(3) Feed the installation tool cord through the cam
bores. Carefully pull the trough and installation tool
out the front. The barrier at the rear of the trough
will assure the tool will be pulled out with it.
(4) Lubricate the tappets with Lubriplate 105, or
equivalent.
(5) Insert the installation tool into the tappet (Fig.
4). To aid in removing the installation tool after the
tappets is installed, work the tool in and out of the
tappet several times before installing the tappets.
Fig. 1 Tappet Removal using a Trough (6) Place the tappet and tool in the trough and
slide the trough back into the cam bore (Fig. 4).
INSPECTION
Inspect the tappet socket, stem and face for exces
sive wear, cracks and other damage (Fig. 2).
The minimum tappet stem diameter is 15.925 mm
(0.627 inch) - (Fig. 2). If the tappet is out of limits,
replace the tappet.
NORMAL
WEAR
J9109-155'
ABNORMAL
WEAR Fig. 4 Insert Installation Tool into Tappet
STEM DIAMETER-
(7) Pull the tool/tappet through the cam bore and
J9109-152 up into the tappet bore (Fig. 5).
(8) Difficulty could be experienced in getting the
Fig. 2 Tappet Inspection tappet to make the bend from the trough up to the
tappet bore (due to the webbing of the block). If this
occurs, pull the trough out enough to allow the tap-
DOWEL TOOL
Fig. 6 Holding Tappets in Place (Cummins Tool

Fig. 5 Pull Tappet/Tool into Position
3822513)
pet to drop down and align itself. Now pull the tap
pet up into the bore carefully.
(9) After the tappet has been pulled up into posi
tion, slide the trough back into the cam bore and ro
tate it 1/2 turn. This will position the round side of
the trough up, which will hold the tappet in place.
(10) Remove the installation tool from the tappet.
(11) Install a wooden dowel into the top of the tap
pet and secure it with a rubber band.
(12) Repeat this process until all tappets have been
installed.
(13) Install the camshaft.
CAMSHAFT
REMOVAL J9109-51
(1) Remove the following parts:
Fig. 7 Align Crankshaft to Camshaft
• Valve covers
• Rocker lever assemblies
• Push rods
• Drive belt
• F a n hub assembly
• Vibration damper
• Gear housing cover
• Lift pump
(2) Insert the dowels through the push tube holes
and into the top of each tappet. When properly in
stalled, the dowels can be used to pull the tappets up
(Fig. 6).
(3) Pull the tappets up and wrap a rubber band
around the top of the dowel rods (Fig. 6). This will
prevent the tappets from dropping down.
(4) Rotate the crankshaft to align the crankshaft
to camshaft timing marks (Fig. 7).
Fig. 8 Thrust Plate Bolt Location
(5) Remove the bolts from the thrust plate (Fig. 8)
(6) Remove the camshaft, gear and thrust plate. Clean the camshaft and gear with solvent and a
lint free cloth.
INSPECTION Inspect the gear teeth for wear and damage. Look
Inspect the lift pump lobe, valve lobes and bearing for cracks at the root of the teeth.
journals for wear, cracking, pitting and other dam Measure the bearing journals, lift pump lobe and
age. valve lobes (Fig. 9).
CAMSHAFT
JOURNAL
J9109-54
Fig. 10 Oil Hole Alignment

(2) Remove all burrs and smooth any rough sur
faces caused by removing the gear.
(3) Install the camshaft key.
CAMSHAFT JOURNAL DIAMETER (MIN. (4) Lubricate the camshaft surface with Lubriplate
53.962 mm (2.1245 inch) 105, or equivalent.
(5) Heat the gear in an oven at 121°C (250°F) for
VALVE LOBE HEIGHT (MIN..)
INTAKE - 47.040 mm (1.852 inch) 45 minutes.
EXHAUST - 46.770 mm (1.841 inch)
WARNING: WEAR PROTECTIVE GLOVES TO HAN
LIFT PUMP LOBE DIAMETER (MIN.) D L E T H E HOT G E A R .
35.500 mm (1.398 inch)
(6) Install the gear with the timing marks visible.
Be sure the gear is seated against the camshaft
J9109-53 shoulder.
(7) If the camshaft is not to be used immediately,
Fig. 9 Bearing Journal/Valve Lobe Measurements
lubricate the lobes and journals to prevent rust.
CAMSHAFT BUSHING-REPLACEMENT
(1) Measure the diameter of each bore. (The limit INSTALLATION
for the bushing in the No.l bore is the same as for (1) Apply a coat of Lubriplate 105 to the camshaft
the other bores without bushings). The limit of the bores.
inside diameter is 54.133 mm (2.1312 inch). If the (2) Lubricate the camshaft lobes, journals and
camshaft bore for the first cam bushing is worn be thrust washer with Lubriplate 105, or equivalent.
yond the limit, install a new service bushing. Inspect
the rest of the camshaft bores for damage or exces C A U T I O N : When installing the camshaft, D O N O T
sive wear. push it in farther than it will g o with the thrust
washer in place. Pushing it too far can dislodge the
(2) If the bores without a bushing are worn beyond
plug in the rear of the camshaft bore and cause an
the limit, the engine must be removed for machining
oil leak.
and installation of service bushings. If badly worn,
replace the cylinder block. (3) Install the camshaft/thrust washer. Align the
(3) Remove the bushing from the No.l bore, using timing marks as illustrated (Fig. 11).
a universal cam bushing tool. (4) Install the thrust washer bolts and tighten to
(4) Mark the cylinder block so you can align the 24 N-m (18 ft. lbs.) torque.
oil hole in the cylinder block with the oil hole in the (5) Verify the camshaft has the correct amount of
bushing. backlash and end clearance (Fig. 12).
(5) Use a universal cam bushing installation tool (6) Install the following parts:
and install the bushing so t h a t it is even with the • Lift pump
front face of the cylinder block. The oil hole must .be • Gear housing cover
aligned. A 3.2 mm (0.128 inch) diameter rod must be • Vibration damper
able to pass through the hole (Fig. 10). • F a n hub assembly
(6) Measure the installed bushing. The limit of the • Drive belt
inside diameter is 54.133 mm (2.1312 inch). • Push rods
• Rocker lever assemblies
CAMSHAFT GEAR-REPLACEMENT • Valve covers
(1) Press the camshaft out of the gear. (7) Install the engine in the vehicle.
Fig. 1 Combustion Deck Face Measurement

Inspect the cylinder bores for damage or excessive
wear.
Measure the cylinder bores (Fig. 2). If the cylinder
bores exceeds the limit, refer to Cylinder Bore Re
pair.
BACKLASH - 0.080-0.330 mm MIN. 102.0 mm (4.0157 inch)

(0.003-0.013 inch) MAX. 102.1 16 mm (4.0203 inch)
CLEARANCE - 0.152-0.254 mm Out-of-Round 0.038 mm (0.0015 inch)
(0.006-0.010 inch) Taper 0.0 76 mm (0.003 inch)
Oversize pistons and rings are
Fig. 12 Camshaft Backlash and End Clearance available for bored cylinder blocks.
(8) Operate the engine at idle for five to ten min J9209-167
utes and check for leaks and loose parts.
Fig. 2 Cylinder Bore Diameter
CYLINDER BLOCK
Inspect the camshaft bores for scoring or excessive
REMOVAL wear.
(1) Remove the engine assembly from the vehicle. Measure the camshaft bores (Fig. 3). Limit for the
(2) Remove the cylinder head from the block. No.l bore applies to the ID of the bushing.
(3) Remove the camshaft. If a bore exceeds the limit, refer to Camshaft Bore
(4) Remove the piston/connecting rod assemblies. Repair.
Inspect the tappet bores for scoring or excessive
INSPECTION wear (Fig. 4).
Measure the combustion deck face using a straight If out of limits, replace the cylinder block.
edge and a feeler gauge (Fig. 1). The distortion of the
combustion deck face is not to exceed 0.010 mm CYLINDER BORES—DE-GLAZE
(0.0004 inch) in any 50.00 m m (2.0 inch) diameter. (1) New piston rings may not seat in glazed cylin
Overall variation end to end or side to side is 0.075 der bores.
mm (0.003 inch). (2) De-glazing gives the bore the correct surface
If the surface exceeds t h e limit, refer to Cylinder finish required to seat the rings. The size of the bore
Block Refacing. is not changed by proper de-glazing.
TOP OF BLOCK
Fig. 5 Cylinder Bore Crosshatch Pattern

(7) Vertical strokes MUST be smooth continuous
passes along the full length of the bore (Fig. 6).
CAMSHAFT BORE DIAMETER
MAX. 5 4 . 1 3 3 mm ( 2 . 1 3 1 2 inch)
J9109-78
Fig. 3 Camshaft Bores
1 STROKE ( f + | ) / P E R S E C O N D
Fig. 6 De-Glazing Drill Speed and Vertical Speed

(8) Inspect the bore after 10 strokes.
(9) Use a strong solution of hot water and laundry
detergent to clean the bores. Clean the cylinder bores
immediately after de-glazing.
(10) Rinse the bores until the detergent is removed
and blow the block dry with compressed air.
BORE DIAMETER (11) Check the bore cleanliness by wiping with a
white, lint free, lightly oiled cloth. If grit residue is
MAX. 16.055 mm (0.632 inch) still present, repeat the cleaning process until all res
idue is removed. Wash the bores and the complete
block assembly with solvent and dry with compressed
J9109-79
air.
Fig. 4 Tappet Bore Diameter (12) Be sure to remove the tape covering the lube
holes after the cleaning process is complete.
(3) Cover the lube holes in the top of the block
with waterproof tape. CYLINDER BLOCK REFACING
(4) A correctly honed surface will have a cross- (1) The combustion deck can be refaced twice. The
hatch appearance with the lines at 15° to 25° angles first reface should be 0.15 mm (0.0059 inch). If addi
(Fig. 5). For the rough hone, use 80 grit honing tional refacing is required, an additional 0.35 mm
stones. To finish hone, use 280 grit honing stones. (0.0138 inch) can be removed. Total allowed refacing
(5) Use a drill, a fine grit Flexi-hone and a mix is 0.50 mm (0.0197 inch) - (Fig. 7).
ture of equal parts of mineral spirits and SAE 30W (2) The upper right corner of the rear face of the
engine oil to de-glaze the bores. block must be stamped with a X when the block is
(6) The Crosshatch angle is a function of drill speed refaced to 0.15 mm (0.0059 inch). A second X must
and how fast the hone is moved vertically (Fig. 6).
GASKET
FOR
0.15 mm
(0.0058 inch)
REFACE
GASKET
FOR
0.50 mm
(0.0197 inch)
REFACE
1st REFACE 0.15 mm (0.0058 inch)

Fig. 9 Proper Head Gasket
2nd REFACE 0.35 mm (0.0138 inch)
• Method 2:—Boring and installing a repair sleeve
® Total 0.50 mm (0.0197 inch)
to l e t u r n the bore to standard dimensions.
® Standard 323.00 mm ±0.10 mni
(12.7165 inch ±0.0039 inch) METHOD 1-0WERS1ZE BORE
1st RE FACE 322.85 mm ±0.10 mm Oversize pistons and rings are available in two
(12.7106 inch ±0.0039 inch) sizes - 0.50 m m (0.0197 inch) and 1.00 m m (0.0393
2nd REFACE 322.50 mm ±0.10 mni inch).
(12.6968 inch ±0.0039 inch) Any combination of standard, 0.50 m m (0.0197
inch) or 1.00 mm (0.0393 inch) overbore m a y be used
J9109-118
in the same engine.
Fig. 7 Refacing Dimensions of the Cylinder Block If more t h a n 1.00 mm (0.0393 inch) overbore is
needed, a repair sleeve can be installed (refer to
Method 2—Repair Sleeve).
Cylinder block bores may be bored twice before use
of a repair sleeve is required (Fig. 10). The first bore
is 0.50 mm (0.0197 inch) oversize. The second bore is
1.00 m m (0.0393 inch) oversize.
After boring to size, use a honing stone to chamfer
the edge of the bore (Fig. 10).
1st REFACE X
A correctly honed surface will have a C r o s s h a t c h
appearance with the lines at 15° to 25° angles with
2nd REFACE XX
the top of t h e cylinder block (Fig. 11). For the rough
hone, use 80 grit honing stones. To finish hone, use
280 grit honing stones.
A maximum of 1.2 micrometer (48 microinch) sur
J9109-116 face finish must be obtained.
After finish honing is complete, immediately clean
Fig. 8 Stamp Block after Reface
the cylinder bores with a strong solution of laundry
be stamped beside t h e first when the block is refaced detergent and hot water.
to 0.50 mm (0.0197 inch) - (Fig. 8). After rinsing, blow the block dry.
(3) Consult the parts catalog for the proper head Check the bore cleanliness by wiping with a white,
gaskets which must be used with refaced blocks to lint-free, lightly-oiled cloth. There should be no grit
ensure proper piston-to-valve clearance (Fig. 9). residue present.
If the block is not to be used right away, coat i t
CYLINDER BORE REPAIR with a rust-preventing compound.
Cylinder bore(s) can be repaired by one of two
methods: METHOD 2—REPAIR SLEEWE
• Method 1:—Over boring and using oversize pistons If more t h a n a 1.00 mm (0.03937 inch) diameter
and rings. oversize bore is required, the block must be bored
and a repair sleeve installed.
9 - 132 5.9L (DIESEL) ENGINE
BORING A N D BORE DIAMETER

H O N I N G DIAMETERS
BLOCK REBORE FOR REPAIR SLEEVE
BORING DIAMETER DIMENSION

BORE DIA. - 104.500 +0.015 mm
(4.1142 +0.0006 inch)
1st REBORE - 102.469 mm
STEP DIM. - 6.35 mm (0.25 inch)
(4.0342 inch)
2nd REBORE - 102.969 mm
(4.0539 inch) J9109-120
H O N I N G DIAMETER DIMENSIONS Fig. 12 Block Bore for Repair Sleeve Dimensions

After machining the block for the new repair
STANDARD 102.020 ±0.020 mm sleeve, thoroughly clean the bore of all metal chips,
(4.0165 ± 0.0008 inch)
debris and oil residue before installing the sleeve.
1st REBORE 102.520 ± 0.020 mm
Cool the repair sleeve(s) to a temperature of -12°C
(4.0362 ± 0.0008 inch)
2nd REBORE 103.020 ±0.020 mm
(10°F) or below for a minimum of one hour. Be ready
(4.0559 ± 0.0008 inch) to install the sleeve immediately after removing it
from the freezer.
CHAMFER DIMENSIONS Apply a coat of Loctite 620, or equivalent to the
bore t h a t is to be sleeved.
Approx. 1.25 mm (0.049 inch) Wear protective gloves to push the cold sleeve into
by 15° the bore as far as possible.
Using a sleeve driver, drive the sleeve downward
J9109-119
until it contacts the step at the bottom of the bore
Fig. 10 Cylinder Bore Dimensions (Fig. 13).
TOP OF BLOCK
Fig. 11 Crosshatch Pattern of Repaired Sleeve(s)

Bore the block cylinder bore to 104.500-104.515
mm (4.1142-4.1148 inch) - (Fig. 12). J9109-121
Repair sleeves can be replaced by using a boring
bar to bore out the old sleeve. DO NOT cut the cyl Fig. 13 Sleeve Installation
inder bore beyond the oversize limit.
• 5 9L (DIESEL) ENGINE 9 - 133
A sleeve driver can be constructed as follows (Fig. 14). Finished bore inside dimension is 102.020 ±0.020
mm (4.0165 ±0.0008 inch).
A maximum of 1.2 micrometer (48 microinch) sur
face finish must be obtained.
After finish honing is complete, immediately clean
the cylinder bores with a strong solution of laundry
detergent and hot water.
After rinsing, blow the block dry with compressed
air.
Wipe the bore with a white, lint-free, lightly oiled
cloth. Make sure there is no grit residue present.
Apply a rust-preventing compound if the block will
DRIVE - ALUMINUM
not be used immediately.
HANDLE - STEEL
A standard diameter piston and a piston ring set
must be used with a sleeved cylinder bore.
A = 127 mm (5 inch)
B = 38 mm (1.5 inch)
CAM BORE REPAIR
C = 6.35 mm (0.25 inch)
D = 25.4 mm (1 inch)
The front cam bushing bore can be bored to 57.740
E = 101 mm (3.976 inch) Mm ±0.018 mm (2.273 inch ±0.0007 inch) oversize.
F = 107.343 mm (4.226 inch) DO NOT bore the intermediate or rear cam bore to
the front cam bore oversize dimensions. Intermediate
J9109-122 and rear cam bores may be bored to 57.240 mm
±0.018 mm (2.253 inch ±0.0007 inch) oversize.
Fig. 14 Sleeve Driver Construction A surface finish of 2.3 micrometers (92 microinch)
Set up a boring bar and machine the sleeve to must be maintained. Not more t h a n 20% of an area
101.956 mm (4.014 inch) - (Fig. 15). of any one bore may be 3.2 micrometers (126 micro-
After removing the boring bar, use a honing stone to inch).
chamfer the corner of the repair sleeve(s) - (Fig. 15). Camshaft bores can be repaired individually. It is
not necessary to repair undamaged cam bores in or
der to repair individually damaged cam bores. The
standard front bushing cannot be used to repair in
termediate or rear bores.
Install all cam bushings flush or below the front
cam bore surface. The oil hole must align to allow a
3.2 mm (0.125 inch) rod to pass through freely (Fig.
16).
SLEEVE DIAMETER - 101.956 mm

(4.014 inch)
SLEEVE PROTRUSION
MIN. - FLUSH WITH BLOCK
MAX. - 0.050 mm (0.0019 inch)
SLEEVE CHAMFER
APPROX. 1.25 mm (0,049 inch)
BY 15° •
J9109-123 Fig. 16 Oil Hole Alignment

CUP PLUG-REPLACEMENT
Fig. 15 Sleeve Machining Dimensions
(1) Remove the cup plugs from the oil passages
A correctly h o n e d surface w i l l h a v e a C r o s s h a t c h (Fig. 17).
appearance w i t h the l i n e s at 15° t o 25° angles w i t h (2) Apply a bead of Loctite 277 around the outside
the top of the c y l i n d e r block. For t h e r o u g h hone, u s e diameter of the oil passage cup plugs.
80 g r i t h o n i n g stones. To finish h o n e , u s e 280 g r i t (3) Drive the cup plugs in until they bottom in the
h o n i n g stones. bore (Fig. 17).
(4) Fill the engine with oil. Run the engine and (2) Remove the piston pin. Heating the piston is
check for leaks. not required.
(5) Stop the engine and check the oil level with the (3) Remove the piston rings (Fig. 1).
dipstick.
RETAINER CONNECTING
CUP PLUG RING ROD
PISTON
PISTON
RIN RETAINER
RING
J9109-30 J9109-62
Fig. 1 Retainer Rings

Fig. 17 Cup Plug Locations in Cylinder Block
CLEANING
INSTALLATION
(1) Install the cylinder head onto the block. CAUTION: DO NOT use bead blast to clean the pis
(2) Install the engine assembly into the vehicle. tons. DO NOT clean the pistons and rods in an acid
tank.
The turbocharged intercooler piston has a Ni-Resist Soak the pistons in cold parts cleaner. Soaking the
insert with a keystone profile for the top compression pistons overnight will usually loosen the carbon de
ring. The new piston has a new design bowl and a 7 posits.
mm longer piston pin. These pistons can not be in Wash the pistons and rods in a strong solution of
terchanged with earlier models. laundry detergent and hot water.
Clean the remaining deposits from the ring grooves
REMOVAL
with the square end of a broken ring. DO NOT use a
(1) Remove the engine assembly from the vehicle.
ring groove cleaner and be sure not to scratch the
(2) Remove the cylinder head from the block.
ring sealing surface in the piston groove.
(3) Remove the oil pan and suction pump.
Wash the pistons again in a detergent solution or
(4) If the cylinder bores have ridges, use a ridge
solvent.
reamer to cut the ridge from the top of the cylinder
Rinse the pistons. Use compressed air to dry.
bore before removing the piston. Make sure the ridge
reamer does not make a deep cut into the bore. DO INSPECTION
NOT remove more metal t h a n is necessary to remove Inspect the rod journals for deep scratches, indica
the ridge.
tion of overheating and other damage.
(5) If cylinders have ridges, the cylinders are over Inspect the pistons for damage and excessive wear.
size and will need boring. Check top of the piston, ring grooves, skirt and pin
(6) Use a hammer and a steel stamp to m a r k the
bore.
cylinder number onto each connecting rod cap. Mark
Measure the piston skirt diameter (Fig. 2). If the
the cylinder number onto the top of each piston.
piston is out of limits, replace the piston.
(7) Remove the connecting rod bolts and rod caps.
The upper groove only needs to be inspected for
Use care so the cylinder bores and connecting rods
damage.
are not damaged.
Use a new piston ring to measure the clearance in
(8) Use a hammer handle or similar object to push
the intermediate ring groove (Fig. 3). If the clearance
the piston and connecting rod through the cylinder
bore. of the intermediate ring exceeds 0.152 mm (0.006
(9) Store the piston/rod assemblies in a rack. inch), replace the piston.
Use a new oil ring to measure the clearance in t h e
DISASSEMBLE oil groove (Fig. 3). If the clearance exceeds 0.127 m m
(1) Remove the retainer rings from the piston (Fig. (0.005 inch), replace the piston.
1).
- j ^ u m m 1 1 / 2 i n c h )
PISTON
• PIN
MIN. DIAMETER
101.823 mm
4.0088 inch
J9109-63
Fig. 2 Piston Skirt Diameter
J910< -66
FEELER GAUGE
Fig. 5 Piston Pin Diameter
Measure the connecting rod pin bore (Fig. 6). The
maximum diameter is 40.092 m m (1.5784 inch). If
out of limits, replace the connecting rod.
CONNECTING
PISTON
J9109-64
Fig. 3 Intermediate and Oil Ring Clearances

Measure the pin bore (Fig. 4). The maximum diam
eter is 40.025 mm (1.5756 inch). If the bore is over
limits, replace the piston,
PISTON
Fig. 6 Connecting Rod Pin Bore

CONNECTING ROD BEARING / CRANKSHAFT
JOURNAL CLEARANCE
Measure the connecting rod bore with the bearings
installed and the bolts tightened to 100 N*m (73 ft.
lbs.) torque.
Record the smaller diameter.
Measure the diameter of the rod journal at the lo
cation shown (Fig. 7). Calculate the average diame
J9109-65
ter for each side of the journal.
Fig. 4 Piston Pin Bore The clearance is the difference between the con
necting rod bore (smallest diameter) and the average
Inspect the piston pin for nicks, gouges and exces diameter for each side of the crankshaft journal.
sive wear. If the crankshaft is within limits, replace the bear
Measure the pin diameter (Fig. 5). The minimum ing. If the crankshaft is out of limits, grind the
diameter is 39.990 mm (1.5744 inch). If the diameter crankshaft to the next smaller size and use oversize
is out of limits, replace the pin. rod bearings.
Inspect the rod for damage and wear. The I-Beam
section of the connecting rod cannot have dents or ASSEMBLE
other damage. Damage to this part can cause stress (1) Be sure the FRONT marking on the piston and
risers which will progress to breakage. the numbers on the rod and cap are oriented (Fig. 8).
TOP RING TOP
INTERMEDIATE
RING
OIL CONTROL
RING J9109-69
Fig. 9 Piston Ring Identification

(5) Position each ring in the cylinder and use a
piston to square it with the bore at a depth of 89.0
mm (3.5 inch) - (Fig. 10).
MIN. 68.962 mm (2.715 inch) (6) Use a feeler gauge to measure the piston ring
MAX. 69.013 mm (2.717 inch) gap (Fig. 11).
Out-of-Round - Max.
0.050 mm (0.002 inch)
Taper - Max.
0.013 mm (0.0005 inch)
Bearing Clearance - Max.

0.089 mm (0.0035 inch)
J9109-91
Fig. 7 Connecting Rod Journal Diameter Limits

Install the retaining ring into the pin groove on the
FRONT side of the piston.
Fig. 10 Position of Ring in Cylinder Bore
Fig. 8 Proper Markings on the Piston and MINIMUM MAXIMUM

Connecting Rod TOP 0.400 mm 0.700 mm
(2) Lubricate the pin and bore with engine oil. (0.0160 inch) (0.0275 inch)
(3) Install the piston pin in the opposite side of the INTERMEDIATE 0.250 mm 0.550 mm
(0.0100 inch) (0.0215 inch)
installed retaining pin. Pistons do not require heat
ing to install the pin, however, the piston does need OIL CONTROL 0.250 mm 0.550 mm
(0.0100 inch) (0.0215 inch)
to be at room temperature or above.
(4) Determine the piston diameter and obtain the J9109-71
appropriate ring set. The piston rings can be identi
fied as shown in Fig. 9. Fig. 11 Piston Ring Gap
(7) The top surface of all of the rings are identified

with the word TOP or the supplier's MARK. Assem
ble the rings with the word TOP or the supplier's
TOP
MARK up.
RING
(8) Position the oil ring expander in the oil control
ring groove (bottom groove).
(9) Install the oil control ring with the end gap INTERMEDIATE
OPPOSITE the ends on the expander (Fig. 12). RING
OIL CONTROL OIL CONTROL
RING RING
J9109-73
Fig. 14 Piston Ring Positioning
EXPANDER STANDARD
PISTON
OVERSIZE
0.250 mm (.0098 in.

J9109-72 0.500 mm (.0197 in.
0.750 mm (.0295 in.
Fig. 12 Oil Control Ring/Expander Location in 1.000 mm (.0394 in.
Groove J9109-82
(10) Install the intermediate piston ring in the sec Fig. 15 Connecting Rod Bearing Size Location
ond groove (Fig. 13).
(11) Install the top piston ring in the top groove pressor tool (Fig. 16). If using a strap-type ring com
(Fig. 13). pressor, make sure the inside end of the strap does
not hook on a ring gap and break the ring.
PISTON RING
INSTALLATION PISTON
TOOL RING
J9109-74 COMPRESSOR TOOL J9109-83
Fig. 13 Piston Ring Installation Tool
Fig. 16 Piston Ring Compressor Tool
(12) Position the rings as shown in Fig. 14.
(13) Install the original bearings as removed or in (4) Bar the crankshaft so the rod journal for the
stall new bearings. If new bearings are used, be sure piston to be installed is at BDC (Bottom Dead Cen
to obtain the proper bearing clearance (Fig. 15). ter) - (Fig. 17).
(14) DO NOT lubricate the side of the bearing t h a t (5) Be sure the FRONT marking on the piston and
is against the connecting rod or cap. Apply a coat of the numbers on tlie rod and cap are oriented as illus
Lubriplate 105, or equivalent to the new upper and trated.
lower connecting rod bearings. (6) Position the piston and rod assembly into the
cylinder bore with the word FRONT on the piston to
INSTALLATION wards the front of the cylinder block. Use care when
(1) Lubricate the cylinder bore with clean engine you install the piston and connecting rod so the cyl
oil. inder bore is not damaged.
(2) Generously lubricate the rings and piston (7) Push the piston into the bore until the top of
skirts with clean engine oil.
the piston is approximately 50 mm (2 inch) below the
(3) Compress the rings using a piston ring com-
SIDE CLEARANCE LIMITS

MIN. 0.100 mm (0.004 inch)
MAX. 0.300 mm (0.012 inch)
J9109-84
Fig. 17 Piston/Rod Assembly at BDC Fig. 19 Side Clearance between Connecting Rod/
Crankshaft
top of the block. Carefully pull the connecting rod
onto the crankshaft journal. CRANKSHAFT
(8) Use clean engine oil to lubricate the threads
REMOVAL
and under the heads of the connecting rod bolts.
(1) Remove the rear crankshaft seal housing.
(9) The 4 digit number stamped on the rod cap at
(2) Remove the gear housing.
the parting line must match and be installed towards
(3) Rotate the engine to a horizontal position and
the oil cooler side of t h e engine (Fig. 18).
remove the main bearing bolts.
(4) The main bearing caps should be numbered. If
they are not, be sure to mark them, beginning with
o -—-—.— f ' - \ number one at the front and ending with number
O ro o seven at the rear (Fig. 1).
O
—
—"k MAIN
BEARING
CAP
J9109-85
Fig. 18 Correct Rod Cap Installation

(10) Install the rod cap and bolts to the connecting
rod. Tighten the connecting rod and bolt evenly in 3
steps.
• Tighten the bolts to 35 Nun (26 ft. lbs.) torque.
• Tighten the bolts to 70 N*m (51 ft. lbs.) torque.
• Tighten the bolts to 100 Nun (73 ft. lbs.) torque. J9109-87
(11) The crankshaft must rotate freely. Check for
Fig. 1 Numbering Main Bearing Caps
freedom of rotation as the caps are installed. If the
crankshaft does not rotate freely, check the installa C A U T I O N : D O N O T pry on the main c a p s to free
tion of the rod bearing and the bearing size. them from the cylinder block.
(12) Measure the side clearance between the con
necting rod and the crankshaft (Fig. 19). DO NOT (5) Use two of the main bearing cap bolts to "wig
measure the clearance between the cap and crank gle" the main cap loose, being careful not to damage
shaft. the bolt threads (Fig. 2). Remove the caps.
(13) Install the suction tube and oil pan.
WARNING: USE A H O I S T TO A V O I D INJURY.
(14) Install the cylinder head onto the block.
(15) Install the engine assembly into the vehicle. (6) Lift the crankshaft and gear from the cylinder
block (Fig. 3).
Inspect the front and rear seal contact areas of t h e

crankshaft for scratches or grooving.
The service seal kit will position the seal slightly
deeper into the seal bore so it will contact the crank
shaft at a different location. If this has already been
done and the crankshaft has two worn areas, install
a wear sleeve to provide a new contact surface for
the seal.
Inspect the rod and main journal for deep scores,
signs of overheating and other abnormal marks.
CRANKSHAFT REWORK
Crankshaft main and rod journals may be ground
in increments of 0.25 mm (0.0098 inch) up to a total
of 1.00 mm (0.0394 inch).
Fig. 2 Main Beating Cap Removal The only exception is the main journal thrust
C A U T I O N : Crankshaft m u s t be lifted straight off the width surface. This journal must be ground in incre
bearings to prevent d a m a g e to the thrust b e a r i n g s . ments of 0.50 mm (0.0197 inch) up to a total of 1.00
mm (0.0394 inch). The thrust surface is located on
the No.6 main bearing. When the t h r u s t surface re
quires grinding, the main journal must be ground to
the same undersize dimension.
MAIN JOURNAL
All main journals are to be ground in the opposite
direction of engine rotation (clockwise as viewed
from the front of crankshaft). Polish the journals in
the same direction as engine rotation.
The main bearing grinding specifications are
shown in Fig. 5.
STANDARD MAIN JOURNAL DIAMETER

83.000 +0.013 mm
(3.2677 ±0.0005 inch)
Fig. 3 Lifting Crankshaft out of Cylinder Block WORN MAIN JOURNAL DIAMETER LIMIT
(7) Remove the main bearings from the block and 82.962 (3.2662 inch)
the main caps. UNDERSIZES REGRIND TO
(8) Remove the piston cooling nozzles by using a 0.25 mm 82.750 ±0.013 mm
3/16 inch pin punch to push them out (Fig. 4). (0.0098 inch) (3.2579 ±0.0005 inch)
0.50 mm 82.500 +0.013 mm
(0.0197 inch) (3.2480 +0.0005 inch)
0.75 mm 82.250 +0.013 mm
(0.0295 inch) (3.2381 ±0.0005 inch)
1.00 mm 82.000 +0.013 mm
(0.0394 inch) (3.2283 ±0.0005 inch)
OUT-OF ROUND & TAPER (MAX.)
0.005 mm (0.0002 inch)
ALL MAIN JOURNALS ARE TO BE PARALLEL
TO THE FRONT AND REAR MAINS WITHIN:
0.030 mm (0.001 inch)
J9109-125
Fig. 4 Piston Cooling Nozzles
Fig. 5 Crankshaft Main Journal Dimensions
Thrust journals can be ground in the same incre
Clean the crankshaft oil galley holes with a nylon ments and using the same specifications as all other
brush. main journals. The main journal radius may be
Rinse in clean solvent and dry with compressed air. ground using either the preferred or the alternative
procedure providing the thrust surface width is not ORIGINAL RADIUS
being ground. The preferred procedure must be used
when the main bearing thrust width surface is
ground. When the thrust surface width requires
grinding, the main journal must be ground to the
same undersize dimension (Fig. 6).
THRUST JOURNAL WIDTH

37.500 ±0.025 mm
(1.4764 ±0.001 inch)
UNDERSIZES REGRIND WIDTH TO
0.50 mm 38.000 ±0.025 mm
(0.0197 inch) (1.4961 ±0.001 inch
1.00 mm 38.500 ±0.025 mm
(0.0394 inch) (1.5158 ±0.001 inch)
J9109-127
JOURNAL SURFACE
Fig. 6 Crankshaft Thrust Journal Width Dimensions
SURFACE FINISH
The thrust surface is to be ground on center within ® 0.8 micrometer (32.0 microinch)
0.10 m m (0.004 inch). It also must be perpendicular for a minimum of 45° into the
fillet beyond journal surface
to the front and rear mains within 0.0015 mm
(0.00006 inch) per radial inch on the thrust area 1.6 micrometer (64.0 microinch)
for remainder of fillet
(Fig. 7). The surface finish requirement is 0.04 mi
crometer (16.0 microinch). © 0.4 micrometer (16.0 microinch)
JOURNAL J9109-129
Fig. 8 Grind Crankshaft Main Journal—Preferred

Method
the front of crankshaft). Polish the journals in the
same direction as engine rotation.
The rod bearing grinding specifications are shown
in Fig. 10.
PREFERRED PROCEDURE:
Smoothly blend a 4.00 ±0.020 (0.1575 ±0.0008
inch) radius to the ground diameters and side faces
(Fig. 11).
ALTERNATIVE PROCEDURE:
J9109-128 Smoothly blend a 1.25 ±0.020 m m (0.0492 ±0.0008
inch) radius to the ground journals (Fig. 12).
Fig. 7 Crankshaft Thrust Surface
CRANKSHAFT FRONT SEAL
PREFERRED PROCEDURE:
Smoothly blend a 4.20 ±0.020 m m (0.1654 ±0.0008 REMOVAL
inch) radius to the ground diameters (Fig. 8). (1) Remove the drive belt.
(2) Remove the vibration damper.
C A U T I O N : D O N O T u s e the Alternative Procedure
(3) Drill two 1/Sth inch holes into the seal face,
when the thrust surface width is ground.
180° apart.
ALTERNATIVE PROCEDURE: (4) Use a slide hammer tool with a # 1 0 metal
Smoothly blend a 1.25 ±0.020 m m (0.0492 ±0.0008 screw. Pull alternating from side-to-side until t h e
inch) radius to t h e ground diameters (Fig. 9). seal is free.
ROD JOURNAL INSTALLATION

All rod journals are to be ground in the opposite di (1) The sealing surface on the crankshaft must be
rection of engine rotation (clockwise as viewed from free from all oil residue to prevent seal leaks.
5-9L (DIESEL) ENGINE 9 - 141
ORIGINAL RADIUS ORIGINAL RADIUS

NEW UNDERCUT RADIUS NEW UNDERCUT RADIUSs
JOURNAL SURFACE
JOURNAL SURFACE
SURFACE FINISH
® 0.8 micrometer (32.0 microinch) SURFACE FINISH
for a minimum of 4 5 ° into the
fillet beyond journal surface © 0.8 micrometer (32.0 microinch)
(D 1.6 micrometer (64.0 microinch) for a minimum of 45° into the
for remainder of fillet fillet beyond journal surface
CD 1.6 micrometer (64.0 microinch)
© 0.4 micrometer (16.0 microinch) for remainder of fillet
WIDTH OF REGRIND/UNDERCUT RADIUS © 0.4 micrometer (16.0 microinch)
® 3 4 . 5 ±0.025 mm (1.358 ±0.001 in)

J9109-130 J9109-131
Fig. 9 Grind Crankshaft Main Journal—Alternative Fig. 11 Crankshaft Rod Journal Grind—Preferred
Method Method
(3) Apply a bead of Loctite 277 to the outside di
STANDARD ROD JOURNAL DIAMETER ameter of the seal.
69.000 +0.013 mm (4) Install the pilot from the seal kit onto the
(2.7165 ±0.0005 inch) crankshaft.
WORN ROD JOURNAL DIAMETER LIMIT (5) Install the seal onto the pilot and start it into
68.962 (2.7150 inch) the gear housing cover seal bore.
UNDERSIZES REGRIND TO (6) Remove the pilot.
0.25 mm 68.750 +0.013 mm (7) Use the alignment/installation tool and a plas
(0.0098 inch) (2.7067 ±0.0005 inch) tic hammer to install the seal to the correct depth.
0.50 mm 68.500 +0.013 mm (8) Install the vibration damper, but DO NOT
(0.0197 inch) (2.6969 ±0.0005 inch)
68.250 +0.013 mm tighten the damper bolt until the belt is installed.
0.75 mm
(0.0295 inch) (2.6870 ±0.0005 inch) (9) Install the drive belt.
1.00 mm 68.000 +0.013 mm (10) Tighten the vibration damper bolts to 125
(0.0394 inch) (2.6772 ±0.0005 inch) Nun (92 ft. lbs.) torque. Use the engine barring tool
OUT-OF ROUND & TAPER (MAX.) to keep the engine from rotating during torquing op
0.005 mm (0.0002 inch) eration.
ALL MAIN JOURNALS ARE TO BE PARALLEL CRANKSHAFT REAR SEAL HOUSING AND
TO THE FRONT AND REAR MAINS WITHIN:
0.030 mm (0.001 inch) SEAL
J9109-126 REMOVAL
Fig. 10 Crankshaft Rod Journal Dimensions (1) Remove the rear seal housing and gasket (Fig.
13).
(2) If the gear cover was replaced, use the align (2) Support the seal area of the rear seal housing
ment tool from the seal kit to make sure the cover is and press/drive out the seal using a hammer and a
aligned with the crankshaft. pin pinch.
(3) Clean the rear seal housing.
ORIGINAL RADIUS Make sure the seal housing is level with both sides
of the block oil pan rail. Tighten the bolts to 9 N*m
(4) Remove the alignment tool and trim the gasket
even with the oil pan mounting surface (Fig. 14).
SURFACE FINISH
® 0.3 micrometer (32.0 microinch)
for a minimum of 45° into the
^ fillet beyond journal surface
v§/ 1.6 micrometer (64.0 microinch)
^ for remainder of fillet Fig. 14 Crankshaft Rear Seal Housing Alignment
v£) 0.4 micrometer (16.0 microinch)
Tool
WIDTH OF REGRIND/UNDERCUT RADIUS
(5) The rubber O.D. rear crankshaft seals are lu
© 34.79 ± 0.025 mm (1.369 ±0.001 in) bricated with soapy water. Seals without rubber O.D.
J9109-132 use Loctite 277, or equivalent.
(6) Install the seal pilot (provided with the replace
Fig. 12 Grind Crankshaft Rod Journal—Alternative ment kit) onto the crankshaft. Push the seal onto the
Method crankshaft (Fig. 15).
(7) Remove the seal pilot.
Fig. 13 Crankshaft Rear Seal Housing/Gasket

INSTALLATION Fig. 15 Crankshaft Rear Seal Pilot
(1) Clean and dry the rear crankshaft sealing sur (8) Use alignment and installation tool packaged
face. The seal lip and the sealing surface on the in the seal kit (Fig. 16). Alternately, drive the seal at
crankshaft must be free from all oil residue to pre the 12, 3, 6 and 9 o'clock positions to prevent bend
vent seal leaks. ing the seal carrier during installation.
(2) Assemble the rear seal housing and gasket to
the cylinder block with the bolts.
(3) Align the seal housing to the crankshaft with
the alignment tool provided in the seal kit (Fig. 14).
(1) Install the seal pilot, provided in the replace

ALIGNMENT AND \
ment kit, on the crankshaft. Push the seal on the pi
INSTALLATION TOOL
lot and crankshaft.
(2) Remove the seal pilot.
(3) Seal O.D. lubricant/sealant:
• Rubber O.D, rear crankshaft seals are lubricated
with soapy water.
• Seals without rubber O.D. use Loctite 277 or
equivalent sealant.
(4) Use the alignment tool to install the seal to the
correct depth in the housing. Use a hammer to drive
the seal into the housing until the alignment tool
stops against the housing (Fig. 18).
(5) Hit the tool at the 12, 3, 6 and 9 o'clock posi
J9109-102
tions to drive the seal evenly and prevent bending
Fig. 16 Crankshaft Rear Seal Alignment/Installation the seal housing.
Tool ALIGNMENT
TOOL-
CRANKSHAFT REAR SEAL
REMOVAL
(1) Remove the transmission (refer to Group 21,
Transmission for the proper procedure).
(2) Remove the clutch cover.
(3) Remove the clutch plate.
(4) Remove the flywheel.
(5) Drill holes 180° apart into the seal. Be careful
not to get the drill against the crankshaft.
(6) Install # 1 0 sheet metal screws in the drilled
holes and remove the rear seal with a slide hammer
(Fig. 17). J9109-6T
\W
NO. 10 Fig. 18 Seal Installation using Alignment Tool
CRANKSHAFT
SCREW FLYWHEEL RING GEAR
REMOVAL
(1) Remove the transmission.
(2) Remove the clutch cover.
(3) Remove the clutch plate.
(4) Remove the flywheel.
WARNING: WEAR E Y E PROTECTION WHEN Y O U

DRIVE THE GEAR FROM THE FLYWHEEL. D O NOT
U S E A S T E E L DRIFT PIN.
J9109-60 (5) Use a drift pin to drive the ring gear from the
flywheel (Fig. 19). Strike the gear at several points
Fig. 17 Crankshaft Rear Seal Removal
around the wheel until it is off.
INSTALLATION (6) Heat the new ring for 20 minutes in an oven
preheated to 127°C (250°F).
C A U T I O N : The seal lip and the sealing surface o n
the crankshaft must be free from all oil residue to WARNING: WEAR PROTECTIVE GLOVES WHEN
prevent seal leaks. YOU INSTALL THE HEATED GEAR.
The crankshaft and seal must be dry when the seal (7) Install the gear. The gear must be installed so
is installed. the bevel on the teeth is towards the crankshaft side
of the flywheel (Fig. 19).
G
ASK
ET
DIAL
INDICATOR
CYLINDER
BLOCK
S
UCT
OIN
J9109-97 T
UBE
Fig. 26 Position of Dial Indicator
CRANKSHAFT
END
CLEARANCE J9109-19
Fig. 1 Oil Pan, Suction Tube and Gasket

(4) Install the pan and gasket (Fig. 1). Tighten the
(5) Install the drain plug with a new sealing
washer and tighten to 80 Nnn (60 ft. lbs.) torque.
CRANKSHAFT (6) Install the engine assembly into the vehicle.
GEAR (7) Fill the engine with clean lubrication oil (refer
MIN. 0.130 mm (0M5 inch) to Group 0, Lubrication and Maintenance). Run the
MAX. 0.300 mm (0.012 inch) engine and check for leaks.
J9109-98 (8) Stop the engine and let it set for five minutes.
Check the oil level, and add oil if needed.
Fig. 27 Crankshaft End Clearance
OIL PUMP
OIL PAN / SUCTION TU1E The non-intercooled turbocharged engine oil pumps
REMOVAL can not be used on intercooled engines.
(1) Remove the engine from the vehicle and mount REMOVAL
on an engine stand. (1) Remove the radiator (refer to Group 7, Cooling
WARNING: HOT O I L C A N C A U S E P E R S O N A L IN
(2) Loosen the crankshaft vibration damper and re
JURY.
move the drive belt.
(3) Remove the fan clutch assembly.
(2) Drain the used engine oil. Dispose of the used
(4) Remove the fan hub.
oil properly.
(5) Remove the oil fill tube.
(3) Remove the oil pan and gasket (Fig. 1). Be sure
(6) Remove the crankshaft vibration damper.
to connect the support bracket.
(7) Remove the gear housing cover.
(4) If required, remove the suction tube and gasket (8) Remove the four mounting bolts and pull the
(Fig. 1). pump from the bore in the cylinder block (Fig. 2).
INSTALLATION CLEAN AND INSPECT
(1) Clean the sealing surface. Visually inspect the lube pump gears for chips,
(2) Install the suction tube and gasket. Tighten the cracks or excessive wear.
bolts to 24 N i n (18 ft. lbs.) torque. Remove the back plate (Fig. 3).
(3) Fill the joint between the pan rail/gear housing Mark TOP on the gerotor planetary using a felt tip
and pan rail/rear cover with sealant. Use Three Bond pen (Fig. 3).
1207-C, or equivalent. Remove the gerotor planetary (Fig. 3).
Measure the clearance of the gerotor drive/gerotor

planetary to port plate (Fig. 5). Maximum clearance
is 0.127 mm (0.005 inch). If t h e oil pump is out of
limits, replace the pump.
PORT GEROTOR
PLATE
© J9109-20 J9109-22
Fig. 5 Gerotor to Port Plate Clearance

Fig. 2 Oil Pump Removal
Measure the clearance of the gerotor planetary to
OIL PUMP
the body bore (Fig. 6). Maximum clearance is 0.381
BACK PLATE mm (0.015 inch). If the oil pump is out of limits, re
place the pump.
GEROTOR
GEROTOR BODY PLANETARY
GEROTOR BORE
PLANETARY.
J9109-156
J9109-23
Fig. 3 Gerotor Planetary and Gerotor
Inspect for excessive wear or damage. Fig. 6 Gerotor Planetary to Body Bore Clearance
Clean all parts in solvent and dry with compressed Measure the gears backlash (Fig. 7). The limits of
air. a used pump is 0.080-0.380 mm (0.003-0.015 inch). If
Inspect the pump housing and gerotor drive for the backlash is out of limits, replace the oil pump.
damaged and excessive wear. Install the back plate.
Install the gerotor planetary in the original posi
tion. The chamfer must be on the O.D. and down. OIL PUMP
DRIVE IDLER GEAR
Measure the tip clearance (Fig. 4). Maximum clear
GEAR
ance is 0.1778 mm (0.007 inch). If the oil pump is out
of limits, replace the pump.
FEELER BACKLASH
GAUGE BACKLASH
J9109-24
Fig. 7 Measure Gear Backlash

INSTALLATION
(1) Lubricate the pump with clean engine oil. Fill
J9109-21 ing the pump with clean engine oil during installa
tion will help to prime the pump at engine start up.
Fig. 4 Tip Clearance
Make sure the idler gear pin is installed in the lo • Thin, black oil indicates fuel dilution.
cating bore in the cylinder block. • Milky discoloration indicates coolant dilution.
(2) Install the pump. Tighten the oil pump mount (4) Clean the area around the lubricating oil filter
ing bolts in two steps and in the sequence shown head. Remove the filter using a 90-95 mm filter
(Fig. 2). wrench.
• Step 1—Tighten to 5 N«m (44 in. lbs.) torque. (5) Clean the gasket surface of the filter head. The
• Step 2 - T i g h t e n to 24 N*m (18 ft. lbs.) torque. filter canister O-Ring seal can stick on the filter
(3) The back plate on the pump seats against the head. Make sure it is removed.
bottom of the bore in the cylinder block. When the
pump is correctly installed, the flange on the pump INSTALLATION
will not touch the cylinder block. (1) Fill the oil filter element with clean oil before
(4) Measure the idler gear to pump drive gear installation. Use the same type oil t h a t will be used
backlash and the idler gear to crankshaft gear back in the engine.
lash (Fig. 8). The backlash should be 0.080-0.330 mm (2) Apply a light film of lubricating oil to the seal
(0.003-0.013 inch). If the backlash is out of limits, re ing surface before installing the filter.
place the oil pump drive gear and the idler gear.
C A U T I O N : Mechanical over-tightening may distort
(5) If the adjoining gear moves when you measure
the threads or damage the filter element seal.
the backlash, the reading will be incorrect.
(3) Install the filter as specified by the filter man
ufacturer.
(4) Clean the drain plug and the sealing surface of
the pan. Check the condition of the threads and seal
ing surface on the oil pan and drain plug.
(5) Install the drain plug using a new sealing washer.
Tighten the plug to 80 N-m (60 ft. lbs.) torque.
(6) Use only High-Quality Multi-Viscosity lubricat
ing oil in the Cummins Turbo Diesel engine. Choose
the correct oil for the operating conditions outlined
in Group 0, Lubrication and Maintenance.
(7) Fill the enginfe with the correct grade of new
Fig. 8 idler Gear to Pump Drive Gear and
oil. The engine capacity is i0.4 liters (11 quarts) in
Crankshaft Gear Backlash
the crankcase and 0.95 liters (1 quart) in the lubri
OIL FILTER cating oil filter.
When replacing the oil filter, Chrysler Corporation (8) Start the engine and operate it at idle for several
recommends use of the replacement filter specified in minutes. Check for leaks at the filter and drain plug.
your Operator's Manual. (9) Stop the engine. Wait approximately 5 minutes
to let the oil in the upper parts of the engine to drain
C A U T I O N : The internal filtering medium of s o m e fil back to the oil pan. Check the oil level again. Add oil
ters h a s been known to disintegrate. Debris from
as necessary to bring the level to the "H" (High)
failed filters may plug the piston oil cooling noz
m a r k on the dipstick.
zles, resulting in scuffed pistons and eventual en
gine failure.
OIL FILTER BYPASS VALWE
REMOVAL REMOVAL
(1) Remove the oil cooler cover (Fig. 9).
W A R N I N G : HOT OIL C A N C A U S E P E R S O N A L IN (2) Remove the valve from the cooler cover (Fig. 9).
JURY.
INSTALLATION
(1) Operate the engine until the water tempera (1) Drive the new valve in until it bottoms against
ture reaches 60°C (140°F). Shut the engine off. the step in the bypass valve bore (Fig. 10).
(2) Use a container t h a t can hold at least 14 liters (2) Install the oil cooler cover.
(15 quarts) to hold the used oil. Remove the oil drain
plug and drain the used engine oil into the container. OIL PRESSURE REGULATOR VALVE / SPRING
(3) Always check the condition of the used oil. This When oil pressure from the oil pump exceeds 448
can give you an indication of some engine problems k P a (65 psi), the regulator valve opens to allow oil to
t h a t might exist. drain back into the pan.
5.9L (DIESEL) ENGINE 9 - 149
VALVE OPEN
FILTER BYPASS- • HEIGHT: 39.98mm (1.574 inch)
VALVE • LOAD: 91 N (20.5 lb)
ASSEMBLED
• HEIGHT: 44.98mm (1.77 inch)
• LOAD: 60 N (13.5 lb)
OIL COOLER COVER n

J9109-16
Fig. 9 Removing Filter Bypass Valve

FILTER J9109-13
BYPASS
VALVE Fig. 12 Oil Pressure Regulator Spring Check
INSTALLATION
(1) Clean and inspect the plunger, bore and seat
before assembly. The plunger must move freely in
the valve bore.
(2) Install the valve, spring, gasket and plug.
Tighten the plug to 80 N*m (60 ft. lbs.) torque.
OIL COOLER OIL COOLER ELEMENT / GASKET

COVER
The non-intercooled turbocharged engine filter
head/coolers can not be used on intercooled engines.
J9109-15
REMOVAL
Fig. 10 Installing New Filter Bypass Valve (1) Drain the cooling system (refer to Group 7,
REMOVAL Cooling System for the proper procedures).
(1) Remove the threaded plug, gasket, spring and (2) Remove the oil filter.
valve (Fig. 11). (3) Clean around the oil cooler cover.
(2) Check the spring for height and load limita (4) Disconnect the turbocharger supply line (Fig.
tions (Fig. 12). Replace the spring if out of limits. 13).
PLUG GASKET
OIL
FILTER
SPRING
J9109-17
Fig. 13 Turbocharger Supply Line

(5) Remove the oil cooler cover, gaskets and cooler
J9109-14 element.
Fig. 11 Oil Pressure Regulator CLEANING AND INSPECTION

Clean the sealing surfaces.
Apply 483 kPa (70 psi) air pressure to the element
to check for leaks. If the element leaks, replace the
element.
INSTALLATION
(1) If a new oil cooler is being installed, remove
the shipping plugs (Fig. 14).
(2) Assemble the oil cooler, gaskets and the cover
(Fig. 14). Tighten the bolts to 24 N-m (18 ft. lbs.)
torque.
(3) Connect the turbocharger oil supply line.
Tighten the n u t to 15 N-m (11 ft. lbs.) torque.
(4) Fill the filter with clean lubricating oil and ap
ply a light coat of oil to the sealing gasket. Install
the oil filter.
(5) Fill the coolant system and operate the engine
to check for leaks. Stop the engine and check the
coolant and oil level.
SHIPPING
PLUG J9109-18
Fig. 14 Oil Cooler

SPECIFICATIONS—5.9L DIESEL ENGINES

VA LVET RA
N
I
Valve Clearance
Intake .0.25 mm (0.010 inch)
0.51 mm (0.020 inch)
Valve Guide Diameter
Minimum 8.019 mm (0.3157 inch)
Maximum . 8 . 0 8 9 mm (0.3185 inch)
Valve Stem Diameter
7.935 mm (0.3126 inch)
Maximum 7.960 mm (0.3134 inch)
Valve Seat Angle
Intake Valve 30°
Exhaust Valve 45°
Valve Depth (Installed)
Minimum ........... 0.99 mm (0.039 inch)
Maximum 1.52 mm (0.060 inch)
Valve Spring
Free Standing Length 55.63 mm (2.19 inch)
Inclination (Max.) , 1.00 mm (0.039 inch)
Minimum Load 49.25 mm (1.94 inch)
289.32 N (65 lbs.)
Valve Rim Thickness (Min.) 0.79 mm (0.031 inch)
Valve Seat Width
Minimum 1.50 mm (0.06b inch)
Maximum . 2.00 mm (0.080 inch)
CYLINDER H EAD
Cylinder Head Flatness
Max. Overall 0.030 mm (0.012 inch)
Max. Variation within 0.01 mm (0.0004 inch) in any
50.8 mm (2.0 inch) diameter area.
GEAR TRAIN
Gear Backlash (all gears) 0.08-0.33 mm (0.003-0.013 inch)
Camshaft End Clearance 0.152-0.254 mm (0.006-0.010 inch)
CAMSHAFT
Journal Diameter (Min.) 53.962 mm (2.1245 inch)
Valve Lobes (Min. Diameter at Peak of Lobe)
Intake .... 47.040 mm (1.852 inch)
Exhaust 46.770 mm (1.841 inch)
Lift Pump Lobe (Min. Diameter at Peak of Lobe) 35.50 mm (1.398 inch)
TAPPETS
Sfem Diameter (Min.) 15.925 mm (0.627 inch)
R OCKE R LEVER
Rocker Lever Bore (Max.) 19.05 mm (0.75 inch)
Shaft Diameter (Min.) 18.94 mm (0.746 inch)
CYLINDER TORES
Cylinder Bore Diameter (Max.) 102.116 mm (4.0203 inch)
Out of Round (Max.) . .0.038 mm (0.0015 inch)
Taper (Max.) 0.076 mm (0.003 inch)
CONNECTING ROD
Pin Bore Diameter (Max.) . 40.053 mm (1.5769 inch)
Side Clearance 0.10-0.30 mm (0.004-0.012 inch)
J9109-246
ENGINE SPECIFICATIONS (CONT.)
PISTONS
Skirt Diameter (Min.)
Nominal ..... . . 101.880 mm (4.0110 inch)
Worn Limits 101.823 mm (4.0088 inch)
Pin Bore Diameter (Max.) 40.025 mm (1.5758 inch)
Ring Groove (Max.)
Intermediate Groove 0.15 mm (0.006 inch)
Oil Control Groove 0.13 mm (0.005 inch)
Piston Pin Diameter (Min.) 39.99 mm (1.5744 inch)
Ring End Gap
Top Ring 0.40-0.70 mm (0.016-0.0275 inch)
Intermediate Ring .. .0.25-0.55 mm (0.010-0.0215 inch)
Oil Control Ring 0.25-0.55 mm (0.010-0.0215 inch)
CRANKSHAFT
Main Bearing Journal Diameter
Standard 82.962 mm (3.2662 inch)
Machined 0.25 mm .82.712 mm (3.2564 inch)
Machined 0.50 mm 82.462 mm (3.2465 inch)
Out of Round (Max.) 0.050 mm (0.002 inch)
Taper (Max.) 0.013 mm (0.0005 inch)
Oil Clearance (Max.) ... . . . .0.119 mm (0.0047 inch)
End Clearance . .0.13-0.30 mm (0.005-0.012 inch)
Connecting Rod Journal
Standard .68.962 mm (2.7150 inch)
Out of Round (Max.) 0.050 mm (0.002 inch)
Taper (Max.) .0.013 mm (0.0005 inch)
Oil Clearance (Max.) 0.089 mm (0.0035 inch)
CYLINDER B L O C K
Top Surface Flatness
(Max. Overall Variation) 0.075 mm (0.003 inch)
Max. Variation any 50 mm
(2 inch) Diameter Area 0.010 mm (0.0004 inch)
Refacing Combustion Deck
First Reface 0.15 mm (0.0058 inch)
Second Reface 0.35 mm (0.0138 inch)
Total .0.50 mm (0.0197 inch)
Surface Finish 1.5-3.2 micrometers (60-126 microinch)
Main Bearing Bore Diameter (Max.)
with bearing installed . .83.106 mm (3.2719 inch)
Camshaft Bore Diameter (Max.)
#1 w / o Bushing 57.258 mm (2.2543 inch)
#1 with Bushing .54.133 mm (2.1312 inch)
#2 thru #7 54.133 mm (2.1312 inch)
Tappet Bore Diameter (Max.) 16.055 mm (0.632 inch)
OIL PUMP
Tip Clearance (Max.) 0.1778 mm (0.007 inch)
Gerotor Drive/Planetary to Port Plate Clearance (Max.) . .0.127 mm (0.005 inch)
Gerotor Planetary to Body Bore Clearance (Max.) .0.381 mm (0.015 inch)
Gear Backlash (Used Pump) 0.08-0.38 mm (0.003-0.015 inch)
J9109-247
5.9L (DIESEL) ENGINE 9-153
COMPONENT TORQUE
Air Fuel Control Banjo Screw (In Pump) . . . . 12 N-m 9 ft. lbs.
Air Fuel Control Fitting (In Head) 8 N-m 6 ft. lbs.
Alternator Ground Cable Mounting to Block 24 N-m 18 ft. lbs.
Alternator Mounting to Water Pump Inlet .. 41 N*m 30 ft. lbs.
Alternator Pulley 80 N-m 60 ft. lbs.
Alternator Support (Upper) 24 N-m 18 ft. lbs.
Battery Cable (Negative) Mounting to Block , 77 N-m 57 ft. lbs.

Belt Tensioner Mounting 43 N-m 32 ft. lbs.
Block Heater Mounting 12 N-m 9 ft. lbs.
Cab Heater Hose Clamp 4 N-m (35 in. lbs.)

Cab Heater Tubing Clamp Mounting....... 24 N-m 18 ft. lbs.
Camshaft Thrust Plate 24 N-m 18 ft. lbs.
Clutch Cover Mounting to Flywheel . . . 23 N-m 17 ft. lbs.
Connecting Rod (Alternately tighten in 3 steps)
Step 1 35 N-m 26 ft. lbs.
Step 2 70 N-m 51 ft. lbs.
Step 3 . 100 N-m 73 ft. lbs.
Cooling Fan Mounting to Fan Clutch 20 N-m 15 ft. lbs.
Crossover Clamp (Air) 5 N-m (44 in. lbs.)
Cylinder Head Mounting Bolts
1. All Bolts.... 90 N-m 66 ft. lbs.
2. Long Bolts . . . . . . . . . 120 N-m 89 ft. lbs.
3. Tighten All Bolts An Additional 90°
Exhaust Manifold 43 N-m 32 ft. lbs.

Exhaust Outlet Pipe - V Band Clamp 8 N-m (72 in. lbs.)
Exhaust Pipe Clamp Mounting 27 N-m 20 ft. lbs.
Exhaust Pipe Steady Rest Mounting to Trans . 68 N-m 50 ft. lbs.
Fan Clutch Mounting/Fan Hub (L Hand Threads).. 57 N-m 42 ft. lbs.

Fan Hub Bracket Mounting 24 N-m 18 ft. lbs.
Fan Hub Bearing Retaining Capscrew 77 N-m 57 ft. lbs.
Fan Pulley to Fan Hub 9 N-m 7 ft. lbs.
Fan Pulley Crankshaft . 9 N-m 7 ft. lbs.
Fan Shroud Mounting Nuts 11 N-m (95 in. lbs.)
Flywheel Bolts 137 N-m 101 ft. lbs.
Flywheel Housing - Adaptor 60 N-m 44 ft. lbs.
Front Engine Mount Isolator Mounting to Mount.. 109 N-m 80 ft. lbs.
Front Engine Mount Through Bolt 41 N-m 30 ft. lbs.
Front Engine Mount to Block 60 N-m 44 ft. lbs.
Front Oil Filler Pipe - Access Cover Hand Tighten
Fuel Banjo Screw (In Fuel Pump) 32 N-m 24 ft. lbs.
Fuel Banjo Screw (In Head) 24 N-m 18 ft. lbs.
Fuel Banjo Screw (In Injector) 8 N-m 6 ft. lbs.
Fuel Filter Vi Turn after contact
Fuel Heater Assembly Mounting 32 N-m 24 ft. lbs.
Fuel Heater Ground Mounting to Intake Manifold 12 N-m 9 ft. lbs.
Fuel Link Fitting (High Pressure) 24 N-m 18 ft. lbs.
Fuel Low Pressure Supply 24 N-m 18 ft. lbs.
Fuel Pump Drive Gear (With Pump Unlocked) 65 N-m 48 ft. lbs.
Fuel Pump Lock (Bosch) 30 N-m 22 ft. lbs.
J9109-261
TORQUE SPECIFICATIONS (CONT.J
COMPONENT TORQUE
24 N-m 18 ft. lbs.

Fuel Pump Mounting Nut ..
Fuel Pump Solenoid 43 N-m 32 ft. lbs.
Fuel Pump Support Bracket 24 N-m 18 ft. lbs.
Fuel Pump Unlock (Bosch) . 13 N-m 10 ft. lbs.
8 N-m 6 ft. lbs.
Fuel Vent Screw (In Banjo) .
24 N-m 18 ft. lbs.
Gear Cover
Gear Housing-to-Block 24 N-m 18 ft. lbs.
Injector Retaining Nut. 60 N-m 44 ft. lbs.

Intake Manifold Cover 24 N-m 18 ft. lbs.
2 N-m (17 in. lbs.)

Intercooler Attaching Bolts • •
Intercooler Duct Clamp Nuts. 8 N-m (72 in. lbs.)
Lift Pump Mounting 24 N-m 18 ft. lbs.

Lifting Bracket (Rear) .. 77 N-m 57 ft. lbs.
Main Bearing Cap Bolts. Step!. 60 N-m 45 ft. lbs.

Step 2. 119 N-m 88 ft. lbs.
Steo3. 176 N-m 129 ft. lbs.
24 N-m 18 ft. lbs.

Oil Cooler Assembly
Oil Fill Tube Bracket 43 N-m 32 ft. lbs.
Oil Filter Turn after contact
Oil Pan Drain Plug 80 N-m 60 ft. lbs.
Oil Pan Mounting......... 24 N-m 18 ft. lbs.
Oil Pressure Regulator Plug 80 N-m 60 ft. lbs.
Oil Pressure Sender/Switch 16 N-m 12 ft. lbs.
Oil Pump Mounting 24 N-m 18 ft. lbs.
Oil Suction Tube (Flange) .. 24 N-m 18 ft. lbs.
Oil Suction Tube Brace 24 N-m 18 ft. lbs.
Power Steering Pump to Vacuum Pump Mounting 24 N-m 18 ft. lbs.
Radiator Hose Clamp - Upper 4 N-m (35 in. lbs.)

Radiator Mounting Nuts 11 N-m (95 in. lbs.)
Rear Seal Mounting 9 N-m 7 ft. lbs.
Refrigerant Compressor Lines - Flange Mounting 20 N-m 15 ft. lbs.
Refrigerant Compressor Mounting 47 N-m 35 ft. lbs.
Rocker Lever Nut 24 N-m 18 ft. lbs.
Rocker Support 24 N-m 18 ft. lbs.
Starter Mounting 43 N-m 32 ft. lbs.

Starter Battery (Positive) Cable Nut 22 N-m 16 ft. lbs.
Starter Solenoid Nut 5 N-m (44 in. lbs.)
Tappet Cover/Fuel Drain Line Supports 24 N-m 18 ft. lbs.

Thermistor , 24 N-m 18 ft. lbs.
Thermostat Housing 24 N-m 18 ft. lbs.
Throttle Bracket Mounting to Mounting Bracket. 24 N-m 18 ft. lbs.
Throttle Rod Mounting to Throttle Lever Nut . . . 10 N-m 73 ft. lbs.
Timing Pin Flange Mounting 5 N-m (44 in. lbs.)
Torque Converter Access Cover Plate Mounting 4 N-m (35 in. lbs.)
Transfer Case Linkage Bracket Mounting/Trans 41 N-m 30 ft. lbs.
Transfer Case Mounting to Transmission . . 47 N-m 35 ft. lbs.
J9109-262
5.9L (DIESEL) ENGINE 9 - 155
TORQUE SPECIFICATIONS (CONT.)
COMPONENT TORQUE
24 N-m 18 ft. lbs.

Trans Kickdown Cable Bracket Mounting/Trans 68 N-m 50 ft. lbs.
68 N-m 50 ft. lbs.
68 N-m 50 ft. lbs.
41 N-m 30 ft. lbs.
54 N-m 40 ft. lbs.
Transmission Oil Cooler Line F l a n g e . . . . . . . . ......... .. ...... 6 N-m (50 in. lbs.)
Transmission Oil to Air Cooler Hose Clamps 2 N-m (18 in. lbs.)
Transmission to Clutch Housing Mounting • 47 N-m 35 ft. lbs.
Transmission Torque Converter Mounting 47 N-m 35 ft. lbs.
Turbine Housing 11 N-m 8 ft. lbs.
Turbo Compressor Housing Clamp 8.5 N-m (75 in. lbs.)
Turbo Mounting Nut 32 N-m 24 ft. lbs.
Turbo Oil Drain Tube • 24 N-m 18 ft. lbs.
Turbo Oil Supply (Both Ends) . 15 N-m 11 ft. lbs.
Vacuum Pump Mounting 9 N-m 7 ft. lbs.

Vacuum Pump to Gear Housing Mounting 77 N-m 57 ft. lbs.
Valve Cover. 24 N-m 18 ft. lbs.
Vibration Damper Mounting 125 N-m 92 ft. lbs.
Water Hose Clamps 4 N-m (35 in. lbs.)

Water Inlet Connection 43 N-m 32 ft. lbs.
Water Pump Mounting 24 N-m 18 ft. lbs.
Water Temperature Sensor 50 N-m 37 ft. lbs.
J9109-263
• EXHAUST SYSTEM AND INTAKE MANIFOLD 11-1
EXHAUST SYSTEM A N DINTAKE MANIFOLD
CONTENTS
page page
EXHAUST SYSTEM DIAGNOSIS 3 SERVICE PROCEDURES (GASOLINE ENGINES) . 4
GENERAL INFORMATION 1 SPECIFICATIONS 27
SERVICE PROCEDURES (DIESEL ENGINES) . 17
GENERAL INFORMATION
EXHAUST SYSTEM is replaced. Also, inspect all other components of the
The gasoline engine exhaust system consists of en exhaust system for heat damage.
gine exhaust manifolds, exhaust pipe(s), catalytic Unleaded gasoline must be used to avoid contami
converter(s), extension pipe(s), exhaust h e a t shields, nating the catalyst core.
muffler(s) and exhaust tailpipe (Fig. 1).
The diesel engine exhaust system consists of an en EXHAUST HEAT SHIELDS (GASOLINE ENGINES)
gine exhaust manifold, turbocharger, exhaust pipe, Exhaust heat shields are needed to protect both the
extension pipe, muffler and exhaust tailpipe (Fig. 2). vehicle and t h e environment from the high tempera
The engine exhaust manifolds on gasoline engines tures developed by the catalytic converter. The com
are equipped with ball flange outlets to assure a bustion reaction facilitated by the catalyst releases
tight seal and strain free connections. additional heat in t h e exhaust system. Under severe
The exhaust system must be properly aligned to operating conditions, the temperature increases in
prevent stress, leakage and body contact. If the sys the area of t h e reactor. Such conditions can exist
tem contacts any body panel, it may amplify objec when the engine misfires or otherwise does not oper
tionable noises from the engine or body. ate a t peak efficiency. DO NOT remove spark plug
When inspecting an exhaust system, critically in wires from plugs or by any other means short out
spect for cracked or loose joints, stripped screw or cylinders. Failure of the catalytic converter can occur
bolt threads, corrosion damage and worn, cracked or due to a temperature increase caused by unburned
broken hangers. Replace all components t h a t are fuel passing through the converter.
badly corroded or damaged. DO NOT attempt to re Do not allow the engine to operate at fast idle for
pair. extended periods (over 5 minutes). This condition
When replacement is required, use original equip may result in excessive temperatures in the exhaust
ment parts (or their equivalent). This will assure system and on the floor pan.
proper alignment and provide acceptable exhaust
noise levels. EXHAUST GAS RECIRCULATION
(EGR)—(GASOLINE ENGINES)
C A U T I O N : Avoid application of rust prevention To assist in the control of oxides of nitrogen (NOx)
c o m p o u n d s or undercoating materials to exhaust in engine exhaust, all engines are equipped with an
system floor pan exhaust heat shields. Light overs- exhaust gas recirculation system. The use of exhaust
pray near the e d g e s is permitted. Application of gas to dilute incoming air/fuel mixtures lowers peak
coating will result in excessive floor pan tempera flame temperatures during combustion, thus limiting
tures and objectionable fumes. the formation of NOx.
Exhaust gases are taken from openings in the ex
haust gas crossover passage in the intake manifold.
CATALYTIC CONVERTER (GASOLINE ENGINES) Refer to Group 25, Emission Control Systems for
The stainless steel catalytic converter body is de complete description, diagnosis and service proce
signed to last t h e life of the vehicle. Excessive heat dures of the exhaust gas recirculation system and
can result in bulging or other distortion, but exces components.
sive heat will not be the fault of the converter. If un-
burned fuel enters the converter, overheating may TURBOCHARGER (5.9L DIESEL ENGINE)
occur. If a converter is heat-damaged, correct t h e A turbocharger is used to force more air into the
cause of the damage at the same time the converter engine cylinders. Exhaust gas energy is used to t u r n
11 - 2 EXHAUST SYSTEM AND INTAKE MANIFOLD
EXHAUST
J9011-41
Fig. 1 Exhaust System—Gasoline Engines (Typical)

the turbine wheel and shaft. At the other end of the Supplying Increased air flow to the engine pro
shaft is the compressor wheel. The compressor wheel vides:
draws air in and forces it into the engine cylinders • Improved engine performance
through the intake manifold. • Lower exhaust smoke density
• Improved operating economy
• Altitude compensation
• Noise reduction.
EXHAUST SYSTEM AND INTAKE MANIFOLD 11-3
EXHAUST MUFFLER TAIL PIPE

PIPE
J91U-42
Fig. 2 Exhaust System—Diesel Engines (Typical)
EXHAUST SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSE CORRECTION
EXCESSIVE EXHAUST NOISE 1. Leaks at pipe joints. 1. Tighten clamps at leaking joints.
2. Burned or blown out muffler. 2. Replace muffler assembly. Check
exhaust system.
3. Burned or rusted out exhaust pipe. 3. Replace exhaust pipe.
4. Exhaust pipe leaking at manifold flange. 4. Tighten connection attaching nuts.
5. Exhaust manifold cracked or broken. 5. Replace exhaust manifold.
6. Leak between manifold and cylinder head. 6. Tighten exhaust manifold to cylinder
head stud nuts or bolts.
7. Restriction in muffler or tail pipe. 7. Remove restriction, if possible.
Replace muffler or tail pipe, as
necessary.
LEAKING EXHAUST GASES 1. Leaks at pipe joints. 1. Tighten clamps at leaking joints.
2. Damaged or improperly installed gaskets. 2. Replace gaskets, as necessary.
ENGINE HARD TO WARM UP 1. Thermostat broken. 1. Replace thermostat.

OR WILL NOT RETURN TO
NORMAL IDLE
2. Blocked crossover passage in intake 2. Remove restriction or replace intake
manifold. manifold.
J9311-10
11 - 4 EXHAUST SYSTEM AND INTAKE MANIFOLD •
S E R V I C E PROCEDURES (GASOLINE ENGINES)
INDEX
page page
Catalytic Converters 4 Exhaust Tailpipe . 5
Engine Exhaust Manifold : . . . . 15 Intake Manifold 13
Exhaust Heat Shields 5 Mufflers 4
Exhaust Pipe 4
EXHAUST PIPE This will assure proper alignment with other parts in
Refer to Figs. 1, 4 , 5 and 6 for t h e following proce the system and provide acceptable exhaust noise lev
dure. els.
(1) Raise vehicle on a hoist. (1) Assemble converter, isolators and clamps
(2) Apply penetrating oil to bolts and clamp nuts. loosely to permit proper alignment of all parts.
(3) Remove clamps, supports and bolts from ex (2) Position the converter for proper clearance with
haust pipe. exhaust heat shields and underbody parts.
(4) Remove the exhaust pipe. (3) Tighten all clamp nuts, bolts and support
(5) Clean ends of pipes to assure mating of all bracket nuts/bolts to the proper torques (Refer to
parts. Figs. 1, 4, 5 and 6).
(6) Discard rusted clamps, broken or worn supports (4) Lower the vehicle.
and attaching parts. Replace a component with orig (5) Start t h e engine and check for leaks.
inal equipment parts, or equivalent. This will assure
proper alignment with other parts in t h e system and MUFFLERS
provide acceptable exhaust noise levels. Refer to Figs. 1, 2, 4, 5, 6 and 7 for the following
procedure.
INSTALLATION
(1) Assemble exhaust pipe, supports and clamps REMOVAL
loosely to permit proper alignment of all parts. (1) Raise vehicle on a hoist.
(2) Position t h e exhaust pipe for proper clearance (2) Apply penetrating oil to bolts and clamp nuts.
with underbody parts. (3) Remove clamps, isolators and bolts.
(3) On models using ball-type connections, alter (4) Remove the muffler.
nately tighten bolts to assure flanges are even and (5) Clean ends of pipes and muffler to assure mat
parallel. ing of all parts.
(4) Tighten all clamp nuts, bolts and support (6) Discard rusted clamps, broken or worn isola
bracket nuts/bolts to t h e proper torques (Refer to tors, supports and attaching parts. Replace a compo
Figs. 1, 4, 5 and 6). nent with original equipment parts, or equivalent.
(5) Lower t h e vehicle. This will assure proper alignment with other parts in
(6) Start the engine and check for leaks. the system and provide acceptable exhaust noise lev
els.
CATALYTIC CONVERTERS
Refer to Figs. 1, 4, 5 and 6 for t h e following proce INSTALLATION
dure. (1) Assemble muffler, isolators and clamps loosely

to permit proper alignment of all parts.
REMOVAL (2) Position t h e muffler for proper clearance with
(1) Raise vehicle on a hoist. the underbody parts.
(2) Apply penetrating oil to bolts and clamp nuts. (3) Tighten all clamp nuts, bolts and support
(3) Remove clamps, isolators and bolts. bracket nuts/bolts to the proper torques (Refer to
(4) Remove t h e catalytic converter. Figs. 1, 2, 4, 5, 6 and 7).
(5) Clean ends of pipes and muffler to assure mat
ing of all parts.
(6) Discard rusted clamps, broken or worn isola
tors, supports and attaching parts. Replace a compo
nent with original equipment parts, or equivalent.
(4) Lower the vehicle. (3) Tighten all clamp nuts, bolts and support
(5) Start the engine and check for leaks. bracket nuts/bolts to the proper torques (Refer to
Figs. 2, 4, 5 and 7).
EXHAUST TAILPIPE (4) Lower t h e vehicle.
Refer to Figs. 2, 4, 5, and 7 for the following pro (5) Start the engine and check for leaks.
cedure.
EXHAUST HEAT SHIELDS
REMOVAL Refer to Figs. 3, 4 and 8 for the following proce
(1) Raise vehicle on a hoist. dure.
(2) Apply penetrating oil to bolts and clamp nuts.
(3) Remove clamps, isolators and bolts. REMOVAL
(4) Remove the exhaust tailpipe. (1) Raise and support the vehicle.
(5) Clean ends of pipes and muffler to assure mat (2) Remove the nuts or bolts holding the exhaust
ing of all parts. h e a t shield to the floor pan, crossmember or bracket.
(6) Discard rusted clamps, broken or worn isola (3) Slide the shield out around the exhaust system.
tors, supports and attaching parts. Replace a compo
nent with original equipment parts, or equivalent. INSTALLATION
This will assure proper alignment with other parts in (1) Position the exhaust heat shield to t h e floor
the system and provide acceptable exhaust noise lev pan, crossmember or bracket and install the nuts or
els. bolts.
(2) Tighten the nuts and bolts to the proper torque
INSTALLATION (refer to Figs. 3, 4 and 8).
(1) Assemble exhaust tailpipe, isolators and clamps (3) Lower t h e vehicle.
loosely to permit proper alignment of all parts.
(2) Position the exhaust tailpipe for proper clear
ance with the underbody parts.
i
11 - 6 EXHAUST SYSTEM A I D INTAKE MANIFOLD
•
HOLE LOCATION FOR SUPPORT HANGER

(4 WHEEL DRIVE) ASSEMBLY
INSULATOR
MUFFLER
REAR
CONVERTER
PIPE CONVERTER
PIPE
( 1 1 5 " WHEELBASE1 (131" WHEELBASE)
5.9L ENGINES 3.9L AND 5.2L ENGINES
J9211-16
Fig. 1 Single Exhaust System—Light Duty Trucks (1 of 3)

INSULATOR
FRAME SIDE RAIL
TAIL PIPE
3.9L AND 5.2L

ENGINES
FRAME
SIDE RAIL
INSULATOR
HANGER
TAIL PIPE ASSEMBLY
TAIL
PIPE
TAIL PIPE
EXTENSION
3.9L AND 5.2L

5.9L ENGINES ENGINES J9211-17
Fig. 2 Single Exhaust System—Light Duty Trucks (2 of 3)

Fig. 3 Single Exhaust System (Exhaust Heat Shields)—Light Duty Trucks (3 of 3)

RETAINER
135" & 159" WHEELBASE
TIGHTENING TORQUE
2 6 N-m ( 1 9 FT. LBS.)
FRONT 4 3 N-m (32 FT. LBS.)

SUSPENSION
CROSSMEMBER 12.7 ± 4.8 M M 2 3 N-m (200 IN. LBS.)
(0.50 ± 0.19 INCH)
1 4 N-m (125 IN. LBS.)
BRAKE 5 4 N-m (40 FT. LBS.)

LINE
TYPICAL SLIP JOINT

(MUST BE FULLY ENGAGED)
BRAKE
LINE
SHIELD
(2 WHEEL DRIVE)
J9211-19
Fig. 4 Dual Exhaust System (5.9L Engines)—Heavy Duty Trucks (1 of 2)

EXHAUST
PIPE EXHAUST
PIPE
BRACE
BRACE
MANUAL TRANS. AUTO TRANS.
FRAMERAIL FRAMERAIL
131 " WHEELBASE

BRACKET 135" WHEELBASE
135" WHEELBASE
131" WHEELBASE
ISOLATORS
MUFFLER ISOLATORS
PIPE
MUFFLER
159" WHEELBASE PIPE
131 " & 135" WHEELBASE
FRAMERAIL
TIGHTENING TORQUE
FRAMERAIL
23 N-m (200 IN. LBS.)
BRACKET
14 N-m (125 IN. LBS.)
28 N-m (250 IN. LBS.)
CONVERTER
PIPE
J9211-20
Fig. 5 Dual Exhaust System (5.9L Engines)—Heavy Duty Trucks (2 of 2)

RETAINER CATALYTIC HEAT

CONVERTER SHIELD
PIPE
FRAMERAIL J9211-22
Fig. 6 Sport Utility Exhaust System (1 of 3)

11-12 EXHAUST SYSTEM AND INTAKE MANIFOLD •
Fig. 7 Sport Utility Exhaust System (2 of 3)

TIGHTENING TORQUE
23 N-m (200 IN. LBS.)
7 N-m (65 IN. LBS.)
5 N-m (40 IN. LBS.)
HEAT HEAT
SHIELD SHIELD
CROSSMEMBER
SKID PLATE CONED WASHER
CATALYTIC UPPER UPPER HEAT SHIELD UPPER HEAT SHIELD

CONVERTER HEAT SHIELD (6 IN. R A I L ) (7 IN. RAIL)
LOWER HEAT SHIELD
J9211-21
Fig. 8 Sport Utility Exhaust System—Exhaust Heat Shields (3 of 3)

INTAKE MANIFOLD THROTTLE
The aluminum intake manifold is a single plane BODY (MPI)
design with equal length runners. The manifold is
sealed by flange side gaskets with front and rear
cross-over gaskets. The intake manifold has internal
EGR.
REMOVAL
(2) Drain the cooling system (refer to Group 7,
Cooling System for the proper procedures).
(3) Remove the generator.
(6) Disconnect the accelerator linkage and if so
down cables.
(8) Remove the distributor cap and wires.
(9) Disconnect the coil wires.
(10) Disconnect the heat indicator sending unit J9209-68
wire.
(11) Disconnect the heater hoses and bypass hose. Fig. 9 Throttle Body Assembly—MPI
(12) Remove the closed crankcase ventilation and (a) Turn the intake manifold upside down. Sup
evaporation control systems. port the manifold.
(13) Remove intake manifold bolts. (b) Remove the bolts and lift the pan off the
(14) Lift the intake manifold and throttle body out manifold. Discard the gasket.
of the engine compartment as an assembly.
(15) Remove and discard the flange side gaskets CLEANING
and the front and rear cross-over gaskets. Clean manifold in solvent and blow dry with com
(16) Remove the throttle body bolts and lift the pressed air.
throttle body off the intake manifold (Fig. 9). Discard Clean cylinder block front and rear gasket surfaces
the gasket. using a suitable solvent.
(17) Remove the plenum pan as follows:
The plenum pan rail must be clean and dry (free of cessive amount of sealant is not required to ensure a
all foreign material). leak proof seal. However, an excessive amount of
INSPECTION gasket. The sealant should be slightly higher t h a n
Inspect manifold for cracks. the cross-over gaskets, approx. 5 mm (0.2 in).
Inspect mating surfaces of manifold for flatness (5) Install the front and rear cross-over gaskets
with a straightedge. onto the dowels (Fig. 11).
INSTALLATION
(1) Install the plenum pan, if removed, as follows:
(a) Turn the intake manifold upside down. Sup \
port the manifold.
(b) Place a new plenum pan gasket onto the seal
rail of the intake manifold. Position the pan over
the gasket. Align all the gasket and pan holes with
the intake manifold.
(c) Hand start all bolts.
(d) Tighten the bolts, in sequence (Fig. 10), as
follows:
V-6 V-8
Fig 11 Cross-Over Gaskets and Locator Dowels

(6) Install the flange gaskets. Ensure t h a t the ver
tical port alignment tab is resting on the deck face of
be in position with the mating cylinder head gasket
tabs (Fig. 12). The words MANIFOLD SIDE should
be visible on the center of each flange gasket.
(7) Carefully lower intake manifold into position
on the cylinder block and cylinder heads. Use the
alignment dowels in the cross-over gaskets to posi
tion the intake manifold. After intake manifold is in
place, inspect to make sure seals are in place.
(8) Install the intake manifold bolts and tighten as
Fig. 10 Plenum Pan Bolt Tightening Sequence follows:
• Step 1 - T i g h t e n bolts to 2.7 N*m (24 in. lbs.) V-6 ENGINE—(Fig. 13)
torque. • Step 1 - T i g h t e n bolts 1 and 2 to 8 Nun (72 in. lbs.)
• Step 2 - T i g h t e n bolts to 5.4 N«m (48 in. lbs.) torque. Tighten in alternating steps 1.4 Nun (12 in.
torque. lbs.) torque at a time.
• Step 3 - T i g h t e n bolts to 9.5 Nnn (84 in. lbs.) • Step 2—Tighten bolts 3 through 12, in sequence,
torque. to 8 Nun (72 in. lbs.) torque.
• Step 4—Check t h a t all bolts are tighten to 9.5 N®m • Step 3—Check that all bolts are tighten to 8 Nun
(84 in. lbs.) torque. (72 in. lbs.) torque.
(2) Using a new gasket, install the throttle body • Step 4—Tighten all bolts, in sequence, to 16 Nun
onto the intake manifold. Tighten the bolts to 23 (12 ft. lbs.) torque.
Nun (200 in. lbs.) torque. • Step 5—Check that all bolts are tighten to 16 Nun
(3) Place the 4 plastic locator dowels into t h e holes (12 ft. lbs.) torque.
in the block Fig. 11).
(4) Apply MOPAR Silicone Rubber Adhesive Seal
FLANGE GASKET
FRONT
OF ENGINE
o
o Fig. 14 Intake Manifold Bolt Tightening
Sequence—5.2L Engines
J9209-60
• Step 2—Tighten bolts 5 through 12, in sequence,

to 8 Nun (72 in. lbs.) torque.
• Step 3—Check t h a t all bolts are tighten to 8 Nun
• Step 4—Tighten all bolts, in sequence, to 16 Nun
• Step 5—Check t h a t all bolts a r e tighten to 16 Nun
CYLINDER (9) Install closed crankcase ventilation and evapo
HEAD GASKET J9209-101
ration control systems.
Fig. 12 Intake Manifold Flange Gasket Alignment (10) Connect the coil wires.
(11) Connect the heat indicator sending unit wire.
INTAKE (12) Connect the heater hoses and bypass hose.
®— MANIFOLD
down cables.
(16) Install the fuel lines,
generator mounting bolt to 41 Nun (30 ft. lbs.)
torque. Tighten the adjusting strap bolt to 23 Nun
(200 in. lbs.) torque. Refer to Group 7, Cooling Sys
tem for the proper adjusting of belt tension.
(18) Install the air cleaner.
ENGINE EXHAUST MANIFOLD

Engine exhaust manifolds are LOG type with port
FRONT OF ENGINE ing for air injection into the LOG.
J9209-59
REMOVAL
Fig. 13 Intake Manifold Bolt Tightening
Sequence—3.9L Engines
(2) Raise and support t h e vehicle.
V-8 ENGINE—(Fig* 14) (3) Remove the bolts and nuts attaching the ex
• Step 1—Tighten bolts 1 through 4, in sequence, to haust pipe to the engine exhaust manifold.
8 Nun (72 in. lbs.) torque. Tighten in alternating (4) Lower the vehicle.
steps 1.4 Nun (12 in. lbs.) torque at a time. (5) Remove the exhaust heat shields.
(6) Remove bolts, nuts and washers attaching
manifold to cylinder head.
(7) Remove manifold from the cylinder head.
CLEANING
Clean mating surfaces on cylinder head and mani
fold. Wash with solvent and blow dry with com
pressed air.
INSPECTION
Inspect manifold for cracks.
Inspect mating surfaces of manifold for flatness
with a straight edge. Gasket surfaces must be flat
within 0.2 mm per 300 mm (0.008 inch per foot).
INSTALLATION
Fig. 15 Engine Exhaust Manifold Installation—3.9L
Engine
C A U T I O N : If the studs came out with the nuts when
removing the engine exhaust manifold, install new
studs. Apply sealer on the coarse thread ends. Wa
ter leaks may develop at the studs if this precaution
is not taken.
(1) Position the engine exhaust manifolds on the

two studs located on the cylinder head. Install coni
cal washers and nuts on these studs (Fig. 15 or 16).
(2) Install two bolts and conical washers at the in
ner ends of the engine exhaust manifold outboard
arms. Install two bolts WITHOUT washers on the
center arm of engine exhaust manifold (Fig. 15 or
16). Starting at the center a r m and working outward,
tighten the bolts and nuts to 34 N t h (25 ft. lbs.) J9311-11
torque.
(3) Install the exhaust heat shields. Fig. 16 Engine Exhaust Manifold Installation—5.2U
(4) Raise and support the vehicle. 5.9L Engines
(5) Assemble exhaust pipe to manifold and secure
with bolts, nuts and retainers. Tighten the bolts and
nuts to 26 N - m (19 ft. lbs.) torque.
• EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 17
8ERY1CE P R O C E D U R E S ( D I E S E L E N G I N E S )
INDEX
page page
Charge Air Cooler (Intercooler) 25 Intake Manifold Cover / Air Intake Heater 19
Engine Exhaust Manifold 18 Muffler and Extension Pipes 17
Exhaust Pipe 17 Turbocharger 21
Exhaust Tailpipe 18
EXHAUST PIPE INSTALLATION

(1) Align t h e front exhaust pipe with the front ex
REMOVAL haust extension pipe and the turbocharger exhaust
(1) Remove the clamp that holds the front exhaust outlet.
pipe clamp to the turbocharger (Fig. 1). (2) Install the exhaust pipe support strap. Tighten
the n u t to 4 1 Nun (30 ft. lbs.) torque.
(3) Install the exhaust pipe support clamps and
nuts. Tighten the n u t s to 54 Nun (40 ft. lbs.) torque.
(5) Install the turbocharger clamp and tighten the
screw to 8 Nun (74 in. lbs.) torque (Fig. 2).
(6) Start t h e engine and check for leaks.
MUFFLER AND EXTENSION PIPES

Rear extension pipes are used on the 135 inch, 149
inch and 159 inch wheelbase vehicles.
REMOVAL
(2) Remove the clamps and nuts from the front ex
tension pipe. Remove the clamps and nuts from the
Fig. 1 Exhaust Pipe to Turbocharger Clamp rear extension pipe or from the muffler rear exten
(2) Raise and support the vehicle on a hoist. sion pipe (Fig. 3).
(3) Remove the bolt from the exhaust pipe support
strap (Fig. 2).
(4) Remove the clamp nuts (Fig. 2).
(5) Separate the exhaust pipe from the front ex
haust extension pipe (Fig. 2).
TURBOCHARGER WELD FRONT EXHAUST
CLAMP JOINT PIPE
SUPPORT STRAP PIPE

J911M
Fig. 2 Front Exhaust Pipe Mounting and Clamps

Fig. 3 Muffler and Extension Pipe(s)
11-18 EXHAUST SYSTEM AND INTAKE MANIFOLD
MUFFLER REAR MUFFLER FRONT FRAME

SUPPORT BRACKET SUPPORT BRACKET RAIL
159" W . B . ) - 2 REQUIRED
MUFFLER
INSULATOR
/
SHOULDER
BOLT
MUFFLER FRONT
MUFFLER SUPPORT BRACKET
INSULATOR (131", 135" & 149" W.B.]
1 REQUIRED
SHOULDER BOLTS J9211-26
Fig. 4 Muffler Front/Rear Support Brackets

(3) Remove the shoulder bolts from the muffler
front and rear support brackets (Fig. 4).
(4) Separate the extension(s) and the muffler from TAIL PIPE
the exhaust tailpipe and the front exhaust pipe. BRACKET J9211-25
(5) If required, remove the muffler support bracket Fig. 5 Exhaust Tailpipe
from the frame rail (Fig. 4).
INSTALLATION
INSTALLATION (1) If removed, install the exhaust tailpipe bracket
(1) If removed, install the muffler support bracket to the frame rail. Tighten the bolts to 23 Nun (200
to the frame rail. Tighten the bolts to 28 Nun (250 in. lbs.) torque.
in. lbs.) torque. (2) Position the exhaust tailpipe into the rear ex
(2) Align the extension(s) and the muffler with the tension pipe or the muffler rear extension pipe.
front exhaust pipe and the exhaust tailpipe. (3) Install the bolt into the exhaust tailpipe
(3) Install the shoulder bolts through the insula bracket. Tighten the bolt to 23 Nun (200 in lbs.)
torque.
tors and into the muffler front and rear support
(4) Position the clamp onto the exhaust tailpipe.
brackets (Fig. 4). Tighten the bolts to 28 N-m (250
Tighten the bolts to 54 Nun (40 ft. lbs.) torque.
in. lbs.) torque.
(4) Position the clamps onto the front exhaust ex
(6) Start the engine and check for leaks.
tension pipe. Tighten the nuts to 54 Nun (40 ft. lbs.)
torque. ENGINE EXHAUST MANIFOLD
(5) Position the clamps onto the rear exhaust ex
tension pipe or onto the muffler rear extension pipe. REMOVAL
Tighten the nuts to 54 Nun (40 ft. lbs.) torque. (1) Disconnect the air intake and exhaust pipes
(6) Lower the vehicle. (Fig. 6).
(7) Start the engine and check for leaks. (2) Disconnect the turbocharger oil supply line and
the oil drain tube from the turbocharger (Fig. 7).
EXHAUST TAILPIPE (3) Disconnect the charge air cooler (intercooler)
inlet duct from the turbocharger (Fig. 7).
REMOVAL (4) Remove the turbocharger and gasket.
(1) Raise and support the vehicle. (5) Remove the cab heater supply and return lines.
(2) Remove the clamp from the pipe (Fig. 5). (6) Remove the engine exhaust manifold and gas
(3) Remove the bolt from the exhaust tailpipe kets (Fig. 8).
bracket. (7) Clean the sealing surfaces.
(4) Separate the exhaust tailpipe from the rear ex
tension pipe or from the muffler rear extension pipe. INSTALLATION
(5) If required, remove the exhaust tailpipe (1) Install the engine exhaust manifold and gas
bracket from the frame rail (Fig. 5). kets. Tighten the exhaust manifold bolts in sequence
to 43 Nun (32 ft. lbs.) torque (Fig. 9).
(2) Install the turbocharger. Tighten the turbo
charger mounting nuts to 32 Nun (24 ft. lbs.) torque.
EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 19
EXHAUST GASKET
MANIFOLD
J9111-5
Fig. 8 Engine Exhaust Manifold and Gaskets

EXHAUST
M A N I F O L D ^ ^ ^ ^
J9111-52
Fig. 6 Air intake Pipe, Exhaust Pipe and

Turbocharger
, t i l l
TURBOCHARGER,
OIL SUPPLY
UNE
GASKET J9111-6
Fig. 9 Engine Exhaust Manifold Bolt Tightening

Sequence
Nun (18 ft. lbs.) torque. Tighten the oil supply line
fitting nut to 15 Nun (11 ft. lbs.) torque.
(6) Connect the cab heater supply and return lines.
Tighten the line nuts to 24 Nun (18 ft. lbs.) torque.
(7) Operate the engine to check for leaks.
INTAKE MANIFOLD COVER / AIR INTAKE HEATER
^J9111-53
REMOVAL
(1) Remove the charge air cooler (intercooler) out
Fig. 7 OH Supply Line and Charge Air Cooler let duct from the air inlet tube (Fig. 10).
(intercooler) inlet Duct (2) Remove the high pressure fuel lines.
(3) Position the charge air cooler (intercooler) inlet (3) Disconnect and remove the air intake heater
ground wire (Fig. 10).
duct to the turbocharger. With the clamp in position,
(4) Disconnect the air intake heater power supply
tighten the clamp n u t to 8 Nun (72 in. lbs.) torque.
lines (Fig. 11). Remove the air intake heater and
(4) Position the air intake pipe and the exhaust
gaskets (Fig. 11). Clean the mounting surface of the
pipe onto the turbocharger. Tighten the clamps to 8
intake manifold cover.
Nun (74 in. lbs.) torque.
(5) Disconnect the charge air temperature sensor
(5) Install the oil drain tube and oil supply line to from the intake manifold cover (Fig. 12).
the turbocharger. Tighten the drain tube bolts to 24 (6) Disconnect the air temperature switch from the
intake manifold cover (Fig. 12).
11-20 EXHAUST SYSTEM AND INTAKE MANIFOLD
AIR INLET AIR

TEMPERATURE
SWITCH
(KSB SOLENOID)
INTERCOOLER/
OUTLET DUCT
X^l /J9111-54. J9114-235
Fig. 10 Air Inlet Tube and Heater Ground Wire Fig. 12 Charge Air Temperature Sensor and Air
Temperature Switch
AAANIFOLD FUEL HEATER
INTAKE GROUND WIRE
COVER
J9111-50
Fig. 13 Manifold Intake Cover and Fuel Heater

Ground Wire
(5) Some of the intake manifold bolt holes are
J9111-51 drilled through and must be sealed. Apply liquid te
flon sealant to the bolts. Install the intake manifold
Fig. 11 Air Intake Heater cover bolts. Tighten the bolts to 24 Nun (18 ft. lbs.)
(7) Disconnect the fuel heater ground wire from in torque.
take manifold cover (Fig. 13). (6) Install a new gasket between the air intake
(8) Remove the manifold intake cover and gasket heater and the intake manifold cover. Install a new
(Fig. 13). Keep the gasket material and any other gasket on top of the air intake heater.
material out of the air intake. (7) Install the air inlet tube. Tighten the air inlet
(9) Clean the sealing surface. tube bolts to 24 Nun (18 ft. lbs.) torque.
(8) Connect the intake manifold heater ground
INSTALLATION wire.
(1) Using a new gasket, install the intake manifold (9) Install and tighten the air intake heater power
cover. supply nuts to 14 Nun (10 ft. lbs.) torque.
(2) Install the fuel heater ground wire. Tighten the (10) Position the charge air cooler (intercooler) out
bolt to 12 Nun (110 in. lbs.) torque. let duct onto the air inlet tube. Tighten the charge
(3) Connect the air temperature switch to the in air cooler (intercooler) outlet duct clamps to 8 Nun
take manifold cover. (74 in. lbs.) torque.
(4) Connect the charge air temperature sensor to (11) Install and bleed the high pressure fuel lines.
the intake manifold cover. Tighten the high pressure fuel line nuts to 24 Nun
TURBOCHARGER
REMOVAL
(2) Disconnect the air intake pipe and exhaust pipe
(Fig. 14).
Fig. 14 Air Intake Pipe, Exhaust Pipe and

Turbocharger
(3) Remove the oil drain tube bolts.
(4) Remove the oil supply line (Fig. 15).
(5) Disconnect the charge air cooler (intercooler)
inlet duct from the turbocharger (Fig. 15).
(6) Remove the turbocharger mounting nuts and
the turbocharger.
(7) If the turbocharger is not to be installed imme
diately, cover the opening to prevent material from
entering into the manifold.
(8) Clean and inspect the sealing surface. Fig. 16 Compressor Housing and Impeller
DISASSEMBLY (8) Remove the diffuser bolts and lockplate (Fig.
(1) Scribe the housing so they can be assembled in 17).
the same position. (9) Remove the diffuser and discard the O-ring
(2) Clamp the turbocharger in a bench vise. (Fig. 18).
(3) Remove the compressor housing V-Band clamps (10) Remove the oil slinger and discard the piston
(Fig. 16). ring (Fig. 18).
(4) Remove the compressor housing and inspect for (11) Inspect for cracks and excessive wear.
impeller contact (Fig. 16). (12) Remove the oil baffle (Fig. 19).
(5) Remove the square cut O-ring (Fig. 16). (13) Remove the thrust bearing and retainer
(6) Remove the impeller nut (Fig. 16). Turn the screws (Fig. 19). Do not reuse the thrust bearing.
impeller n u t to the right to loosen. The n u t and shaft (14) Remove the thrust collar (Fig. 19).
have left hand threads. (15) Inspect the collar for excessive wear.
(7) Remove the impeller and inspect the blades for (16) Remove the turbine housing lock plates and
damage. The wheel and shaft assembly is balanced clamp plates (Fig. 20).
as a unit. If the impeller is damaged the complete as (17) Remove the bearing housing (Fig. 20).
sembly must be replaced.
DIFFUSER BEARING
HOUSING
LOCK
PLATE
TURBINE
HOUSING LOCKPLATE J9111-9 J9111-12
Fig. 17 Diffuser and Lockplate Fig. 20 Turbine Housing Lock Plates and Clamp
Plates
O-RING OIL
SLINGER TURBINE WHEEL
SHAFT
PISTON RING
TYPE SEAL
HEAT
J9111-13 SHIELD
Fig. 21 Turbine Wheel Shaft and Heat Shield

MO (20) Remove and discard the piston ring type seal
(Fig. 21).
Fig. 18 Diffuser, O-Ring and Oil Slinger
C A U T I O N : The wheel and shaft assembly is bal
THRUST anced a s a unit. If the turbine blades or shaft are
COLLAR
damaged, the complete assembly must be replaced.
(21) Remove and discard the outer retainer rings
(Fig. 22).
(22) Remove and discard the turbocharger shaft
OIL
bearings (Fig. 22).
BAFFLE (23) Remove and discard the inner snap rings (Fig.
22).
CLEANING
Use a stiff bristle nylon brush and solvent to clean
all parts. Do not use a wire brush on the compressor
wheel. Do not bead blast the parts.
Remove the carbon build up from the housing with
J9111-11 a scraper and a 240 grit emery cloth.
Polish the bearing surfaces with crocus and kero
Fig. 19 Oil Baffle, Thrust Bearing and Collar
sene or diesel fuel.
(18) Remove the turbine shaft and heat shield After rinsing in clean solvent, use compressed air
(Fig. 21). to dry the parts.
(19) Inspect the turbine blades and the shaft for
excessive wear. INSPECTION
In addition to the inspection specified during disas
sembly, inspect all parts after cleaning.
HEAT SHIELD
OUTER RETAINER
RINGS
BREAKING,
HOUSING J9111-18
Fig. 24 Turbine Shaft/Heat Shield to Bearing

Housing
INNER INNER
RETAINING RETAINING
RINGS RING
J9111-14
Fig. 22 Snap Rings and Shaft Bearing

Measure the shaft bearing diameter (Fig. 23). The
minimum diameter should be 10.97 mm (0.432 inch).
SHAFT BEARING
DIAMETER
J911M6
Fig. 25 Beveled Face of Inner Retainer Ring

OUTER OUTER
RETAINING RETAINING
RING RING
J9111-15
Fig. 23 Shaft Bearing Diameter

ASSEMBLE
The balance marks must be aligned to make sure
the wheel and shaft assembly is balanced.
(1) Install the piston ring and lubricate the groove
with engine oil.
(2) Install the heat shield (Fig. 24).
(3) Clamp a socket in a soft jawed vice and posi
tion the shaft in the socket.
J9111-17
(4) Install the inner retainer rings. The beveled
face must be towards the bearing (Fig. 25). Fig. 26 Beveled Face of Outer Retainer Ring
(5) Lubricate the turbocharger bearing with engine
(8) Install the thrust collar. Align the balance
oil and install the bearings in the housing.
(6) Install the outer retainer ring. The beveled face mark with the balance mark on the shaft. Mark the
must be towards the bearings (Fig. 26). top surface with a marker pen so alignment can be
(7) Assemble the turbine shaft and heat shield to verified after installing the thrust bearing.
the bearing housing. Rotating the housing as you (9) Lubricate the thrust bearing with engine oil
press downward will assist in properly seating the and install it on the housing. Tighten the torx bolts
piston ring. to 4.5 N»m (40 in. lbs.) torque.
(10) Install the oil baffle. Check the balance mark

alignment.
(11) Install the piston ring type seal on the oil
slinger (Fig. 27).
Fig. 29 Align Balance Marks—Impeller

Fig. 27 Piston Ring Type Seal
(12) Mark the top surface of the oil slinger line
with the balance mark.
(13) Lubricate the oil slinger with engine oil and
install it into the diffuser.
(14) Install the O-ring into the diffuser.
(15) Install the diffuser. Align the balance marks
on the shaft and the oil slinger (Fig. 28).
Fig. 30 Bearing Housing Assembly/Turbine Housing
Fig. 28 Align Balance Marks—Shaft and Oil Slinger

(16) Align the balance m a r k and install the impel
ler (Fig. 29). Be careful not to move the bearing
housing.
(17) Do not allow the impeller to t u r n when in
stalling the nut. The impeller nut and the shaft have
LEFT hand threads. Tighten the n u t to 14 N-m (129
in. lbs.) torque.
(18) Install the bearing housing assembly into the
Fig. 31 Install Clamp Plates/Lock Plates
turbine housing (Fig. 30).
(19) Align the scribe marks (Fig. 30). (22) Install the lock plates and bolts into the dif
(20) Apply anti-seize compound to the bolt threads. fuser (Fig. 32).
(21) Install the clamp plates, lock plates and bolts (23) After tightening the bolts to 5.7 N-m (50 in.
(Fig. 31). Tighten the bolts to 11.3 N-m (100 in. lbs.) lbs.) torque, bend the lockplate tabs to lock the bolts.
torque. Be sure the scribe marks are aligned.
(2) Install the turbocharger. Tighten the turbo

charger mounting n u t s to 32 N-m (24 ft. lbs.) torque.
(3) Use a new gasket and connect the drain line.
Tighten the drain line connection bolts to 24 N-m (18
ft. lbs.) torque.
(4) New turbocharger must be pre-lubricated with
clean engine lubricating oil before start up. Pour
50-60 cc (2-3 ounces) of oil into supply fitting.
W A R N I N G : D O NOT U S E Y O U R F I N G E R T O T U R N
THE TURBINE WHEEL.
(5) Rotate the turbine wheel to allow oil to enter

the turbocharger.
(6) Install the oil supply line. Tighten the oil sup
ply line fitting nut to 15 N-m (11 ft. lbs.) torque.
Fig. 32 Diffuser and Lockpiate (7) Position the Charge air cooler (intercooler) in
(24) Measure the end play (Fig. 33). For turbo let duct to the turbocharger. With the clamp in posi
charger with a serial number before 840638 the end tion, tighten the clamp nut to 8 N-m (72 in. lbs.)
play should be 0.102-0.152 mm (0.004-0.006 inch). torque.
For turbocharger with a serial number of 840638 and (8) Position the air intake pipe and the exhaust
after the end play should be 0.026-0.076 mm (0.001- pipe onto the turbocharger. Tighten the clamps to 8
0.003 inch). N-m (72 in. lbs.) torque.
(25) Measure radial clearance of the shaft (Fig. (9) Connect the negative cable to the battery.
33). The clearance should be 0.300-0.460 mm (0.012- (10) Operate the engine and check for leaks.
0.018 inch).
CHARGE AIR COOLER (INTERCOOLER)
Intake air is drawn through the air cleaner and
into the turbocharger compressor housing. Pressur
ized air from the turbocharger then flows forward
through the charge air cooler (intercooler) located in
front of the radiator. From the charge air cooler (in
tercooler) the air flows back into the intake manifold.
The charge air cooler (intercooler) is a heat ex
changer that uses air flow to dissipate heat from the
intake air. As the turbocharger increases air pres
sure, the air temperature increases. Lowering the in
take air temperature increases engine efficiency and
power.
REMOVAL
W A R N I N G : IF T H E E N G I N E W A S J U S T T U R N E D
Fig. 33 End Play/Radial Clearance of Shaft OFF, T H E I N T A K E A N D O U T L E T D U C T S M A Y B E
HOT.
(26) Install the square cut O-ring.
(27) Be sure the scribe marks are aligned. Install (1) Remove the grille (refer to Group 23, Body for
the compressor housing and V-Band clamp. Apply the proper procedure).
anti-seize compound to the V-Band bolt threads. (2) Remove the front support bracket (Fig. 34).
Tighten the clamp to 8 N-m (72 in. lbs.) torque. Tap (3) If the vehicle is equipped with air conditioning,
against the clamp on 4 places around its circumfer remove the condenser as follows:
ence. Again tighten the clamp to 8 N-m (72 in. lbs.) (a) Discharge the air conditioning system (refer
torque. to Group 24, Heating and Air Conditioning for the
proper procedures).
INSTALLATION (b) Remove the bolt from the sealing plate (Fig.
(1) Install a new gasket and apply anti-seize com 34).
pound to the mounting studs. (c) Remove the n u t s holding the condenser to the
charge air cooler (intercooler) (Fig. 34). Lift the
condenser and sealing plate assembly away from
the charge air cooler (intercooler).
Fig. 35 Charge Air Cooler (Intercooler) Ducts

(2) Install the inlet and outlet ducts to the charge
Fig. 34 Condenser and Charge Air Cooler air cooler (intercooler)—(Fig. 35). With the clamps in
(Intercooler) position, tighten the clamp n u t to 8 N-m (72 in. lbs.)
torque.
(4) Remove the inlet and outlet ducts from the
(3) If the vehicle is equipped with air conditioning,
charge air cooler (intercooler)—(Fig. 35). install the condenser as follows:
(5) Remove the charge air cooler (intercooler) bolts. (a) Position the condenser and sealing plate as
Pivot the charge air cooler (intercooler) forward and sembly onto the charge air cooler (intercooler)
up to remove. studs. Install the nuts and tighten.
(b) Connect the halves of the sealing plate (Fig.
INSTALLATION 34). Install the bolt and tighten.
(1) Position the charge air cooler (inter (c) Charge the air conditioning system (refer to
cooler)—(Fig. 34). Install the bolts and tighten to 2 Group 24, Heating and Air Conditioning for the
N-m (17 in. lbs.) torque. proper procedures).
(4) Install the front support bracket (Fig. 34). In
stall and tighten the bolts.
(5) Install the grille (refer to Group 23, Body for
the proper procedure).
SPECIFICATIONS
TURBOCHARGER SPECIFICATIONS
COMPONENT DIMENSIONS
Air Intake Restrictions 635 mm Water (25 in. Water) Max.
Turbo Radial Clearance 0.300-0.460 mm (0.012-0.018 inch)
Turbo Rotor Assembly End Play
Before S/N 840638 0.102-0.152 mm (0.004-0.006 inch)

S/N 840638 AND AFTER . 0.026-0.076 mm (0.001-0.003 inch)
Turbo Shaft Bearing Diameter 10.97 (0.432 inch)
J9111-26
Adjusting Strop Bolt 23 N-m (200 in. lbs.) Muffler-to-Tail Pipe Clamp Nuts 43 N-m (32 ft. lbs.)
Air Heater Power Supply Nuts 14 N-m (10ft.lbs.)
Plenum Pan Bolts (3.9L & 5.2L)
Cab Heater Supply/Return Line Nuts 24 N-m (18ft.lbs.) 1st Step 2.7 N-m (24 in. lbs.)
Catalytic Converter-to-Muffler 2nd Step 5.4 N-m (48 in. lbs.)
Clamp Nuts 43 N-m (32 ft. lbs.) 3rd Step 9.5 N-m (84 in. lbs.)
Exhaust Manifold-to-Cylinder Throttle Body (MPI) Bolts 23 N-m (200 in. lbs.)
Head Bolts (5.9L Diesel) 43 N-m (32ft.lbs.) Throttle Control Bracket
Exhaust Manifold-to-Cylinder Mounting Bolts 24 N-m (18 ft. lbs.)
Head Bolts/Nuts 34 N-m (25 ft. lbs.) Thrust Bearing Torx Bolts............................ 4.5 N-m (40 in. lbs.)
Exhaust Pipe-to-Catalytic Turbocharger Bearing Housing/
Converter Clamp Nuts 43 N-m (32 ft. lbs.) Diffuser Bolts 5.7 N-m (50 in. lbs.)
Exhaust Pipe-to-Exhaust Turbocharger Bearing Housing/
Manifold Bolts/Nuts 26 N-m (19 ft. lbs.) Turbine Housing Bolts 11.3 N-m (100 in. lbs.)
Fuel Heater Ground Bolt . 12 N-m (110 in. lbs.) Turbocharger Impeller Nut 14 N-m (129 in. lbs.)
Fuel Line Nuts 24 N-m (18ft. lbs.) Turbocharger Mounting Nuts 32 N-m (24 ft. lbs.)
Turbocharger Oil Drain Tube Bolts... 24 N-m (18 ft. lbs.)
Generator Mounting Bolt 41 N-m (30 ft. lbs.) Turbocharger Oil Supply Line Fitting Nut.. 15 N-m (11 ft. lbs.)
Turbocharger V-Band Clamp 8.5 N-m (75 in. lbs.)
Intake ManiFolcf Capbolts Refer to Procedure in
Service Manual.
Intake Manifold Cover Bolts 24 N-m (18 ft. lbs.) J9311-12
Intercooler Attaching Bolts............................. 2 N-m (17 in. lbs.)
Intercooler Duct Clamp Nuts 8 N-m (72 in. lbs.)
• • • FRAME AND BUMPERS 13 - 1
FRAME AND BUMPERS
CONTENTS
page page
ATTACHED COMPONENTS . . .
BB B B . 30 FRAME 20
BUMPERS 1 SNOW PLOW 3
BUMPERS
FRONT BUMPER BOLT FRAME
RAIL
REMOVAL/DISASSEMBLY
(1) Support bumper.
(2) Remove bumper nuts and bolts from the
bumper brackets.
(3) Remove support and bumper from vehicle.
(4) Remove nuts and bolts, and bumper brackets
from frame rails. NUT-LOCK
INSTALLATION
(1) Position the bumper brackets on the frame
rails. Install bolts and nuts. Tighten to 68 Nnn (50 ft.
lbs) torque. NUT
(2) Position and support the bumper at the front of
the vehicle. Align bumper bolt holes with bracket
holes.
(3) Insert bumper bolts in brackets. Install nuts.
Verify the bumper is aligned with grille and fenders.
Tighten n u t s to 41 N*m (30 ft. lbs.) torque. BUMPER
BRACKET J9123-326
REAR BUMPER
Fig. 1 Front Bumper
TEMPORARY BUMPER
INSTALLATION
REMOVAL (1) Position the bumper brackets on the bumper
with the bolt holes aligned. Install the bolts and
(1) Support bumper.
nuts. Tighten to 41 N«m (30 ft. lbs.) torque.
(2) Remove bumper bracket nuts and bolts from
the frame rails. (2) Position and support the bumper at the rear of
the vehicle. Align the bumper bracket bolt holes with
(3) Remove support and remove bumper from the
the frame side rail holes.
vehicle.
(3) Insert bumper bracket bolts in the brackets and
STANDARD BUMPER the frame side rails. Install nuts. Verify bumper is
aligned with the rear corner panels. Tighten the nuts
REMOVAL to 68 N-m (50 ft. lbs.) torque.
(1) Support the bumper, (4) Remove the support from the bumper.
(2) Remove bumper nuts and bolts from the frame
side rails and bumper brackets. BUMPER FILLER PANEL-RAMCHARGER
(3) Remove support and bumper from vehicle.
REMOVAL
(4) Remove nuts and bolts, and remove bumper
(1) Remove the filler panel screws from the rear
brackets from bumper.
cross sill.
13 - 2 FRAME AND BUMPERS •
(4) Lower the bumper and remove as a unit.
(5) Remove the bracket and brace bolts to the
bumper. Remove the brackets and braces from the
bumper (Fig. 5).
INSTALLATION
(1) Attach brackets and braces to the bumper with
the bolts and nuts. Tighten the support bracket nuts
to 68 N*m (50 ft. lbs.) torque. Tighten the brace nuts
to 41 N»m (30 ft. lbs.) torque.
(2) Position step bumper assembly to the rear of
the vehicle.
(3) Align the support bracket and brace holes with
the holes in the frame rails. Install the bracket at
taching bolts and nuts.
(4) Ensure t h a t the bumper is correctly aligned
Fig. 2 Standard Rear Bumper with the cargo box rear corner panels. Tighten to 68
(2) Remove the filler panel from the rear cross sill N«m (50 ft. lbs.) torque.
(5) Connect the license plate lamp bulb sockets to
and rear bumper.
the lamps. Attach the wire harness to the bumper
INSTALLATION with the clip retainers (Fig. 4).
(6) Remove the support from the bumper.
(1) Position the filler panel lip under the rear
bumper. Position the flange against the rear cross LOCATOR LAMP
CLIP WIRE
sill.
(2) Align the filler panel flange screw holes with
the sill holes. Install the screws. Tighten the screws
until the heads are seated.
BUMPER SCREW J9123429
Fig. 4 License Plate Lamp Wire Harness
TO SILL BUMPER J9123-361
Fig. 3 Bumper Filler Panel

STEP BUMPER
REMOVAL
(1) Remove the wire harness clip retainers. Discon
nect the bulb sockets from each license plate lamp.
Detach the wire harness from the step bumper (Fig.
4).
(2) Support the step bumper.
(3) Remove the nuts and bolts t h a t attach each
bumper support bracket and brace to the frame rails
(Fig. 5).
Fig. 5 Rear Step Bumper
• FRAME AND BUMPERS 13 - 3
S N O W PLOW
NDEX
page page
Power Angling Cylinder Service 16 Snow Plow Malfunction Diagnosis and Tests 4
Power Unit . . 13 Snow Plow Pivot Bracket 16
Service Information 3 Snow Plow Wiring Diagrams 4
Snow Plow Control Module 17 System Description and Operation 3
S n o w Plow Frame 16
SERVICE INFORMATION • Sector shear pin — Self-locking pin t h a t locks

A snow plow is optionally available for 4WD Ram the moldboard in either a straight ahead or an an
Truck and Ramcharger vehicles. The primary me gled plowing position
chanical components are illustrated in Figure 1. If the blade impacts obstructions, the pin will
shear to protect the s n o w plow and the vehicle
LIFT ARM
from damage. The pin is not u s e d with p o w e r
angle plowing.
• P o w e r angling cylinders — Enable the operator
to move the moldboard either straight ahead or to
the side
• Hinge pins — Allows the A-Frame to pivot up
and down. The pins act as attaching points.
• Cutting e d g e — Replaceable blade edge extends
the life of the blade
• Runners — Adjustable runners retain the cutting
edge at the proper height
• Sno-Flo paint — Specially developed high-
• visibility, yellow paint provides fast, smooth snow-
rolling action
• Hydraulic p u m p and motor (Electro-Touch ™)
— Hydraulically raises, lowers and angles the snow
plow
• A-frame — Provides the means for attaching the
snow plow to the vehicle
• Lift arm — Raises and lowers the snow plow.
SYSTEM DESCRIPTION AND OPERATION

HYDRAULIC CYLINDER AND MOTOR
The hydraulic cylinder and motor unit is designed
RUNNERS J9001-2
to raise, lower and angle the blade.
Fig. 1 Snow Plow Components The power unit is a high torque, 12-volt motor t h a t
COMPONENT DESCRIPTION is coupled to a gear-type hydraulic pump.
The primary snow plow components are described The toggle switches operate the solenoid valves.
within the following list: The following components control the snow plow
• Moldboard — Snow blade constructed from high blade positioning:
tensile steel • Solenoid valves designated A,B, and C
• Trip springs — Allow the moldboard to tilt for • Mechanical hydraulic check valves
ward and slide over obstructions without losing the • Pilot check valve
snow load • Crossover relief valve
• Sector — Used for positioning the moldboard SOLENOID fELEGTRO'MEGHANIGALj VALVES
• straight ahead or angling it to the right or left Three solenoid valves are used for snow plow con
trol. Each valve is comprised of two components:
• Cartridge — Comprised of a valve and a solenoid.
13 - 4 FRAME AND BUMPERS •
• Coil — The electrical component t h a t retracts the into the right side cylinder.
cartridge solenoid. The other check valve is located between valve B
With power applied, the solenoid retracts and pulls and valve C. It prevents fluid from being forced
the poppet valve into the OPEN position. through solenoid valve B.
When power is turned off, the spring forces the so
lenoid back to its normal, CLOSED position. PILOT CHECK VALVE
A pilot check valve has a piston in addition to a
SOLENOID VALVE A
ball seat and spring. A pilot check valve is located
The solenoid valve A cartridge contains a poppet between solenoid valve C and the reservoir. It has
valve. This valve is normally de-energized in the two functions:
CLOSED position. When closed, the valve retains • Prevents the hydraulic fluid in either angling cyl
pressure in the lift cylinder. When it is energized inder from leaking back to the reservoir.
(valve opened), it allows the fluid to flow from the • Allows the hydraulic fluid from a retracting an
lift cylinder back to the reservoir. This enables the gling cylinder to return to the reservoir.
plow blade to lower via gravity. The valve action is done by fluid moving the pis
Solenoid valve A is designed to remain energized ton, which forces the check ball off its seat.
(valve open) during plowing to provide a floating
blade position. This ensures t h a t the plow blade is CROSSOVER RELIEF VALVE
guided up-down by the surface deviations.
This valve protects against damage by a sudden
SOLENOID VALVE B impact against the end of the blade. This will cause
high hydraulic pressure to accumulate in one of the
The solenoid valve B cartridge contains a spool angling cylinders.
valve. This valve is normally in the de-energized The hydraulic pressure increases enough to open
CLOSED position. This allows the fluid to flow to the the crossover relief valve. The valve allows the
C solenoid. In the energized OPEN position, the fluid highly pressurized hydraulic fluid to flow to the
is diverted to the lift cylinder. This causes the plow other cylinder. This cushions the impact and changes
blade to be raised. the position of the blade.
SOLENOID VALVE C
SYSTEM OPERATION
The solenoid valve C cartridge contains a spool Refer to Figures 2 through 5 for voltage application
valve t h a t is normally in the de-energized CLOSED and hydraulic fluid flow for each snow plow function.
position. This allows the fluid to flow to the right- Each figure shows the components t h a t are actuated
side power angling cylinder. This angles the blade to for each function.
the left. At the same time, it allows the fluid from
the retracting left-side power angling cylinder to re SNOW PLOW WIRING DIAGRAMS
t u r n to the pump reservoir. Refer to Figures 6, 7 and 8 for wiring diagrams.
Energizing the solenoid valve will route fluid to Refer to Specifications chart at the end of this
the left side angling cylinder. This angles the plow group.
blade to the right. Also, the fluid is forced from the
retracting right side cylinder. It flows through the C SNOW PLOW MALFUNCTION DIAGNOSIS AND
cartridge valve and returns to the pump reservoir. TESTS
Refer to the charts and illustrations for proper di
MECHANICAL HYDRAULIC VALVES
agnosis.
The mechanical hydraulic valves all have the same
function: they control the direction of the hydraulic SOLENOID VALVE COIL FUNCTIONAL TEST
fluid flow. Test the coils for proper operation, according to the
following procedure.
CHECK V A L V E S
(1) Hold a screwdriver blade about 1/8 inch above
Check valves allow fluid to flow freely in one direc the nut on the coil to be tested.
tion while preventing fluid from flowing in the oppo (2) Have a helper operate the control switch t h a t
site direction. energizes the applicable coil.
A pump check valve is used to prevent fluid from
leaking back through the pump to the reservoir. C A U T I O N : D o not connect an ohmmeter to a coil
Two additional check valves are necessary because when it is applied. This can cause internal damage
solenoid valves B and C have some leakage. to the ohmmeter.
One check valve is located between solenoid valve
B and the lift cylinder. It prevents fluid in the lift (3) If the coil is working, the electromagnetic ac
cylinder from leaking back through solenoid valve B. tion will pull the screwdriver down to the retaining
If fluid leaks back, it could angle the blade to the nut. If this does not occur, use an ohmmeter to check
left. This would force fluid through solenoid valve C the coil for continuity.
FRAME AND BUMPERS 13 -
TAN- ORANGE WITH IGNITION SWITCH

WHITE
TRACER
-o
SWITCH
6 o
SWITCH ANGLE
I RAISE O ORANGE BATTERY
| AND j
! LOWER x
WITH
WHITE TRACER
BLACK* TAN
FUSE
LIGHT » + •o
'GREEN
RED-
SOLENOID SWITCH
• MOTOR
ENERGIZED: MOTOR A N D " B " COIL
PRESSURE RELIEF B
" " SOLENOID 'C" SOLENOID
JUL.
ANGLING CYLINDER
CSSE] OPERATING PRESSURE

EXHAUST
INTAKE OR DRAIN
METERED FLOW
RB525
Fig. 2 Raise Blade—Voltage Application & Hydraulic Fluid Flow

- 6 FRAME AND BUMPERS •
TAN IGNITION SWITCH
ORANGE _ L _
WITH
SWITCH WHITE 6 o
TRACER
ANGLE
BATTERY
ORANGE WITH FUSE
WHITE TRACER
L f
>+ •o
LIGHT GREEN
RED
N
u==c
ENERGIZED: "A" COIL
SOLENOID SWITCH
C" SOLENOID
POWER
ANGLING
CYLINDER
LOWER A N D FLOAT
(FORCE APPLIED AGAINST LIFT RAM)
OPERATING PRESSURE
EXHAUST
INTAKE OR DRAIN
METERED FLOW
RB526
Fig. 3 Lower & Float Blade—Voltage Application & Hydraulic Fluid Flow
FRAME AND BUMPERS 13 - 7
IGNITION SWITCH
L
BLACK
mm OPERATING PRESSURE
EXHAUST
^SS3 INTAKE OR DRAIN
METERED FLOW
RB527
Fig, 4 Angle Blade Right-Voltage Application & Hydraulic Fluid Flow

13 - 8 FRAME AND BUMPERS
TAN
IGNITION SWITCH
BLACK
WSSm OPERATING PRESSURE

mm EXHAUST
ESBS3 INTAKE OR DRAIN
METERED FLOW
J9001-1
Fig. 5 Angle Blade Left—Voltage Application & Hydraulic Fluid Flow

• FRAME AND 1UMPERS -13 - S
SNOW PLOW DIAGNOSIS
Condition Possible Coys® Correction

PLOW BLADE WILL NOT LIFT OR (n) Low hydraulic fluid level. (a) Add fluid to proper level.
LIFTS SLOWLY (b) Discharged battery. (b) Recharge battery.
(c) Leaking or open "A" cartridge. (c) Clean or replace "A" cartridge.
(d) No voltage at "B" coil. (d) Locate malfunction and repair.
(e) Inoperative "B" coil. (e) Replace "B" coil.
(f) Malfunctioning motor. (f) Repair or replace motor.
(g) Malfunctioning pump. (g) Replace pump.
PLOW BLADE WILL NOT ANGLE RIGHT- (a) Improper coupler engagement. (a) Engage coupler properly.
MOTOR IS OPERATIONAL (b) Mechanical bind or interference. (b) Eliminate mechanical bind or
interference.
(c) Malfunctioning coupler. (c) Repair or replace coupler.
(d) No voltage at "C" coil. (d) Locate malfunction and repair.
(e) Inoperative "C" coil. (e) Replace "C" coil.
(f) Inoperative "C" cartridge. (f) Clean or replace "C" cartridge.
PLOW BLADE WILL NOT ANGLE LEFT- (a) Improper coupler engagement. (a) Engage coupler properly.
interference.
(c) Malfunctioning coupler. (c) Repair or replace coupler.
(d) Leaking or open crossover relief (d) Clean or replace crossover relief
valve. valve.
PLOW BLADE WILL NOT ANGLE- (a) Improper coupler engagement. (a) Engage coupler properly.
interference.
(c) Leaking or open crossover relief (c) Clean or replace crossover relief
valve. valve.
PLOW WILL NOT REMAIN IN (a) Air in cylinders and hoses. (a) Purge cylinders and hoses.
ANGLED POSITION (b) Leaking "C" cartridge O-ring seals. (b) Replace O-ring seals.
(c) Leaking or open pilot check valve. (c) Clean or replace pilot check valve.
(d) Leaking crossover relief valve. (d) Clean or replace crossover relief
valve.
(e) Crossover relief valve opening (e) Replace crossover relief valve.
pressure too low.
MOTOR DOES NOT OPERATE (a) Discharged or defective battery. (a) Recharge or replace battery.
(b) Loose or corroded electrical (b) Clean and tighten electrical
connections. connections.
(c) Inoperative solenoid switch. (c) Replace solenoid switch.
(d) Malfunctioning control switch. (d) Replace control switch.
(e) Malfunctioning motor. (e) Repair or replace motor.
PLOW BLADE WILL NOT LOWER (a) No voltage at "A" coil. (a) Locate malfunction and repair.
(b) "A" cartridge jammed in closed
position. (b) Clean or replace "A" cartridge.
(c) Inoperative "A" coil.
(c) Replace "A" coil.
PLOW BLADE CREEPS DOWNWARD (a) Leaking "A" cartridge.
(b) Leaking "A" cartridge O-ring seal. (a) Clean or replace "A" cartridge.
(c) Leaking B-Check Valve. (b) Replace O-ring seal.
(d) Leaking Ram Packing Cup. (c) Clean or replace Pump Check Valve.
(e) Leaking O-ring seal at bottom of (d) Replace Ram Packing Cup.
cylinder. (e) Replace O-ring seal.
PLOW BLADE WILL NOT (a) Runner height incorrect. (a) Adjust runners.
CLEAN SURFACE (b) Cutting edge unevenly worn. (b) Replace.
BLADE WILL NOT FOLLOW (a) Not in "Lower Float Position". (a) Position switch at "Lower Float"
SURFACE DEVIATIONS (b) Insufficient slack in lift chain. (b) Adjust lift chain.
SNOW STICKS TO FACE (a) Sno-Flo paint worn off. (a) Refinish.
OF BLADE
J9001-3
TO TURN FUSE # 5
SIGNAL FLASHER < (20 AMP)
y -Dl 18RD/YL*
(SEE SHEET 27)
Dl 18RD/YL*
TO R.W.A.L.
j MODULE
(SEE SH 51, 53)
BLACK
TO
IGNITION
SWITCH
(SEE SH 10)
-SP4 18WT/BR* -SP4 18WT/BR*-
-SP4 18WT/BR*
-SP4 18WT/BR*
-Dl 18RD/YL*
-SP1 18WT/BK* I
PLOW
CONTROL Dl 18RD/YL*
SWITCH
UP & DOWN L. -SP3 18 WT/RD*
-SP3 18WT/RD*-
-SP1 18WT/BK*-
Dl -SP4 18WT/BR*- SP4 18WT/BR* I

18RD -SP4 18WT/BR*- SP4 18WT/BR* !
YL*
-Dl 18RD/YL*-
PLOW -SP4 18WT/BR* j
CONTROL
SWITCH —Dl 18RD/YL*
LEFT TO -SP5 18WT/LG* I
RIGHT
-SP4 18WT/BR* -SP5 18WT/LG*-
-Dl 18RD/YL*- -T2 18LG/RD*-
TRANSMISSION OIL
TEMPERATURE LAMP
8901-3
Fig. 6 Snow Plow Control Wiring Diagram

SNOW PLOW DOWN
SOLENOID (FRONT
SNOW PLOW FRAME)
SNOW PLOW
RIGHT SOLENOID
(FRONT SNOW
PLOW FRAME)
TRANSMISSION OIL
TEMPERATURE SWITCH
(RIGHT SIDE
TRANSMISSION OIL BELOW RADIATOR) 8901-4
TEMPERATURE LAMP
Fig. 7 Snow Plow Control Wiring Diagram (Cont'd)

TO FRONT TO FRONT
END WIRING END WIRING
TO HEADLAMP Jr -L2 14LG (SEE SH 22)
(SEE SH 21)
SWITCH
T T
1 8 B K
18BK
YL*
BLACK BLACK
(RIGHT
SIDE
RADIATOR
YOKE
PANEL)
(RIGHT
' UPPER
SNOW
PLOW
FRAME)
BLACK
LEFT AUXILIARY
PARK AND TURN RIGHT AUXILIARY
SIGNAL LAMP LEFT AUXILIARY RIGHT AUXILIARY PARK AND TURN
HEADLAMP SIGNAL LAMP
HEADLAMP
8901-2
Fig. 8 Snow Plow Auxiliary Lighting Wiring Diagram

POWER UNIT (24) Remove and clean solenoid valve C with spe
cial tool J-25399 (Fig. 9). Inspect the solenoid valve
DISASSEMBL Y/INSPECTION for external damage.
(1) Remove the drain plug (Fig. 9). Drain the unit. (25) Disassemble the four-way valve (Fig. 12). Dis
(2) Extend the r a m and piston rod completely. card the O-ring seals (Fig. 12).
Drain the remaining oil from the cylinder. (26) Test solenoid valve B and C coils for electrical
(3) Remove the cover locknuts (Fig. 9). Remove the continuity. The normal coil DC resistance is 3.7
cover. ohms.
(4) Inspect the casting for damage and cracks. In (27) Remove the pilot check valve plug, the spring
spect the seal for cuts (Fig. 9). and the ball from the bottom of the valve block.
(5) Remove the r a m and the piston. Inspect the ny (28) Inspect the spring for damage and the ball
lon sleeve, the piston, and the piston follower for ex seat for nicks.
cessive wear (Fig. 10). (29) Remove the acorn nut for access to the cross
over valve components (Fig. 9).
(6) Inspect the cylinder for pitting and scoring in
(30) Remove the crossover valve components (Fig.
the bore (Fig. 10).
13). Inspect for external damage. Discard the O-ring
(7) Inspect the r a m for nicks, scratches, and corro seals.
sion (Fig. 10). (31) Clean the block with compressed air to re
(8) Inspect the piston packing cup for wear (Fig. move all foreign material.
10).
(9) Clean and inspect the base strainer. ASSEMBLY
(10) Replace all the O-ring seals during assembly. Verify t h a t all components are thoroughly clean
(11) Loosen the motor bolts. Do not remove the and free of foreign material. Use replacement gas
bolts from the motor. Retain the motor end plate dur kets and seals during assembly. Petroleum jelly
ing removal. Temporarily install two 1/4-20 nuts on should used for installing the rubber O-ring seals.
the motor bolts to retain the motor intact. (1) Install the crossover valve components in the
Both Prestolite and American B o s c h motors valve block with replacement O-ring seals (Fig. 13)
are u s e d in s n o w p l o w p o w e r units. A Prestolite (2) Install the ball, spring and pressure plug with
motor can b e identified b y a d o m e d top cover a replacement O-ring seal in the bottom of the valve
and the trade n a m e stamped o n the body. Amer block (Fig. 13)
ican B o s c h motors have a flat top cover a n d n o (3) Assemble solenoid valve C with replacement
identifying n a m e or marks. O-ring seals and nylon retainer rings (Fig. 12).
(12) Remove the pump drive shaft seal. (4) Install solenoid valve C with Tool J-25399 (Fig.
(13) Verify the seal kit components are correct for 9).
the unit. (5) Assemble solenoid valve B with replacement
(14) Dip the new seal in oil. Install it over the O-ring seals.
pump shaft with the seal lip facing down. (6) Install the ball, spring and solenoid valve B
(15) Position the seal in the pump housing slightly with Tool J-25399 (Fig. 9).
below the boss face. (7) Install the valve block and the replacement
(16) Remove solenoid valve A coil from the base. O-ring seals on the pump base.
Test it for continuity. The normal coil DC resistance (8) Install the retainer, the spring, the ball, t h e in
is 9.0 ohms ±10%. sert valve and the pump housing with replacement
(17) Remove solenoid valve A cartridge with a 1 O-ring seals (Fig. 11). Tighten the pump housing
and 1/8-inch diameter deep socket wrench. Inspect base nuts to 11.3 N*m (100 in. lbs.) torque.
for external damage. (9) Install the filters and the plugs with replace
(18) Remove the filters. Clean the screens with ment O-ring seals (Fig. 9).
cleaning solvent and compressed air. Discard the (10) Install solenoid valve A cartridge in the pump
O-ring seals and the nylon retaining rings. base with replacement O-ring seals (Fig. 9).
(19) Remove the pump housing (Fig. 9). Remove (11) Install solenoid valve A coil (Fig. 9).
the insert valve, the ball, the spring, and the re (12) Install the motor on the pump housing (Fig.
tainer from the pump housing (Fig. 11). Inspect all 9). Engage the gear shaft tang with the notch in the
the components for damage and contamination. Dis motor output shaft. Tighten the motor housing cap-
#
card the O-ring seals. screws to 5 N m (45 in. lbs.) torque.

(20) Remove the socket-head screws. Remove the (13) Install the r a m and piston with replacement
valve block from the pump housing (Fig. 9). Discard O-ring seals (Fig. 9).
the O-ring seals. (14) Position the cover on the reservoir. Secure it
(21) Remove solenoid valve B with special tool with locknuts (Fig. 9). Tighten the locknuts to 11.3
J-25399 (Fig. 9). N r n (100 in. lbs.) torque.
(22) Remove the ball and spring from the valve
block (Fig. 9). Clean the solenoid valve. Inspect it for
external damage.
(23) Disassemble the three-way valve (Fig. 9). Dis
card the O-ring seal.
14 FRAME AND BUMPERS •
RB530
Fig. 9 Power Unit—Exploded View

LEGEND FOR FIG. 9
1. Plastic Washer I f . ' i m p Housing 31. Valve Block 46. 3-Way Coil
2. Locknut V/. cppet
p
32. Socket Head Cap Screw 47. Cap Plug
3. Pressure Relief Valve 18. Spring 33. Filter 48. Check Spring
4. Filler Plug 19. Guide 34. Plug 49. Cylinder Tank
5. Cover arid Seal 20. Retainer 35. Strainer 50. Valve Block
6. O-Rirtg Seal 21. Setscrew 36. Check Valve Retainer 51. Cage
7. Sleeve 22. Aluminum Washer 37. Ball 52. O-Ring Seal/Glide Ring
8. Washer 23. Jamnut 38. Insert Valve 53. Crossover Valve
9. Ram 24. Acorn N ut 39. Cylinder Tank 54. Pilot Check Valve
10. Piston 25. Stud 40. Cylinder 55. Spacer
11. Packing Cup 26. Brass Washer 41. 4-Way Solenoid 56. Disc
12. Piston Follower 27. 2-Way Solenoid 42. 4-Way Valve 57. Adjustment Screw
13. Locknut 28. 2-Way Coil 43. 4-Way Coil 59. Drain Plug
14. Motor 29. 2-Way Valve 44. 3-Way Solenoid
15. Shaft Seat 30. Ease and Strainer 45. 3-Way Valve
J9001-6
COVER TANK
ASSEMBLY RESERVOIR BRASS NUT LOCK NUT
CYLINDER
I COIL
PISTON
3
LOCKNUT
I
i
VALVE CARTRIDGE
O-RING
S PACKINC
RAM WASHER O-RINGS
CUP SPRING
PISTON
FOLLOWER
PLUNGER
RB531
Fig. 10 Lift Cylinder Components

VALVE
SNAP RING
NYLON WASHER
O-RINGS
NYLON WASHER
O-RING
NOTE: NYLON WASHERS NYLON WASHER

A N D O-RINGS SHOULD
BASE
TAPER DOWN TO VALVE SHAPE
RETAINER
FROM VALVE DOWN. RB533
Fig. 12 Solenoid Valve C/Four-Way Valve-Exploded

O-RING SPRING View
NSERT
VALVE
O-RING
RB532
Fig. 11 Insert Valve —Exploded View

13 - 16 FRAME AND i U M P E R S •
SNOW PLOW FRAME
REMOVAL
(1) Support the snow plow frame.
(2) Eemove the nuts and bolts t h a t attach the
bumper brackets to the snow plow frame (Fig. 15).
(3) Remove the nuts and bolts t h a t attach the sup
port straps to the snow plow frame (Fig. 15).
(4) Remove the nuts, washers and bolts t h a t attach
the snow plow frame to the vehicle frame side rails
and front crossmember (Fig. 15).
(5) Remove the snow plow frame and support from
the front of the vehicle frame (Fig. 15).
INSTALLATION
(1) Position and support the snow plow frame a t
the front of the vehicle frame with the bolt holes
aligned (Fig. 15).
RB534
(2) Install the snow plow frame attaching bolts,
Fig. 13 Crossover Relief Valve—Disassembled washers and nuts finger-tight (Fig. 15).
(3) Install the support strap attaching bolts and
POWER ANGLING CYLINDER SERVICE nuts finger-tight (Fig. 15).
If angling cylinder fluid leakage occurs, the cause (4) Install the bumper bracket attaching bolts and
could be a loose gland n u t (Fig. 14). Tighten the nuts finger-tight (Fig. 15).
gland nut. (5) Tighten all the attaching nuts to 68 N*m (50 ft.
lbs.) torque.
C A U T I O N : Over-tightening the gland nut c a n lock (6) Remove the support from under the snow plow
the cylinder. Leakage will not c e a s e immediately be frame.
cause fluid has accumulated between the packing
and the gland nut. If the leakage persists, replace SNOW PLOW PIVOT BRACKET
the rod packing (Fig. 14),
REMOVAL
(1) Support the snow plow pivot bracket.
(2) Remove the nuts and bolts t h a t attach the sup
port straps to the pivot bracket (Fig. 15).
Fig. 14 Angling Cylinder—Exploded View

Fig. 15 Snow Plow Frame Removal/Installation

(3) Remove the nuts, washers and bolts t h a t attach FRAME FRAME
the pivot bracket to the vehicle frame side rails (Fig.
16).
(4) Remove the pivot bracket from the vehicle
frame rails (Fig. 16).
INSTALLATION
(1) Position and support the pivot bracket at the
vehicle frame rails with t h e bolt holes aligned (Fig.
16).
(2) Install the pivot bracket attaching bolts, wash
ers and nuts finger-tight (Fig. 16).
(3) Install the support strap attaching bolts and
nuts (Fig. 15). Tighten the n u t s to 68 N*m (50 ft.
lbs.) torque.
(4) Tighten the pivot bracket attaching nuts to 68
Nrni (50 ft. lbs.) torque.
(5) Remove the support from under the pivot
bracket.
SNOW PLOW CONTROL MODULE

REMO VAUDISASSEMBL Y J9101-1
(1) Remove the screws and module retainers from
the instrument panel (Fig. 17). Fig. 16 Snow Plow Pivot Bracket
(2) Remove the control module from the instru Removal/Installation
ment panel (Fig. 17).
(3) Remove the module housing attaching screws (5) Detach the lamp holders from the switch cover.
(Fig. 18). Disconnect the wire harness connectors from the
(4) Separate the switch cover from the housing switches (Fig. 18).
(Fig. 18).
(6) Remove the nut, ring washer and loekwasher

from each toggle switch (Fig. 18). INSTRUMENT
(7) Remove the toggle switches from the switch PANEL
cover (Fig. 18).

(8) Carefully pry the auxiliary headlamp switch
outward from the switch cover face. Remove it from WIRE
HARNESS
the switch cover (Fig. 18).
AUXILLARY
ASSEMBL Y/INSTALLA TION HEADLAMP
(1) Insert the auxiliary headlamp switch in the SWITCH
switch cover opening. Carefully push inward until it
is completely seated against the cover face (Fig. 18).
(2) Position the toggle switches in the switch cover
openings. Install the lockwashers, ring washers and SWITCH
nuts (Fig. 18). Tighten the nuts with 5 Nnn (45 in. COVER A N D BEZEL
lbs.) torque. BLADE HOUSING
(3) Insert the lamp holders in the switch cover RAISE/LOWER
SWITCH BLADE
openings. Connect the wire harness connectors to the ANGLE
switches (Fig. 18). SWITCH
(4) Mate the switch cover with the module hous RETAINER
J9123-424
ing. Install the housing attaching screws (Fig. 18).
Tighten the screws until the screw heads are seated Fig. 17 Snow Plow Control Module Removal/
against the housing. Installation
(5) Position the control module on the instrument BLADE SWITCH AUXILIARY
panel with the slots aligned with the holes. Install ANGLE COVER HEADLAMP
SWITCH SWITCH
the retainers and screws (Fig. 17). Tighten the
screws until the module is tightly attached to the in TRANS OIL NUT
TEMP LAMP
strument panel. (AUTO TRANS)
RING
WASHER
TO AUXILLARY
H/LAMP SWITCH
LOCKWASHER
WIRE
HARNESS
'ILLUMINATION*
HOUSING LAMP' \
SCREW BLADE
RAISE/LOWER
SWITCH
TO SNO-PLOW CONTROL
SWITCH
(ANGLE)
TO S N O PLW CONTROL SWITCH
(RAISE/LOWER) J9123-425
Fig. 18 Snow Plow Control Module Disassembled

SNOW PLOW SPECIFICATIONS
ELECTRICAL SPECIFICATIONS SOLENOID VALVES A. B, AND C SPECIFICATIONS

MOTOR SPECIFICATIONS A Coll
American Bosch M0SS1M6A Applied Voltage — 12 Volts DC
No load (motor not attached to pump) operation: Current — 0.83 Amperes
C A U T I O N : D o n o t o p e r a t e motor continuously for m o r e Nominal resistance (one ohmmeter probe to coil wire, other
than 30 seconds. to metal coil cover)—9.0 ± 10% ohms.
A p p l i e d V o l t a g e — 12 Volts D C i and C Colls
Max. Current — 24 A m p e r e s Applied Voltage — 12 Volts DC
Speed (Min.) — 5900 r p m Current — 1.24 Amperes
W i t h load ( p u m p operating): Nominal resistance (one ohmmeter probe to coil wire, other
C A U T I O N : Do not operate motor continuously for more to metaT coil cover)—-3.5 ± 10% ohms.
than 5 seconds.
Applied Voltage — 12 Volts DC SOLENOID SWITCH
Max. Current — 230 Amperes Applied Voltage — 12 Volts D C
Prestolite MGL4105 Max. Current — 5 Amperes
No load (motor not attached to pump) operation: Nominal resistance (one ohmmeter probe to coil wire, other
to metal foot)—2.65-4.5 ohms.
CAUTION: Do not operate motor continuously for more
than 30 seconds. HYDRAULIC FLUID CAPACITY
Applied Voltage — 10 Volts DC
Max. Current — 45 Amperes NOTE: 1 Quart = 32 Fluid Ounces
Speed (Min.) — 10,000 rpm A Reservoir and Pump 28 oz.
Under Load (pump operating): Hoses & 1-1/2 x 10 Cylinders 16 oz.
CAUTION: Do not operate motor continuously for more Total 1 qt., 12 oz.
than 5 seconds. (44 oz.)
Applied Voltage —- 12 Volts DC B Reservoir and Pump 28 oz.
Max. Current — 230 Amperes Hoses & 1-1/2 x 12 Cylinders 19 oz.
Total 1 qt., 15 oz.
HYDRAULIC SPECIFICATIONS (47 oz.)
C Reservoir and Pump 1 qt., 4.5 oz.
PUMP m (36.5 oz.)
Pressure Output (pump relief valve opening pressure Hoses & 2 x 12 Cylinders 28 oz.
1650 ±50 psi Total 2 qt., 5 oz.
(64.5 oz.)
CROSSOVER RELIEF VALVE
Opening Pressure 3800 ± 400 psi J9001-4
13 - 20 FRAME AND IUMPERS •
FRAME
INDEX
page page
Frame Inspection/Measurements 25 General Information . . 20
Frame Repair 29
GENERAL INFORMATION Ram Chassis Cabs and Ram Trucks with 8-foot
cargo boxes are equipped with frames t h a t have
DESIGN adapters attached to the top of the frame rails (Fig.
Ram Truck, Chassis Cab and Ramcharger vehicles 2).
have a ladder-type frame (Fig. 1) t h a t has: BOLT
FRONT BODY-TO- REAR
• A box-section front, FRAME ADAPTER BODY-TO-FRAME
• A dropped center ADAPTER
• Open-channel side rails and crossmembers. BOLT
REAR
SPRING REAR
REAR SPRING
^CROSSMEMBER FRONT
.CROSSMEMBER
NUT
ENGINE
> MODEL
KAC 64 CAB A N D
FRONT SUPPORT
CROSSMEMBER CHASSIS VEHICLES
REAR
BODY-TO-
REAR
FRAME ADAPTER
SHOCK BOLT
ABSORBER NUT
CROSSMEMBER BOLT
MID-FRAME
CROSSMEMBER FRONT
BODY-TO-x\
ENGINE/TRANSMISSION FRONT FRAME ADAPTER
REAR CROSSMEMBER
SUPPORT NUT
CROSSMEMBER J9113-20
MODEL 63 CAB A N D CHASSIS
NUT AND 8-FT CARGO BOX VEHICLES J9113-14
Fig. 1 Ram Truck, Chassis Cab and Ramcharger
Frame
Fig. 2 Ram Chassis Cab & Truck (8-Ft Cargo Box)
The frame crossmembers are attached to the side Adapters
rails by either rivets or bolts to form a ladder-shaped
The frames used with 2 W D vehicles (Figs. 3 and 4)
frame (Fig. 1). The cab is attached to the front of the are designed for independent front suspension. The
frame with holddowns. The holddowns are comprised front suspension crossmember is riveted to and a
of bolts, insulators, spacers and brackets. The cargo part of the frame. The engine mounts are welded to
box is attached to the rear of the frame with screws. the crossmember and riveted to the side rails. The
rear suspension brackets are riveted to the side rails.
The frame used for 4 W D vehicles (Figs. 5 and 6)
are basically the same as the 2 W D vehicle versions.
The difference is the front crossmember is replaced
with a smaller engine mount crossmember.
30
>
O
m
MID FRAME CROSSMEMBER

(EXTRA) (159"-165" W.B.)
30
ENGINE/SUSPENSION FRONT
SUPPORT CROSSMEMBER
ALL FASTENERS ARE OS
RIVETS EXCEPT AS NOTED I
PU892C
Fig. 3 AD1, 2 & 3 Frame Structure

Fig. 4 AD4 Frame Structure
RIVETS EXCEPT AS NOTED
PU893B
Fig. 5 ADS, 6 & 7 Frame Structure
FUNCTION HORIZONTAL/DIAGONAL FRAME MEASUREMENTS

The frame is the foundation and the structural cen Determine the frame horizontal, according to the
ter of the vehicle. The primary function of a frame is following procedure.
to provide support and attachment locations: (1) Select several reference points along one frame
• For all t h e chassis/drivetrain components side rail, preferably a t the crossmember junctions.
• For the cab/body (2) Transfer these reference points to the surface/
• For the vehicle payload floor. Paper sheets can be attached to the surface be
While limiting deflections and twisting of the low the reference points.
frame members.
(3) Locate the same reference points on the other
The frame maintains the correct relationship and
frame side rail. Transfer t h e m to the surface/floor.
alignment of the powertrain. This relationship and
(4) Move the vehicle away. Measure between all
alignment ensures normal operation of the attached
the reference points diagonally from and parallel to
units.
the side rails (Fig. 10). The corresponding measure
CONSTRUCTION MATERIAL ments should not differ by more t h a n 6 m m (1/4 in).
High-strength, carbon steel with a minimum yield (5) Measure the distance between the two front
strength of 32,000 psi is used to construct frame side reference points. Measure the distance between the
rails. A frame made of 32,000 psi minimum yield two rear reference points. Divide each distance in
strength steel has, in reality, a range of 32,000 to half and indicate the two half-way points on the sur
44,000 psi yield strength. face/floor. Designate t h e front point as 1 and the rear
For 4WD vehicle applications, the frame side rails point as 2 (Fig. 10).
reinforcements are constructed of the same high- (6) Place a chalk-line between points 1 and 2 (Fig.
strength, carbon steel as the side rails. 10) and snap the string.
(7) Determine how close the center line is to the
BENDING RESISTANCE diagonal intersection points in Figure 10.
A frame reacts to its load and the road surface de
(8) The m a r k s on the floor will show the amount of
viations by deflecting and twisting. The primary de
frame misalignment.
flecting frame members are the side rails. Resistance
(9) The reference point transferred from one side
to frame twist is provided by the crossmembers.
rail should be within 3 m m (1/8 in) of the opposite
FRAME INSPECTION/MEASUREMENTS reference point.
(10) Frame bow to the side should not exceed 3
INSPECTION mm per 2540 mm (1/8 inch per 100 inches) in frame
Inspect the frame members for visible damage and length.
metal deformations. Inspect all riveted, bolted and (11) The overall width of the frame should not
welded connections for looseness and/or missing vary more t h a n 3 mm (1/8 in).
hardware. (12) Repeat steps (1) through (11) after straighten
All damaged areas must be repaired and/or the ing the frame.
frame members replaced, as necessary. Refer to Figures 7, 8, a n d 9 for frame horizon
tal alignment reference dimensions.
MEASUREMENTS
Measure the frame for mis-alignment with the cab/ TWIST AND PARALLEL FRAME MEASUREMENTS
body and cargo box attached to the frame. Figures 7,
Determine the amount of frame twist using the fol
8, 9 provide the frame alignment reference dimen
lowing procedure.
sions.
The following information applies to all measure (1) Mark the vertical reference points under the
ments. frame side rails at 305-mm (12-in) intervals. Start at
(1) Place the vehicle on a level surface. the rear frame crossmember.
(2) If the vehicle is loaded, verify the vehicle does (2) Measure the distance up from a level surface/
not exceed the gross vehicle weight rating (GVWR). floor to each corresponding reference point.
Verify the load is distributed in the vehicle as evenly (3) The distance to a reference point under one
as possible. For better measurement results, remove side rail should be a maximum of 3 mm (1/8 in) dif
the cargo/payload from the vehicle. ference t h a n the opposite side rail.
(3) Measure the tire inflation pressures. Adjust as Refer to Figures 7, 8 a n d 9 for frame vertical
necessary. alignment reference dimensions.
INSIDE O F METAL
TO OUTSIDE O F METAL
37.68
5.55
CENTERLINE OF FRONT WHEELS 750 DIAMETER GAUGE HOLE REAR OVERHANG

'SEE SPECIFICATIONS"
m m
Fig. 7 Frame Dimensions—AD1, 2 & 3

R
N88
8
Fig. 10 Frame Horizontal Aligi ent Reference Points—Typical

FRAME REPAIR WELDING
It is recommended t h a t electric welding equipment
GENERAL INFORMATION be used to weld frame side rails and crossmembers.
Frames t h a t are either bent or twisted can be This method imparts heat only to a small area.
straightened by application of heat, The temperature A damaged frame member should be examined for
must not exceed 566°C/1050°F (a dull red glow). Ex hairline cracks. Repair frame member cracks accord
cessive heat will decrease the strength of the metal. ing to the following procedure.
This will result in a weakened frame. (1) Stop-drill a hole at each end of the crack with a
Damaged frame side rails, crossmembers, and 3-mm (1/8-in) diameter drill bit.
brackets are repaired either by straightening them (2) V-groove the crack to allow good weld penetra
tion.
or by replacement.
(3) Weld the crack.
Welding joints between the frame side rails and
(4) Grind the weld surface area smooth. Install a
crossmembers are not recommended. reinforcement section at the welded area.
The flanges on reinforcement channel, should
FRAME MEMBER STRAIGHTENING
not e x c e e d the width of the side rail flanges.
A straightening repair process should be limited to This will avoid the necessity of welding along
frame members that are not severely damaged. The the outer e d g e of the side rail flanges. Longitu
hardware t h a t is used to join the frame members dinal w e l d s are acceptable. Transverse w e l d s
should conform to the same specifications as the orig must be avoided.
inals.
FRAME REPAIR HARDWARE
FRAME MEMBER REPLACEMENT Bolts, nuts and rivets can be used to repair frames.
Frame member replacement is recommended if the When it is necessary to use a bolt for a rivet, install
shape is not recognizable. the next-larger-size diameter bolt. This will prevent
the bolt from loosening. Ream the hole to fit the bolt.
FRAME MEMBER REPAIRS Conical-type lockwashers are preferred over the
split-ring type lockwashers.Grade-3 bolts (or less)
DRILLING HOLES should not be used. Tightening bolts/nuts with the
Holes should not be drilled in frame side rail correct torque is mandatory to prevent them from
flanges. This will reduce the frame strength. loosening.
REINFORCEMENT SECTIONS
A reinforcement section must overlap beyond the
repair area. A reinforcement section can be cut from
channel steel, angle steel, or flat stock steel. Com
mon carbon steel t h a t is equal in thickness to the
frame member is acceptable.
ATTACHED C O M P O N E N T S
SKID PLATES member. Install the bolts at the frame side rails.
Tighten the nuts and bolts to 23 N*m (200 in. lbs.)
TRANSFER CASE SKID PL ATF 4 WD torque.
VEHICLES
(3) Remove the support from under the skid plate.
REMOVAL FRAME FRAME
(1) Position a support under the skid plate.
(2) Remove the bolts t h a t attach the skid plate to
the frame crossmember. Remove the bolts for the
crossmember support to the frame rail.
(3) Remove the crossmember support and the skid
plate.
INSTALLATION
(1) Position and support the skid plate and the
crossmember support at the frame rail. Align the
bolt holes.
(2) Insert the bolts through the frame crossmember
and frame rail. Install the nuts. Tighten to 23 N*m
(3) Remove the support from under the skid plate.
Fig. 2 Fuel Tank Skid Plate-4WD Vehicles

SPARE TIRE/WHEEL CARRIER
REMOVAL
(1) Remove t h e n u t and insert from the support
rod.
(2) Lower the hanger and remove the spare tire/
wheel from the underside of the frame crossmember.
(3) Remove the retaining nut, lockwasher and
hanger from the left frame rail.
(4) Refer to removal procedures for installation.
Fig. 1 Transfer Case Skid Plate—4WD Vehicles BOLT BOLT FRAME
FUEL TANK SKID PLATE-4WD VEHICLES
REMOVAL
(1) Position a support under the fuel t a n k skid
plate.
(2) Remove the nuts and bolts t h a t attach the skid
plate to the frame rails, rear crossmember and the
support bracket.
(3) Remove the skid plate from the fuel t a n k and
the vehicle.
INSTALLATION
(1) Position and support the skid plate under the
fuel tank. Insert the studs in the support bracket.
(2) Install t h e nuts to attach the skid plate to t h e
support bracket. Install the bolts at the rear cross- Fig. 3 Spare The/Wheel Carrier
1 • FRAME AND BUMPERS 13 - 31
PIVOT BOL T ADJUSTMENT (10) Disconnect all remaining connections between

(1) Refer to the Pivot Bolt Height chart and deter the cab and the frame components.
mine the length of dimension A for the pivot bolt. (11) Remove the restraint cable from the cab.
PIVOT BOLT HEIGHT (12) Remove the cab front holddown nuts and
washers (Fig. 4). The n u t s are accessible at the front,
underside of the cab.
PIVOT BOLT HEIGHT (13) Remove the cab holddown bolts (Fig. 5). The
RIM SIZE TIRE SIZE BOLT HEIGHT bolts are accessible from the underside of the cab.
15 x 6.5 P195/75R-15 4.0"
P205/75R-15 4.0" (14) Separate and remove the cab from the frame.
P235/75R-15XL 5.0" BOLT
15 x 7.0 P235/75R-15XL 5.2"
10R-15LT-B 5.62"
16 x 6.0 7.50-16 SINGLE & DUAL 6.75"
LT215/85R-16 SINGLE 4.5"
LT215/85R-16 DUAL 5.0"
LT235/85R-16 5.0"
16.5 x 6.0 8.00-16.5 SINGLE 4.12"
8.00-16.5 DUAL 5.0"
16.5 x 6.75 8.75-16.5 5.0"
NOTE: 7.50 x 16 TIRE SHOULD
BE INSTALLED IN A DISH
UP POSITION ONLY
(2) Loosen the pivot bolt n u t and adjust dimension

A to required length.
INSTALLATION
(1) Position the hanger under the frame side rails
and insert the pivot bolt in the frame rail hole.
(2) Install the lockwasher and the n u t on the pivot
bolt. Tighten the nut to 61 N*m (45 ft. lbs).
(3) Position the spare tire/wheel on the hanger.
Raise the hanger and insert the support rod in the
hole. Fig. 4 Front Cab Holddown
(4) Install the washer,nut and insert on the sup
port rod. Tighten the nut to 11 Nnn (95 in. lbs.).
CAB
REMOVAL
The cab is attached to the frame with holddowns
(Figs. 4 and 5). The cab can be removed for repair or
service. Refer to the associated component procedure
when necessary.
(1) Disconnect the battery cables from t h e termi
nals. Remove the battery from the tray.
(2) Disconnect the wire harness connectors from
the engine components. Disconnect from the frame.
(3) Disconnect the parking brake cable and the
brake lines.
(4) Disconnect the engine controls.
(5) Disconnect the heater and A/C hoses.
(6) Disconnect the cable from the starter motor. CAB FRONT DOWN HOLD CAB REAR DOWN HOLD
(7) Disconnect the transmission and transfer case
(if equipped) shift linkage. J9113-18
(8) Disconnect the tubing from the clutch master
cylinder (if equipped). Fig. 5 Cab Holddowns—Typical
(9) Disconnect the steering shaft from the steering
gear.
13 - 32 FRAME AND BUMPERS • r
INSTALLATION (7) Remove the cargo box from the frame (Fig. 6).
(1) Verify the insulators and spacers are positioned
CARGO CARGO BOX
on the frame holddown brackets (Figs. 4 and 5).
(2) Position the cab on the frame.
(3) Install the cab holddown nuts and bolts (Figs. 4
and 5). Tighten the nuts to 68 N-m (50 ft. lbs.)
torque. Tighten the bolts to 81 Nnn (60 ft. lbs.)
torque.
(4) Position the restraint cable ends on the cab
rear seat belt anchor bolts. Install the retaining nuts.
Tighten the nuts to 45 N-m. (33 ft. lbs.) torque.
(5) Connect the steering shaft to the steering gear.
(6) Connect the tubing to the clutch master cylin
der (if equipped).
(7) Connect the transmission and transfer case (if
equipped) shift linkage.
(8) Connect the cable to the starter motor.
(9) Connect the heater and A/C hoses.
(10) Connect the engine controls.
(11) Connect the parking brake cable and the
brake lines.
(12) Connect the wire harness connectors to the
engine components and to the frame.
(13) Connect all remaining items between the cab
and the frame components.
(14) Install the battery in the tray. Connect the ca
bles to the terminals.
(15) Inspect the installation of the cab on the
frame and verify that:
• All connecting hardware is tightened
• All fluids and lubricants are full
• All electrical, engine, drivetrain and chassis com
ponents are operational.
FWD HOSE CLAMP J9123-551
CARGO BOX
Fig. 7 Fuel & Vent Hoses
REMOVAL
The cargo box is attached to the rear frame struc INSTALLATION
ture with holddown bolts (Fig. 6). The box can be re (1) Position cargo box on the frame (Fig. 6).
moved for repair or service access. Refer to the (2) Insert the spacers. Install the holddown bolts
associated component procedures when necessary. (Fig. 6). Tighten the bolts to 47 Nnn (35 ft. lbs.)
(1) Disconnect the battery cables from the termi torque.
nals. (3) Connect the fuel and vent hoses to the nozzle
(2) Disconnect the rear lamp wire harness connec tubes (Fig. 7). Tighten the fuel hose clamp screw to 3
tors. Nnn (20 in. lbs.) torque. Tighten the vent hose clamp
(3) Support the exhaust pipe. Disconnect the sup screw to 2 Nnn (14 in. lbs.) torque.
port hanger from the cargo box. (4) Connect the tail pipe to the hanger on the
(4) Loosen the clamps. Disconnect the fuel and cargo box. Remove the support.
vent hoses from the nozzle tubes (Fig. 7). (5) Connect rear lamp wire harness connectors.
(5) Remove the cargo box holddown bolts (Fig. 6). (6) Connect the battery cables to the terminals.
The bolts are accessible from the underside of the (7) Inspect the installation of the cargo box on the
cargo box. frame and verify that:
(6) Identify, m a r k and retain the spacers (if used) • All connecting hardware is tightened
for installation reference. • All electrical system components are operational
• FUEL SYSTEM 14 - 1
FUEL SYSTEM
page page
ACCELERATOR PEDAL AND THROTTLE GENERAL INFORMATION 1
CABLE ................ 25 MULTI-PORT FUEL INJECTION ( M P I ) -
DIESEL FUEL INJECTION-COMPONENT COMPONENT DESCRIPTION/SYSTEM
DESCRIPTION/SYSTEM OPERATION 76 OPERATION-EXCEPT DIESEL 29
DIESEL FUEL INJECTION-GENERAL MULTI-PORT FUEL INJECTION ( M P I ) -
DIAGNOSIS 88 COMPONENT REMOVAL/INSTALLATION-
DIESEL FUEL INJECTION-SERVICE EXCEPT DIESEL 64
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . 106 MULTI-PORT FUEL INJECTION ( M P I ) -
FUEL DELIVERY S Y S T E M - E X C E P T DIESEL . . 3 GENERAL DIAGNOSIS-EXCEPT DIESEL ...43
FUEL DELIVERY-DIESEL ENGINE 15 SERVICE ADJUSTMENTS-DIESEL 122
FUEL TANKS . . . . 20 SPECIFICATIONS 123
GENERAL INFORMATION
Throughout this group, references are made to par Also to be considered part of the fuel system is the
ticular vehicle models by alphabetical designation or Evaporation Control System. This is designed to
by the particular vehicle nameplate. A chart showing reduce the emission of fuel vapors into the atmo
a breakdown of the alphabetical designations is in sphere. The description and function of the Evapora
cluded in the Introduction section at the beginning of tive Control System is found in Group 25, Emission
this manual. Control Systems.
The 5.9L (V-8) gas powered engine will be referred
to in this group as either the: LDC (Light Duty Cy FUEL USAGE STATEMENT-GAS ENGINES
cle) or HDC (Heavy Duty Cycle) engine. The HDC Your vehicle was designed to meet all emission
engine can be easily identified by the use of an en regulations and provide excellent fuel economy using
gine mounted air injection pump. The 3.9L/5.2L/5.9L high quality unleaded gasoline. Only use unleaded
LDC engine will not use an air injection pump. gasolines having a minimum posted octane of 87.
This Fuel System group will cover all fuel system If your vehicle develops occasional light spark
components for the 3.9L (V-6), 5.2L (V-8), 5.9L LDC knock (ping) at low engine speeds, this is not harm
(V-8), 5.9L HDC (V-8) and 5.9L (in-line six cylinder) ful. However, continued h e a v y knock at h i g h
diesel engines. speeds c a n c a u s e d a m a g e and should b e re
The Fuel System consists of: the fuel tank, an ported to your dealer immediately. Engine dam
electric (fuel tank mounted) fuel pump and fuel fil age as a result of heavy knock operation may not be
ter. It also consists of fuel tubes/lines/hoses, vacuum covered by the new vehicle warranty.
hoses, throttle body and fuel injector(s). In addition to using unleaded gasoline with the
The Fuel Delivery System consists of: the electric proper octane rating, those that contain deter
fuel pump, fuel filter, fuel tubes/lines/hoses, fuel rail, gents, corrosion and stability additives are rec
fuel injectors and fuel pressure regulator. ommended. Using gasolines t h a t have these
A Fuel Return System is used on all vehicles (all additives will help improve fuel economy, reduce
engines) except the 5.9L (V-8) gas powered engine. emissions and maintain vehicle performance. Gener
On this engine, a returnless type fuel system is ally, premium unleaded gasolines contain more addi
used. The fuel return system consists of fuel tubes/ tive than regular unleaded gasolines.
lines and hoses t h a t route fuel back to the fuel tank. P o o r quality gasoline can cause problems such as
The Fuel Tank Assembly consists of: the fuel hard starting, stalling and stumble. If you experience
tank, filler tube, fuel gauge sending unit/electric fuel these problems, use another brand of gasoline before
pump module, a pressure relief/rollover valve and a considering service for the vehicle.
pressure-vacuum filler cap.
14 - 2 FUEL SYSTEM •
GASOLINE/OXYGENATE BLENDS 17 percent ETBE. Gasoline blended with MTBE or
Some fuel suppliers blend unleaded gasoline with ETBE may be used in your vehicle.
materials t h a t contain oxygen such as alcohol, MTBE
and ETBE. The type and amount of oxygenate used CLEAN AIR GASOLINE
in the blend is important. The following are gener Many gasolines are now being blended t h a t con
ally used in gasoline blends: tribute to cleaner air, especially in those areas of the
country where air pollution levels are high. These
ETHANOL
new blends provide a cleaner burning fuel and some
Ethanol (Ethyl or Grain Alcohol) properly blended, are referred to as R e f o r m u l a t e d Gasoline.
is used as a mixture of 10 percent ethanol and 90 In areas of the country where carbon monoxide lev
percent gasoline. G a s o l i n e w i t h e t h a n o l m a y b e els are high, gasolines are being treated with oxy
u s e d in y o u r vehicle.
genated materials such as MTBE, ETBE and
METHANOL
ethanol.
Chrysler Corporation supports these efforts toward
CAUTION: D O NOT U S E G A S O L I N E S CONTAINING cleaner air and recommends t h a t you use these gas
M E T H A N O L . Use of methanol/gasoline blends may re olines as they become available.
sult in starting and driveability problems. In addition,
damage may be done to critical fuel system compo FUEL REQUIREMENTS-DIESEL ENGINE
nents. Use good quality diesel fuel from a reputable sup
plier in your Chrysler Corporation vehicle. For most
Methanol (Methyl or Wood Alcohol) is used in a va year-round service, number 2 (two) diesel fuel meet
riety of concentrations blended with unleaded gaso ing ASTM specification D-975 will provide good per
line. You may encounter fuels containing 3 percent formance. If the vehicle is exposed to extreme cold
or more methanol along with other alcohols called co- (below -18°C - 0°F), or for any reason is required to
solvents. operate at colder than normal conditions for pro
Problems t h a t are the result of using methanol/gas longed periods, then dilution of the 2D fuel with 50
oline blends are not the responsibility of Chrysler percent kerosine or number ID diesel fuel will pro
Corporation. They may not be covered by the vehicle vide better protection from fuel gelling or wax-plug
warranty. ging of the fuel filters. Diesel fuel is seldom
completely free of water. To prevent fuel system
MTBE/ETBE trouble, including fuel tube (line) freezing in winter,
Gasoline and MTBE (Methyl Tertiary Butyl Ether) drain the accumulated water using the drain pro
blends are a mixture of unleaded gasoline and up to vided. If you buy good quality fuel and follow the
15 percent M T B E . Gasoline and E T B E (Ethyl Ter cold weather advice above, fuel conditioners should
tiary Butyl Ether) are blends of gasoline and up to not be required in your vehicle.
• FUEL SYSTEM 14 • 3
FUEL DELIVERY S Y S T E M - E X C E P T DIESEL
INDEX
page page
Fuel Filter—3.9L/5.2L G a s Engine . . . . . . . . . . . . 10 Fuel Pump Module—5.9L Engine ............. 3
Fuel Filter—5.9L G a s Engine 11 Fuel System Pressure Release . . . . . . . . . . . . . . . 5
Fuel Pressure Leak Down Test—3.9L/5.2L Engine . 8 Fuel System Pressure Test—3.9L/5.2L Engine ... 5
Fuel Pressure Leak Down Test—5.9L Engine . . . . 9 Fuel System Pressure Test—5.9L Engine 7
Fuel Pump Capacity Test—All G a s Engines . . . . . 8 Fuel Tubes/Lines/Hoses and Clamps . . . . . . . . . . 11
Fuel Pump Control ........................ 5 General Information 3
Fuel Pump Module—3.9L/5.2L Engines 3 Quick-Connect Fittings 11
GENERAL INFORMATION • Fuel pump gauge sending unit

Two different types of fuel delivery/fuel return sys • Fuel supply and return tube connections
tems are used. The system used with the 3.9L/5.2L
engine will route excess fuel pressure back to t h e
fuel tank through a fuel return line. The system used
with the 5.9L engine will not have a separate fuel re
turn line. This system will be referred to as a re-
turnless type. The fuel pump module used with t h e
5.9L engine will contain a combination fuel pressure
regulator and fuel filter. Refer to t h e following Fuel
Pump Module for additional information or, refer to
the Multi-Port Fuel Injection sections of this Fuel
System group.
A separate frame mounted fuel filter will not be
used with any 5.9L gas powered engine.
FUEL PUMP M0DULE-3.9L/5.2L ENGINES

The fuel pump module on vehicles equipped with
3.9L/5.2L engines is installed in the top of t h e fuel
t a n k (Fig. 1). The fuel pump module contains t h e fol
lowing components (Fig. 2):
• Fuel pump
• Fuel pump reservoir
• A separate in-tank fuel filter
• Pressure relief/rollover valve
PRESSURE RELIEF/ PUMP/GAUGE
J9114-147
Fig. 2 Fuel Pump Module Components—Typical

FUEL PUMP MODULE—5.9L ENGINE
The fuel pump module on vehicles equipped with a
5.9L gas powered engine is installed in t h e top of the
fuel t a n k (Fig. 3). The fuel pump module contains
the following components (Fig. 2):
• Fuel filter/fuel pressure regulator
• Fuel pump
• Fuel pump reservoir
• A separate in-tank fuel filter
• Pressure relief/rollover valve
Fig. 1 Top View of Fuel Pump Module—3.9U5.2L • Fuel pump gauge sending unit
Engine • Fuel supply tube connection
14-4 FUEL SYSTEM •
(1) Drain the fuel tank. Refer to Draining Fuel
Tank in the Fuel Tank section of this group.
(2) Remove fuel tank. Refer to the Fuel Tank sec
tion of this group.
(3) The fuel pump module locknut is threaded onto
the fuel tank. Remove the fuel pump module locknut
(Figs. 1 or 3). The fuel pump module will spring up
when the locknut is removed.
(4) Remove module from fuel tank.
DISASSEMBLY- FUEL GAUGE SENDING UNIT

(1) Remove sending unit mounting screws (Fig. 4).
(2) Mark the sending unit electrical wires before
FUEL G A U G E TABS
Fig. 3 Top View of Fuel Pump Module—5.9L Engine

FUEL PUMP
The fuel pump used in this system has a perma
nent magnet electric motor. The pump is part of the
fuel pump module (Fig. 2). The fuel pump module is
suspended in fuel in the fuel tank. Fuel is drawn in
through a filter and pushed through the electric mo
tor to the outlet. The pump contains a check valve.
This valve is located near the pump outlet. It re
stricts fuel movement in either direction to maintain
fuel supply line pressure when the pump is not oper IN-TANK
ational. Voltage to operate the pump is supplied FUEL FILTER J9114-146
through the auto shut down (ASD) and fuel pump re
lays. Fig. 4 Module Service—Typical
removal for correct installation. Carefully disconnect
W A R N I N G : T H E FUEL S Y S T E M I S U N D E R A C O N electrical wires from sending unit. Remove sending
S T A N T P R E S S U R E ( E V E N WITH T H E E N G I N E OFF). unit.
B E F O R E S E R V I C I N G T H E F U E L P U M P , FUEL (3) Reverse order of removal for installation.
T U B E S (LINES), FUEL FILTER, O R FUEL INJEC
T O R ^ ) , T H E F U E L S Y S T E M P R E S S U R E M U S T BE IN-TANK FUEL FILTER
RELEASED. The in-tank filter is attached to the bottom of the
fuel pump module (Fig. 4).
(1) Pry the mounting tabs back and remove the in-
FUEL PUMP REPLACEMENT
t a n k fuel filter.
The fuel pump is not serviceable. If the fuel pump
(2) Install new fuel filter into retaining tabs.
needs replacement, the complete fuel pump module
must be replaced. Perform the Fuel System Pressure FUEL PUMP MODULE INSTALLATION
Release procedure before servicing the fuel pump.
C A U T I O N : Whenever the fuel pump module is ser
FUEL PUMP MODULE REMOVAL viced, the locknut and gasket must be replaced.
W A R N I N G : T H E FUEL S Y S T E M I S U N D E R A C O N (1) Using a new gasket, position fuel pump module
S T A N T P R E S S U R E ( E V E N WITH T H E E N G I N E OFF). into opening in fuel tank.
B E F O R E S E R V I C I N G THE F U E L P U M P M O D U L E , (2) Position new locknut over top of fuel pump
THE F U E L S Y S T E M P R E S S U R E M U S T B E R E module.
LEASED. (3) Tighten locknut.
(4) Install fuel tank. Refer to Fuel Tank Installa
C A U T I O N : Whenever the fuel pump module is ser tion in this section.
viced, the locknut and gasket must be replaced.
• FUEL SYSTEM 14-5
FUEL PUMP CONTROL

The powertrain control module (PCM) computer en
ergizes the fuel pump through the automatic shut
down (ASD) and fuel pump relays. Battery voltage is
applied to t h e relay from t h e ignition switch. The coil
in the relay is energized when a ground is provided
by the PCM. The relays are located in the engine
compartment (Fig. 5).
DATA UNK CONTROL

Fig. 5 Fuel Pump and ASD Relays

FUEL SYSTEM PRESSURE RELEASE
ALL GAS ENGINES
The fuel system is under constant fuel pressure
(even with the engine off).
WARNING: BECAUSE THE FUEL SYSTEM IS UN

DER CONSTANT FUEL PRESSURE, THIS PRES
SURE MUST BE RELEASED BEFORE SERVICING
ANY FUEL SUPPLY OR FUEL RETURN SYSTEM
COMPONENT. THIS DOES NOT APPLY TO THROT
TLE BODY REMOVAL.

(2) Remove the fuel t a n k filler tube cap to release
fuel t a n k pressure.
(3) Remove protective cap from pressure test port
on the fuel rail (Figs. 6, 7 or 8). CONNECTOR HOSES J9214-27
WARNING: DO NOT ALLOW FUEL TO SPILL ONTO Fig. 7 Fuel Pressure Test Port—5.2L (V-8) Engine
THE ENGINE INTAKE OR EXHAUST MANIFOLDS. (5) Place one end of hose (gauge end) into an ap
PLACE SHOP TOWELS UNDER AND AROUND THE proved gasoline container.
PRESSURE PORT TO ABSORB FUEL WHEN THE (6) Place a shop towel under the test port.
PRESSURE IS RELEASED FROM THE FUEL RAIL. (7) To release fuel pressure, screw the other end of
hose onto the fuel pressure test port.
(8) After fuel pressure has been released, remove
WARNING: WEAR PROPER EYE PROTECTION the hose from the test port.
WHEN RELEASING FUEL SYSTEM PRESSURE. (9) Install protective cap to fuel test port.
(4) Obtain the fuel pressure gauge/hose assembly FUEL SYSTEM PRESSURE TEST-3.9L/5.2L
from fuel pressure gauge tool set 5069. Remove the ENGINE
gauge from the hose. Fuel systems on vehicles equipped with a 3.9L or
I l ///// u u m line disconnected, fuel pressure should rise to
PROTECTIVE CAP approximately 269 kPa (39 psi).
AND TEST PORT
Fuel pressure should be approximately 55-69 kPa
(8-10 psi) higher with vacuum line removed from
regulator. If not, inspect pressure regulator vacuum
line for leaks, kinks or blockage. If vacuum line
checks OK and fuel pressure does not rise approxi
mately 8-10 psi after disconnecting vacuum line, re
place fuel pressure regulator.
The fuel pressure regulator is n o t a d j u s t a b l e .
(4) If fuel pressure exceeds 45 psi, check fuel re
t u r n line for kinks or obstructions.
If the previous tests checked good, fuel pump pres
sure is correct. If pump pressure was low, proceed as
J9314-168 follows:
(5) Release fuel system pressure. Refer to the pre
Fig. 8 Fuel Pressure Test Port—5.9L (V-8) Engine vious Fuel Pressure Release Procedure in this group.
5.2L engine are equipped with a vacuum assisted (6) Disconnect the 5/16 inch fuel return line quick-
fuel pressure regulator (Figs. 6 or 7). With engine at connect fitting (Fig. 10) on fuel rail near fuel pres
idle speed, system fuel pressure should be approxi sure regulator. Connect Fuel Line (Tube) Pressure
mately 214 kPa (31 psi) with the vacuum line con Test Adapter Tool number 6539 (5/16 in.) between
nected to the regulator. With the vacuum line the disconnected fuel return tube and fuel rail (Fig.
disconnected from the regulator, fuel pressure should 11).
be approximately 269 kPa (39 psi). This is 55-69 k P a
FUEL TUBE REMOVAL QUICK CONNECT
(8-10 psi) higher.
FITTING
(1) Remove the protective cap at the fuel rail (Figs.
6 or 7). Connect the 0-414 kPa (0-60 psi) fuel pres
sure gauge (from Gauge Set 5069) to test port pres
sure fitting on fuel rail (Fig. 9).
PUSH
FUEL PRESSURE
TEST G A U G E
INSTALLATION
X PUSH- PUSH
/
PLASTIC
RETAINER J9314-100
Fig. 10 Removing Quick-Connect Fitting

W A R N I N G : T H E FUEL S Y S T E M P R E S S U R E IN T H E
F O L L O W I N G T E S T M A Y E X C E E D 100 P S I . B E F O R E
S T A R T I N G T E S T , VERIFY G O O D C O N N E C T I O N S AT
J9214-28
E N D S O F A D A P T E R T O O L 6539. B E S U R E T O O L I S
L O C K E D O N T O FUEL R A I L A N D F U E L R E T U R N
Fig. 9 Fuel Pressure Test— Typical
LINE. P U L L FIRMLY O N E N D S O F T O O L TO V E R
(2) Note pressure gauge reading. Fuel pressure IFY.
should be approximately 214 kPa (31 psi) at idle.
(3) Disconnect vacuum line at fuel pressure regu (7) To activate the fuel pump and pressurize the
lator (Figs. 6 or 7). Note gauge reading. With vac system, obtain the DRB II scan tool. Refer to the ap-
tween fuel filter and fuel rail for kinks or

obstructions. Proceed to the Fuel P u m p Capacity
Test.
FUEL SYSTEM PRESSURE TEST—5.9L ENGINE

Fuel systems on vehicles equipped with a 5.9L en
gine are equipped with a fuel t a n k module mounted,
combination fuel filter/fuel pressure regulator (Fig.
12). The fuel pressure regulator is not controlled by
engine vacuum.
Fig. 1"f Adapter Tool—Typical Connection

propriate Powertrain Diagnostic Procedures service
manual for DRB II operation.
(8) M O M E N T A R I L Y pinch the rubber hose por
tion of adapter tool 6539. Pressure should rise to ap
proximately 75 psi within two (2) seconds. D O N O T
pinch hose for longer t h a n five seconds.
If fuel pump pressure rises to approximately 75 psi
within two seconds, pump is operating at its maxi ROLLOVER VALVE J9314-167
mum and is correct.
Fig. 12 Fuel Filter/Fuel Pressure Regulator—5.9L
If fuel pump pressure does not rise to approxi
Engine
mately 75 psi within two seconds, proceed as follows:
(9) Release fuel system pressure. Refer to the pre With engine at idle speed, system fuel pressure
vious Fuel Pressure Release Procedure in this group. should be approximately 241-310 kPa (35-45 psi).
(10) Raise and support vehicle. (1) Remove the protective cap at the fuel rail (Fig.
(11) Disconnect fuel supply line at inlet (fuel t a n k 13). Connect the 0-414 kPa (0-60 psi) fuel pressure
side) of fuel filter. Connect Fuel Line (Tube) Pressure gauge (from Gauge Set 5069) to test port pressure fit
Test Adapter Tool number 6631 (3/8 in.) between fuel ting on fuel rail (Fig. 14).
filter and fuel supply line.
W A R N I N G : T H E F U E L S Y S T E M P R E S S U R E IN T H E
F O L L O W I N G T E S T M A Y E X C E E D 100 P S I . B E F O R E
S T A R T I N G TEST, V E R I F Y G O O D C O N N E C T I O N S A T
E N D S O F A D A P T E R T O O L 6631. B E S U R E T O O L I S
L O C K E D O N T O F U E L FILTER A N D F U E L S U P P L Y
LINE. PULL FIRMLY O N E N D S O F T O O L T O V E R
IFY.
(12) To activate the fuel pump and pressurize the

system, obtain the DRB II scan tool. Refer to the ap
M O M E N T A R I L Y pinch the rubber hose portion of
adapter tool 6631. Pressure should rise to approxi
mately 75 psi within two (2) seconds. D O N O T pinch
Fig. 13 Fuel Pressure Test Port—5.9L Engines
hose for longer t h a n five seconds.
If fuel pump pressure now rises to approximately (2) Note pressure gauge reading. Fuel pressure
75 psi within two seconds, but this pressure could not should be approximately 241-310 k P a (35-45 psi) at
be met at the fuel rail, check for a plugged or re idle.
stricted fuel filter. Also check the fuel supply line be
riod of time may be caused by:
• Fuel pressure bleeding past the fuel pressure reg
ulator.
• Fuel pressure bleeding past the check valve in the
outlet end of the fuel tank mounted fuel pump.
(1) Remove protective cap at fuel rail test port
(Figs. 15 or 16). With the engine off, connect an ac
curate 0-689 kPa (0-100 psi) fuel gauge to the pres
sure test port fitting on the fuel rail. The fitting on
the pressure tester must be in good condition and
free of any leaks before performing this test.
PRESSURE REGULATOR
Fig. 14 Fuel Pressure Test—Typical

(3) If pressure is at O psi, connect DRB II scan tool
and refer to operating instructions in the appropriate
Powertrain Diagnostics Procedures service manual.
If operating pressure is above 45 psi, fuel pump is
OK. Replace fuel filter/fuel pressure regulator assem-
bly.
FUEL PUMP CAPACITY TEST-ALL GAS ENGINES

Before performing this test, verify fuel pump pres
sure by performing the previous tests.
(1) Release the fuel system pressure from fuel sys
tem. Refer to the previous Fuel Pressure Release
Procedure in this group.
(2) Disconnect the fuel supply line at fuel rail near
pressure regulator.
(3) Connect Fuel Line (Tube) Pressure Test
Adapter Tool number 6631 (3/8 in.) into the discon
nected fuel supply line (tube). Insert the other end of
Adapter Tool 6631 into an approved gasoline con
tainer.
(4) To activate the fuel pump and pressurize the
system, obtain the DRB II scan tool. Refer to the ap
(5) 3.9L/5.2L E n g i n e s : A good fuel pump will de
liver approximately 1 liter of fuel per minute. 5.9L
E n g i n e s : A good fuel pump will deliver approxi
mately 2 liters of fuel per minute.
FUEL PRESSURE LEAK DOWN T E S T - 3 JL/5.2L

ENGINE
ENGINE OFF CONNECTOR HOSES J9214-27
Abnormally long periods of cranking to restart a
Fig. 16 Fuel Pressure Test Port—5.2L Engine
hot engine t h a t has been shut down for a short pe
(2) Start the vehicle and let engine idle. Check installation in this group. If pressure drop is within
fuel pressure reading on gauge. Fuel pressure should specifications, proceed to next step.
be within specifications. Refer to the previous Fuel (13) Clamp off the rubber hose portion of adapter
System Pressure Tests. tool number 6631 connected to the fuel supply line.
(3) Shut engine off. Observe and record fuel pres Allow engine to set for 30 minutes. If pressure h a s
sure reading on gauge. Leave fuel pressure gauge dropped more t h a n 138 kPa (20 psi) in 30 minutes,
connected. Allow engine to set for 30 minutes and pressure is bleeding past the fuel pressure regulator.
then compare the fuel pressure reading on the gauge Replace fuel pressure regulator. Refer to Fuel Pres
with t h e reading taken when engine was shut down. sure Regulator removal and installation in the Com
A pressure drop of up to 138 k P a (20 psi) within 30 ponent Removal/Installation section of this group.
minutes is within specifications.
(4) If the fuel pressure drop is within specifica FUEL PRESSURE LEAK DOWN TEST—5.9L
tions, the fuel pump outlet check valve and fuel pres ENGINE
sure regulator are both operating normally.
(5) If fuel pressure drop is greater t h a n 138 kPa ENGINE OFF
(20 psi), it must be determined if this drop is being Abnormally long periods of cranking to restart a
caused by (in-tank mounted) fuel pump outlet check hot engine t h a t has been shut down for a short pe
valve or fuel pressure regulator. Proceed to next step. riod of time may be caused by:
(6) Release the fuel system pressure from fuel sys • Fuel pressure bleeding past a fuel injector.
tem. Refer to the previous Fuel Pressure Release • Fuel pressure bleeding past the check valve in t h e
Procedure in this group. fuel filter/fuel pressure regulator.
(7) Disconnect both fuel tubes (lines) at fuel rail (1) Disconnect the fuel inlet tube at fuel rail (Fig.
near fuel pressure regulator. 18). This is done by pushing on plastic part of quick-
(8) Connect Fuel Line (Tube) Pressure Test connect fitting on tube (Fig. 19).
Adapter Tool number 6631 (3/8 in.) between the dis
connected fuel supply line and fuel rail (Fig. 17).
connected fuel return line and fuel rail (Fig. 17).
Fig. 18 Fuel Pressure Test Port—5.9L Engines

connected fuel tube and fuel rail.
(3) Connect the 0-414 kPa (0-60 psi) fuel pressure
Fig. 17 Adapter Tools—Typical Connections test gauge (from Gauge Set 5069) to the test port on
(10) Start engine. Observe and record fuel system tool 6631. T h e fittings o n b o t h t o o l s m u s t b e i n
pressure. g o o d c o n d i t i o n a n d free from a n y small l e a k s
(11) Shut engine off. b e f o r e p e r f o r m i n g t h e p r o c e e d i n g test,
(12) Clamp off the rubber hose portion of adapter (4) Start engine and bring to normal operating
tool number 6539 connected to the fuel return line. temperature.
Allow engine to set for 30 minutes. If pressure has (5) Observe test gauge. Normal operating pressure
dropped more than 138 kPa (20 psi) in 30 minutes, should be 241-310 kPa (35-45 psi).
pressure is bleeding past the (in-tank mounted) fuel (6) Shut engine off.
pump outlet check valve. Replace Fuel Pump Module (7) Pressure should not fall below 24 psi for five
assembly. Refer to Fuel Pump Module removal and minutes.
FUEL TUBE REMOVAL REMOVAL
QUICK CONNECT
FITTING
W A R N I N G : THE F U E L S Y S T E M I S U N D E R A C O N
PUSH S T A N T P R E S S U R E (EVEN WITH THE E N G I N E OFF).
BEFORE S E R V I C I N G THE FUEL FILTER, THE FUEL
PUSH
SYSTEM P R E S S U R E MUST BE RELEASED.
PUSH
The fuel filter is located under the vehicle and near
the fuel tank. It is mounted to the frame rail (Fig.
20).
(1) Perform Fuel System Pressure Release proce
dure.
INSTALLATION
(4) Remove and discard both fuel hose-to-fuel filter
X PUSH •PUSH hose clamps.

(5) Wrap a shop towel around hoses to absorb fuel.
Remove hoses at filter.
/
PLASTIC
(6) Remove filter from frame.
RETAINER J9314-100
Fig. 19 Removing/Installing Quick-Connect Fitting

(8) If pressure falls below 24 psi, it must deter
mined if a fuel injector, the fuel module mounted fuel
pressure regulator or a fuel tube/line is leaking.
(9) Again, start engine and bring to normal oper
ating temperature.
(10) Shut engine off. FUEL
FUEL HOSES FILTER
(11) Checking for fuel injector leakage: Clamp
off the rubber hose portion of tool 6539 between the
HOSE
disconnected fuel tube (line) and test port inlet. If CLAMPS
pressure now holds at or above 24 psi, a fuel injector . FILTER MOUNTING
BOLT J9214-68
or the fuel rail is leaking.
Checking for fuel pressure regulator or fuel Fig. 20 Fuel Filter—3.9U5.2L Engine
tube leakage: Clamp off the rubber hose portion of
tool 6539 between the fuel rail and test port inlet. If INSTALLATION
pressure now holds at or above 24 psi, a leak can be C A U T I O N : The tubes/hoses used on fuel injected
found at a fuel tube/line. If no leaks are found at fuel vehicles are of a special construction. This is due
tubes, replace the fuel filter/fuel pressure regulator. to the higher fuel pressures and the possibility of
contaminated fuel in this system. If it is necessary
MECHANICAL MALFUNCTIONS
to replace these tubes/hoses, only tubes/hoses
Mechanical malfunctions are more difficult to diag marked EFM/EFI may be used.
nose with this system. The powertrain control mod
ule (PCM) has been programmed to compensate for
some mechanical malfunctions such as incorrect cam C A U T I O N : The hose clamps used on fuel injected
timing, vacuum leaks, etc. If engine performance vehicles are of a special rolled edge construction to
problems are encountered and a diagnostic trouble prevent the edge of the clamp from cutting into the
code (DTC) is not displayed, the problem may be me hose. Only these rolled edge type clamps may be
chanical rather t h a n electronic. used in this system. All other types of clamps may
cut into the hoses and cause high pressure fuel
FUEL FILTER-3.9L/5.2L GAS ENGINE leaks.
For diesel engines, refer to Fuel/Water Separator
(1) Install fuel filter to frame rail. Tighten mount
Filter in the Diesel Fuel Injection—Service Proce
ing bolt to 8 N»m (75 in. lbs.) torque.
dures section of this group.
(2) Install new original equipment clamps to fuel
hoses.
(3) Install hoses to filter. Tighten clamps to 1 N*m to the higher fuel pressures and the possibility of
(10 in. lbs.) torque. contaminated fuel in this system. If it is necessary
(4) Lower vehicle. to replace these tubes/hoses, only tubes/hoses
(5) Connect battery cable to battery. marked E F M / E F I may be used.
(6) Start engine a n d check for leaks.
FUEL FILTER—5.9L GAS ENGINE C A U T I O N : The hose clamps used o n fuel injected
For diesel engines, refer to Fuel/Water Separator vehicles are of a special rolled edge construction to
Filter in the Diesel Fuel Injection—Service Proce prevent the edge of the clamp from cutting into the
dures section of this group. hose. Only these rolled edge type clamps may be
The fuel filter and fuel pressure regulator (Fig. 21) used in this system. All other types of clamps may
are one non-repairable component. For service, refer cut into the h o s e s and cause high pressure fuel
to Fuel Filter/Fuel Pressure Regulator. This can be leaks.
found in the Multi-Port Fuel Injection (MPI)—Com
Use new original equipment type hose clamps.
ponent Removal/Installation section of this group.
Tighten hose clamps to 1 N*m (10 in. lbs.) torque.
QUICK-CONNECT FITTINGS
Also refer to t h e previous Fuel Tubes/Lines/Hoses
and Clamps.
Two different types of Quick-Connect fittings are
used at several fuel system connections. One type of
fitting will be referred to as a Tab Type Fitting. The
other will be referred to as a Plastic Ring Type fit
ting.
C A U T I O N : Quick-connect fittings are not serviced

separately. Do not attempt to repair damaged quick-
connect fittings or fuel tubes. Replace the complete
fuel tube/quick-connect fitting assembly.
ROLLOVER VALVE J9314-167
Fig. 21 Fuel Filter/Fuel Pressure Regulator—5.9L TAB TYPE FITTING

Engine This fitting is equipped with a retainer t a b (Figs.
22 or 23) t h a t must be released prior to disconnecting
FUEL TUBES/LINES/HOSES AND CLAMPS
the fitting from the fuel tube. This type of fitting can
Also refer to Quick-Connect Fittings in this sec
be disassembled either manually or with a straight
tion.
blade screwdriver.
WARNING: THE FUEL SYSTEM IS UNDER A CON
S T A N T P R E S S U R E ( E V E N WITH T H E E N G I N E OFF).
BEFORE SERVICING A N Y FUEL SYSTEM H O S E S ,
FITTINGS O R L I N E S , T H E F U E L S Y S T E M P R E S
S U R E MUST B E R E L E A S E D - REFER TO THE FUEL
PRESSURE RELEASE PROCEDURE IN T H I S
GROUP.
Inspect all hose connections such as clamps, cou

plings and fittings to make sure they are secure and
leaks are not present. The component should be re
placed immediately if there is any evidence of degra
dation t h a t could result in failure.
Avoid contact of any fuel tubes/hoses with other ve
hicle components t h a t could cause abrasions or scuff
TUBE E N D TAB J9114-167
ing. Be sure t h a t the plastic fuel tubes are properly
routed to prevent pinching and to avoid heat sources.
Fig. 22 Tab Type Fitting
C A U T I O N : The tubes/hoses used o n fuel injected
vehicles are of a special construction. This is due
PULL TAB
RETAINER TAB RETAINER TAB BENT

IN ORIGINAL UPRIGHT D O W N FOR
POSITION REMOVAL J9114-168
Fig. 23 Retainer Tabs Fig. 25 Manually Disconnecting Fitting

MANUAL DISASSEMBLY (6) Pull the fuel tube out of quick-connect fitting
(Fig. 26).
W A R N I N G : R E L E A S E FUEL S Y S T E M P R E S S U R E (7) Inspect the quick-connect fitting body and re
B E F O R E DISCONNECTING A QUICK-CONNECT FIT tainer for damage. Replace as necessary.
TING. R E F E R TO THE FUEL P R E S S U R E R E L E A S E FUEL QUICK CONNECT
PROCEDURE. TUBE FITTING
(1) Disconnect negative cable from the battery,

(2) Perform the Fuel Pressure Release Procedure.
Refer to the Fuel Pressure Release Procedure in this
section.
(3) Bend the retainer tab downward (Fig. 23).
CAUTION: If the retainer tab on the removable pull

tab is not bent down prior to disconnecting quick-
connect fitting, the connector could be damaged.
(4) While pushing upward on the bottom side of

the pull tab, release the retainer legs by pulling
them away from each other (Fig. 24). STOP J9114-171
(5) Raise the pull tab until the hooks on the re
tainer legs clear the stop on the fuel tube fitting Fig. 26 Fuel Tube and Fitting
(Fig. 25). (8) Prior to connecting the fuel tube to quick-con
PULL nect fitting, check condition of tube and clean the
fuel tube and fitting with a lint-free cloth. Lubricate
it with clean engine oil.
(9) Insert the fuel tube into quick-connect fitting
until stop on fuel tube rests against back of fitting.
Push retainer down until it locks in place. Pull back
on fuel tube and fitting to be sure of a complete con
nection.
DISASSEMBLY WITH SCREWDRIVER

W A R N I N G : R E L E A S E FUEL S Y S T E M P R E S S U R E
B E F O R E DISCONNECTING A QUICK-CONNECT FIT
TING. R E F E R TO THE FUEL P R E S S U R E R E L E A S E
PROCEDURE.
Fig. 24 Separating Retainer Legs
(1) Disconnect negative cable from the battery.

section.
(3) Bend t h e retainer tab downward.
C A U T I O N : If the retainer tab on the removable pull

tab is not bent d o w n prior to disconnecting the
quick-connect fitting, the connector could be d a m
aged.
(4) Insert screwdriver tip between connector body

and retainer pull tab (Fig. 27).
RETAINER SCREWDRIVER J9114-181
Fig. 29 Disconnecting Fitting

(9) Prior to connecting fuel tube to quick-connect
fitting, check condition of tube and clean the fuel
tube and fitting with a lint-free cloth. Lubricate it
with clean engine oil.
(10) Insert fuel tube into quick-connect fitting un
til stop on fuel tube rests against back of fitting.
Push retainer down until it locks in place. Pull back
on fuel tube and fitting to be sure of a complete con
nection.
J
911
41
-7
2 PLASTIC RING TYPE FITTING
Fig. 27 Disassembly with Screwdriver WARNING: RELEASE FUEL SYSTEM P R E S S U R E

B E F O R E D I S C O N N E C T I N G A Q U I C K - C O N N E C T FIT
(5) Turn screwdriver 90 degrees to lift retainer up
TING. R E F E R T O T H E FUEL P R E S S U R E R E L E A S E
(Fig. 28). PROCEDURE.
RETAINER SCREWDRIVER
PULL TAB This type of fitting contains non-serviceable sealed
O-rings.
(1) Disconnect negative cable from the battery.
section.
(3) To release the fuel tube from the fitting, push
in on the tube while pushing the spring loaded plas
tic retainer ring into the fitting (Fig. 30). With the
plastic ring depressed, pull the tube from fitting. Af
ter disconnection, the plastic retainer ring will re
main on the fitting.
(4) Inspect fitting connector body and plastic re
tainer ring (Fig. 30) for damage. Replace as neces
J9114-173
sary.
(5) Prior to connecting fuel tube to quick-connect
Fig. 28 Releasing Retainer
fitting, check condition of tube and clean the fuel
(6) Raise the pull tab until the hooks on the re tube and fitting with a lint-free cloth. Lubricate it
tainer legs clear the stop on the fuel tube fitting with clean engine oil.
(Fig. 29). (6) Insert the fuel tube into quick-connect fitting
(7) Pull fuel tube out of quick-connect fitting. (Fig. 30) until a click is felt. Pull back on fuel tube
(8) Inspect fitting body and retainer for damage. and fitting to be sure of a complete connection.
Replace as necessary. (7) Connect negative cable to battery.
14 - 14 FUEL SYSTEM
FUEL TUBE REMOVAL QUICK CONNECT

FITTING
PUSH
INSTALLATION
^ PUSH »- •PUSH
/
PLASTIC
RETAINER J93U-100
Fig. 30 Plastic Ring Type Fitting

FUEL DELIVERY—DIESEL ENGINE
INDEX
page page
Fuel Gauge Sending Unit Module 15 Mechanical Lift Pump 15
General Information 15 Quick Connect Fittings—Except Chassis
Manual Shut Down Lever . . 17 Fuel Tubes 17
GENERAL INFORMATION
The fuel system of the 5.9L turbo-diesel engine
consists of the:
• Fuel t a n k
• Low and high pressure fuel supply lines
• Mechanical lift pump
• Fuel/water separator filter
• Fuel heater
• Fuel injection pump
• Fuel injectors
• Fuel return lines
For information regarding fuel requirements of t h e
5.9L turbo diesel engine, refer to the Fuel Require
ments—Diesel Engines paragraph at the front of this
group.
Fig. 1 Lift Pump
MECHANICAL LIFT PUMP
The mechanical lift pump is located on t h e left side The lift pump has a manual lever.(Fig. 2). The le
of the engine cylinder block. The lift pump is driven ver is located on the lower right side of the pump
by an eccentric on the camshaft t h a t actuates a housing. The purpose of the lever is to prime the fuel
spring loaded lever in the pump (Fig. 1). The lever is system and bleed air from the system if the vehicle
connected to the pump diaphragm. When the eccen has run out of fuel. To prime the system up to the
tric on the camshaft pushes the lever upward, the le injector pump, raise and lower the lever until resis
ver in t u r n pulls the diaphragm to its extended tance is felt. During vehicle operation the pump le
position. Fuel is drawn into the pump chamber ver must be in the up position.
through the inlet check valve. When the pump gath
ers more fuel in the fuel chamber t h a n the engine
can consume, the outlet check valve is held closed.
The fuel gathered in lift pump chamber prevents the
diaphragm from relaxing. The lever will continue to
move up and down on the shaft connecting it to the
diaphragm. However, the lever is prevented from op
erating the diaphragm until the check valve again
opens to expel fuel from the pump chamber. This pro
cess continues as long as the engine is running.
Minimum lift pump output pressure is 21 Kpa (3
psi). Lift pump output volume is 0.75 liters (0.70 U.S.
quarts) per 30 seconds of engine cranking.
The lift pump housing has a weep hole at the bot
tom of the casing (Fig. 1). If the diaphragm ruptures, J9114-3
fuel will exit out of the weep hole and the pump
Fig. 2 Lift Pump Manual Lever
must be replaced. The lift pump is not serviceable
and must be replaced as a complete assembly. FUEL GAUGE SENDING UNIT MODULE
The fuel gauge sending unit module is installed in
C A U T I O N : Do not operate the engine if the fuel sup the top of the fuel t a n k (Fig. 3). The fuel gauge send
ply line h a s a restriction of more than 95 M M Hg ing unit module contains the following components
(3.75 in Hg). (Fig. 4).
• Fuel t a n k reservoir (1) Drain the fuel tank. Eefer to Draining Fuel
• Separate in-tank fuel filter Tank in the Fuel Tank section of this group.
• Pressure relief/rollover valve (2) Remove fuel tank. Refer to Fuel Tanks in this
• Fuel gauge sending unit group.
• Fuel filler vent (3) The fuel module locknut (collar) is threaded
onto the fuel tank. Remove the fuel module locknut
(Fig. 3). The fuel module will spring up when the
locknut is removed.
(4) Remove module from fuel tank.
DISASSEMBLY
FUEL GAUGE SENDING UNIT

(1) Remove sending unit mounting screws (Fig. 5).
(2) Mark the sending unit electrical wires for cor-
FUEL G A U G E TABS
Fig. 3 Top View of Fuel Gauge Sending Unit
IN-TANK
FUEL FILTER J9114-146
Fig. 5 Fuel Gauge Sending Unit and In-Tank Filter

Service
rect installation when the new unit is installed.
Carefully disconnect electrical wires from sending
unit. Remove sending unit.
(3) Reverse order of removal for installation.
IN-TANK FUEL FILTER
C A U T I O N : The diesel in-tank fuel filter is similar in

appearance to filter used with gasoline engines ex
cept for color. The in-tank filter must be replaced
with filter intended for diesel vehicles.
The in-tank filter is attached to the bottom of the

fuel module (Fig. 5).
(1) Pry the mounting tabs back and remove the in-
J9114-229
t a n k fuel filter.
(2) Install new fuel filter into retaining tabs.
Fig. 4 Fuel Gauge Sending Unit Module--Diesel
Engine FUEL GAUGE SENDING UNIT MODULE
INSTALLATION
REMOVAL
C A U T I O N : Whenever the fuel module is serviced,
C A U T I O N : Whenever the fuel module i s s e r v i c e d , the locknut and gasket must be replaced.
the locknut (collar) a n d gasket must be replaced.
(1) Using a new gasket, position fuel module into PULL TAB
opening in fuel tank.
(2) Position new locknut over top of fuel module.
(3) Tighten locknut.
tion in this section.
MANUAL SHUT DOWN LE¥ER

The injection pump has a m a n u a l shut down lever
(Fig. 6). In an emergency, the engine can be shut
down by turning the lever forward.
RETAINER TAB RETAINER TAB BENT

IN ORIGINAL UPRIGHT DOWN FOR
POSITION REMOVAL J9114-168
Fig. 8 Retainer Tabs

MANUAL DISASSEMBLY
C A U T I O N : If retainer tab on removable pull tab is

not bent down before disconnecting quick connect
fitting, connector could be damaged.

PULL
Fig. 6 Manual Shut Down Lever

QUICK CONNECT FITTINGS-EXCEPT CHASSIS
FUEL TUBES
Quick Connect fittings are used at several fuel sys
tem connections (Fig. 7). The fittings have a retainer
tab. The retainer must be released before disconnect
ing the fittings from the fuel tube (Fig. 8).
Fig. 9 Separating Retainer Legs

(2) While pushing upward on the bottom side of
the pull tab, release t h e retainer legs by pulling
them away from each other (Fig. 10).
(3) Raise the pull tab until hooks on the retainer
legs clear t h e stop on t h e fuel tube fitting (Fig. 10).
(4) Pull fuel tube out of connector (Fig. 11).
(5) Inspect connector body and retainer for dam
age. Replace as necessary.
Before connecting the fuel tube to the quick con
Fig. 7 Quick Connect Fittings
nect fitting, clean the fuel tube fitting. Lubricate the
DISASSEMBLY fitting with clean engine oil.
Quick Connect fittings can be disassembled either (6) Insert fuel tube into quick connect fitting until
manually or with a straight blade screwdriver. stop on fuel tube rests against back of fitting. Push
PULL
TAB
RETAINER
CLEAR OF ff
FUEL TUBE \
t
iiiilil
FUEL TUBE J9114-170 J9114-172
Fig. 10 Manually Disconnecting Quick Connect Fig. 12 Disassembly with Screwdriver

Fitting
FUEL QUICK CONNECT PULL TAB
TUBE FITTING
FUEL
TUBE J9114-173
STOP J9114-171
Fig. 13 Releasing Retainer
Fig. 11 Fuel Tube and Quick Connect Fitting
RETAINER ^SCREWDRIVER
retainer down until it locks in place. Pull back on
fuel tube and fitting to be sure of a complete connec
tion.
DISASSEMBLY WITH SCREWDRIVER
CAUTION: If the retainer tab on the removable pull

tab is not bent down before disconnecting the
quick connect fitting, the connector could be dam
aged.

(2) Insert screwdriver tip between connector body
and retainer pull tab (Fig. 12).
J9114-181
(3) Turn screwdriver 90 degrees to lift retainer up
(Fig. 13). Fig. 14 Disconnecting Quick-Connect Fitting
(4) Raise pull tab until hooks on the retainer legs
clear the stop on the fuel tube fitting (Fig. 14). Before connecting fuel tube to quick connect fit
(5) Pull fuel tube out of connector (Fig. 11). ting, clean the fuel tube fitting. Then lubricate the
(6) Inspect connector body and retainer for dam fitting with clean engine oil.
age. Replace as necessary.
(7) Insert fuel tube into quick connect fitting until

stop on fuel tube rests against back of fitting. Push QUICK CONNECT
retainer down until it locks in place. Pull back on
fuel tube and fitting to be sure of a complete connec
tion.
CHASSIS FUEL TUBE QUICK-CONNECT

FITTINGS
Quick-connect fuel tube fittings are used at the
ends of the chassis fuel tubes (lines) (Fig. 15). The
, w r L C
fitting consists of O-rings and a plastic release collar COLLAR J9014-188

to disconnect the fitting from the fuel tube.
Fig. 16 Quick-Connect Fitting Assembly—Chassis
QUICK-CONNECT Fuel Tubes
FITTING
FUEL
TUBE
QUICK-CONNECT
FUEL
FITTING J9014-189
Fig. 17 Assembled Quick-Connect Fitting—Chassis

J9014-187 Fuel Tubes
Fig. 15 Quick-Connect Fitting—Chassis Fuel Tubes
At the end of the fuel tube fitting is a raised shoul
der. When the fuel tube is installed into the quick-
connect fitting, the shoulder is locked in place by
tangs inside the fitting (Fig. 16). After the tube is in
stalled into the fitting, Verify t h a t connection is se
cure by firmly pulling back on fuel tube (Fig. 17).
The tube should be locked in place.
To disconnect the fitting from the fuel tube, pull
the release collar back into the fitting. Then slide the
fitting off the fuel tube (Fig. 18).
Fig. 18 Quick-Connect Fitting
Disassembly— Chassis Fuel Tubes
F U E L TANKS
INDEX
page page
Fuel Gauge Sending Unit 24 Fuel Tank Skid Plate . 20
Fuel Pump 22 Fuel Tanks 21
Fuel Reservoir 23 General Information 20
Fuel Tank Filler Tube C a p 20 Heat Shields 21
Fuel Tank Pressure Relief/Rollover Valve . . . . . . 24 No-Lead Fuel Tank Filler Tube 20
GENERAL INFORMATION diameter t h a n those used for non-catalyst vehicles to

All Dodge Trucks pass a full 360 degree rollover with permit entry of only the smaller no-lead fuel nozzles.
out fuel leakage. To accomplish this, fuel and vapor A deflector is installed in the fuel filler opening. The
flow controls are required for all fuel tank connections. deflector is opened by the no-lead fuel nozzle.
All models have a pressure relief/rollover valve The fuel filler tube on these models has a one-way
mounted in the top of the fuel tank. On vehicles ball check valve. The valve is designed to prevent
equipped with a return line from fuel pump to fuel fuel back splash which may occur while filling the
tank, a one-way check valve is used to provide required tank.
protection. In addition to the valve, improved flow con
A label is attached to instrument panel under fuel
trol is used in the fuel pump. Fuel flow is controlled if
gauge t h a t reads UNLEADED FUEL ONLY as a re
pump is subjected to higher than normal pressure dur
minder to driver. A similar label is located near fuel
ing rollover. For the same reason, a fuel tank filler tube
cap (gas cap) with higher pressure setting is used to t a n k filler.
control fuel flow on vehicles with side fill.
An evaporation control system is used to reduce
FUEL TANK FILLER TUBE CAP
The loss of any fuel or vapor out of filler neck is
emissions of fuel vapors into atmosphere by evapora
tion and to reduce unburned hydrocarbons emitted prevented by the use of a pressure-vacuum fuel tank
by vehicle engine. When fuel evaporates from fuel filler tube cap. Relief valves inside cap will release
tank, vapors pass through vent hoses or tubes to a only under significant pressure of 6.58 to 8.44 kPa
charcoal canister. The are temporarily held in the (1.95 to 2.5 psi). The vacuum release for all gas caps
canister. When the engine is running, the vapors are is between .97 and 2.0 k P a (.14 and .29 psi). This cap
drawn into intake manifold. Refer to Group 25, must be replaced by a similar unit if replacement is
Emission Control System for additional information. necessary. This is in order for the system to remain
Inspect all hose connections to make sure they are effective.
secure and not leaking. Hoses should be replaced im
mediately if there is any evidence of degradation C A U T I O N : Remove fuel tank filler tube cap before
t h a t could result in failure. servicing any fuel system component. This is done
Avoid contact with clamps or other components to help relieve tank pressure.
t h a t cause abrasions or scuffing. Be sure t h a t the FUEL TANK CAPACITIES
rubber hoses are properly routed to prevent pinching
and to avoid heat sources.
The hoses used on fuel injected vehicles are of a TANK: LITERS GALLONS
special construction due to higher fuel pressures in Standard 83.0 22
volved in system. If hoses need replacement, only use Optional 114 30
hoses marked EFM/EFI. Ramcharger 120.9 34
The hose clamps used on fuel injected vehicles have
Nominal refill capacities are shown. A variation may be observed
a special rolled edge construction. This prevents the
from vehicle to vehicle due to manufacturing tolerances and refill
edge of the clamp from cutting into the hose. Only procedures.
these rolled edge type clamps may be used on this
J9014-182
system. Other clamps may cut into the hoses. This
could cause high pressure fuel leaks. FUEL TANK SKID PLATE
A protective metal skid plate is available for the
NO-LEAD FUEL TANK FILLER TUBE Ramcharger thirty-four (34) gallon fuel t a n k (Fig. 1).
All catalyst equipped vehicles have a special fuel The plate is mounted to the frame rails and to brack
t a n k filler tube. The fuel filler opening is smaller in ets attached to frame crossmembers.
FRAME RAIL REMOVAL-MID-FRAME MOUNTED TANKS

(1) Drain fuel tank. Refer to Draining Fuel Tank
in this group.
(3) Remove fuel tank filler tube cap.
(4) Pump all fuel from fuel t a n k into an approved
portable holding tank. If this equipment is not avail
able, disconnect fuel tube (line) and drain t a n k dry
into a properly identified Gasoline safety container.
Refer to Draining Fuel Tank.
(5) Raise vehicle on hoist. Disconnect all vent
hoses and filler hose (Figs. 2 and 3).
F U E L F , L T E R
PRESSURE RELIEF/
SKID PLATE
RN869
Fig. 1 Fuel Tank Skid Plate

HEAT SHIELDS
The sheet metal heat shields must be removed
when servicing fuel tank, fuel tubes/lines or vapor
vent line. It is very important that these h e a t
shields b e reinstalled after service. They are used
to protect lines and t a n k from heat of exhaust sys J9014-191
tem. See Group 11 in this manual for proper instal
Fig. 2 Hose Connections—Mid-Frame Mounted Fuel
lation.
Tanks—Typical
FUEL TANKS (6) Place a transmission jack under the center of
the fuel tank. Apply a slight amount of pressure to
DRAINING FUEL TANK
fuel tank with transmission jack.
(1) Remove fuel tank filler tube cap to release fuel
tank pressure. WARNING: WRAP SHOP TOWELS AROUND HOSES
(2) Perform Fuel System Pressure Release proce TO CATCH ANY G A S O L I N E SPILLAGE.
dure as described in this group.
(3) Raise vehicle on hoist. (7) Remove fuel tank mounting strap nuts at the
(4) Drain fuel into an approved portable holding crossmembers (Fig. 4). Lower fuel t a n k enough to
tank or a properly labeled gasoline safety container. permit fuel gauge wire and fuel tubes to be discon
• If fuel pump operates, fuel can be drained through nected from fuel pump module at top of fuel tank.
fuel supply hose. The DRB II scan tool can be used to Disconnect fuel tubes from fuel pump module (Fig.
operate the electric fuel pump (gas engines only). 5). Refer to Quick-Connect Fittings in the Fuel De
• If pump does not operate, but fuel level in fuel livery sections of this group.
tank is below fuel filler hose, fuel can be siphoned (8) Lower fuel tank.
through fuel filler hose. The hose will have to be dis
connected from filler neck. INSTALLA TION—MID-FRAME MOUNTED
• If fuel t a n k is full and fuel pump does not operate, TANKS
drain fuel from filler neck. Support fuel tank with a (1) Place fuel tank on top of transmission jack.
transmission jack. Loosen fuel t a n k mounting straps Raise tank until fuel supply tube, return tube and
with passenger side fuel strap loosened slightly more pump/gauge sending unit connector can be connected
than driver side strap. Lower the t a n k slightly. to fuel pump module. Refer to Quick-Connect Fit
Loosen the filler neck-to-filler hose clamp. Slide tings in the Fuel Delivery sections of this group.
clamp back on hose. Wrap shop towels around fuel (2) Raise tank into position under frame cross-
filler hose to absorb any spilled fuel. Disconnect filler members and connect the two end mounting straps.
hose from filler neck. Drain fuel t a n k through filler Remove transmission jack. Tighten all straps firmly.
hose. Do not over tighten retaining strap nuts.
CLAMP
CLAMP (20 INCH-POUNDS)
(2)
VIEW IN DIRECTION
OF ARROW Z RB1362A
Fig. 3 Fuel Tank Filler Tube Connections- -Mid-Frame Mounted Fuel Tanks—Typical
(3) Connect vent hoses. (8) Remove fuel tank filler tube hose and fill vent
(4) Connect fuel tube (line) if it was disconnected hose from tank (Figs. 7 and 8).
to drain tank. (9) Lower the fuel tank.
(5) Refill fuel t a n k and inspect all hoses and lines
for leaks. Connect battery cable to battery. INSTALLATION
(1) Position tank on transmission jack.
REMO VA L—RAMCHARGER MODELS (2) Raise tank until fuel supply tube, return tube
(1) Drain fuel tank. Refer to Draining Fuel Tank and pump/gauge sending unit connector can be con
in this section. nected to fuel pump module. Refer to Quick-Connect
(2) Disconnect negative battery cable at battery. Fittings in the Fuel Delivery sections of this group.
(3) Remove fuel t a n k filler tube cap to release fuel (3) Raise tank into position.
t a n k pressure. (4) Install tank mounting straps. Connect J-bolts
(4) Pump all fuel from fuel t a n k into an approved and tighten nuts as shown in Fig. 7.
portable holding tank. If this equipment is not avail (5) Remove jack.
able, disconnect the fuel tube (line) and drain t a n k (6) Connect t a n k filler tube and all vent hoses. In
dry into a properly identified Gasoline safety con stall new hose clamps and tighten securely.
tainer. (7) Fill fuel tank and inspect all hoses and lines
(5) Raise vehicle on hoist. for leaks.
(6) Place transmission jack under center of t a n k (8) Connect battery cable to battery.
and apply slight pressure. Disconnect the t a n k
mounting straps J-bolts and remove retaining straps FUEL PUMP
(Fig. 6).
REMOVAL/INSTALLA TION
(7) Lower fuel t a n k enough to permit fuel gauge
Gas Engines: Refer to Fuel Pump Module in the
wire and fuel tubes to be disconnected from fuel
Fuel Delivery System section of this group.
pump module. The fuel pump module is located at
Diesel Engines: Refer to Mechanical Lift Pump in
top of fuel tank. Disconnect fuel tubes from fuel
the Diesel section of this Group.
pump module on top of t a n k (Fig. 7). Refer to Quick-
Connect Fittings in t h e Fuel Delivery sections of this
group.
USED WITH
7-INCH RAIL TIGHTENING TORQUE REAR
A 30 FT LBS (41 N-m) STRAP
B TIGHTEN TO SECURE TANK

C 100 IN LBS (11 N-m)
VIEW IN CIRCLE Z
(30 G A L TANK)
J9014-183
Fig. 4 Mid-Frame Mounted Fuel Tank Removal/Installation—Typical

PRESSURE RELIEF/ PUMP/GAUGE NUT (2)
ROLLOVER VALVE SENDING ASSEMBLY
UNIT (200 INCH-POUNDS)
ELECTRICAL
CONNECTOR
FUEL
SUPPLY
TUBE
LOCKNUT
FUEL
RETURN
TUBE
J9114-232
Fig. 5 Fuel Pump Module Connections—Typical

TIGHTEN NUT TO
FUEL RESERVOIR END OF THREAD
FUEL TANK O N STUD
The fuel reservoir (Fig. 9) is part of the lower end ÔUNTWG ASSEMBLY VIEW A -
of the fuel pump module. The purpose of the reser ol KAP5> STRAP ADJUSTMENT J9014-184
voir is to provide fuel at the pump intake during all
driving conditions. This is especially those times Fig. 6 Ramcharger Fuel Tank Removal/Installation
FUEL TUBES FUEL
HOUSING J9114-162
Fig. 9 Fuel Reservoir Housing—Typical

FUEL GAUGE SENDING UNIT
The fuel gauge sending unit is attached to the fuel
TO FILLER pump module. Refer to Fuel Delivery System in this
N E C K
J9014-185 group for fuel gauge sending unit service.
Fig. 7 Fuel Tube Connections—Ramcharger FUEL TANK PRESSURE RELIEF/ROLLOVER VALVE
The fuel tanks of all vehicles have a pressure re
lief/rollover valve. The valves relieve fuel t a n k pres
sure and prevent fuel flow through fuel t a n k vent
hoses during rollover. All vehicles pass a full 360 de
gree rollover without fuel leakage.
The pressure relief/rollover valve (Fig. 5) is
mounted at top of fuel pump module.
REMOVAL
(1) Remove fuel tank. Refer to Fuel Tanks section
in this group.
(2) Wedge the blade of a straight screwdriver be
tween rubber grommet and fuel t a n k where support
rib is located. Do not w e d g e b e t w e e n valve a n d
grommet or d a m a g e to valve may result u p o n re
moval.
(3) Use a second screwdriver as a support to pry
valve and grommet assembly from tank.
(4) To remove grommet from valve, place valve up
CLAMP right on a flat surface. Push down on the grommet.
Peel the grommet off the valve.
J9014-186
INSTALLATION
Fig. 8 Fuel Tank Tube Connections
(1) Install rubber grommet in fuel tank and work
when low fuel levels are present. The fuel return line it around the curled lip.
directs fuel into the reservoir. (2) Lubricate grommet with power steering fluid
and push valve downward into grommet. Twist valve
until properly positioned.
tion.
FUEL SYSTEM 14-25
A C C E L E R A T O R PEDAL AND T H R O T T L E CABLE
INDEX
page page
Accelerator Pedal . . . . . . . . . . . . . . . . . . . . . . . . 25 Throttle Cable—Except Diesel . . . . . . . . . . . . . . . 2 5
General Information 25 Throttle Linkage Adjustment—Diesel Engine . . . . 26
GENERAL INFORMATION PINCH

All gas powered models have torsion return springs SIDES
on the throttle body. Models equipped with a manual
transmission have a n additional pedal return spring
(Fig. 1). These springs give positive throttle return
and lower throttle pedal efforts while meeting safety
requirements.
Fig. 1 Throttle Body Return Spring—Manual

Transmission—Except Diesel
ACCELERATOR PEDAL PEDAL J9314-103
C A U T I O N : B e careful not to damage or kink the ca Fig. 2 Accelerator Pedal—Removal or Installation
ble core wire (within the cable sheathing) while ser
The plastic retainer is snapped into the pedal arm.
vicing accelerator pedal or cables.
When installing the plastic retainer to t h e accelera
tor pedal arm, note t h e index tab on the pedal a r m
REMOVAL (Fig. 3). Align the index slot (Fig. 3) on the plastic
(1) From inside t h e vehicle, hold up accelerator cable retainer to this index tab.
pedal. Remove plastic cable retainer and throttle ca
ble core wire from upper end of pedal arm (Fig. 2). THROTTLE CABLE-EXCEPT DIESEL
The plastic cable retainer snaps into pedal arm.
(2) Remove 2 accelerator pedal/bracket nuts (Fig. C A U T I O N : B e careful not to damage or kink the c a
2) and remove pedal/bracket assembly from vehicle. ble core wire (within the cable sheathing) while ser
vicing accelerator pedal or cables.
INSTALLATION
(1) Position pedal/bracket assembly over t h e two
dash panel mounting studs and install retaining REMOVAL
nuts. (1) From inside the vehicle, hold up accelerator
(2) Tighten nuts to 7 N*m (65 in. lbs.) torque. pedal. Remove plastic cable retainer and throttle ca
(3) From inside t h e vehicle, hold up t h e accelerator ble core wire from upper end of pedal arm (Fig. 2).
pedal. Install the throttle cable core wire and plastic Plastic cable retainer snaps into pedal arm.
cable retainer into the upper end of t h e pedal arm. (2) Remove the cable core wire a t the pedal arm.
INDEX
SLOT
INDEX TAB
PEDAL CABLE
^^J9314-105
ARM RETAINER J9314-104
Fig. 3 Index Tab and Slot Fig. 5 Cable Release Tab—Except Diesel—Typical
(3) From inside the vehicle, pinch both sides of the (2) Install the remaining cable housing end into
cable housing retainer at the dash panel (Fig. 2). Re the dash panel opening (snaps into position).
move cable housing from dash panel and pull into (3) Install the ball end of the cable wire through
the engine compartment. the hole in the pedal arm. Install the plastic cable re
(4) Remove the air cleaner housing. tainer. The plastic retainer is snapped into the pedal
(5) Remove the throttle cable ball end socket at arm. When installing the retainer to the accelerator
throttle body linkage (Fig. 4) (snaps off). pedal arm, note the index tab on the pedal arm (Fig.
3). Align the index slot (Fig. 3) on the plastic re
(6) Remove cable housing at throttle body mount
tainer to this index tab.
ing bracket by pressing forward on release tab with a
small screwdriver (Fig. 5). To prevent cable hous
THROTTLE LINKAGE ADJUSTMENT-DIESEL
ing breakage, press on the tab only e n o u g h to
release the cable from the bracket. Lift the cable ENGINE
housing straight up from bracket while pressing on The throttle linkage between the throttle cam and
release tab. Remove cable housing. fuel pump lever is adjustable. Adjust linkage to be
sure of full travel of throttle lever.
(7) Disconnect cable from radiator fan shroud rout
ing clip. C A U T I O N : Before adjusting injection pump throttle
(8) Remove cable from vehicle. linkage, verify that engine is set at correct low idle
SPEED
speed. Refer to Low Idle Speed Setting in the Ser
TRANS.
CONTROL CONTROL vice Adjustments—Diesel section of this group.
CABLE CABLE
(1) Disconnect throttle cable from ball stud on
CABLE
END throttle cam (Fig. 6).
THROTTLE BALL
LEVER STUD
THROTTLE
CONTROL CABLE
Fig. 4 Throttle Cable—Except Diesel—Typical

INSTALLATION
(1) Connect cable end to throttle body linkage ball BREAKOVER THROTTLE.
(snaps on). Connect cable to throttle body bracket, SPRING CABLE ^J9114 207r
(push down and lock). Connect cable to fan shroud

clip. Fig. 6 Throttle Cable and Bali Stud-Diesel
(2) Insert a 0.50 mm (0.020 inch) feeler gauge be

tween throttle cam and cam stop (Fig. 7).
BALL
STUD ' BREAKOVER
SPRING
J9114-209
Fig. 9 Incorrect Breakover Spring Position—Diesel

J9114-206
THROTTLE
Fig. 7 Throttle Cam and Cam Stop—Diesel ACTUATION
ROD
(3) Verify t h a t injection pump throttle lever is con
tacting the low idle speed stop screw (Fig. 6).
(4) Verify t h a t the spring load breakover lever has
moved off the stop and is against breakover spring
(Fig. 8).
BREAKOVER
SPRING L INDICATING
LEFT HAND
THREAD NUT J9114-210
Fig. 10 Throttle Actuation Rod—Diesel

(8) The throttle actuation rod can be rotated to in
crease or decrease adjustment (Fig. 10).
(9) Adjust the throttle actuation rod until:
• The throttle lever contacts idle stop screw.
• The spring loaded breakover lever has moved off
J9114-208
the stop and is against breakover spring (Fig. 8).
(10) Tighten locking nuts.
Fig. 8 Correct Breakover Spring Position—Diesel (11) Remove the feeler gauge.
(12) Connect throttle cable to ball stud on throttle
(5) If throttle lever does not contact idle stop screw cam.
and breakover spring is not against stop (Fig. 9), the (13) With engine off, operate the throttle from ac
throttle actuation rod must be adjusted. celerator pedal and check for throttle lever breakover
(6) One of the throttle actuation rod lock nuts is a in both idle and full positions (Fig. 11).
left hand thread. An L is marked on the flat of rod to (14) Check engine rpm at low idle speed and at
identify which locking n u t has left hand thread (Fig. full throttle. Check with the air conditioning on and
10). transmission in drive (automatic transmission). Be
(7) Hold the actuation rod on the flat and loosen sure t h a t the parking brake is set. If engine will not
locking nuts. meet full throttle limit and low pressure fuel system
and injectors are functioning correctly, remove injec
tion pump for service.
LOW IDLE STOP SPEED-DIESEL
Transmission M i n i m u m RPM
Automatic 700 RPM
Manual 750 RPM

J9114-212
FULL THROTTLE STOP SPEED-DIESEL
Minimum RPM M a x i m u m RPM

Fig. 11 Checking For Breakover—Diesel
2825 RPM 2925 RPM
J9114-213
• FUEL SYSTEM 1 4 - 2 9
MULTI-PORT FUEL INJECTION (MPI)-COMPONENT DESCRIPTION/SYSTEM

OPERATION-EXCEPT DIESEL
INDEX
page page
Air Conditioning (A/C) Clutch R e l a y - P e r n Output . 3 5 Ignition C o i l - P C M Output 37
Air Conditioning (A/C) Controls—PCM Input . . . . 31 Malfunction Indicator L a m p — P C M Output 37
Auto Shut Down ( A S D ) R e l a y - P C M Output . . . . 36 Manifold Absolute Pressure ( M A P ) S e n s o r -
Automatic Shut Down (ASD) S e n s e - P C M Input . 31 P C M Input 33
Battery V o l t a g e - P C M Input 32 Open Loop/Closed Loop Modes of Operation . . . 38
Brake S w i t c h - P C M Input 32 Overdrive/Override Switch 34
Camshaft Position S e n s o r — P C M Input 32 Oxygen ( 0 ) S e n s o r — P C M Input
2 33
Charge Air Temperature S e n s o r — P C M Input . . . 32 Park/Neutral Switch—PCM Input 34
Crankshaft Position S e n s o r - P C M Input . . . . . . . 32 Power Ground 34
Electric Exhaust G a s Recirculation Transducer Powertrain Control Module (PCM) 30
(EET) S o l e n o i d - P C M Output . . . . . . . . . . 36 S C I R e c e i v e - P C M Input . 34
Engine Coolant Temperature S e n s o r — P C M Input . 3 3 S C I T r a n s m i t - P C M Output 37
E V A P Canister Purge Solenoid—PCM Output . . . 37 Sensor Return — P C M Input 35
Fuel I n j e c t o r s - P C M Output 37 Shift I n d i c a t o r - P C M Output 38
Fuel Pressure Regulator 41 Speed C o n t r o l - P C M Input 34
Fuel Rail 41 Speed C o n t r o l - P C M Output 38
General Information . . . . . . . . . . . . . . . . . . . . . . . 2 9 S R I L a m p - P C M Output 36
Generator F i e l d - P C M Output 36 Tachometer—PCM Output 38
Generator L a m p - P C M Output 36 Throttle Body 40
Idle Air Control (IAC) M o t o r - P C M Output . . . . . . 36 Throttle Position Sensor ( T P S ) - P C M Input 35
Ignition Circuit S e n s e — P C M Input 33 Vehicle Speed S e n s o r - P C M Input 35
GENERAL INFORMATION an air/fuel ratio of 14.7 to 1 by constantly adjusting

All gas powered engines are equipped with sequen injector pulse width. Injector pulse width is t h e
tial Multi-Port Fuel Injection (MPI). The MPI system length of time t h a t the injector opens and sprays fuel
(Fig. 1) provides precise air/fuel ratios for all driving into the chamber. The PCM adjusts injector pulse
conditions. width by opening and closing t h e ground path to the
The Powertrain Control Module (PCM) operates injector.
the fuel system. The PCM was formerly referred to Manifold absolute pressure (air density) and engine
as t h e SBEC or engine controller. The PCM is a pre rpm (speed) are the primary inputs t h a t determine
programmed, dual microprocessor digital computer. fuel injector pulse width. The PCM also monitors
It regulates ignition timing, air-fuel ratio, emission other inputs when adjusting air-fuel ratio.
control devices, charging system, speed control, air Inputs That Effect Fuel Injector P u l s e Width:
conditioning compressor clutch engagement and idle • Exhaust gas oxygen content
speed. The PCM can adapt its programming to meet • Coolant temperature
changing operating conditions. • Manifold absolute pressure (MAP)
Powertrain Control Module (PCM) Inputs rep • Engine speed
resent t h e instantaneous engine operating conditions. • Throttle position
Air-fuel mixture and ignition timing calibrations for • Battery voltage
various driving and atmospheric conditions are pre • Air conditioning selection
programmed into t h e PCM. The PCM monitors and • Transmission gear selection (auto, trans.)
analyzes various inputs. It then computes engine fuel • Speed control
and ignition timing requirements based on these in The powertrain control module (PCM) adjusts igni
puts. Fuel delivery control and ignition timing will tion timing by controlling ignition coil operation. The
then be adjusted accordingly. ignition coil receives battery voltage when the igni
Other inputs to t h e PCM are provided by t h e brake tion key is in the r u n or starter (crank) position. The
light switch, air conditioning select switch and the PCM provides a ground for t h e ignition coil. The coil
speed control switches. All inputs to t h e PCM are discharges when the PCM supplies a ground. By
converted into signals. switching the ground path on and off, t h e PCM reg
Electrically operated fuel injectors spray fuel in ulates ignition timing.
precise metered amounts into the intake port directly The sensors and switches t h a t provide inputs to t h e
above the intake valve. The injectors are fired in a powertrain control module (PCM) comprise the En-
specific sequence by the PCM. The PCM maintains
14 - 30 FUEL SYSTEM
INPUTS OUTPUTS
DRB II
POWERTRAIN CONTROL SCAN TOOL
MODULE
SPEED
CONTROL MALFUNCTION
INDICATOR
PARK/NEUTRAL TORQUE CONVERTER LAMP
A/C LOW SWITCH CLUTCH SOLENOID
PRESSURE CUTOFF
BRAKE SWITCH VEHICLE
SWITCH SPEED SENSOR
TACHOMETER
A/C CLUTCH AUTO SHUTDOWN OVERDRIVE

RELAY SOLENOID
RELAY
ENGINE
m HEATED i COOLANT yy BATTERY
TEMPERATURE
* O X Y G E N SENSOR SPEED SHIFT
SENSOR MAP SENSOR
CONTROL INDICATOR
IDLE AIR LAMP
i—r CONTROL MOTOR EMISSION
CONTROL SOLENOIDS
CHARGE AIR
AIR CHARGE
TEMPERATURE
SENSOR TEMPERATURE
SENSOR
PARK THROTTLE
DISTRIBUTOR IGNITION COIL SOLENOID
WITH CAMSHAFT r
POSITION
GENERATOR
SENSOR (| OVERDRIVE ASD
OVERRIDE SENSE FUEL
SWITCH INJECTORS FUEL
PUMP
CRANKSHAFT
RELAY
POSITION J9314-117
Fig. 1 Multi-Port Fuel Injection Components—Except Diesel

gine Control System. It is also comprised of the PCM A / C CLUTCH RELAY STARTER RELAY
Outputs (engine control devices t h a t the are operated TORQUE CONVERTER AUTO SHUTDOWN RELAY
by the PCM). CLUTCH RELAY
FUEL PUMP RELAY
SYSTEM DIAGNOSIS
The powertrain control module (PCM) tests many
of its own input and output circuits. If a diagnostic
trouble code (DTC) is found in a major system, this
information is stored in the PCM memory. Refer to
On-Board Diagnostics in the Multi-Port Fuel Injec
tion—General Diagnosis—Except Diesel section of
this group for DTC information.
POWERTRAIN
POWERTRAIN CONTROL MODULE (PCM) DATA UNK CONTROL
The Powertrain Control Module (PCM) (Fig. 2) op CONNECTOR MODULE J9314-164
erates the fuel system. The PCM was formerly re
ferred to as the SBEC or engine controller. The PCM Fig. 2 Powertrain Control Module (PCM) Location
is a pre-programmed, dual microprocessor digital and idle speed. The PCM can adapt its programming
computer. It regulates ignition timing, air-fuel ratio, to meet changing operating conditions.
emission control devices, charging system, speed con The PCM receives input signals from various
trol, air conditioning compressor clutch engagement switches and sensors. Based on these inputs, the
PCM regulates various engine and vehicle operations
through different system components. These compo • EVAP canister purge solenoid
nents are referred to as Powertrain Control Module • SCI transmit (DRB II connection)
(PCM) Outputs. The sensors and switches t h a t pro • Shift indicator lamp (manual transmission only)
vide inputs to the PCM are considered Powertrain • Speed control vacuum solenoid
Control Module (PCM) Inputs. • Speed control vent solenoid
The PCM adjusts ignition timing based upon in • Tachometer (on instrument panel, if equipped)
puts it receives from sensors t h a t react to: engine The powertrain control module (PCM) contains a
rpm, manifold absolute pressure, engine coolant tem voltage convertor. This converts battery voltage to a
perature, throttle position, transmission gear selec regulated 8.0 volts. It is used to power the crankshaft
tion (automatic transmission), vehicle speed and the position sensor and camshaft position sensor. The
brake switch. PCM also provides a five (5) volt supply for the man
The PCM adjusts idle speed based on inputs it re ifold absolute pressure (MAP) sensor and throttle po
ceives from sensors t h a t react to: throttle position, sition sensor (TPS).
vehicle speed, transmission gear selection, engine
coolant temperature and from inputs it receives from AIR CONDITIONING (A/C) CONTROLS-PCM INPUT
the air conditioning clutch switch and brake switch. The A/C control system information applies to fac
tory installed air conditioning units.
Based on inputs that it receives, the PCM adjusts
A/C S E L E C T S I G N A L : When the A/C switch is
ignition coil dwell. The PCM also adjusts the gener
in the ON position and the A/C low pressure switch
ator charge rate through control of the generator
is closed, an input signal is sent to the powertrain
field and provides speed control operation.
control module (PCM). The signal informs the PCM
Powertrain Control Module (PCM) Inputs: t h a t the A/C has been selected. The PCM adjusts idle
• Generator output speed to a pre-programmed rpm through the idle air
• A/C request (if equipped with factory A/C) control (IAC) motor to compensate for increased en
• A/C select (if equipped with factory A/C) gine load.
• Auto shut down (ASD) sense A/C R E Q U E S T S I G N A L : Once A/C has been se
• Charge air temperature sensor lected, the powertrain control module (PCM) receives
• Battery voltage the A/C request signal from the evaporator switch.
• Brake switch The input indicates t h a t the evaporator temperature
• Engine coolant temperature sensor is in the proper range for A/C application. The PCM
• Crankshaft position sensor uses this input to cycle the A/C compressor clutch
• Ignition circuit sense (ignition switch in run posi (through the A/C relay). It will also determine the
tion) correct engine idle speed through the idle air control
• Manifold absolute pressure (MAP) sensor (IAC) motor position.
• Overdrive/override switch If the A/C low pressure switch opens (indicating a
• Oxygen sensor(s) low refrigerant level), the PCM will not receive an
• Park/neutral switch (auto, trans, only) A/C select signal. The PCM will then remove the
• SCI receive (DRB II connection) ground from the A/C relay. This will deactivate the
• Speed control resume switch A/C compressor clutch.
• Speed control set switch If the evaporator switch opens, (indicating t h a t
• Speed control on/off switch evaporator is not in proper temperature range), the
• Camshaft position sensor signal PCM will not receive the A/C request signal. The
• Throttle position sensor PCM will then remove the ground from the A/C re
• Vehicle speed sensor lay, deactivating the A/C compressor clutch.
• Sensor return
• Power ground AUTOMATIC SHUT DOWN (ASD) S E N S E - P C M
• Signal ground INPUT
Powertrain Control Module (PCM) Outputs: A 12 volt signal at this input indicates to the PCM
• A/C clutch relay t h a t the ASD has been activated. The ASD relay is
• Idle air control (IAC) motor located in the engine compartment (Fig. 2). It is used
• Auto shut down (ASD) relay to connect the oxygen sensor(s) heater element, igni
• Generator field tion coil, generator field winding and fuel injectors to
• Malfunction indicator lamp 12 volt + power supply.
• Service reminder indicator lamp This input is used only to sense t h a t the ASD relay
• EGR valve control solenoid is energized. If the powertrain control module (PCM)
• Fuel injectors does not see 12 volts at this input when the ASD
• Fuel pump relay should be activated, it will set a diagnostic trouble
• Ignition coil code (DTC).
BATTERY VOLTAGE—PCM INPUT manifold varies, t h e sensor resistance changes. This
The battery voltage input provides power to the results in a different input voltage to the PCM.
powertrain control module (PCM). It also informs the
PCM what voltage level is supplied to t h e ignition
coil and fuel injectors.
If battery voltage is low, the PCM will increase injec
tor pulse width (period of time that the injector is ener
gized). This is done to compensate for the reduced flow
through injector caused by the lowered voltage.
BRAKE SWITCH-PCM INPUT

When the brake light switch is activated, the pow
ertrain control module (PCM) receives an input indi
cating t h a t the brakes are being applied. After
receiving this input, the PCM maintains idle speed
to a scheduled rpm through control of t h e idle air
control (IAC) motor. The brake switch input is also
used to operate the speed control system.
Fig. 4 Charge Air Temperature Sensor—Typical
CAMSHAFT POSITION SENSOR—PCM INPUT CRANKSHAFT POSITION SENSOR-PCM INPUT
A sync signal is provide by the camshaft position sen
This sensor is a hall effect device t h a t detects
sor located in the ignition distributor (Fig. 3). The sync
notches in the flywheel (manual transmission), or
signal from this sensor works in conjunction with the
flexplate (automatic transmission).
crankshaft position sensor to provide the powertrain
This sensor is used to indicate to the powertrain
control module (PCM) with inputs. This is done to es
control module (PCM) t h a t a spark and or fuel injec
tablish and maintain correct injector firing order.
tion event is to be required. The output from this
Refer to Camshaft Position Sensor in Group 8D, Ig
sensor, in conjunction with the camshaft position
nition System for more information.
sensor signal, is used to differentiate between fuel in
jection and spark events. It is also used to synchro
nize the fuel injectors with their respective cylinders.
The sensor is bolted to the cylinder block near the
rear of the right cylinder head (Fig. 5).
Fig. 3 Camshaft Position Sensor

CHARGE AIR TEMPERATURE SENSOR-PCM
INPUT
The intake manifold charge air temperature sensor
is installed in the intake manifold with t h e sensor el
ement extending into the air stream (Fig. 4). The
sensor provides an input voltage to t h e powertrain
control module (PCM) indicating intake manifold air
temperature. The input is used along with inputs
from other sensors to determine injector pulse width. Fig. 5 Crankshaft Position Sensor—Typical
As t h e temperature of the air-fuel stream in the
Refer to Group 8D, Ignition System for more crank ning. The PCM uses this input along with inputs
shaft position sensor information. from other sensors to adjust air-fuel mixture.
The engine will not operate if the PCM does not re The MAP sensor is mounted on t h e side of t h e en
ceive a crankshaft position sensor input. gine throttle body (Fig. 7). The sensor is connected to
the throttle body with a rubber L-shaped fitting.
ENGINE COOLANT TEMPERATURE S E N S O R - P C M
MANIFOLD ABSOLUTE
INPUT
The engine coolant temperature sensor is installed
next to the thermostat housing (Fig. 6) and protrudes
into t h e water jacket. The sensor provides an input
voltage to t h e powertrain control module (PCM) re
lating coolant temperature. The PCM uses this input
along with inputs from other sensors to determine in
jector pulse width and ignition timing. As coolant
temperature varies, the coolant temperature sensor
resistance will change. This change in resistance re
sults in a different input voltage to the PCM.
When the engine is cold, the PCM will operate in
Open Loop cycle. It will demand slightly richer air-
fuel mixtures and higher idle speeds. This is done
until normal operating temperatures are reached.
Fig. 7 Manifold Absolute Pressure (MAP)

Sensor— Typical
OXYGEN (0 ) SENSOR—PCM INPUT
2
3.9L/5.2L/S»9L ENGINE
LDC
The single 0 sensor on the 3.9L, 5.2L or 5.9L light
2
duty cycle (LDC) engine is located in the exhaust

down pipe (Fig. 8). It provides an input voltage to the
powertrain control module (PCM) relating the oxy
gen content of the exhaust gas. The PCM uses this
Fig. 6 Coolant Temperature Sensor— Typical information to fine t u n e the air-fuel ratio by adjust
ing injector pulse width.
IGNITION CIRCUIT S E N S E - P C M INPUT
The 0 sensor produces voltages from 0 to 1 volt.
2
The ignition circuit sense input tells the power-
This voltage will depend upon the oxygen content of
train control module (PCM) the ignition switch has
the exhaust gas in the exhaust manifold. When a
energized the ignition circuit. Refer to the wiring di
large amount of oxygen is present (caused by a lean
agrams for circuit information.
air-fuel mixture), the sensor produces a low voltage.
MANIFOLD ABSOLUTE PRESSURE (MAP) When there is a lesser amount present (rich air-fuel
SENSOR-PCM INPUT mixture) it produces a higher voltage. By monitoring
The MAP sensor reacts to absolute pressure in the the oxygen content and converting it to electrical
intake manifold. It provides an input voltage to the voltage, the sensor acts as a rich-lean switch.
powertrain control module (PCM). As engine load The oxygen sensor is equipped with a heating ele
changes, manifold pressure varies. The change in ment t h a t keeps the sensor at proper operating tem
manifold pressure causes MAP sensor voltage to perature during all operating modes. Maintaining
change. The change in MAP sensor voltage results in correct sensor temperature at all times allows t h e
a different input voltage to the PCM. The input volt system to enter into closed loop operation sooner.
age level supplies the PCM with information about In Closed Loop operation, the powertrain control
ambient barometric pressure during engine start-up module (PCM) monitors the 0 sensor input (along
2
(cranking) and engine load while the engine is run with other inputs). It then adjusts the injector pulse
14 - 34 FUEL SYSTEM
width accordingly. During Open Loop operation, the The overdrive/override switch is normally closed. It
PCM ignores the 0 sensor input and adjusts injector
2 opens when the operator presses the switch. The
pulse width to a preprogrammed value (based on transmission will not enter overdrive when the oper
other sensor inputs). ator presses the override switch. The transmission
downshifts if the operator presses the override switch
while in overdrive.
The overdrive switch circuit contains two other
switches: A transmission thermo-switch and a cool
ant temperature switch. When either switch opens,
the transmission will not shift into overdrive, or
downshift (if already in overdrive).
Refer to Group 21 for more information.
PARK/NEUTRAL SWITCH-PCM INPUT

The park/neutral switch is located on the transmis
sion housing and provides an input to the powertrain
control module (PCM). This will indicate t h a t the au
EXHAUST tomatic transmission is in Park, Neutral or a drive
PIPE J9214-5 gear selection. This input is used to determine idle
speed (varying with gear selection), fuel injector
Fig. 8 Oxygen Sensor Location—3.9L/5.2L/5.9L LDC
pulse width and ignition timing advance. Refer to
Engine
Group 21, Transmissions, for testing, replacement
5,9L HDC ENGINE and adjustment information.
Dual 0 sensors are used on the 5.9L heavy duty
2
cycle (HDC) engine (Fig. 9). Each sensor will monitor POWER GROUND
the oxygen content in each exhaust downpipe. The The power ground is used to control ground circuits
left sensor monitors the odd numbered cylinders (1-3- for the following powertrain control module (PCM)
5-7). The right sensor monitors the even numbered loads:
cylinders (2-4-6-8), • Generator field winding
For sensor operational information, refer to the • 8 volt (PCM) power supply
paragraphs in the previous 3.9L/5.2/5.9L LDC oxygen • Fuel injectors
sensor section. • Ignition coil
SCI RECEIVE-PCM INPUT

SCI Receive is the serial data communication re
ceive circuit for the DRB II scan tool. The powertrain
control module (PCM) receives data from the DRB II
through the SCI Receive circuit.
SPEED CONTROL-PCM INPUT

The speed control system provides three separate
inputs to the powertrain control module (PCM); On/
Off, Set and Resume. The On/Off input informs the
PCM t h a t the speed control system has been acti
vated. The Set input informs the PCM t h a t a fixed
vehicle speed has been selected. The Resume input
indicates to the PCM t h a t the previous fixed speed is
requested.
The speed control operating range is from 50 km/h
Fig. 9 Oxygen Sensor Location—5.9L HDC Engine
to 142 km/h (35 to 85 mph). Inputs t h a t effect speed
OVERDRIVE/OWERRIDE SWITCH control operation are:
On vehicles equipped with overdrive, the power- • Park/neutral switch
train control module (PCM) regulates the 3-4 over • Vehicle speed sensor
drive up-shift and down-shift through the overdrive • Throttle position sensor
solenoid. An override switch is located on the instru Refer to Group 8H for further speed control infor
ment panel. mation.
SENSOR RETURN—PCM INPUT t h e vehicle is stopped at idle, a closed throttle signal

Sensor Return provides a low noise ground refer is received by the PCM (but a speed sensor signal is
ence for all system sensors. not received).
Under deceleration conditions, the PCM adjusts the
THROTTLE POSITION SENSOR (TPS)-PCM INPUT idle air control (IAC) motor to maintain a desired
The throttle position sensor (TPS) is mounted on MAP value. Under idle conditions, the PCM adjusts
the throttle body (Fig. 10). The TPS is a variable re t h e IAC motor to maintain a desired engine speed.
sistor t h a t provides the powertrain control module
(PCM) with a n input signal (voltage) t h a t represents
throttle blade position. The sensor is connected to the
throttle blade shaft. As t h e position of the throttle
blade changes, the resistance of the TPS changes.
The PCM supplies approximately 5 volts to the
TPS. The TPS output voltage (input signal to the
PCM) represents the throttle blade position. The
PCM receives an input signal voltage from the TPS.
This will vary in an approximate range of from 1
volt at minimum throttle opening (idle), to 4 volts at
wide open throttle. Along with inputs from other sen
sors, the PCM uses the TPS input to determine cur
rent engine operating conditions. In response to
engine operating conditions, the PCM will adjust fuel
injector pulse width and ignition timing.
MANIFOLD ABSOLUTE
Fig. 11 Vehicle Speed Sensor—Typical
AIR CONDITIONING (A/C) CLUTCH RELAY—PCM
OUTPUT
The powertrain control module (PCM) activates the
A/C compressor through the A/C clutch relay. The
PCM regulates A/C compressor operation by switch
ing the ground circuit for t h e A/C clutch relay on
and off. The relay is located in the engine compart
ment (Fig. 12).
Fig. 10 Throttle Position Sensor—Typical

VEHICLE SPEED SENSOR—PCM INPUT
The speed sensor (Fig. 11) is located in the exten DATA LINK CONTROL
sion housing of the transmission (2WD) or on the
transfer case extension housing (4WD). The sensor Fig. 12 Relay Location
input is used by the powertrain control module
(PCM) to determine vehicle speed and distance trav When the PCM receives a request for A/C from A/C
eled. evaporator switch, it will adjust idle air control (IAC)
The speed sensor generates 8 pulses per sensor rev motor position. This is done to increase idle speed.
olution. These signals, in conjunction with a closed The PCM will then activate the A/C clutch through
throttle signal from the throttle position sensor, indi the A/C clutch relay. The PCM adjusts idle air con-
cate a closed throttle deceleration to the PCM. When
trol (IAC) stepper motor position to compensate for
MOUNTING SCREWS
increased engine load from the A/C compressor.
By switching the ground path for the relay on and MAP SENSOR
off, the PCM is able to cycle the A/C compressor
clutch. This is based on changes in engine operating
RUBBER FITTING
conditions. If, during A/C operation, the PCM senses
low idle speeds or a wide open throttle condition, it
will de-energize the relay. This prevents A/C clutch
engagement. The relay will remain de-energized un
til the idle speed increases or the wide open throttle
condition exceeds 15 seconds or no longer exists. The
PCM will also de-energize the relay if coolant tem
perature exceeds 125°C (257°F).
IDLE AIR CONTROL (IAC) MOTOR-PCM OUTPUT J9314-87

The IAC motor is mounted to the back of the throt
tle body (Fig. 13) and is controlled by the powertrain Fig. 14 Throttle Body Air Control Passage
control module (PCM).
AUTO SHUT DOWN (ASD) RELAY—PCM OUTPUT
AAANIFOLD ABSOLUTE The ASD relay is located in the engine compart
PRESSURE SENSOR
ment (Fig. 12).
The ASD supplies battery voltage to the fuel pump,
fuel injector, ignition coil, generator field winding
and oxygen ( 0 ) sensor(s) heating element. The
2
ground circuit for the coil in the ASD relay is con

trolled by the powertrain control module (PCM). The
PCM operates the relay by switching the ground cir
cuit on and off.
The fuel pump relay is controlled by the PCM
through same circuit t h a t the ASD relay is con
trolled.
GENERATOR F I E L D - P C M OUTPUT
The powertrain control module (PCM) regulates
the charging system voltage within a range of 12.9 to
15.0 volts. Refer to Group 8A for charging system in
formation.
THROTTLE
POSITION GENERATOR L A M P - P C M OUTPUT
SENSOR J9314-86 If the powertrain control module (PCM) senses a
low charging condition in the charging system, it
Fig. 13 IAC Motor—Typical will illuminate the generator lamp on the instrument
The throttle body has an air control passage t h a t panel. For example, during low idle with all accesso
provides air for the engine at idle (the throttle plate ries turned on, the light may momentarily go on.
is closed). The IAC motor pintle protrudes into the Once the PCM corrects idle speed to a higher rpm,
air control passage (Fig. 14) and regulates air flow the light will go out. Refer to Group 8A for charging
through it. Based on various sensor inputs, the pow system information.
ertrain control module (PCM) adjusts engine idle ELECTRIC EXHAUST GAS RECIRCULATION
speed by moving the IAC motor pintle in and out of TRANSDUCER (EET) S 0 L E N 0 I D - P C M OUTPUT
the air control passage. The IAC motor is positioned Refer to Group 25, Emission Control System for in
when the ignition key is turned to the On position. formation. See Electric Exhaust Gas Recirculation
A (factory adjusted) set screw is used to mechani Transducer (EET) Solenoid.
cally limit the position of the throttle body throttle
plate. Never attempt to adjust the engine idle SRI L A M P - P C M OUTPUT
s p e e d u s i n g this screw. All idle speed functions are The instrument panel mounted service reminder
controlled by the PCM. indicator (SRI) lamp was formerly referred to as the
emission maintenance reminder (EMR) lamp. It is
used only on vehicles equipped with the 5.9L heavy MALFUNCTION INDICATOR L A M P - P C M OUTPUT
duty cycle (HDC) engine. Refer to Group 25, Emis The malfunction indicator lamp (formerly referred
sion Control System for information. to as the check engine lamp) illuminates at the bot
tom of the instrument panel each time the ignition
EVAP CANISTER PURGE SOLENOID-PCM key is turned on. It will stay on for three seconds as
OUTPUT a bulb test.
Refer to Group 25, Emission Control System. See If the powertrain control module (PCM) receives an
EVAP Canister Purge Solenoid. incorrect signal, or no signal from certain sensors or
emission related systems, t h e lamp is turned on. This
FUEL INJECTORS-PCM OUTPUT is a warning t h a t the PCM has recorded a system or
The fuel injectors are attached to the fuel rail (Fig. sensor malfunction. In some cases, when a problem is
15). 3.9L engines use six injectors. 5.2L and 5.9L en declared, the PCM will go into a limp-in mode. This
gines use eight injectors. is an attempt to keep the system operating. It signals
The nozzle ends of the injectors are positioned into an immediate need for service.
openings in the intake manifold just above the in The lamp can also be used to display a diagnostic
take valve ports of the cylinder head. The engine trouble code (DTC). Cycle the ignition switch On-Off-
wiring harness connector for each fuel injector is On-Off-On within three seconds and any codes stored
equipped with an attached numerical tag (INJ 1, I N J in the PCM memory will be displayed. This is done
2 etc.). This is used to identify each fuel injector with in a series of flashes representing digits. Refer to On-
its respective cylinder number. Board Diagnostics in the General Diagnosis section
The injectors are energized individually in a se of this group for more information.
quential order by the powertrain control module
(PCM). The PCM will adjust injector pulse width by IGNITION C O I L - P C M OUTPUT
switching the ground path to each individual injector System voltage is supplied to the ignition coil pos
on and off. Injector pulse width is the period of time itive terminal. The powertrain control module (PCM)
t h a t the injector is energized. The PCM will adjust operates the ignition coil. B a s e (initial) ignition
injector pulse width based on various inputs it re t i m i n g is not a d j u s t a b l e . The PCM adjusts ignition
ceives. timing to meet changing engine operating conditions.
During start up, battery voltage is supplied to the The ignition coil is located near the front of the
injectors through the ASD relay. When the engine is right cylinder head (Fig. 16 or 17).
operating, voltage is supplied by the charging sys Refer to Group 8D, Ignition System for additional
tem. The PCM determines injector pulse width based information.
on various inputs.
Fig. 16 Ignition Coii-3.9U5.2U5.9L LDC-Gas

Engine
SCI TRANSMIT—PCM OUTPUT
FUEL
SCI Transmit is the serial data communication
INJECTOR J9214-30 transmit circuit for the DRB II scan tool. The power-
train control module (PCM) transmits data to the
Fig. 15 Fuel injectors—Typical DRB II through the SCI Transmit circuit.
MODES
• Open Loop
• Closed Loop
During Open Loop modes, the powertrain control
module (PCM) receives input signals and responds
only according to preset PCM programming. Input
from the oxygen ( 0 ) sensor(s) is not monitored dur
2
ing Open Loop modes.

During Closed Loop modes, the PCM will monitor
the oxygen ( 0 ) sensor input. This input indicates to
2
the PCM whether or not the calculated injector pulse

width results in the ideal air-fuel ratio. This ratio is
14.7 parts air-to-1 part fuel. By monitoring the ex
haust oxygen content through the 0 sensor, the
2
PCM can fine tune the injector pulse width. This is

done to achieve optimum fuel economy combined
Fig. 17 Ignition Coil—5.9L HDC-Gas Engine
with low emission engine performance.
SHIFT INDICATOR-PCM OUTPUT The fuel injection system has the following modes
Vehicles equipped with manual transmissions have of operation:
an Up-Shift indicator lamp. The lamp is controlled • Ignition switch ON
by the powertrain control module (PCM). The lamp • Engine start-up (crank)
illuminates on the instrument panel to indicate when • Engine warm-up
the driver should shift to the next highest gear for • Idle
best fuel economy. The PCM will t u r n the lamp off • Cruise
after 3 to 5 seconds if the shift of gears is not per • Acceleration
formed. The up-shift light will remain off until vehi • Deceleration
cle stops accelerating and is brought back to range of • Wide open throttle (WOT)
up-shift light operation. This will also happen if ve • Ignition switch OFF
hicle is shifted into fifth gear. The ignition switch On, engine start-up (crank),
The indicator lamp is normally illuminated when engine warm-up, acceleration, deceleration and wide
the ignition switch is turned on and it is turned off open throttle modes are Open Loop modes. The idle
when the engine is started up. With the engine run and cruise modes, (with the engine at operating tem
ning, the lamp is turned on/off depending upon en perature) are Closed Loop modes.
gine speed and load.
IGNITION SWITCH (KEY-ON) MODE
SPEED CONTROL-PCM OUTPUT This is an Open Loop mode. When the fuel system
Speed control operation is regulated by the power- is activated by the ignition switch, the following ac
train control module (PCM). The PCM controls the tions occur:
vacuum to the throttle actuator through the speed • The powertrain control module (PCM) pre-posi-
control vacuum and vent solenoids. Refer to Group tions the idle air control (IAC) motor.
8H for Speed Control Information. • The PCM determines atmospheric air pressure
from the MAP sensor input to determine basic fuel
TACHOMETER—PCM OUTPUT strategy.
The powertrain control module (PCM) supplies en • The PCM monitors the engine coolant temperature
gine rpm values to the instrument cluster tachome sensor input. The PCM modifies fuel strategy based
ter. Refer to Group 8E for tachometer information. on this input.
• Intake manifold charge air temperature sensor in
OPEN LOOP/CLOSED LOOP MODES OF put is monitored.
OPERATION • Throttle position sensor (TPS) is monitored.
As input signals to the powertrain control module • The auto shut down (ASD) relay is energized by
(PCM) change, the PCM adjusts its response to the the PCM for approximately three seconds.
output devices. For example, the PCM must calculate • The fuel pump is energized through the fuel pump
different injector pulse width and ignition timing for relay by the PCM. The fuel pump will operate for ap
idle t h a n it does for wide open throttle (WOT). There proximately one second unless the engine is operat
are several different modes of operation t h a t deter ing or the starter motor is engaged.
mine how the PCM responds to the various input sig • The 0 2 sensor(s) heater element is energized
nals. through the fuel pump relay. The 0 sensor(s) input
2
is not used by the PCM to calibrate air-fuel ratio • The PCM operates the A/C compressor clutch
during this mode of operation, through the clutch relay. This is done if A/C has
• The up-shift indicator light is illuminated (manual been selected by the vehicle operator and requested
transmission only). by the A/C thermostat.
• If the vehicle has a manual transmission, t h e up
ENGINE START-UP MODE shift light is operated by the PCM.
This is an Open Loop mode. The following actions « When engine has reached operating temperature,
occur when the starter motor is engaged. the PCM will begin monitoring 0 sensor(s) input.
2
The powertrain control module (PCM) receives in The system will then leave t h e warm-up mode and
puts from: go into closed loop operation.
• Battery voltage
• Engine coolant temperature sensor IDLE MODE
• Crankshaft position sensor When the engine is at operating temperature, this
• Intake manifold charge air temperature sensor is a Closed Loop mode. At idle speed, the powertrain
• Manifold absolute pressure (MAP) sensor control module (PCM) receives inputs from:
Air conditioning select signal (if equipped)
• Throttle position sensor (TPS)
• Air conditioning request signal (if equipped)
• Starter motor relay
• Battery voltage
• Camshaft position sensor signal
• Crankshaft position sensor
The PCM monitors the crankshaft position sensor.
• Engine coolant temperature sensor
If the PCM does not receive a crankshaft position
• Intake manifold charge air temperature sensor
sensor signal within 3 seconds of cranking the en • Manifold absolute pressure (MAP) sensor
gine, it will shut down the fuel injection system. • Throttle position sensor (TPS)
The fuel pump is activated by t h e PCM through • Camshaft position sensor signal (in the distributor)
the fuel pump relay. ® Battery voltage
Voltage is applied to the fuel injectors with the • Park/Neutral switch (gear indicator signal—Auto,
PCM. The PCM will then control the injection se trans, only)
quence and injector pulse width by turning the • Oxygen sensor
ground circuit to each individual injector on and off. Based on these inputs, the following occurs:
The PCM determines the proper ignition timing ac • Voltage is applied to the fuel injectors with the
cording to input received from the crankshaft posi powertrain control module (PCM). The PCM will
tion sensor. then control injection sequence and injector pulse
width by turning the ground circuit to each individ
ENGINE WARM-UP MODE ual injector on and off.
This is an Open Loop mode. During engine warm- • The PCM monitors the 0 sensor(s) input and ad
2
up, the powertrain control module (PCM) receives in justs air-fuel ratio by varying injector pulse width. It
puts from: also adjusts engine idle speed through the idle air
• Battery voltage control (IAC) motor.
• Crankshaft position sensor • The PCM adjusts ignition timing by increasing
• Engine coolant temperature sensor and decreasing spark advance.
• Intake manifold charge air temperature sensor • The PCM operates the A/C compressor clutch
• Manifold absolute pressure (MAP) sensor through the clutch relay. This happens if A/C has
• Throttle position sensor (TPS) been selected by the vehicle operator and requested
• Camshaft position sensor signal (in the distributor) by the A/C thermostat.
• Park/Neutral switch (gear indicator signal—auto,
CRUISE MODE
trans, only)
When the engine is at operating temperature, this
• Air conditioning select signal (if equipped) is a Closed Loop mode. At cruising speed, the power-
• Air conditioning request signal (if equipped) train control module (PCM) receives inputs from:
Based on these inputs the following occurs: • Air conditioning select signal (if equipped)
• Voltage is applied to the fuel injectors with the • Air conditioning request signal (if equipped)
powertrain control module (PCM). The PCM will • Battery voltage
then control the injection sequence and injector pulse • Engine coolant temperature sensor
width by turning the ground circuit to each individ • Crankshaft position sensor
ual injector on and off. • Intake manifold charge air temperature sensor
• The PCM adjusts engine idle speed through the • Manifold absolute pressure (MAP) sensor
idle air control (IAC) motor and adjusts ignition tim • Throttle position sensor (TPS)
ing. • Camshaft position sensor signal (in the distributor)
• Park/Neutral switch (gear indicator signal—auto, WIDE OPEN THROTTLE MODE
trans, only) This is an Open Loop mode. During wide open
• Oxygen ( 0 ) sensor(s)
2 throttle operation, the powertrain control module
Based on these inputs, the following occurs: (PCM) receives the following inputs.
• Voltage is applied to the fuel injectors with the • Battery voltage
PCM. The PCM will then adjust the injector pulse • Crankshaft position sensor
width by turning the ground circuit to each individ • Engine coolant temperature sensor
ual injector on and off. • Intake manifold charge air temperature sensor
• The PCM monitors the 0 sensor(s) input and ad
2 • Manifold absolute pressure (MAP) sensor
justs air-fuel ratio. It also adjusts engine idle speed • Throttle position sensor (TPS)
through the idle air control (IAC) motor. • Camshaft position sensor signal (in the distributor)
• The PCM adjusts ignition timing by turning the During wide open throttle conditions, the following
ground path to the coil on and off. occurs:
• The PCM operates the A/C compressor clutch • Voltage is applied to the fuel injectors with the
through the clutch relay. This happens if A/C has powertrain control module (PCM). The PCM will
been selected by the vehicle operator and requested then control the injection sequence and injector pulse
by the A/C thermostat. width by turning the ground circuit to each individ
ACCELERATION MODE ual injector on and off. The PCM ignores the oxygen
This is an Open Loop mode. The powertrain control sensor input signal and provides a predetermined
module (PCM) recognizes an abrupt increase in amount of additional fuel. This is done by adjusting
throttle position or MAP pressure as a demand for injector pulse width.
increased engine output and vehicle acceleration. • The PCM adjusts ignition timing by turning the
The PCM increases injector pulse width in response ground path to the coil on and off.
to increased throttle opening. • The PCM opens the ground circuit to the A/C
clutch relay to disengage the A/C compressor clutch.
DECELERATION MODE This will be done for approximately 15 seconds (if the
When the engine is at operating temperature, this air conditioning system is operating).
is an Open Loop mode. During hard deceleration, the If the vehicle has a manual transmission, the up
powertrain control module (PCM) receives the follow shift light is operated by the PCM.
ing inputs.
• Air conditioning select signal (if equipped) IGNITION SWITCH OFF MODE
• Air conditioning request signal (if equipped) When ignition switch is turned to OFF position,
• Battery voltage the PCM stops operating the injectors, ignition coil,
• Engine coolant temperature sensor ASD relay and fuel pump relay.
• Crankshaft position sensor
• Intake manifold charge air temperature sensor THROTTLE BODY
• Manifold absolute pressure (MAP) sensor Filtered air from the air cleaner enters the intake
• Throttle position sensor (TPS) manifold through the throttle body (Fig. 18). Fuel
• Camshaft position sensor signal (in the distributor) does not enter the intake manifold through the throt
• Park/Neutral switch (gear indicator signal —auto, tle body. Fuel is sprayed into the manifold by the
trans, only) fuel injectors. The throttle body is mounted on the
If the vehicle is under hard deceleration with the intake manifold. It contains an air control passage
proper rpm and closed throttle conditions, the PCM (Fig. 19) controlled by an idle air control (IAC) mo
will ignore the oxygen sensor input signal. The PCM tor. The air control passage is used to supply air for
will enter a fuel cut-off strategy in which it will not idle conditions. A throttle valve (plate) is used to
supply battery voltage to the injectors. If a hard de supply air for above idle conditions.
celeration does not exist, the PCM will determine the The throttle position sensor (TPS), idle air control
proper injector pulse width and continue injection. (IAC) motor and manifold absolute pressure sensor
Based on the above inputs, the PCM will adjust en (MAP) are attached to the throttle body. The acceler
gine idle speed through the idle air control (IAC) mo ator pedal cable, speed control cable and transmis
tor. sion control cable (when equipped) are connected to
The PCM adjusts ignition timing by turning the the throttle arm.
ground path to the coil on and off. A (factory adjusted) set screw is used to mechani
The PCM opens the ground circuit to the A/C cally limit the position of the throttle body throttle
clutch relay to disengage the A/C compressor clutch. plate. Never attempt to adjust the engine idle
This is done until the vehicle is no longer under de s p e e d using this screw. All idle speed functions are
celeration (if the A/C system is operating). controlled by the PCM.
THROTTLE FUEL RAIL

BODY CONNECTING
HOSES
J9214-32
Fig. 20 Fuel Rail—Typical

R e g u l a t o r O p e r a t i o n : The fuel pressure regulator
is a mechanical device t h a t is not controlled by the
THROTTLE BODY powertrain control module (PCM).
MOUNTING BOLTS J9214-31 The fuel pressure regulator used is a vacuum bal
anced, nonadjustable type. The regulator is mounted
Fig. 18 Throttle Body on the output end of the fuel rail and is connected to
intake manifold vacuum (Figs. 21 or 22). The fuel re
MOUNTING SCREWS
t u r n tube (to the fuel tank) is connected to the fuel
MAP SENSOR pressure regulator.
E L
d o c c PRESSURE REGULATOR
RUBBER FITTING „ VACUUM LINE
MAP REGULATOR
SENSOR
J9314-87
Fig. 19 Air Control Passage

FUEL RAIL
The fuel rail supplies fuel to the injectors and is
mounted to the intake manifold (Fig. 20). On vehi
cles equipped with a 3.9L or 5.2L engine, the fuel PROTECTIVE CAP
pressure regulator is attached to the rail and the fuel
pressure test port is integral with the rail. On vehi
\
J9214-26
cles equipped with a 5.9L engine, the fuel pressure
regulator is not part of the fuel rail. It is located on Fig. 21 Fuel Pressure Regulator—3.9L Engine
the fuel tank mounted fuel pump module. The fuel The regulator is calibrated to maintain fuel system
rail is not repairable. operating pressure at approximately 214 kPa (31
psi). This is with vacuum applied while the engine is
FUEL PRESSURE REGULATOR
at idle. Fuel pressure will be 55-69 kPa (8-10 psi)
3.9L/5.2L higher if vacuum is not applied to the regulator.
On vehicles equipped with a 3.9L or 5.2L engine, The pressure regulator contains a diaphragm, cali
the fuel pressure regulator is integral with the fuel brated spring and a fuel return valve. Fuel pressure
rail. operates on one side of the regulator, while spring
VACUUM PROTECTIVE CAP INTERNAL
LINE FUEL FILTER
RUBBER FUEL FILTER/FUEL

GROMMET PRESSURE REGULATOR
AT PUMP
MODULE
CALIBRATED
FUEL SPRINGS X EXCESS FUEL BACK
PRESSURE TO TANK
REGULATOR FUEL RAIL
C O N N E C T O R HOSES J9214-27 FUEL INLET J9314-170
Fig. 22 Fuel Pressure Regulator—5.2L Engine Fig. 23 Side View—Filter/Regulator—5.9L Engine
pressure and intake manifold vacuum operate on the LOCKNUT FUEL SUPPLY FUEL FILTER/
TUBE FUEL PRESSURE
other side. Spring pressure on one side of the dia REGULATOR
phragm tries to force the return valve closed. Fuel
pressure on other side of diaphragm, with assistance
from manifold vacuum on spring side of diaphragm,
act against spring pressure to open the return valve.
System fuel pressure is the amount of fuel pressure
required to force against spring pressure and unseat
the return valve.
Without vacuum applied to the spring side of the
regulator, the spring is calibrated to open the fuel re
t u r n outlet. This happens when the pressure differen
PUMP/GAUGE
tial between the fuel injectors and the intake ELEC. C O N N E C T I O N
manifold reaches approximately 269 k P a (39 psi).
Since manifold vacuum varies with engine operating PRESSURE RELIEF/ , II
conditions, t h e amount of vacuum applied to the ROLLOVER VALVE J9314-167
spring side of the diaphragm varies. For this reason, Fig. 24 Filter/Regulator Location—5.9L Engine
fuel pressure varies, depending upon intake manifold is a mechanical device t h a t is not controlled by the
vacuum. With low vacuum, such as during wide open powertrain control module (PCM).
throttle conditions, minimal vacuum assistance is The regulator is calibrated to maintain fuel system
available. Full spring pressure is exerted to seal the operating pressure at approximately 241-310 k P a
fuel outlet. This causes the system pressure to in (35-45 psi).
crease. With high vacuum, such as at engine idle or The regulator contains a diaphragm, calibrated
during vehicle deceleration, fuel pressure on one side springs and a fuel return valve. The internal fuel fil
of the diaphragm is balanced by intake manifold ter (Fig. 23) is part of the assembly.
pressure. This is done on the spring side of the dia Fuel is supplied by the electric fuel pump through
phragm and results in lower system fuel pressure. an opening tube at the bottom of filter/regulator (Fig.
23). The calibrated pressure regulator allows a con
5.9L ENGINE stant fuel system operating pressure of approxi
On vehicles equipped with a 5.9L engine, the fuel mately 241-310 kPa (35-45 psi). Fuel flows through
filter and fuel pressure regulator are one combined regulator and fuel filter and on to fuel injectors at
part (Fig. 23). The fuel filter/fuel pressure regulator engine.
is located on the top of the fuel pump module (Fig. If the fuel pressure at regulator exceeds approxi
24). It is pressed into a rubber grommet on module mately 45 psi, an internal diaphragm closes and ex
(Fig. 23). cess fuel pressure is routed back into pump module
R e g u l a t o r O p e r a t i o n : The fuel pressure regulator and returned to fuel t a n k (Fig. 23).
MULTI-PORT FUEL INJECTION (MPI)—GENERAL DIAGNOSIS—EXCEPT DIESEL
INDEX
page page
Camshaft Position Sensor Testing . . . . . . . . . . . . 52 On-Board Diagnostics (OBD) 59
Charge Air Temperature Sensor Test 52 Oxygen ( 0 ) Sensor Heating Element Test
2 54
Coolant Temperature Sensor Test 52 Powertrain Control Module ( P C M ) 60-Way
Crankshaft Position Sensor Test 54 Connector . 47
Diagnostic Trouble Code (DTC) 60 Relays—Operation/Testing 56
D R B II Scan Tool . . . . . . . . . . . . . . . . . . . . . . . . 60
Fuel Injector Test 57 Starter Motor Relay Test 57
Fuel Pump Pressure Test 57 System Schematics . 47
Idle Air Control (IAC) Motor Test 55 Throttle Position Sensor (TPS) Test 54
Manifold Absolute Pressure (MAP) Sensor Test . 53 Visual Inspection 43
VISUAL INSPECTION connections. Inspect relays for signs of physical dam

A visual inspection for loose, disconnected, or incor age and corrosion. The relays are located in t h e en
rectly routed wires and hoses should be made. This gine compartment (Fig. 2).
should be done before attempting to diagnose or ser
vice the fuel injection system. A visual check will
TORQUE CONVERTER
help spot these faults and save unnecessary test and AUTO SHUTDOWN RELAY
CLUTCH RELAY
diagnostic time. A thorough visual inspection will in FUEL PUMP RELAY
clude the following checks:
(1) Verify t h a t t h e 60-way connector is fully in
serted into the connector of t h e powertrain control
module (PCM) (Fig. 1). Verify t h a t the connector
#
mounting screw is tightened to 4 N m (35 in. lbs.)
torque.
PCM
MOUNTING
BOLTS
POWERTRAIN
DATA UNK CONTROL
Fig. 2 Relay Location

(4) Inspect ignition coil connections. Verify t h a t
coil secondary cable is firmly connected to coil (Fig. 3
or 4).
PCM CONNECTOR
CONNECTOR MOUNTING
BOLT J9314-165
Fig. 1 Powertrain Control Module (PCM)

(2) Inspect t h e battery cable connections. Be sure
t h a t they are clean and tight.
| X COIL
(3) Inspect fuel pump relay and air conditioning frCONNECTOR J9214-7
compressor clutch relay (if equipped). Inspect the
ASD relay connections. Inspect starter motor relay Fig. 3 Ignition Coil—3.9U5.2L/5.9L LDC-Gas Engine
(9) On 3.9L and 5.2L engines, verify t h a t vacuum
hose is firmly connected to fuel pressure regulator
and manifold fitting (Figs. 6 or 7).
Fig. 4 ignition Coil—5.9L HDC-Gas Engine

(5) Verify t h a t distributor cap is correctly attached
to distributor. Be sure t h a t spark plug cables are
firmly connected to the distributor cap and the spark
plugs are in their correct firing order. Be sure t h a t
coil cable is firmly connected to distributor cap and
coil. Be sure t h a t camshaft position sensor wire con
nector (at the distributor) is firmly connected to har
ness connector. Inspect spark plug condition. Refer to
Group 8D, Ignition. Connect vehicle to an oscillo
scope and inspect spark events for fouled or damaged
spark plugs or cables.
(6) Verify t h a t generator output wire, generator
connector and ground wire are firmly connected to
the generator.
(7) Inspect the system body grounds for loose or
dirty connections. Refer to Group 8, Wiring for
ground locations.
(8) Verify positive crankcase ventilation (PCV)
valve operation. Refer to Group 25, Emission Control
System for additional information. Verify PCV valve
hose is firmly connected to PCV valve and manifold
(Fig. 5).
CONNECTOR HOSES J9214-27
Fig. 7 Pressure Regulator Vacuum Hose—5.2L

Engine
(10) Inspect fuel* tube quick-connect fitting-to-fuel
rail connections.
(11) Verify t h a t hose connections to all ports of
vacuum fittings on intake manifold are tight and not
leaking.
Fig. 5 PCV Valve Hose Connections—Typical
(12) Inspect accelerator cable, transmission throt

tle cable (if equipped) and cruise control cable con
nections (if equipped). Check their connections to the
throttle arm of throttle body for any binding or re
strictions (Fig. 8).
Fig. 10 Air Temperature Sensor—5.2U5.9L (V-8)

Engines
MANIFOLD ABSOLUTE
Fig. 8 Throttle Body Cables—Typical

(13) If equipped with vacuum brake booster, verify
t h a t vacuum booster hose is firmly connected to fit
ting on intake manifold. Also check connection to
brake vacuum booster.
(14) Inspect the air cleaner inlet and air filter ele
ment for dirt or restrictions.
(15) Inspect radiator grille area, radiator fins and
air conditioning condenser for restrictions.
(16) Verify that the intake manifold charge air
temperature sensor wire connector is firmly con
nected to harness connector (Figs. 9 or 10).
Fig. 11 MAP Sensor—Typical

order. Each harness connector is numerically tagged
with the injector number (INJ 1, INJ 2 etc.) of its
corresponding fuel injector and cylinder number.
(19) Verify harness connectors are firmly con
nected to idle air control (IAC) motor, throttle posi
tion sensor (TPS) and manifold absolute pressure
(MAP) sensor (Fig. 11).
(20) Verify t h a t wire harness connector is firmly
Fig. 9 Air Temperature Sensor—3.9L (V-6) Engine connected to the engine coolant temperature sensor
(Fig. 13).
(17) Verify t h a t MAP sensor electrical connector is
firmly connected to MAP sensor (Fig. 11). Also verify (21) Raise and support the vehicle.
that rubber L-shaped fitting from MAP sensor to the (22) Verify t h a t oxygen sensor wire connector (or
throttle body is firmly connected (Fig. 12). connectors) are firmly connected to the sensor (or
(18) Verify t h a t fuel injector wire harness connec sensors). Inspect sensor(s) and connector(s) for dam
tors are firmly connected to injectors in the correct age (Figs. 14 or 15).
Fig. 12 Rubber L-Shaped Fitting—MAP Sensor-to- Fig. 15 Dual Oxygen Sensor Location—5.9L HDC
Throttie Body Engine
(24) Inspect for exhaust system restrictions such as
pinched exhaust pipes, collapsed muffler or plugged
catalytic convertor.
(25) If equipped with automatic transmission, ver
ify t h a t electrical harness is firmly connected to
park/neutral switch. Refer to Automatic Transmis
sion section of Group 21.
(26) Verify t h a t the harness connector is firmly
connected to the vehicle speed sensor (Fig. 16).
Fig. 13 Engine Coolant Temperature

Sensor— Typical
Fig. 16 Vehicle Speed Sensor— Typical

(27) Verify t h a t fuel pump/gauge sender unit wire
connector is firmly connected to harness connector.
(28) Inspect fuel hoses at fuel pump/gauge sender
unit for cracks or leaks.
(29) Inspect transmission torque convertor housing
EXHAUST ~~
(automatic transmission) or clutch housing (manual
PIPE J9214-5
transmission) for damage to timing ring on drive
Fig. 14 Single Oxygen Sensor Location-3.9U5.2L/ plate/flywheel.
5.9L LDC Engine (30) Verify t h a t battery cable and solenoid feed
wire connections to the starter solenoid are tight and
(23) Inspect for pinched or leaking fuel tubes. In
clean. Inspect for chaffed wires or wires rubbing up
spect for pinched, cracked or leaking fuel hoses.
against other components.
POWERTRAIN CONTROL MODULE (PCM) 60-WAY SYSTEM SCHEMATICS

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

•
THROTTLE
POSITION
SENSOR
CO
Fig. 18 System Schematic—3.9L (V-6) Engine CO

CJ1
m
r-
co
-<
CO
J9314-120
Fig. IS System Schematic—5.2U5.9L LDC (V-8) Engine

-<
m
J9314-172
Fig. 20 System Schematic-SSL HDC (V-8) Engine

CAMSHAFT POSITION SENSOR TESTING SENSOR RESISTANCE (OHMS)-COOLANT
Refer to Group 8D, Ignition Systems for testing. TEMPERATURE SENSOR/CHARGE AIR
TEMPERATURE SENSOR
COOLANT TEMPERATURE SENSOR TEST
To perform a complete test of the engine coolant
temperature sensor and its circuitry, refer to DRB II TEMPERATURE RESISTANCE ( O H M S )
tester and appropriate Powertrain Diagnostics Proce
dures manual. To test the sensor only, refer to the C F MIN MAX
following:
(1) Disconnect wire harness connector from coolant -40 -40 291,490 381,710
temperature sensor (Fig. 21). -20 -4 85,850 108,390
E n g i n e s w i t h a i r c o n d i t i o n i n g ; When removing -10 14 49,250 61,430
0 32 29,330 35,990
the connector from sensor, do not pull directly on 10 50 17,990 21,810
wiring harness. Fabricate an L-shaped hook tool 20 68 11,370 13,610
from a coat hanger (approximately eight inches 25 77 9,120 10,880
long). Place the hook part of tool under the connector 30 86 7,370 8,750
40 104 4,900 5,750
for removal. The connector is snapped onto the sen 50 122 3,330 3,880
sor. It is not equipped with a lock type tab. 60 140 2,310 2,670
70 158 1,630 1,870
80 176 1,170 1,340
90 194 860 970
100 212 640 720
no 230 480 540
120 248 370 410
J928D-4
CHARGE AIR TEMPERATURE SENSOR TEST
To perform a complete test of the intake manifold
charge air temperature sensor and its circuitry, refer
to DRB II tester and appropriate Powertrain Diag
nostics Procedures manual. To test the sensor only,
refer to the following:
(1) Disconnect the wire harness connector from the
charge air temperature sensor (Fig. 22).
Fig. 21 Engine Coolant Temperature

Sensor— Typical
(2) Test the resistance of the sensor with a high in
put impedance (digital) volt-ohmmeter. The resis
tance (as measured across the sensor terminals)
should be less t h a n 1340 ohms with the engine
warm. Refer to the Coolant Temperature sensor/
Charge Air Temperature sensor resistance chart. Re
place the sensor if it is not within the range of
resistance specified in the chart.
(3) Test continuity of the wire harness. Do this be
tween the powertrain control module (PCM) wire
harness connector terminal 2 and the sensor connec
tor terminal. Also test continuity of wire harness ter
minal 4 to the sensor connector terminal. Repair the
Fig. 22 Charge Air Temperature Sensor—Typical
wire harness if an open circuit is indicated.
(4) After tests are completed, connect electrical (2) Test the resistance of the sensor with an input
connector to sensor. The sensor connector is symmet impedance (digital) volt-ohmmeter. The resistance
rical (not indexed). It can be installed to the sensor (as measured across the sensor terminals) should be
in either direction. less t h a n 1340 ohms with the engine warm. Refer to
the Coolant Temperature sensor/Charge Air Temper-
ature sensor resistance chart. Replace t h e sensor if it

is not within the range of resistance specified in the
chart.
(3) Test the resistance of the wire harness. Do this
between the powertrain control module (PCM) wire
harness connector terminal 21 and the sensor connec
tor terminal. Also check between terminal 4 to the
sensor connector terminal. Repair the wire harness
as necessary if the resistance is greater t h a n 1 ohm.

TEST
To perform a complete test of MAP sensor (Fig. 23)
and its circuitry, refer to DRB II tester and appropri
ate Powertrain Diagnostics Procedures manual. To
test the MAP sensor only, refer to the following:
(1) Inspect the rubber L-shaped fitting from the Fig. 24 Rubber L-Shaped Fitting—MAP Sensor-to-
MAP sensor to the throttle body (Fig. 24). Repair as Throttle Body
necessary.
MANIFOLD ABSOLUTE
A. Ground
B. Output Voltage
C . 5 Volts
J8914-91
Fig. 25 MAP Sensor Connector Terminals—Typical

(4) Test MAP sensor supply voltage at sensor con
Fig. 23 Manifold Absolute Pressure (MAP) nector between terminals A and C (Fig. 25) with the
Sensor— Typical ignition ON. The voltage should be approximately 5
volts (±0.5V). Five volts (±0.5V) should also be at
C A U T I O N : When testing the M A P sensor, be sure terminal 6 of the powertrain control module (PCM)
that the harness wires are not damaged by the test wire harness connector. Repair or replace the wire
meter probes. harness as necessary.
(5) Test the MAP sensor ground circuit at sensor
(2) Test the MAP sensor output voltage at the
connector terminal A (Fig. 25) and PCM connector
MAP sensor connector between terminals A and B
terminal/pin-4. Repair the wire harness if necessary.
(Fig. 25). With the ignition switch ON and the en
(6) Test the MAP sensor ground circuit at the
gine OFF, output voltage should be 4-to-5 volts. The
PCM connector between terminal/pin-4 and terminal/
voltage should drop to 1.5-to-2.1 volts with a hot,
pin-11 with an ohmmeter. If the ohmmeter indicates
neutral idle speed condition.
an open circuit, inspect for a defective sensor ground
(3) Test powertrain control module (PCM) pin-1 for
connection. Refer to Group 8W, Wiring Diagrams for
the same voltage described above to verify the wire
location of this connection. If the ground connection
harness condition. Repair as necessary.
is good, replace the PCM. If terminal/pin-4 has a Powertrain Diagnostics Procedures manual. To test
short circuit to 12 volts + , correct this condition be the TPS only, refer to the following:
fore replacing the PCM. The TPS can be tested with a digital voltmeter.
The center terminal of the TPS is the output termi
CRANKSHAFT POSITION SENSOR TEST nal (Fig. 28).
To perform a complete test of this sensor (Fig. 26)
AAANIFOLD ABSOLUTE
and its circuitry, refer to the DRB II tester and ap
propriate Powertrain Diagnostics Procedures manual.
To test the sensor only, refer to the following:
(1) Near the rear of the right cylinder head, dis
connect the sensor pigtail harness connector from the
main wiring harness.
Fig. 28 Throttle Position Sensor (TPS)

Connector— Typical
With the ignition key in the ON position, check the
TPS output voltage at the center terminal wire of the
connector. Check this at idle (throttle plate closed)
and at wide open throttle (WOT). At idle, TPS output
Fig. 26 Crankshaft Position Sensor— Typical voltage should must be greater t h a n 200 millivolts.
At wide open throttle, TPS output voltage must be
(2) Place an ohmmeter across terminals B and C
less t h a n 4.8 volts. The output voltage should in
(Fig. 27). Ohmmeter should be set to lK-to-lOK scale
crease gradually as the throttle plate is slowly
for this test. The meter reading should be open (no
opened from idle to WOT.
resistance). Replace sensor if a low resistance is indi
cated. OXYGEN (0 ) SENSOR HEATING ELEMENT TEST
2
To perform a complete test of single or dual 0 sen-

2
sor(s) and circuitry, refer to DRB II tester and appro

priate Powertrain Diagnostics Procedures manual. To
test the 0 sensor only, refer to the following:
2
On 3.9L/5.2L/5.9L LDC engines, the single 0 sen

2
sor is located on the right exhaust down pipe (Fig.

29). On 5.9L HDC engines, the dual 0 sensors are
2
located on each (left and right) exhaust down pipe

VIEW LOOKING INTO (Fig. 29).
CPS WIRING CONNECTOR The 0 heating element can be tested with an ohm
2
meter as follows:
Fig. 27 Sensor Wiring Connector Disconnect the 0 sensor connector. Connect the
2
ohmmeter test leads across the white wire terminals

THROTTLE POSITION SENSOR (TPS) TEST
of the sensor connector. Resistance should be be
To perform a complete test of the TPS and its cir
tween 5 and 7 ohms. Replace the sensor if the ohm
cuitry, refer to the DRB II tester and appropriate
meter displays an infinity (open) reading.
MANIFOLD ABSOLUTE
Fig. 31 IAC Motor—Typical
Fig. 30 Dual Oxygen Sensors—5.9L HDC Engine

IDLE AIR CONTROL (IAC) MOTOR TEST
To perform a complete test of IAC motor (Fig. 81)
and its circuitry, refer to DRB II scan tool and appro
priate Powertrain Diagnostics Procedures manual. To
test the IAC motor only, special IAC motor exerciser
tool number 7558 (Fig. 32) may be used.
C A U T I O N : Proper safety p r e c a u t i o n s must be taken

when testing the I A C motor,
• Set the parking brake and block the drive wheels Fig. 32 IAC Motor Testing— Typical
• Route all tester cables away from the cooling fans, (3) Connect the red clip of exerciser tool (7558) to
drive belt, pulleys and exhaust components battery positive terminal. Connect the black clip to
• Provide proper ventilation while operating the en negative battery terminal. The red light on the exer
gine ciser tool will be illuminated when the exerciser is
• Always return the engine idle speed to normal be properly connected to battery.
fore disconnecting the exerciser tool (4) Start engine.
(1) With the ignition OFF, disconnect the IAC mo When the switch is in the HIGH or LOW position,
tor wire connector at throttle body (Fig. 31). the light on the exerciser tool will flash. This indi
(2) Plug the exerciser tool (7558) harness connector cates t h a t voltage pulses are being sent to the IAC
into the IAC motor (Fig. 32). stepper motor.
(5) Move the switch to the HIGH position. The en Pump. For operations/tests on all other relays, refer
gine speed should increase. Move the switch to the to the appropriate section of this service manual.
LOW position. The engine speed should decrease. These relays are located in the engine compart
(a) If the engine speed changes while using the ment (Fig. 34).
exerciser tool, the IAC motor is functioning prop
erly. Disconnect the exerciser tool and connect the
IAC stepper motor wire connector to the stepper
motor.
(b) If the engine speed does not change, t u r n the
ignition OFF and proceed to step (6). Do not discon
nect exerciser from the IAC stepper motor.
(6) Remove the IAC stepper motor from the throt
tle body.
C A U T I O N : When checking I A C motor operation with

the motor removed from the throttle body, d o not
extend the pintle (Fig. 33) more than 6.35 m m (.250
in). If the pintle is extended more than this amount, it
DATA LINK CONTROL
may separate from the IAC stepper motor. The IAC mo CONNECTOR MODULE J9314-164
tor must be replaced if the pintle separates from the
motor. Fig. 34 Relay Location
WIRE HARNESS The relay terminal numbers from (Fig. 35) can be
found on the bottom of the relay.
• Terminal number 30 is connected to battery volt
age and can be switched or B + (hot) at all times.
• The center terminal number 87A is connected (a
circuit is formed) to terminal 30 in the de-energized
(normally OFF) position.
• Terminal number 87 is connected (a circuit is
formed) to terminal 30 in the energized (ON) posi
tion. Terminal number 87 then supplies battery volt
age to the component being operated.
• Terminal number 86 is connected to a switched
( + ) power source.
• Terminal number 85 is grounded by the power-
PINTLE J9314-116
train control module (PCM).
Fig. 33 IAC Stepper Motor Pintle—Typical
TESTING
(7) With the ignition OFF, cycle the exerciser tool (1) Remove relay before testing.
switch between the HIGH and LOW positions. Ob (2) Using an ohmmeter, perform a resistance test
serve the pintle. The pintle should move in-and-out between terminals 85 and 86. Resistance value
of the motor. (ohms) should be 75 ± 5 ohms for resistor equipped
(a) If the pintle does not move, replace the IAC relays.
motor. Start the engine and test the replacement (3) Connect the ohmmeter between terminals num
motor operation as described in step (5).
ber 87A and 30. Continuity should be present at this
(b) If the pintle operates properly, check the IAC
time.
motor bore in the throttle body bore for blockage
(4) Connect the ohmmeter between terminals num
and clean as necessary. Install the IAC motor and
ber 87 and 30. Continuity should not be present at
retest. If blockage is not found, refer to the DRB II
scan tool and the appropriate Powertrain Diagnos this time.
tics Procedures service manual. (5) Use a set of jumper wires (16 gauge or small
er). Connect one jumper wire between terminal num
RELAYS—OPERATION/TESTING ber 85 (on the relay) to the ground side (-) of a 12
Volt power source.
OPERATION (6) Attach the other jumper wire to the positive
The following operations/tests apply to t h e s e side ( + ) of a 12V power source. Do not connect this
relays only: Automatic Shut Down (ASD) and Fuel jumper wire to relay at this time.
•
BOTTOM VIEW RELAY

OF RELAY CONNECTOR
DE-ENERGIZED ENERGIZED
RELAY RELAY 9214-157
Fig. 35 Relay Terminals

CAUTION: DO NOT ALLOW THE OHMMETER TO FUEL INJECTOR
C O N T A C T T E R M I N A L S 85 O R 86 D U R I N G T H E S E HARNESS CONNECTORS
TESTS. DAMAGE TO OHMMETER MAY RESULT.
(7) Attach the other jumper wire (12V + ) to termi

nal number 86. This will activate the relay. Continu
ity should now be present between terminals number
87 and 30. Continuity should not be present between
terminals number 87A and 30.
(8) Disconnect jumper wires from relay and 12
Volt power source.
If continuity or resistance tests did not pass, re
place relay. If tests passed, refer to Group 8W, Wir
ing Diagrams for (fuel system) relay wiring
schematics and for additional circuit information.
STARTER MOTOR RELAY TEST

Refer to Group 8A, Battery/Starting/Charging Sys
tem Diagnostics, for starter motor relay testing.
FUEL
FUEL INJECTOR TEST INJECTOR J9214-30
Disconnect the fuel injector wire harness connector
from the injector (Fig. 36). Place an ohmmeter across Fig. 36 Fuel Injector Wiring Connector— Typical
the injector terminals. Resistance reading should be FUEL PUMP PRESSURE TEST
approximately 14.5 ohms ±1.2 ohms at 20°C (68°F). Refer to Fuel Pump Pressure Test in the Fuel De
Proceed to following Fuel Injector diagnosis chart. livery System section of this group.
14 - 58 FUEL SYSTEM
•
INJECTOR DIAGNOSIS-VEHICLE RUNS ROUGH AND/OR HAS A MISS
DO PRELIMINARY INSPECTION OF START VEHICLE, PULL THE TEST THE INJECTOR RESISTANCE
DISTRIBUTOR CAP, IGNITION ELECTRICAL CONNECTORS OFF USING A N OHMMETER ACROSS
CABLES SPARK PLUGS, AND THE INJECTORS ONE AT A TIME THE INJECTOR TERMINALS WITH
TO DETERMINE WHICH CYLINDER THE INJECTOR CONNECTOR
CHECK FOR VACUUM LEAKS.
IS NOT FIRING. REMOVED.
REPLACE THE INJECTOR -NO •
PLACE A 12 VOLT TEST LAMP

ACROSS THE INJECTOR
ELECTRICAL CONNECTOR
TERMINALS. OBSERVE THE TEST
LAMP WHILE CRANKING THE
ENGINE.
CHECK POWER FEED AND

GROUND CIRCUITS BETWEEN
POWERTRAIN CONTROL MODULE
AND THE INJECTOR CONNECTOR.
REFER TO WIRING SCHEMATIC - NO-
FOR COLOR CODES AND PIN
TERMINAL NUMBERS.
CIRCUIT IS OK. CHECK FOR FUEL

DELIVERY AT SUSPECT INJECTOR
YES BY REMOVING THE INJECTOR
TEST THE VEHICLE WITH THE DRB II FROM THE RAIL A N D OBSERVING
SCAN TOOL FOR FUEL A N D / O R RESTRICTIONS
IN THE RAIL OR INJECTOR FUEL
INLET.
NO
REPAIR OR REPLACE THE WIRING

HARNESS A S NECESSARY.
REPLACE INJECTOR IF VISUALLY

PLUGGED AT INJECTOR FUEL
INLET.
-NO
REPLACE FUEL RAIL IF VISUALLY
PLUGGED OR RESTRICTED AT
INJECTOR DELIVERY COUPLING.
WITH INJECTOR REMOVED FROM

THE FUEL RAIL, CONNECT A 12V
SOURCE TO ONE TERMINAL O N
THE INJECTOR CONNECTOR A N D
A GROUND WIRE TO THE OTHER
TERMINAL. THE INJECTOR
SHOULD "CLICK" EACH TIME THE
GROUND WIRE IS CONNECTED
A N D DISCONNECTED TO THE
TERMINAL.
REPLACE INJECTOR •NO-
J9314-114
fill DHADn HI
A f
5Mf
l
C Ti
pQ /f|Rn\ NON-MONITORED CIRCUITS
The powertrain control module (PCM) has been The PCM does not monitor the following circuits,
programmed to monitor many different circuits of the systems or conditions that could have malfunctions
fuel injection system. If a problem is sensed in a t h a t result in driveability problems. A diagnostic
monitored circuit often enough to indicate an actual trouble code (DTC) may not be displayed for these
problem, a diagnostic trouble code (DTC) is stored. conditions.
The DTC will be stored in the PCM memory for Fuel Pressure: Fuel pressure is controlled by the
eventual display to the service technician. If the vacuum assisted fuel pressure regulator. The PCM
problem is repaired or ceases to exist, the PCM can cannot detect a clogged fuel pump inlet filter, clogged
cels t h e DTC after 51 engine starts. in-line fuel filter, or a pinched fuel supply or return
Certain criteria must be met for a diagnostic trou line. However, these could result in a rich or lean
ble code (DTC) to be entered into PCM memory. The condition causing an oxygen sensor DTC to be stored
criteria may be a specific range of engine rpm, en in the PCM.
gine temperature and/or input voltage to the PCM. Secondary Ignition Circuit: The PCM cannot de
It is possible t h a t a DTC for a monitored circuit tect an inoperative ignition coil, fouled or worn spark
may not be entered into memory even though a mal plugs, ignition cross firing, or open circuited spark
function has occurred. This may happen because one plug cables.
of the DTC criteria for the circuit has not been met. Engine Timing: The PCM cannot detect an incor
Example: assume t h a t one of the criteria for the rectly indexed timing chain, camshaft sprocket or
MAP sensor circuit is t h a t the engine must be oper crankshaft sprocket. The PCM also cannot detect an
ating between 750 and 2000 rpm to be monitored for incorrectly indexed distributor. However, these could
a DTC. If the MAP sensor output circuit shorts to result in a rich or lean condition causing an oxygen
ground when the engine rpm is above 2400 rpm, a 0 sensor DTC to be stored in t h e PCM.
volt input will be seen by the PCM. A DTC will not Cylinder Compression: The PCM cannot detect
be entered into memory because the condition does uneven, low, or high engine cylinder compression.
not occur within the specified rpm range. Exhaust System: The PCM cannot detect a
A DTC indicates t h a t the powertrain control mod plugged, restricted or leaking exhaust system.
ule (PCM) has recognized an abnormal signal in a Fuel Injector Malfunctions: The PCM cannot de
circuit or the system. A DTC may indicate the result termine if the fuel injector is clogged, or the wrong
of a failure, but never identify the failed component injector is installed. However, these could result in a
directly. rich or lean condition causing an oxygen sensor DTC
There are several operating conditions t h a t the to be stored in the PCM.
PCM does not monitor and set a DTC for. Refer to Excessive Oil Consumption: Although the PCM
the following Monitored Circuits and Non-Monitored monitors exhaust stream oxygen content through ox
Circuits in this section. ygen sensor (closed loop), it cannot determine exces
sive oil consumption.
MONITORED CIRCUITS Throttle Body Air Flow: The PCM cannot detect
The powertrain control module (PCM) can detect a clogged or restricted air cleaner inlet or air filter
certain problems in the fuel injection system. element.
Open or Shorted Circuit - The PCM can deter Evaporative System: The PCM will not detect a
mine if sensor output (which is the input to PCM) is restricted, plugged or loaded EVAP canister.
within proper range. It also determines if the circuit V a c u u m Assist: Leaks or restrictions in the vac
is open or shorted. u u m circuits of vacuum assisted engine control sys
Output Device Current Flow - The PCM senses tem devices are not monitored by the PCM. However,
whether the output devices are hooked up. a vacuum leak at the MAP sensor will be monitored
If there is a problem with the circuit, the PCM and a diagnostic trouble code (DTC) will be gener
senses whether the circuit is open, shorted to ground ated by the PCM.
(-), or shorted to ( + ) voltage. Powertrain Control Module (PCM) System
Oxygen Sensor - The PCM can determine if the Ground: The PCM cannot determine a poor system
oxygen sensor is switching between rich and lean. ground. However, a DTC may be generated as a re
This is, once the system has entered Closed Loop. Re sult of this condition.
fer to Open Loop/Closed Loop Modes Of Operation in Powertrain Control Module (PCM) Connector
the Component Description/System Operation section Engagement: The PCM cannot determine spread or
for an explanation of Closed (or Open) Loop opera damaged connector pins. However, a DTC may be
tion. generated as a result of this condition.
14 - SO FUEL SYSTEM •
HIGH AND LOW LIMITS EXAMPLES
The powertrain control module (PCM) compares in • If the lamp flashes 4 times, pauses and flashes 1
put signal voltages from each input device. It will es more time, a diagnostic trouble code (DTC) number
tablish high and low limits t h a t are programmed 41 is indicated.
into it for t h a t device. If the input voltage is not • If the lamp flashes 4 times, pauses and flashes 6
within specifications and other diagnostic trouble more times, a diagnostic trouble code (DTC) number
code (DTC) criteria are met, a DTC will be stored in 46 is indicated.
Refer to the Diagnostic Trouble Code (DTC) charts
memory. Other DTC criteria might include engine
for DTC identification.
rpm limits or input voltages from other sensors or
If the problem is repaired or ceases to exist, the
switches. The other inputs might have to be sensed powertrain control module (PCM) cancels the DTC
by the PCM when it senses a high or low input volt after 51 engine starts.
age from the control system device in question. Diagnostic trouble codes indicate the results of a
failure, but never identify the failed component di
ACCESSING DIAGNOSTIC TROUBLE CODES rectly.
A stored diagnostic trouble code (DTC) can be dis The circuits of the data link connector are shown
played by cycling the ignition key On-Off-On-Off-On in (Fig. 38).
within three seconds and observing the malfunction
indicator lamp. This lamp was formerly referred to GROUND
D-1
as the check engine lamp. The lamp is located on the
instrument panel. D-2 Im/c
They can also be displayed through the use of the
Diagnostic Readout Box II (DRB II scan tool). The
D-3 SCI TRANS
DRB II connects to the data link connector in the ve D-4 SCI RECEIVE
hicle (Fig. 37). For operation of the DRB II, refer to
the appropriate Powertrain Diagnostic Procedures D-5 IGNITION
service manual.
J9214-20 D-6 NOT USED
A / C CLUTCH RELAY . STARTER RELAY
TORQUE CONVERTER Fig. 38 Data Link Connector Schematic
AUTO SHUTDOWN RELAY
CLUTCH RELAY
FUEL PUMP RELAY ERASING TROUBLE CODES
The DRB II scan tool must be used to erase a di
agnostic trouble code (DTC). Refer to the appropriate
Powertrain Diagnostic Procedures service manual for
operation of the DRB II scan tool.
DRB II SCAN TOOL

For operation of the DRB II scan tool, refer to the
appropriate Powertrain Diagnostic Procedures ser
vice manual.
POWERTRAIN
DATA LINK CONTROL DIAGNOSTIC TROUBLE CODE (DTC)
CONNECTOR MODULE J9314-164 On the following pages, a list of diagnostic trouble
codes is provided for all gas powered engines. A DTC
Fig. 37 Data Link Connector Location—Typical indicates t h a t the powertrain control module (PCM)
has recognized an abnormal signal in a circuit or the
system. A DTC may indicate the result of a failure,
but never identify the failed component directly.
DIAGNOSTIC TROUBLE CODE {DTC) DESCRIPTION
Diagnostic DRB II Display Description of Trouble Code Condition

Trouble Code
11 No Crank Reference No distributor reference signal detected during engine cranking.

Signal at PCM
13+** No Change in AAAP No variation in MAP sensor signal is detected.

From Start to Run
No difference is recognized between the engine MAP reading and

the barometric pressure reading at start up.
14+** MAP Voltage Too Low MAP sensor input below minimum acceptable voltage.
or
MAP Voltage Too High MAP sensor input above maximum acceptable voltage.
15** No Vehicle Speed No speed sensor signal detected during road load conditions.
Sensor Signal
17 Engine is Cold Too Long Engine coolant temperature remains below normal operating temperatures
during vehicle travel (thermostat).
21** O2 Signal Stays at Neither rich or lean condition is detected from the oxygen sensor input.
Center
or
Oo Signal Shorted to Oxygen sensor input voltage maintained above normal operating range.
Voltage
22+** ECT Sensor Coolant temperature sensor input below the minimum acceptable voltage.
Voltage Too Low
or
ECT Sensor Coolant temperature sensor input above the maximum acceptable voltage.
Voltage Too High
23 Charge Air Temperature Charge Air Temperature Sensor input above/below acceptable minimum.
Sensor Voltage High
or
Charge Air Temperature
Sensor Voltage Low
24+** Throttle Position Throttle position sensor (TPS) input above the maximum acceptable voltage.
Sensor Voltage High
or Throttle position sensor (TPS) input below the minimum acceptable voltage.
Throttle Position
Sensor Voltage Low
** Check Engine Lamp ON (California only)

+ Check Engine Lamp ON
J9314-126
DIAGNOSTIC TROUBLE CODE (DTC) DESCRIPTION-CONTINUED
Diagnostic DRB If Display Description of Trouble Code Condition

Trouble Code
25** Idle Air Control A shorted condition detected in one or more of the idle air control
Motor Circuits actuator circuits.
(ISC Actuator)
27+** Control Circuit Injector output driver does not respond properly to the control signal.
31** EVAP Purge An open or shorted condition detected in the purge solenoid circuit.
Solenoid Circuit
32** EGR System Failure An open or shorted condition detected in the EGR solenoid circuit.
Required change in air-fuel ratio not detected during diagnostic test

(California emissions packages only).
33 A/C Clutch Relay An open or shorted condition detected in the A/C clutch relay circuit.
Circuit
34 Speed Control An open or shorted condition detected in the speed control vacuum or
Solenoid Circuits vent solenoid circuits.
37 Torque Converter An open or shorted condition detected in the torque converter clutch
Clutch Solenoid solenoid circuit (vehicles with automatic transmissions only).
Circuit (CKT)
41+** Generator Field Not Generator field not switching properly.

Switching Properly
42 Auto Shutdown Relay An open or short condition detected in the auto shutdown relay circuit.
Control Circuit
or
No ASD Relay Voltage No ASD voltage sensed at PCM.
Sense at Controller
** Check Engine Lamp ON (California only)

+ Check Engine Lamp ON J9314-127
DIAGNOSTIC TROUBLE CODE (DTC) DESCRIPTION-CONTINUED
Diagnostic
Trouble D R B 11 D i s p l a y Description o f Trouble C o d e C o n d i t i o n
Code
44 Battery Temperature Battery temperature sensor volts out of limit.

Voltage
45 Overdrive Solenoid An open or shorted condition detected in overdrive solenoid circuit.
46 + * * Charging System Charging system voltage too high.

Voltage Too High
47 + * * Charging System Charging system voltage too low.

Voltage Too Low
51** 0 Signal Stays

2 0 2 sensor signal stays lean.
Below Center (Lean)
or
Additive Adaptive Additive adaptive memory at rich limit.
Memory at Rich Limit
52** 0 Signal Stays

2 0 2 sensor signal stays rich.
Above Center (Rich)
or
Additive Adaptive Additive adaptive memory at lean limit.
Memory at Lean Limit
53 Internal PCM Failure Internal failure in the PCM {Powertrain Control Module)
54 Sync Pick-up Signal N o fuel sync signal detected during crankshaft rotation.
55 NA Completion of trouble code display on the Malfunction Indicator (MIL) lamp.
62 PCM Failure PCM (Powertrain Control Module) failure - SRI miles not stored.
SRI Miles Not Stored
63 PCM Failure PCM (Powertrain Control Module) failure - EEprom write denied.
EEprom Write Denied
+Check Engine Lamp ON **Check Engine Lamp ON (California only)
J9314-177
MULTI-PORT FUEL INJECTION ( M P I ) - C O M P O N E N T
REMOVAL/INSTALLATION —EXCEPT DIESEL
INDEX
page page
Accelerator Pedal and Throttle Cable . 64 Fuel Rail 69
Air Conditioning (A/C) Clutch Relay 64 Fuel System Pressure Release Procedure . . . . . . 71
Air Filter/Filter Housing 64 Fuel Tank Pressure Relief/Rollover Valve 71
Automatic Shut Down ( A S D ) Relay . 64 Fuel Tanks 71
Brake Switch 64 Fuel Tubes/Lines/Hoses and Clamps 71
Camshaft Position Sensor . . . . . . . . . . . . . . . . . . 64 Idle Air Control (IAC) Motor 71
Charge Air Temperature Sensor 64 Ignition Coil 71
Crankshaft Position Sensor 64 Intake Manifold 71
Engine Coolant Temperature Sensor 65 Manifold Absolute Pressure (MAP) Sensor 71
E V A P Canister Purge Solenoid 65 Oxygen ( 0 ) Sensor
2 72
Fuel Filter 65 Park/Neutral Switch . 73
Fuel Filter/Fuel Pressure Regulator—5.9L Engine . 65 Powertrain Control Module ( P C M ) 73
Fuel Injector(S) 67 Quick-Connect Fittings 73
Fuel Pressure Regulator 67 Throttle Body 73
Fuel Pump Module 68 Throttle Position Sensor (TPS) ...... 74
Fuel Pump Relay 68 Vehicle Speed Sensor 75
ACCELERATOR PEDAL AND THROTTLE CABLE BRAKE SWITCH

Refer to t h e Accelerator Pedal and Throttle Cable Refer to Group 5, Brakes for removal/installation
section of this group for removal/installation proce procedures.
dures.
CAMSHAFT POSITION SENSOR
AIR CONDITIONING (A/C) CLUTCH RELAY For removal/installation procedures, refer to Group
The A/C clutch relay is located in t h e engine com 8D, Ignition System. See Camshaft Position Sensor.
partment (Fig. 1).
CHARGE AIR TEMPERATURE SENSOR
The intake manifold charge air temperature sensor
is located in t h e front/side of t h e intake manifold
(Fig. 2 or 3).
REMOVAL
(1) Remove air cleaner assembly.
(2) Disconnect electrical connector a t sensor (Figs.
2 or 3).
INSTALLATION
(1) Install sensor to intake manifold. Tighten to 28
Nnn (20 ft. lbs.) torque.
DATA LINK CONTROL (2) Install electrical connector.
(3) Install air cleaner.
Fig. 1 Relay Location
CRANKSHAFT POSITION SENSOR
AIR FILTER/FILTER HOUSING Refer to Group 8D, Ignition System for removal/in
Refer to Air Filter/Filter Housing—Gas Engines in stallation procedures.
Group 25, Emission Control System for removal/in
stallation procedures.
AUTOMATIC SHUT DOWN (ASD) RELAY

The ASD relay is located in t h e engine compart
m e n t (Fig. 1).
Fig. 2 Ait Temperature Sensor—3.9L (¥-6) Engine Fig. 4 Coolant Temperature Sensor—Typical
INSTALLATION
(1) Install sensor.
(2) Tighten to 11 Nnn (8 ft. lbs.) torque.
(3) Connect electrical connector to sensor.
The sensor connector is symmetrical (not indexed).
It can be installed to the sensor in either direction.
(4) Replace any lost engine coolant. Refer to Group
7, Cooling System.
E¥AP CANISTER PURGE SOLENOID

Refer to Group 25, Emission Control System for re
moval/installation procedures.
FUEL FILTER
3.9L/5.21. ENGINE
Fig. 3 Air Temperature Sensor—5.2U5.9L (V-8) The fuel filter on vehicles equipped with a 3.9L
Engines
(V-6) or a 5.2L (V-8) engine is mounted to the frame
ENGINE COOLANT TEMPERATURE SENSOR rail. Refer to the Fuel Delivery System section of this
group for removal/installation procedures.
REMOVAL
5.91 ENGINE
WARNING: HOT, PRESSURIZED COOLANT C A N
On vehicles equipped with the 5.9L (V-8) engine,
C A U S E INJURY B Y SCALDING- COOLING S Y S T E M
the fuel filter and fuel pressure regulator are one
MUST B E PARTIALLY DRAINED BEFORE REMOV
combined part. Refer to the following Fuel Filter/
ING T H E C O O L A N T T E M P E R A T U R E S E N S O R . R E Fuel Pressure Regulator—5.9L Engine for removal
FER TO GROUP 7, COOLING. and installation procedures.
(1) Partially drain cooling system. Refer to Group
FUEL FILTER/FUEL PRESSURE REGULATOR—5JL
7, Cooling.
ENGINE
(2) Disconnect electrical connector from sensor
(Fig. 4). WARNING: THE FUEL SYSTEM IS UNDER A CON
E n g i n e s w i t h a i r c o n d i t i o n i n g : When removing STANT PRESSURE, EVEN WITH ENGINE OFF. BE
the connector from sensor, do not pull directly on FORE SERVICING THE FUEL FILTER/FUEL
wiring harness. Fabricate an L-shaped hook tool PRESSURE REGULATOR, THE FUEL SYSTEM
from a coat hanger (approximately eight inches PRESSURE MUST BE RELEASED.
long). Place the hook part of tool under the connector
for removal. The connector is snapped onto the sen Refer to Fuel System Pressure Release in the Fuel
sor. It is not equipped with a lock type tab. Delivery System section of this group.
14 - 66 FUEL SYSTEM
REMOVAL
The fuel filter/fuel pressure regulator is located on
the top of fuel pump module (Fig. 5).
Fig. 7 Plastic Tube and Snap Ring
ROLLOVER VALVE J9314-167
Fig. 5 Filter/Regulator Location—5.9L Engine

Fuel pump module removal is not necessary.
(1) Drain fuel tank and remove tank. Refer to Fuel
Tanks in this group.
(2) The fuel filter/regulator is pressed into a rub
ber grommet. Remove by twisting and pulling
straight up (Fig. 6).
C A U T I O N ; D o not pull the filter/regulator more than

three inches from the fuel pump module. Damage to
the coiled fuel tube (line) may result.
Fig. 8 Fuel Tube and Clamp

(5) Remove the plastic fuel tube from the filter/reg
ulator by gently pulling downward. Remove filter/
regulator from fuel pump module.
INSTALLATION
(1) Install a new clamp over the plastic fuel tube.
(2) Install filter/regulator to fuel tube. Rotate the
filter/regulator in the fuel tube until it is in the 10
o'clock position.
(3) Tighten clamp to fuel tube (line) using special
Hose Clamp Pliers number C-4124 or equivalent
(Fig. 9). Do not use conventional side cutters to
tighten this type of clamp.
Fig. 6 Filter/Regulator Removal and (4) Slide the convoluted plastic tube (cover) up to
Installation—5.9L Engine
the bottom of filter/regulator and install snap ring
(3) Remove the snap ring retaining the convoluted (Fig. 7).
tube (cover) to the filter/regulator (Fig. 7). Slide the (5) Press the filter/regulator (by hand) into the
plastic tube down the fuel tube to clear the fuel tube rubber grommet. Position the filter to the 10 o'clock
clamp. position.
(4) Gently cut the old fuel tube (line) clamp (Fig. (6) Install fuel tank. Refer to Fuel Tanks in this
8) taking care not to damage the plastic fuel tube. group.
Remove and discard the old fuel tube clamp.
INSTALLATION
(1) Apply a small amount of engine oil to each fuel
injector O-ring. This will help in fuel rail installa
tion.
(2) Install injector(s) and injector clip(s) to fuel
rail.
(3) Install fuel rail assembly. Refer to Fuel Rail in
stallation.
(5) Start engine and check for leaks.
FUEL PRESSURE REGULATOR

WARNING: THE FUEL SYSTEM IS UNDER A CON
S T A N T P R E S S U R E (EVEN WITH T H E ENGINE
TURNED OFF). BEFORE SERVICING THE FUEL
Fig. 9 Tightening Fuel Tube Clamp PRESSURE REGULATOR, THE FUEL SYSTEM
PRESSURE MUST B E RELEASED.
FUEL INJECTOR(S)
W A R N I N G ; THE F U E L SYSTEM IS U N D E R A C O N To release fuel pressure, refer to the Fuel Delivery
S T A N T P R E S S U R E ( E V E N WITH T H E E N G I N E System section of this group. See Fuel System Pres
T U R N E D OFF). B E F O R E SERVICING T H E FUEL IN sure Release.
J E C T O R ^ ) , THE F U E L SYSTEM P R E S S U R E M U S T
REMOVAL—3JL (V-6) ENGINE
BE RELEASED.
The pressure regulator is located (mounted horizon
To release fuel pressure, refer to the Fuel Delivery tally) in the fuel rail assembly near the dash panel
System section of this group. See Fuel System Pres (Fig. 11). It is held to the fuel rail with a snap ring
sure Release. (Fig. 12).
To remove one or more fuel injectors, the fuel rail
assembly must be removed from engine.
REMOVAL
(2) Remove fuel rail assembly. Refer to Fuel Rail
removal in this section.
(3) Remove the clip(s) retaining the injector(s) to
fuel rail (Fig. 10).
CUP
Fig. 11 Fuel Pressure Regulator—3.9L Engine

(1) Perform the fuel pressure release procedure.
Fig. 10 Fuel Injector and Retaining Clip (2) Remove the air cleaner.
(3) Remove the vacuum line from the pressure reg
(4) Remove injector(s) from fuel rail. ulator.
SNAP SNAP RING VACUUM PROTECTIVE CAP
PLIERS LINE
RING
FUEL
PRESSURE
REGULATOR,
FUEL RAIL J9214-47
Fig. 12 Regulator Snap Ring—3.9L Engine

(4) Using a pair of 90 degree snap-ring pliers, re FUEL
move the snap-ring (Fig. 12) from pressure regulator. PRESSURE
REGULATOR FUEL RAIL
A small hand held mirror will aid in removal of this CONNECTOR HOSES J9214-27
snap-ring.
(5) Remove pressure regulator from fuel rail. Fig. 13 Fuel Pressure Regulator—5.2L Engine
FUEL MOUNTING
INSTALLATION—3.9L ENGINE PRESSURE BOLT
(1) Install new O-ring seals to pressure regulator. REGULATOR
(2) Install pressure regulator to fuel rail. The vac
u u m nipple on the regulator must be pointed straight
up.
(3) Install snap-ring. Be sure snap-ring is seated.
(4) Install vacuum line to pressure regulator.
R E M O V A L - 5 . 2 1 (¥-8) ENGINE
The pressure regulator is located (mounted verti
cally) in the fuel rail assembly near the dash panel REGULATOR
(Fig. 13). It is Jield to the fuel rail with a clamp and MOUNTING
CLAMP J9214-48
bolt (Fig. 14).
(1) Perform the fuel pressure release procedure. Fig. 14 Pressure Regulator Mounting—5.2L Engine
(3) Remove the vacuum line from the pressure reg combined part. Refer to Fuel Filter/Fuel Pressure
ulator. Regulator—5.9L Engine for removal and installation
(4) Remove the clamp bolt and regulator retaining procedures.
clamp from fuel rail.
(5) Remove pressure regulator from fuel rail. FUEL PUMP MODULE
Refer to the Fuel Delivery System section of this
INSTALLATION—5.2L ENGINE group for removal/installation procedures.
(1) Install new O-ring seals to pressure regulator.
(2) Install pressure regulator to fuel rail. FUEL PUMP RELAY
(3) Install retaining clamp and clamp bolt. The Fuel Pump relay is located in the engine com
(4) Install vacuum line to pressure regulator. partment (Fig. 1).
REMOVAL/INSTALLATION—iJL (V-8) ENGINE

On vehicles equipped with the 5.9L (V-8) engine,
the fuel filter and fuel pressure regulator are one
FUEL RAIL AIR CONDITIONING
/COMPRESSOR SUPPORT BRACKET
WARNING: THE FUEL S Y S T E M I S U N D E R A CON
S T A N T P R E S S U R E ( E V E N WITH T H E E N G I N E
TURNED OFF). B E F O R E SERVICING THE FUEL
RAIL A S S E M B L Y , THE FUEL S Y S T E M P R E S S U R E
MUST B E R E L E A S E D .
To release fuel pressure, refer to the Fuel Delivery

System section of this group. See Fuel System Pres
sure Release.
C A U T I O N : The left and right fuel rails are replaced

a s an assembly. Do not attempt to separate the rail
halves at the connecting hose(s) (Fig. 15). Due to MOUNTING BOLTS ' " J9214-49
the design of these connecting hose(s), they d o not
use any clamps. Never attempt to install a clamping Fig. 16 A/C Compressor Support Bracket— Typical
device of any kind to the hose(s). When removing FUEL INJECTOR
FUEL
the fuel rail assembly for any reason, be careful not RAIL HARNESS CONNECTORS
to bend or kink the connecting hose(s).
FUEL RAIL
CONNECTING
HOSES
J9214-32
Fig. 15 Fuel Rail Assembly— Typical ' FUEL

REMOVAL INJECTOR J9214-30
(1) Remove negative battery cable at battery.
Fig. 17 Fuel Injector Connectors—Typical
(2) Remove air cleaner.
(3) Perform the fuel pressure release procedure. (9) Remove EVAP canister purge solenoid/bracket
Refer to the Fuel Delivery System section of this assembly (Fig. 19) from intake manifold (one nut on
group. 3.9L, one bolt on 5.2L/5.9L).
(4) Remove throttle body from intake manifold. Re (10) Disconnect fuel tube(s) (lines) at rear of fuel
fer to Throttle Body removal in this group. rail. Refer to Fuel Tubes/Lines/Hoses and Clamps in
(5) If equipped with air conditioning, remove the the Fuel Delivery System section of this group.
A/C compressor-to-intake manifold support bracket (11) Remove the remaining fuel rail mounting
(three bolts) (Fig. 16). bolts (Fig. 20).
(6) Disconnect electrical connectors at all fuel in (12) Gently rock and pull the left fuel rail until
jectors (Fig. 17). The factory fuel injection wiring the fuel injectors just start to clear the intake mani
harness is numerically tagged (INJ 1, I N J 2, etc.) for fold. Gently rock and pull the r i g h t fuel rail until
injector position identification. the fuel injectors just start to clear the intake mani
(7) If equipped with a 3.9L or 5.2L engine, remove fold. Repeat this procedure (left/right) until all fuel
vacuum line at fuel pressure regulator (Fig. 18). injectors have cleared the intake manifold.
(8) 3.9L (V-6) engine only: Disconnect electrical (13) Remove fuel rail (with injectors attached)
connector at intake manifold charge air temperature from engine.
sensor. Do not remove sensor.
INJECTOR J9214-24
Fig. 21 Fuel Injector Clip—Typical

(6) Install fuel rail mounting bolts.
VACUUM (7) Install EVAP canister purge solenoid to intake
CONNECTOR
manifold.
CANISTER PURGE (8) Connect electrical connector to intake manifold
SOLENOID/BRACKET J9214-50
charge air temperature sensor.
(9) Connect wiring to all fuel injectors. The injec
Fig. 19 EVAP Canister Purge Solenoid tor wiring harness is numerically tagged.
(14) Remove the clip(s) retaining the injector(s) to (10) Install the A/C support bracket (if equipped).
fuel rail (Fig. 21). (11) Install throttle body to intake manifold. Refer
to Throttle Body installation in this section of the
INSTALLATION group.
(1) Apply a small amount of engine oil to each fuel (12) If equipped, install vacuum line to fuel pres
injector O-ring. This will help in fuel rail installa sure regulator.
tion. (13) Install fuel tube(s) (lines) at rear of fuel rail.
(2) Install injector(s) and injector clip(s) to fuel Refer to Fuel Tubes/Lines/Hoses and Clamps in the
rail. Fuel Delivery System section of this group.
(3) Position the fuel rail/fuel injector assembly to (14) Install air cleaner.
the injector openings on the intake manifold. (15) Connect battery cable to battery.
(4) Guide each injector into the intake manifold. (16) Start engine and check for leaks.
Be careful not to tear the injector O-ring.
(5) Push the r i g h t fuel rail down until fuel injec
tors have bottomed on injector shoulder. Push the
left fuel rail down until fuel injectors have bottomed
on injector shoulder.
FUEL SYSTEM PRESSURE RELEASE PROCEDURE REMOVAL

WARNING: THE FUEL S Y S T E M IS UNDER A CON (2) Disconnect electrical connector from IAC motor.
S T A N T P R E S S U R E ( E V E N WITH T H E E N G I N E (3) Remove two mounting bolts (screws) (Fig. 23).
T U R N E D OFF). B E F O R E S E R V I C I N G T H E FUEL
P U M P , FUEL L I N E S ( T U B E S ) , F U E L FILTER, O R
F U E L INJECTOR(S), T H E F U E L S Y S T E M P R E S S U R E
MUST B E RELEASED.
To release fuel pressure, refer to the Fuel Delivery

System section of this group. See Fuel System Pres
sure Release Procedure.
FUEL TANKS
Refer to the Fuel Tank section of this group for re
FUEL TANK PRESSURE RELIEF/ROLLOVER VALVE

Refer to the Fuel Tank section of this group for re
J9214-23
Fig. 23 Mounting Bolts (Screws)—IAC Motor
FUEL TUBES/LINES/HOSES AND CLAMPS
Refer to Fuel Tubes/Lines/Hoses and Clamps in the (4) Remove IAC motor from throttle body.
Fuel Delivery System section of this group for remov
al/installation procedures. INSTALLATION
Also refer to Quick-Connect Fittings in the Fuel (1) Install IAC motor to throttle body.
Delivery System section of this group for removal/in (2) Install and tighten two mounting bolts (screws)
stallation procedures. to 7 N»m (60 in. lbs.) torque.
(3) Install electrical connector.
IDLE AIR CONTROL (IAC) MOTOR (4) Install air cleaner assembly.
The IAC motor is located on the back of the throt
tle body (Fig. 22). IGNITION COIL
Refer to Group 8D, Ignition Systems for removal/
MANIFOLD ABSOLUTE
installation procedures.
INTAKE MANIFOLD
Refer to Group 11, Exhaust System and Intake
Manifold for removal/installation procedures.

The MAP sensor is located on the front of the
throttle body (Fig. 24). An L-shaped rubber fitting is
used to connect the MAP sensor to throttle body (Fig.
25).
REMOVAL
The throttle body must be removed from the intake
manifold for MAP sensor removal.
(2) Remove throttle body. Refer to Throttle Body
removal in this section.
(3) Remove two MAP sensor mounting bolts
(screws) (Fig. 24).
(4) While removing MAP sensor, slide the vacuum
rubber L-shaped fitting (Fig. 25) from the throttle
Fig. 22 idle Air Control Motor—Typical body.
(5) Remove rubber L-shaped fitting from MAP sen
sor.
MANIFOLD ABSOLUTE
Fig. 24 MAP Sensor— Typical
Fig. 27 Dual Oxygen Sensors—5.9L HDC Engine

REMOVAL
WARNING: THE EXHAUST MANIFOLD BECOMES

VERY HOT DURING ENGINE OPERATION. ALLOW
ENGINE TO COOL BEFORE REMOVING OXYGEN
Fig. 25 MAP Sensor L-Shaped Rubber Fitting SENSOR.
INSTALLATION
(1) Install rubber L-shaped fitting to MAP sensor. (1) Raise and support the vehicle.
(2) Position sensor to throttle body while guiding (2) Disconnect the wire connector from the 0 2 sen
rubber fitting over throttle body vacuum nipple. sor.
(3) Install MAP sensor mounting bolts (screws).
C A U T I O N : When disconnecting the sensor electrical
Tighten screws to 3 N»m (25 in. lbs.) torque.
connector, d o not pull directly on wire going into
(4) Install throttle body. Refer to Throttle Body in
sensor.
stallation in this section.
(5) Install air cleaner. (3) Remove the 0 2 sensor from the exhaust mani
fold.
OXYGEN (0 ) SENSOR
2
On 3.9L/5.2L/5.9L LDC engines, the single 0 sen

2 INSTALLATION
sor is located on the right exhaust down pipe (Fig. Threads of new oxygen sensors are factory coated
26). On 5.9L HDC engines, the dual 0 sensors are
2 with anti-seize compound to aid in removal. DO
located on each (left and right) exhaust down pipe NOT a d d any additional anti-seize c o m p o u n d to
(Fig. 27). the threads of a n e w o x y g e n sensor.
(1) Install the 0 sensor into the exhaust manifold.

2 (3) Remove three mounting bolts (Fig. 29).
Tighten to 30 N*m (22 ft. lbs.) torque. (4) Remove PCM from vehicle.
(2) Connect the 0 sensor wire connector.
2
(3) Lower the vehicle. INSTALLATION

(1) Install PCM to inner fender.
PARK/NEUTRAL SWITCH (2) Check inside of 60-way wiring harness connec
Refer to Group 21, Transmission and Transfer Case tor for bent pins or corrosion. Repair as necessary.
for removal/installation procedures. (3) Install 60-way connector to PCM. Tighten
e
mounting screw to 4 N m (35 in. lbs.), torque.
POWERTRAIN CONTROL MODULE (PCM) (4) Install battery cable to battery.
The powertrain control module (PCM) is located in
the engine compartment behind the battery (Fig. 28). QUICK-CONNECT FITTINGS
Refer to the Fuel Delivery System section of this
REMOVAL group for removal/installation procedures.
THROTTLE BODY
A (factory adjusted) set screw is used to mechani
cally limit the position of the throttle body throttle
plate. N e v e r a t t e m p t t o a d j u s t t h e e n g i n e idle
s p e e d u s i n g t h i s s c r e w . All idle speed functions are
controlled by the powertrain control module (PCM).
REMOVAL
(2) Disconnect throttle body electrical connectors
at MAP sensor, IAC motor and TPS (Fig. 30).
MANIFOLD ABSOLUTE
DATA LINK CONTROL
Fig. 28 Powertrain Control Module (PCM) Location

(2) Carefully remove 60-way wiring connector from
PCM (one screw) (Fig. 29).
PCM
MOUNTING
Fig. 30 Sensor Electrical Connectors—Typical

(3) Remove vacuum line at throttle body.
(4) Remove (unsnap) all control cables from throt
tle body (lever) arm. Refer to the Accelerator Pedal
and Throttle Cable section of this group for addi
PCM CONNECTOR
CONNECTOR M O U N T I N G tional information.
BOLT J9314-165 (5) Remove four throttle body mounting bolts (Fig.
31).
Fig. 29 Powertrain Control Module (PCM) (6) Remove throttle body from intake manifold.
THROTTLE THROTTLE
Fig. 32 TPS Mounting Screws

THROTTLE THROTTLE
BODY POSITION
THROTTLE BODY
MOUNTING BOLTS J9214-31
Fig. 31 Throttle Body Mounting Bolts—Typical

(7) Discard old throttle body-to-intake manifold
gasket.
INSTALLATION
(1) Clean the mating surfaces of the throttle body
and the intake manifold.
(2) Install new throttle body-to-intake manifold
gasket. THROTTLE SOCKET LOCATING
(3) Install throttle body to intake manifold. SHAFT TANGS J9214-52
(4) Install four mounting bolts. Tighten bolts to 23
N»m (200 in. lbs.) torque. Fig. 33 TPS Installation—Typical
(5) Install control cables. (3) Manually operate the throttle control lever by
(6) Install vacuum line to throttle body. hand to check for any binding of the TPS.
(7) Install electrical connectors. (4) Connect TPS electrical connector to TPS.
(8) Install air cleaner. (5) Install air intake tube.
THROTTLE POSITION SENSOR (TPS)
REMOVAL
The TPS is located on the side of the throttle body
(Fig. 30).
(1) Remove air intake tube at throttle body.
(2) Disconnect TPS electrical connector.
(3) Remove two TPS mounting screws (Fig. 32).
(4) Remove TPS from throttle body.
INSTALLATION
The throttle shaft end of the throttle body slides
into a socket in the TPS (Fig. 33). The TPS must be
installed so t h a t it can be rotated a few degrees. If
the sensor will not rotate, install the sensor with the
throttle shaft on the other side of the socket tangs.
The TPS will be under slight tension when rotated.
(1) Install the TPS and two retaining screws.
(2) Tighten screws to 7 N»m (60 in. lbs.) torque.
VEHICLE SPEED SENSOR

The vehicle speed sensor (Fig. 34) is located on the
extension housing of the transmission on 2WD mod
els. It is located on the transfer case on 4WD models.
REMOVAL
Fig. 35 Sensor and Components—Typical

Fig. 34 Vehicle Speed Sensor Location—Typical (5) Remove the sensor.
(2) Disconnect the electrical connector from the INSTALLATION
sensor. (1) Install new sensor into speedometer adapter.
(3) Remove (unscrew) the speedometer cable (if (2) Tighten sensor mounting nut.
equipped) from the sensor (Fig. 35). (3) Connect electrical connector to sensor.
(4) Loosen the sensor mounting nut (Fig. 35). (4) Connect the speedometer cable (if equipped).
D I E S E L FUEL I N J E C T I O N — C O M P O N E N T DESCRIPTION/SYSTEM OPERATION
NDEX
page page
Air Conditioning (A/C) Clutch R e l a y - P C M Output . 81 Mechanical Lift Pump 86
Air Conditioning (A/C) C o n t r o l s - P C M Input .... 77 Overdrive Indicator L a m p — P C M Output ....... 82
Air Intake Heater R e l a y s — P C M Output . . . . . . . . 81 Overdrive S o l e n o i d - P C M Output . . . . . . . . . . . . 82
Auto Shut Down (ASD) R e l a y - P C M Output . . . . 82 Overdrive/Override Switch—PCM Input . . . . . . . . 79
Automatic Shut Down (ASD) S e n s e - P C M input . 78 Park/Neutral S w i t c h - P C M Input 79
Battery V o l t a g e - P C M Input 78 Power G r o u n d - P C M Input . 79
Brake Switch—PCM Input ....... 78 Powertrain Control Module (PCM) 76
Charge Air Temperature S e n s o r — P C M Input ... 78 S C I R e c e i v e - P C M Input . . 80
Engine Speed S e n s o r — P C M Input ........... 78 S C I T r a n s m i t - P C M Output ... 82
Fuel Drain Manifold 83 Sensor R e t u r n - P C M Input . . . . . . . . . . . . . . . . . 80
Fuel Heater 83 Signal G r o u n d - P C M Input . 80
Fuel Injection Pump 83
Fuel Injectors 84 Speed C o n t r o l - P C M Input 80
Fuel Solenoid 84 Speed C o n t r o l - P C M Output 82
Fuel/Water Separator Filter . . . . . . . . . . . . . . . . . 84 System Diagnosis 76
General Information 76 System Operation 86
Generator F i e l d - P C M Output . 81 T a c h o m e t e r - P C M Output 82
High Pressure Fuel Lines 85 Throttle Position Sensor ( T P S ) - P C M Input 80
Ignition S e n s e — P C M Input 78 Vehicle Speed S e n s o r - P C M Input 80
K S B Solenoid . . . . . . . 85 Wait-To-Start L a m p - P C M Output 82
Malfunction Indicator L a m p — P C M Output . . . . . . 82 Water-ln-Fuel L a m p - P C M Output 83
Manual Shut Down Lever . . . . . . . . . . . . . . . . . . 85 Water-ln-Fuel S e n s o r - P C M input 80
GENERAL INFORMATION this group for DTC information. The DRB II scan
The fuel system of the 5.9L (in-line six-cylinder) tool can be used to access the DTC messages stored
turbo-diesel engine (Fig. 1) consists of the following in the PCM memory.
components:
• Fuel t a n k POWERTRAIN CONTROL MODULE (PCM)
• Low and high pressure fuel supply lines The powertrain control module (PCM) (Fig. 2) was
• Mechanical lift pump formerly referred to as the SBEC or engine control
• Fuel/water separator filter ler. The PCM is a pre-programmed, dual micropro
• Fuel heater cessor digital computer.
• Fuel injection pump The PCM is located in the engine compartment be
• Fuel injectors hind the battery and under the left front fender (Fig.
• Fuel return lines 2).
For information regarding fuel requirements of the The PCM contains a voltage convertor, which con
5.9L turbo-diesel engine, refer to the Fuel Require verts battery voltage to a regulated 8.0 volts. This is
ments—Diesel Engines paragraph at the front of this used to power the engine speed sensor. The PCM also
group. provides a 5 volt supply for the throttle position sen
Although various components, relays and switches sor (TPS). The TPS is not used if equipped with a
are operated by the powertrain control module manual transmission.
(PCM), the diesel fuel injection system (Fig. 1) is not Various sensors, switches and relays provide the
directly regulated by the PCM. Refer to the proceed inputs necessary for operation of the PCM.
ing Powertrain Control Module section for additional T h e P C M I n p u t s a r e from:
information. 9 Air conditioning control switch
• Automatic shut down (ASD) sense circuit
SYSTEM DIAGNOSIS • Battery voltage
The PCM tests many of its own input and output • Brake light switch
circuits. If a diagnostic trouble code (DTC) is found • Charge air temperature sensor
in a major system, this information is stored in the ® Coolant temperature sensor (Auto, trans, only)
PCM memory. Refer to On-Board Diagnostics in the • Engine speed sensor
Diesel Fuel Injection—General Diagnosis section of • Ignition
• Overdrive/override switch
• Park/neutral switch (Auto, trans, only)
FUEL FROM SUPPLY TANK

LIFT PUMP
LOW PRESSURE SUPPLY LINE
FUEL/WATER SEPARATOR FILTER
4A. FUEL HEATER
4B. FUEL/WATER DRAIN VALVE
W.I.F. (WATER IN FUEL) SENSOR
CHARGE AIR TEMP. SENSOR
BLEED SCREW
LOW PRESSURE SUPPLY LINE
INJECTION PUMP
TURBO BOOST CONTROL LINE
POWERTRAIN CONTROL MODULE
FUEL DRAIN MANIFOLD
(RETURN FUEL TO TANK)
HIGH PRESSURE LINES
INJECTORS
KSB SOLENOID
MANUAL SHUT D O W N LEVER
TDC TIMING PIN
AIR TEMP. SWITCH
NOTE: #10 CONTROLS INTAKE HEATER,

KSB VALVE, FUEL HEATER, WIF SENSOR J9314-179
Fig. 1 Diesel Fuel System Components

A / C CLUTCH RELAY STARTER RELAY Based on these inputs, the PCM regulates various
TORQUE CONVERTER engine and vehicle operations through different sys
AUTO SHUTDOWN RELAY
CLUTCH RELAY tem components. These are called PCM outputs.
FUEL PUMP RELAY PCM outputs are to the:
• A/C compressor clutch relay
• Air intake heater relays
• Generator field control
• ASD relay
• Malfunction indicator lamp
• Overdrive indicator lamp
• Overdrive solenoid
• SCI transmit
• Speed control functions
POWERTRAIN
DATA UNK CONTROL
• Tachometer (if equipped)
CONNECTOR MODULE J9314-164 • Water-in-fuel indicator lamp
• Wait-to-start indicator lamp
Fig. 2 PCM Location—Typical
Power ground
AIR CONDITIONING (A/C) CONTROLS-PCM INPUT
SCI receive (DRB II connection) The A/C control system information applies to fac
Sensor return tory installed air conditioning units only.
Signal ground
Speed control switch A/C REQUEST SIGNAL
Throttle position sensor (Auto, trans, only) Once A/C has been selected, the PCM receives the
Transmission thermo-switch (Auto, trans, only) A/C request signal from the evaporator switch. The
Vehicle speed sensor input indicates that the evaporator temperature is in
Water-in-fuel sensor the proper range for A/C application. The PCM uses
this input to cycle the A/C compressor clutch
(through the A/C relay).
If the A/C low pressure switch opens (indicating a AIR
low refrigerant level), t h e PCM will not receive an TEMPERATURE
SWITCH
A/C select signal. The PCM will then remove the (KSB SOLENOID)
ground from the A/C relay. This will deactivate the
A/C compressor clutch.
If evaporator switch opens, (indicating t h a t evapo
rator is not in proper temperature range), PCM will
not receive t h e A/C request signal. The PCM will
then remove t h e ground from the A/C relay, deacti
vating the A/C compressor clutch.
AUTOMATIC SHUT DOWN (ASD) S E N S E - P C M

INPUT
A 12 volt signal a t this input indicates to the PCM
t h a t the ASD h a s been activated. The ASD relay is j9114-235
located in t h e engine compartment (Fig. 3). It is used
Fig. 4 Charge Air Temperature Sensor
to power a circuit to t h e generator field winding.
ENGINE SPEED SENSOR-PCM INPUT
A / C CLUTCH RELAY . STARTER RELAY
The engine speed sensor (sometimes referred to as
CLUTCH RELAY the crankshaft position sensor) is mounted to the
FUEL PUMP RELAY front of engine (Fig. 5). It generates an rpm signal to
the PCM. The engine speed sensor input is used
along with the vehicle speed sensor and throttle po
sition sensor inputs to determine when to shift the
automatic transmission into and out of overdrive.
The speed sensor signal is also used as an input for
the ASD relay (for control of generator field), vehicle
speed control and instrument panel mounted tachom
eter.
POWERTRAIN SENSOR MOUNTING BOLTS
DATA LINK CONTROL
Fig. 3 Relay Location—Typical

BATTERY VOLTAGE-PC! INPUT
The battery input provides power to operate the
PCM. Battery voltage is needed to keep PCM mem
ory alive. The memory stores diagnostic trouble code
(DTC) messages and t h e minimum TPS value from
the previous key-on,
BRAKE SWITCH-PCM INPUT

If t h e PCM receives a brake switch input while the
speed control system is on, it will disable speed con
trol.
CHARGE AIR TEMPERATURE SENSOR—PCM

INPUT
The charge air temperature sensor is located on top
VIBRATION
of the intake manifold (Fig. 4). It provides an input DAMPER J9214-69
to the PCM t h a t indicates air temperature in the
manifold. Based on t h e charge air temperature input, Fig. 5 Engine Speed Sensor
the PCM determines if and how long to energize t h e IGNITION S E N S E - P C M INPUT
air intake heaters. Refer to Air Intake Heaters in The ignition circuit (J2) sense input informs the
this section. PCM that the ignition switch is in the r u n position.
OVERDRIVE/OVERRIDE SWITCH-PCM INPUT

The overdrive/override switch is not used with
manual transmissions.
On vehicles equipped with overdrive, the PCM reg
ulates the 3-4 overdrive upshift and downshift
through the overdrive solenoid. An override switch is
located on the instrument panel.
The overdrive/override switch is a momentary con
tact switch. The switch contacts are normally open.
When the switch is activated, the PCM will receive a
ground signal. The transmission will not enter over
drive when the operator presses the override switch.
The transmission downshifts if the operator presses
the override switch while in overdrive.
THERMO SWITCH J9214-62
COOLANT TEMPERATURE SENSOR
Fig. 7 Transmission Thermo-Switch—Typical
The coolant temperature sensor is not used with
manual transmissions. to the PCM. The input indicates if the automatic
The coolant temperature sensor (Fig. 6) monitors transmission is in park, neutral or a drive gear se
engine coolant temperature. This input is used to in lection.
hibit transmission upshift into overdrive when the If transmission is in overdrive and operator shifts
engine coolant temperature is below 16 degrees C (60 vehicle into neutral, the overdrive solenoid will be
degrees F). de-energized. Normal PCM operation will resume
when the transmission is shifted back into drive po
sition.
The PCM uses the park/neutral switch input when
determining speed control strategy. The PCM will
disable the speed control if the operator shifts t h e
transmission into neutral. The speed control will
have to be reset once the vehicle is placed back into
drive.
The park/neutral switch is sometimes referred to as
the neutral safety switch. Refer to Group 21 Trans
missions for adjustment, replacement and test infor
mation.
Fig. 6 Coolant Temperature Sensor

TRANSMISSION THERMO-SWITCH
The transmission thermo-switch is not used with
manual transmissions.
The transmission thermo-switch opens when the
transmission fluid temperature is above 134°C
(273°F). When the thermo-switch opens, the trans
mission will not shift into overdrive. The transmis
sion downshifts if it is in overdrive when the thermo-
switch opens. Once the thermo-switch opens, it will
not close until transmission fluid temperature drops
to 116°C (240°F). The switch is located in the trans
mission-to-radiator cooling line (Fig. 7). Fig. 8 Park/Neutral Switch—Typical
POWER G R O U N D - P C M INPUT
PARK/NEUTRAL SWITCH-PCM INPUT Provides a common ground for power devices (sole
The park/neutral switch (Fig. 8) is located on the noid and relay).
automatic transmission housing. It provides an input
SCI RECEIVE-PCM INPUT the transfer case extension housing (4WD). A signal
The serial communication interface (SCI) receive is sent from this sensor, along with signals from both
and transmit outputs allow the PCM to communicate the TPS and the engine speed sensor, to the PCM.
with the DRB II scan tool. The PCM will then use this information to determine
when to shift into and out of overdrive.
SENSOR RETURN-PCM INPUT The speed sensor is also used in determining speed
Sensor return provides a low noise ground refer control set, decelerate, accelerate, maximum set
ence for all system sensors. speed (85 mph) and minimum set speed (35 mph) op
erations.
SIGNAL GROUND-PCM INPUT
Provides a common ground for the input signals. VEHICLE
SPEED
SPEED CONTROL-PCM INPUT SENSOR
The PCM regulates the speed control system based
on inputs it receives. The speed control operating
range is from 35 to 85 mph. Inputs t h a t effect speed
control operation are:
• Park/neutral switch
• Vehicle speed sensor
• Throttle position sensor
• Engine speed sensor
• Brake switch
THROTTLE POSITION SENSOR (TPS) —PCM INPUT

The throttle position sensor is not used with man
ual transmissions.
The throttle position sensor (TPS) is mounted on Fig. 10 Vehicle Speed Sensor—Typical Location
the top of the fuel injection pump (Fig. 9). The TPS
provides an input to the PCM. It senses how far the WATER-IN-FUEL SENSOR-PCM INPUT
throttle is open (past the idle position). The PCM The water-in-fuel (WIF) sensor is located at the
uses the TPS input, along with vehicle speed sensor bottom of the fuel/water separator filter (Fig. 11).
and engine speed sensor inputs to determine 3-4 up The sensor sends an input to the PCM when it senses
shift (overdrive) and 4-3 downshift. water in the fuel. The PCM looks at the water-in-fuel
The TPS is a potentiometer. The PCM supplies 5 sensor signal when the ignition key is put in the ON
volts to the sensor. TPS output to the PCM varies position. It also monitors the input at the end of the
from approximately 1.0 volt at idle to 3.5 volts at intake heater post-heat cycle.
wide open throttle (WOT). The PCM turns the water-in-fuel indicator lamp to
the ON position if water is detected in the fuel. The
water-in-fuel indicator lamp is located in the instru
ment panel.
T \ J9114-237
Fig. 9 Throttle Position Sensor

VEHICLE SPEED S E N S O R - P C M INPUT J91 14-85
The vehicle speed sensor (Fig. 10) is located in the
extension housing of the transmission (2WD) or on Fig. 11 Water-in-Fuel Sensor
AIR CONDITIONING (A/C) CLUTCH RELAY—PCM

HEATER
OUTPUT RELAYS
The PCM activates the A/C compressor through the
A/C clutch relay. The PCM regulates A/C compressor
operation by switching the ground circuit for the A/C
clutch relay on and off. The relay is located in the
engine compartment (Fig. 3).
By switching the ground path for the relay on and
off, the PCM is able to cycle the A/C compressor
clutch. This is based on changes in engine operating
conditions. If, during A/C operation, the PCM senses
a low idle speed, it will de-energize the relay. This
prevents A/C clutch engagement. The relay will re
main de-energized until the idle speed increases. WELL J9114-67
GENERATOR FIELD-PCM OUTPUT Fig. 12 Air Intake Heater Relays

The PCM regulates the charging system voltage
within a range of 12.9 to 15.0 volts. It will control
ASD relay operation. The input (through the PCM)
for the ASD relay comes from the engine speed sen
sor.
When engine running speed is above 384 rpm, a
signal is sent from the PCM to engage the ASD re
lay. This supplies the necessary generator field wind
ing control. When rpm drops below 320, the signal to
the ASD relay is stopped. Refer to Group 8A, for
charging system information.
AIR INTAKE HEATER RELAYS-PCM OUTPUT

The PCM operates the air intake heaters through
the air intake heater relays (Fig. 12). The relays may
be energized before and after cranking, depending
upon intake manifold air temperature. The PCM
monitors intake manifold air temperature through Fig. 13 Air Intake Heaters—Typical
the charge air temperature sensor. Refer to Air In PREHEAT CYCLE
take Heaters in this section. The PCM powers up when the ignition key is
The relays are not energized during engine crank turned to the On position. If intake manifold air tem
ing. When they are energized they make a clicking perature is 15°C (59°F) or below, the intake heaters
noise. are energized and the wait-to-start light is illumi
nated. The heaters are energized for a specific
C A U T I O N : Do not energize the air intake heater re
amount of time. This is based on the intake manifold
lays more than once per 15 minutes. If the relays
are cycled and the key is turned off and then turned
air temperature. Refer to the Air Intake Heater Cy
back o n , the engine could be damaged. Wait 15
cle Chart.
minutes before turning the key back to the O N po Once the heaters have cycled, the wait-to-start
sition. light goes out. While the engine is cranked, the heat
ers are not energized.
AIR INTAKE HEATER POST-HEAT CYCLE

When energized, the air intake heaters warm in After engine has been started, the post-heat cycle
coming air as it enters the intake manifold. The air will begin if intake manifold air temperature was
intake heaters (Fig. 13) are energized by the PCM 15°C (59°F) or below when ignition switch was
through the air intake heater relays. Intake manifold turned on. Depending upon intake manifold temper
air temperature determines when the heaters are en ature, either: both heaters are energized, or they are
ergized. They may be energized before cranking and cycled on and off (when one is energized, the other is
after cranking, or both. Refer to Pre-Heat Cycle and not). The time the heaters are energized depends
Post-Heat Cycle. The heaters are not energized dur upon intake manifold air temperature. Refer to the
ing cranking. Air Intake Heater Cycle Chart.
14 - 82 FUEL 'SYSTEM — . — ~ — — — «
INTAKE HEATER CYCLE CHART emission related systems, the lamp is turned on. This
is a warning t h a t the PCM has recorded a system or
sensor malfunction. In some cases, when a problem is
Intake Preheat Cycle Time Pestheat Cycle
Ignition l£ey O N Ignition Key O N declared, the PCM will go into a limp-in mode. This
featperafwre Engine Not Running Snglne Running is an attempt to keep the system operating. It signals
an immediate need for service.
Above 15 °C 0 Seconds No The lamp can also be used to display a diagnostic
(59 °F) trouble code (DTC). Cycle the ignition switch On-Off-
On-Off-On within three seconds and any codes stored
-8°C(18°F)to 10 Seconds Yes in the PCM memory will be displayed. This is done
15°C (59 °F) in a series of flashes representing digits. Refer to On-
Board Diagnostics in the General Diagnosis section
of this group for more information.
-17°C(1 °F) 15 Seconds Yes
-9 °C(]6°F)
OVERDRIVE INDICATOR L A M P - P C M OUTPUT
Indicates the state of the overdrive defeat switch
«2d°C(-15°F) 17.5 Seconds Yes
on the instrument panel.
to-18°C(0 °F)
OVERDRIVE S0LEN0ID-PCM OUTPUT
Below-26 °C 20 Seconds Yes The overdrive solenoid is used on vehicles t h a t
(-15 *F)
J9114-239 have an automatic transmission. The solenoid is op
erated by the PCM. It controls shifting in and out of
AUTO SHUT DOWN (ASD) RELAY-PCM OUTPUT overdrive through the overdrive solenoid. Refer to
The ASD relay is located in the engine compart Group 21 for overdrive solenoid service.
ment (Fig. 14).
SCI TRANSMIT—PCM OUTPUT
SCI Transmit is the serial data communication
TORQUE CONVERTER transmit circuit for the DRB II scan tool. The PCM
AUTO SHUTDOWN RELAY
CLUTCH RELAY
FUEL PUMP RELAY
transmits data to the DRB II through the SCI Trans
mit circuit.
SPEED C0NTR0L-PCM OUTPUT

The speed control vacuum and vent solenoids are
operated by the PCM. The vacuum solenoid main
tains vacuum at a required pressure to resume, set
or accelerate the speed control system. The vent so
lenoid allows vacuum to bleed off during decelera
tion, when the brakes are applied, or the
POWERTRAIN transmission is shifted into park or neutral.
DATA LINK CONTROL
CONNECTOR MODULE J9314-164 TACHOMETER-PCM OUTPUT
This output generates the necessary signal needed
Fig. 14 Relay Location—Typical to operate a dealer installed tachometer (if equipped).
The ASD relay supplies battery voltage to the gen The input for this signal is from the engine speed
erator field winding to provide regulation of the sensor.
charging system. The ground circuit for the ASD re
WAIT-TO-START L A M P - P C M OUTPUT
lay is controlled by the PCM. The PCM operates the
The wait-to-start lamp is turned on and off by the
relay by switching the ground circuit on and off.
PCM based on the charge air temperature sensor in
put.
MALFUNCTION INDICATOR L A M P - P C M OUTPUT The light is turned on when the ignition is first ac
The malfunction indicator lamp (formerly referred
tivated. It will remain on for two seconds as a bulb
to as the check engine lamp) illuminates at the bot test. If the PCM reads intake manifold air tempera
tom of the instrument panel each time the ignition ture below 15°C (59°F), it will t u r n the wait-to-start
key is turned on. It will stay on for three seconds as light on for the intake heater preheat cycle. The
a bulb test. light stays on until the preheat cycle is over.
If the powertrain control module (PCM) receives an The wait-to-start light will flash on and off if the
incorrect signal, or no signal from certain sensors or charge air temperature sensor input to the PCM is
below minimum value or above maximum value. The

PCM stores a DTC when these conditions occur.
WATER-IN-FUEL L A M P - P C M OUTPUT
The water-in-fuel lamp is turned on and off by the
PCM. The lamp is turned on by the PCM when it re
ceives an input from the water-in-fuel sensor. The
sensor sends an input to the PCM when it detects
water in the fuel/water separator filter.
FUEL DRAIN MANIFOLD

Some fuel is continually vented from the injection
pump to cool the pump and the fuel injectors. During
injection, a small amount of fuel
flows past the injector nozzle and is not injected
into the combustion chamber. This fuel, along with
Fig. 16 Fuel Heater
the fuel vented from the injection pump, drains into
the fuel drain manifold (Fig. 15). Fuel in the drain
manifold is routed back to the fuel tank.
Fig. 17 Injection Pump

The injection pump varies injector timing to corre
spond with changing engine speed. As engine speed
Fig. 15 Fuel Drain Manifold increases, the internal pump pressure increases. Fuel
FUEL HEATER flows through an orifice in the advance mechanism
The 5.9L turbo-diesel engine has a fuel heater to piston (Fig. 18). The piston is opposed by a spring.
prevent the fuel from waxing in the fuel/water sepa The spring regulates injection pump timing advance.
rator. The fuel heater is located in the top of the fil As pump pressure increases, the piston moves
ter/separator adapter (Fig. 16). against the spring, advancing injection timing. The
The heater has a built in monitor t h a t senses fuel spring holds the advance mechanism in the starting
temperature. Voltage to operate the fuel heater is position during cranking and idle.
supplied through the ignition switch. The heater op The mechanical lift pump delivers fuel under a low
erating range is from 6° - 13.5°C (43° - 53°F). pressure of 21-35 kPa (3-5 psi) to the injection pump
through the fuel/water separator filter. The injection
FUEL INJECTION PUiVSP pump supplies high pressure fuel of approximately
The injection pump is a Bosch VE Distributor type 59,000 kPa (8,000 psi) to each injector in precise me
(Fig. 17). The injection pump is driven by the engine tered amounts at the correct time.
camshaft. A gear on the end of the pump shaft The injection pump contains the KSB (cold start)
meshes with the camshaft gear. The pump is timed solenoid, fuel solenoid, turbo boost control line and
to the engine. Fuel injection occurs near the end of manual shut down valve.
the compression stroke for each cylinder. Refer to In
jection Pump Removal and Installation in the Diesel
Service Procedures section of this group for injection
pump timing procedures.
HIGH
PRESSURE
FUEL FROM
INJECTION
PUMP
ORIFICE
PISTON
J9114-33
J91 14-82
Fig. 18 injection Pump Timing Advance Mechanism
Fig. 20 Fuel Injector Operation
FUEL INJECTORS
The fuel injectors are mounted on the left side of FUEL SOLENOID
the cylinder head (Fig. 19). The injectors are con The fuel solenoid (Fig. 21) is mounted on the injec
nected to the fuel injection pump by the high pres tor pump. When energized, the solenoid allows fuel
sure fuel lines. to reach the high pressure chamber of the injection
HIGH pump.
PRESSURE
FUEL LINE FUEL
(6) SOLENOID
J9114-74 =
Fig. 19 Fuel Injectors Fig. 21 Fuel Solenoid

The injectors consist of the nozzle holder, O-ring Battery voltage is supplied to the solenoid when
water seal, shims, spring, needle valve and nozzle the ignition key is in the ON position. When ener
(Fig. 20). Fuel enters the injector at the fuel inlet gized, the solenoid pulls a plunger off its seat allow
(top of injector) and is routed, to the needle valve ing fuel to flow to the high pressure head of the
bore. When fuel pressure rises to approximately injection pump. When the ignition key is turned to
24,445 kPa (3550 psi), the needle valve spring ten
the OFF position, the solenoid is not energized and
sion is overcome. The needle valve rises and fuel
the plunger blocks the flow of fuel to high pressure
flows through the spray holes in the nozzle tip into
chamber.
the combustion chamber. The pressure required to
lift the needle valve is the operating pressure set A minimum of ten volts is required to allow the so
ting, sometimes referred to as the POP pressure set lenoid to lift the plunger off its seat. A minimum of
ting. six volts is required to hold the plunger in the open
Fuel pressure in the injector circuit decreases after position.
injection. The injector needle valve is immediately
closed by the needle valve spring and fuel flow into FUEL/WATER SEPARATOR FILTER
the combustion chamber is stopped. Exhaust gases The fuel/water separator filter protects the injec
are prevented from entering the injector nozzle by tion pump by removing water and contaminants from
the needle valve. the fuel. The separator filter construction allows fuel
to pass through it, but prevents moisture (water)

from doing so. Moisture collects at the bottom of the
separator filter.
WARNING: EXTINGUISH A L L S M O K I N G MATERI

ALS BEFORE DRAINING THE FUEL/WATER SEPA
R A T O R FILTER.
There is a drain at the bottom of the separator fil

ter (Fig. 16). Place a drain pan under the drain tube.
With the engine not running, push up on the drain
to remove the water from the separator filter. Hold
the drain open until all water and contaminants
have been removed and clean fuel exits the drain.
Dispose of mixture in drain pan according to applica
ble regulations.
Refer to the maintenance schedules in Group 0 in Fig. 23 Air Temperature Switch
this manual for the recommended fuel/water separa
tor filter replacement intervals. MANUAL SHUT DOWN LEVER
The injection pump has a manual shut down lever
KSB SOLENOID (Fig. 24). In an emergency, the engine can be shut
The KSB solenoid is not an output of the PCM. The down by turning the lever counterclockwise.
solenoid is located on the injector pump (Fig. 22). It
contains a valve t h a t controls venting of the injection
pump internal pressure regulator. When voltage is
supplied to the solenoid, it closes off the vent circuit
in the injection pump. When the vent circuit is closed
off, internal pump pressure increases and injection
timing advances. The KSB solenoid allows the injec
tion pump timing to reach full advance sooner.
When the KSB solenoid is energized, internal
pump pressure reaches 8 bars (116 psi). When the so
lenoid is not energized, internal pump pressure
should be approximately 4 bars (58 psi).
The KSB solenoid circuit contains an air tempera
ture switch. Battery voltage is supplied to the sole
noid through the ignition switch.
The air temperature switch is mounted on the in
take manifold next to the charge air temperature Fig. 24 Manual Shut Down Lever
sensor (Fig. 23). The air temperature switch is open
at or above 32°C (90°F).
HIGH PRESSURE FUEL LINES
C A U T I O N : High pressure fuel lines must be held s e
curely in place in the holders. The lines cannot con
tact each other or other components. D o not
attempt to weld high pressure fuel lines or to repair
lines that are damaged. Only use the recommended
lines when replacement of high pressure fuel line is
necessary.
High pressure fuel lines deliver fuel under pressure

of approximately 59,000 kPa (8,000 psi) from the in
jection pump to the fuel injectors. The lines expand
and contract from the high pressure fuel pulses gen
erated during the injection process. All high pressure
fuel lines are of the same length and inside diameter.
Correct high pressure fuel line usage and installation
is critical to smooth engine operation.
Fig. 22 KSB Solenoid— Typical
14-86 FUEL SYSTEM
W A R N I N G : U S E E X T R E M E C A U T I O N W H E N IN The lift pump has a manual lever (Fig. 26). The le
S P E C T I N G F O R HIGH P R E S S U R E F U E L L E A K S . I N ver is located on the lower right side of the pump
S P E C T F O R HIGH P R E S S U R E F U E L L E A K S WITH A housing. The purpose of the lever is to prime the fuel
S H E E T O F C A R D B O A R D . HIGH F U E L INJECTION system and bleed air from the system if the vehicle
P R E S S U R E C A N C A U S E P E R S O N A L INJURY IF has r u n out of fuel. Raise and lower the lever until
C O N T A C T I S M A D E WITH T H E S K I N . resistance is felt to prime the system up to the injec
tor pump. D u r i n g vehicle o p e r a t i o n t h e p u m p le
v e r m u s t b e i n t h e u p position.
The mechanical lift pump is located on the left side of
the engine cylinder block. The lift pump is driven by an
eccentric on the camshaft that actuates a spring loaded
lever in the pump (Fig. 25). The lever is connected to
the pump diaphragm. When the eccentric on the cam FUEL
shaft pushes the lever upward, the lever in turn pulls PUMP
the diaphragm to its extended position. With the lever
in the extended position, fuel is drawn into the pump
chamber through the inlet check valve. When the pump
gathers more fuel in the fuel chamber than the engine
can consume, the outlet check valve is held closed. Fuel MANUAL J K T /
gathered in lift pump chamber prevents the diaphragm LEVER ——-—• . L J*y^"^^
from relaxing. The lever will continue to move up and
down on the shaft connecting it to the diaphragm. How J9114-3
ever, it is prevented from operating the diaphragm until Fig. 26 Lift Pump Manual Lever
the check valve again opens and the fuel in the pump
chamber is expelled. This process continues as long as SYSTEM OPERATION
the engine is running. IGNITION SWITCH ON
Minimum lift pump output pressure is 21 Kpa (3 When the ignition switch is put in the ON (run)
psi). Lift pump output volume is 0.75 liters (0.70 U.S. position, the following occurs:
quarts) per 30 seconds of engine cranking. • The PCM receives an ignition sense input. It then
powers up. Battery voltage is supplied through the
battery voltage input.
• The wait-to-start lamp and the water-in-fuel lamp
are turned on by the PCM for 2.8 seconds as a bulb test.
• The PCM monitors the charge air temperature
sensor input. If manifold air temperature is at or be
low 15°C (59°F), the PCM will start the air intake
heater preheat cycle. It will energize the intake heat
ers by grounding the air intake heater relays. The
PCM will t u r n the wait-to-start light on until the
preheat cycle is over. If PCM receives a crank signal
from engine speed sensor before preheat cycle is over,
it will abort preheat cycle.
• The PCM monitors engine speed. When the engine
speed is above 384 rpm, the PCM determines t h a t
the engine is running.
Fig. 25 Lift Pump • The PCM will t u r n on the water-in-fuel lamp if a
The lift pump housing h a s a weep hole at the bot signal is received from the water-in-fuel sensor.
tom of the casing (Fig. 25). If t h e diaphragm rup
tures, fuel will exit out of t h e weep hole and t h e ENGINE START-UP
pump must be replaced. The lift pump is not service When the ignition key is put in the start position,
able and must be replaced as a complete assembly. the following occurs:
• The PCM receives a crank signal input from the
CAUTION: D o not operate the engine if the fuel s u p engine speed sensor.
ply line h a s a restriction of more than 95 M M H g • The air intake heaters are not energized during
(3.75 in Hg). cranking.
ENGINE WARM-UP • If the transmission thermo-switch is open, the

• The PCM may start the air intake heater post-heat transmission will not be allowed to enter into over
cycle depending on intake air temperature. If manifold drive (automatic transmission). If the switch opens
air temperature was at or below 15°C (59°F) when the when t h e vehicle is in overdrive, the transmission
ignition switch was turned on, the cycle is started. will be downshifted. The transmission thermo-switch
• If intake manifold air temperature is below 32°C opens at 134°C (273°F). The thermo-switch will close
(90°F), the KSB solenoid will be energized through once t h e transmission fluid temperature drops to
the air temperature switch. The solenoid remains en 116°C (240°F).
ergized until the air temperature switch opens. The • The PCM will t u r n on the water-in-fuel lamp if a
switch opens when intake manifold air temperature signal is received from the water-in-fuel sensor.
is above 32°C (90°F). • If the speed control system resume/accelerate func
• If the coolant temperature is below 16°C (60° F), tion is being used, the PCM will only allow the vehi
the transmission will not be allowed to enter over cle to accelerate at a predetermined rate. If a speed
drive (automatic transmission). control h a s been set and the resume/accelerate but
• The PCM will t u r n on the water-in-fuel lamp if a ton is momentarily pushed in, the PCM will increase
signal is received from the water-in-fuel sensor. vehicle speed by two miles per hour.
CRUISE OR IDLE • If the brakes are applied, the PCM will disable the
• The PCM monitors intake manifold air tempera speed control.
ture through the charge temperature sensor input.
DECELERATION
• If intake manifold air temperature is below 32°C
• The vehicle speed sensor, engine speed sensor and
(90°F), the KSB solenoid will be energized through
the air temperature switch. The solenoid remains en throttle position sensor inputs are used to control
ergized until the air temperature switch opens. The transmission overdrive operation.
switch opens when intake manifold air temperature • If the coolant temperature is below 16° C (60° F),
is above 32°C (90°F). the transmission will not be allowed to enter over
• The air intake heater post-heat cycle will be com drive (automatic transmission).
pleted, if it is not already over. • If the transmission thermo-switch is open, the trans
• The vehicle speed sensor, engine speed sensor and mission will not be allowed to enter into overdrive (au
throttle position sensor inputs are used to control tomatic transmission). If the switch opens when the
transmission overdrive operation. vehicle is in overdrive, the transmission will be down
• If the coolant temperature is below 16° C (60° F), shifted. The transmission thermo-switch opens at 134°C
the transmission will not be allowed to enter over (273°F). The thermo-switch will close once the transmis
drive (automatic transmission). sion fluid temperature drops to 116°C (240°F).
• If the transmission thermo-switch is open, the • The PCM will turn on the water-in-fuel lamp if a
transmission will not be allowed to enter into over signal is received from the water-in-fuel sensor.
drive (automatic transmission). If the switch opens • If intake manifold air temperature is below 32°C
when the vehicle is in overdrive, the transmission (90°F), the KSB solenoid will be energized through
will be downshifted. The transmission thermo-switch the air temperature switch. The solenoid remains en
opens at 134°C (273°F). ergized until the air temperature switch opens. The
• The thermo-switch will close once the transmission switch opens when intake manifold air temperature
fluid temperature drops to 116°C (240°F). is above 32°C (90°F).
• The PCM will t u r n on the water-in-fuel lamp if a • If the speed control system coast/set function is be
signal is received from the water-in-fuel sensor. ing used, the PCM will only allow the vehicle to de
celerate at a predetermined rate. If the coast/set
ACCELERATION switch is pushed while the system is operating, the
• The vehicle speed sensor, engine speed sensor and PCM will set speed control to the rate the vehicle is
throttle position sensor inputs are used to control traveling at when the switch is released.
transmission overdrive operation. • If the brakes are applied, the PCM will disable the
• If the coolant temperature is below 16° C (60° F), speed control.
the transmission will not be allowed to enter over
drive (automatic transmission). IGNITION SWITCH OFF
• If intake manifold air temperature is below 32°C • When the ignition switch is turned to the off posi
(90°F), the KSB solenoid will be energized through tion, the PCM still receives battery voltage through
the air temperature switch. The solenoid remains en the battery input. Battery voltage is needed to keep
ergized until the air temperature switch opens. The PCM memory alive. The PCM memory stores diag
switch opens when intake manifold air temperature nostic trouble code (DTC) messages and the mini
is above 32°C (90°F). m u m TPS value from the previous key-on.
DIESEL FUEL INJECTION—GENERAL DIAGNOSIS
INDEX
page page
Air in Fuel System 90 Fuel/Water Separator Filter 92
Air Intake Heater . 90 High Pressure Fuel Line Restrictions 93
Diagnostic Trouble Code (DTC) . 95 K S B Solenoid . 93
D R B II Scan Tool 95 Mechanical Lift Pump 93
Engine Speed Sensor 91 On-Board Diagnostics (OBD) 94
Fuel Heater 91
Fuel Injection Pump 91 System Schematics—5.9L Diesel Engine . . . . . . . 95
Fuel Injectors 92 Throttle Position Sensor Test 94
Fuel Supply Restrictions 92 Visual Inspection 88
VISUAL INSPECTION PCM

A visual inspection for loose, disconnected, or incor MOUNTING
rectly routed wires and hoses should be made before BOLTS
attempting to diagnose or service the fuel injection
system. A visual check will help find these condi
tions. It also saves unnecessary test and diagnostic
time. A thorough visual inspection of the fuel injec
tion system includes the following checks:
(1) Be sure t h a t t h e battery connections are tight
and not corroded (Fig. 1).
• POSITIVE
v^3t ^TERMINAL
PCM CONNECTOR
CONNECTOR MOUNTING
BOLT J9314-165
Fig. 2 Powertrain Control Module (PCM)
HEATER
QUICK RELAYS
J91 14 DISCONNECT
Fig. 1 Battery Connections
(2) Be sure t h a t the 60-way connector is fully en
gaged with the P C M . Verify t h a t the connector
mounting screw is tight (Fig. 2).
(3) Be sure t h a t the electrical connections at the
air intake heater relays (Fig. 3) are tight and not
corroded.
(4) Inspect the starter motor and starter solenoid
connections for tightness and corrosion (Fig. 4). WHEEL ^
(5) Verify t h a t the electrical connectors are con WELL J9114-67
nected to the charge air temperature sensor and air
temperature switch. Inspect the connectors for corro Fig. 3 Air Intake Heater Relays
sion or damaged wires (Fig. 5).
(6) Verify t h a t the electrical connector is connected
to the air temperature switch (Fig. 5).
FUEL SYSTEM 14-89
(8) Place a drain pan under the drain tube (Fig. 6).
With the engine not operating, hold the drain open
until all water and contaminants have been removed
and clean fuel exits the drain. Dispose of mixture in
drain pan according to applicable regulations.
(9) Verify that the electrical connector is connected
to the fuel solenoid on the injection pump (Fig. 7). In
spect the connector for corrosion or damage.
(10) Verify that the electrical connector is con
nected to the KSB solenoid on the injection pump
(Fig. 7). Inspect the connector for corrosion or dam
age.
Fig. 4 Starter Motor Connections—Typical
Fig. 5 Charge Air Temperature Sensor and Air

Temperature Switch
(7) Verify t h a t the Water-in-Fuel (WIF) sensor
electrical connector is connected to the sensor (Fig.
6). Inspect the connector for corrosion or damaged
wires.
Fig. 8 Air Intake Heater

(12) Inspect the throttle linkage and accelerator
linkage for binding (Fig. 9).
(13) Be sure t h a t the throttle return spring is con
nected.
(14) Inspect all fuel lines for signs of leakage.
(15) Be sure t h a t the ground cable connection at
the front of the cylinder head is tight and free of cor
Fig. 6 Water-in-Fuel (WIF) Sensor rosion.
Fig. 11 Charge Air Cooler (Intercooler)

Inspect the fuel system from the lift pump to the
injectors for loose connections. Leaking fuel is an in
dicator of loose connections or defective seals. Air can
also enter the fuel system between the fuel tank and
the lift pump. Inspect the fuel t a n k and fuel lines for
damage that might allow air into the system.
AIR INTAKE HEATER

PREHEAT/POST-HEAT CYCLE
The PCM provides a ground path for the air intake
heater relays. The ground path is provided if intake
manifold temperature is below 16°C (60°F) when the
Fig. 10 Air Filter Element—Diesel
ignition key is in the ON position. When the ground
(17) Be sure t h a t the turbocharger output hose is is provided, the intake heaters are energized to start
connected to the charge air cooler (intercooler) inlet the preheat cycle.
tube. Verify t h a t the charge air cooler output hose is The preheat cycle can be tested with a voltmeter or
connected to the cooler and the intake manifold (Fig. test light. If the intake manifold temperature is
11). above 16°C (60°F), the wait-to-start light will not
(18) Be sure t h a t the vacuum pump-to-brake come on and the air intake heaters will not be ener
booster hose is connected and not damaged. gized.
(19) Be sure t h a t the accessory drive belt is not
damaged or slipping. C A U T I O N : Do not energize the air intake heater re
lays more than once per 15 minutes. If the relays
AIR IN FUEL SYSTEM are cycled, the key turned off a n d then turned back
Air will enter the fuel system whenever fuel supply on, the engine could be damaged. Wait 15 minutes
lines, separator filters, injection pump, high pressure before turning the key back to the O N position.
lines or injectors are removed or disconnected. Air
trapped in the fuel system can result in hard start (1) With the engine not running and ambient air
ing, a rough running engine, engine misfire, low temperature below 16°C (60°F), t u r n the ignition key
power, excessive smoke and fuel knock. After service to the ON position.
is performed, air must be bled from the system before (2) The wait-to-start light will come on and the air
starting the engine. intake heater relays should click on signaling the
start of the preheat cycle.
(3) Check for battery voltage at both intake air SENSOR MOUNTING BOLTS
heater terminals. T h e h e a t e r s will only b e e n e r
gized for 10 to 20 s e c o n d s . Refer to the Preheat
Cycle Time Interval Chart.
PREHEAT CYCLE TIME INTERVAL
Intake Preheat Cycle Time Pestheat Cycle

Manifold Ignition Key O N Ignition Key O N
temperature Engine Net R u n n i n g Ingin© Running
Above 15 °C 0 Seconds No
(59 °F)
-8°C{18°F)*o 10 Seconds Yes

15°C(59 °F)
-17°C{1 °F) 15 Seconds Yes

•9°C(16°F)
VIBRATION
-26°C(-15°F) Yes DAMPER J9214-69
17.5 Seconds
fo-18°C (0 °F)
Fig. 12 Engine Speed Sensor
Below -26 °C 20 Seconds Yes volts is required to operate the fuel heater. The re
(15T) sistance value of the heater unit is 2.5 - 3.0 ohms.
J9114-239
««. * rr ,,
AIR INTAKE HEATER TEST
(2) Note wire positions on heater terminals for as
sembly. Disconnect wires from heater.
(3) Use an ohmmeter to test resistance from each
heater terminal to ground. The resistance should be
zero (0). If the resistance is not to specifications, in
spect for corroded or dirty connections. Clean or re
pair the connections and retest before replacing
heaters.
ENGINE SPEED SENSOR

The engine speed sensor (sometimes referred to as J9114-84
the crankshaft position sensor) is located on the front
of engine (Fig. 12). Fig. 13 Fuel Heater
To perform a complete test of the engine speed sen
FUEL INJECTION PUMP
sor and its circuitry, refer to the DRB II scan tool.
Also refer to the appropriate Powertrain Diagnostics The fuel solenoid is the only serviceable component
Procedures manual. of the fuel injection pump. The injection pump is
not to be serviced or the warranty may be
FUEL HEATER voided. If the injection p u m p requires service,
A malfunctioning fuel heater can cause a wax the complete assembly must be replaced.
build-up in the fuel/water separator (Fig. 13). Wax Incorrect injection pump timing can cause poor per
build-up in the fuel/water separator can cause engine formance, excessive smoke and emissions and poor
starting problems and prevent the engine from rev fuel economy. Refer to the 5.9L Diesel Service Proce
ving up. It can also cause miss fire under load and dures section of this manual for injection pump tim
blue or white fog like exhaust. ing.
Voltage to operate the fuel heater is supplied
through the ignition switch. The heater operating
range is from 6° - 13.5°C (43° - 53°). A minimum of 7
A broken injection pump timing mechanism spring W A R N I N G : DO N O T B L E E D A I R F R O M T H E F U E L
will cause the timing to be fully advanced resulting S Y S T E M O F A HOT ENGINE. D O NOT A L L O W FUEL
in torque loss, a fuel knock and possible engine over TO S P R A Y ONTO THE E X H A U S T MANIFOLD W H E N
heating. BLEEDING AIR FROM THE FUEL S Y S T E M .
An improperly operating KSB (cold start) solenoid
will cause white smoke during engine warm-up. The To determine which fuel injector is malfunctioning,
KSB solenoid is not serviceable. r u n the engine and loosen the high pressure fuel line
A defective or non-adjustable fuel injection pump nut at the injector. Listen for a change in engine
can cause starting problems or prevent the engine speed (Fig. 14). Tighten the line nut. If engine speed
from revving up. It can also cause: drops, the injector was operating normally. If engine
• Engine surge at idle speed remains the same, the injector is malfunction
• Rough idle (warm engine) ing. Test all injectors in the same manner one at a
• Engine miss under load time.
• Low power
• Excessive fuel consumption
• Poor performance
• Low power
• Black smoke from the exhaust
• Blue or white fog like exhaust
• Incorrect idle or maximum speed
A worn fuel injection pump plunger can effect fuel
pressure and the amount of fuel injected. This results
in reduced engine power. In most cases, if the injec
tion pump is delivering fuel from one outlet, it will
deliver fuel from all outlets. If the internal plunger
is defective, the fuel injection pump must be re
placed.
Engine power is also effected by the governor set
ting and performance. Do not attempt to adjust the
governor. If the governor seals o n the external Fig. 14 Inspecting Injector Operation
adjustment screw are broken, the fuel rate m a y Once an injector has been found to be malfunction
be out of adjustment. The warranty of the injec ing, remove it from the engine and replace it. Refer
tion pump and the engine m a y be void if the to Diesel Engine Service Procedures for injector re
seals h a v e b e e n tampered w i t h or removed. moval and installation.
FUEL INJECTORS FUEL SUPPLY RESTRICTIONS

A leaking fuel injector can cause fuel knock, poor
performance, black smoke, poor fuel economy and C A U T I O N : D o not operate the engine if the fuel sup
rough engine idle. If the fuel injector needle valve ply line has a restriction of more than 12.7 kPa (3.75
does not operate properly, the engine may misfire in Hg). Refer to Lift Pump Test.
and produce low power.
A leak in the injection pump-to-injector high pres Fuel supply line restrictions can cause starting
sure fuel line can cause many of the same symptoms problems and prevent the engine from revving up.
as a malfunctioning injector. Inspect for a leak in the The starting problems include; engine miss under
high pressure lines before checking for a malfunc load, low power and blue or white fog like exhaust.
tioning fuel injector. Test all fuel supply lines for restrictions or blockage.
Flush or replace as necessary. Bleed the fuel system
W A R N I N G : T H E INJECTION P U M P S U P P L I E S HIGH
of air once a fuel supply line has been replaced.
P R E S S U R E FUEL O F A P P R O X I M A T E L Y 59,000 K P A
(8,000 P S I ) T O E A C H I N D I V I D U A L INJECTOR
T H R O U G H T H E HIGH P R E S S U R E L I N E S . F U E L UN
DER THIS AMOUNT OF P R E S S U R E C A N P E N E A blocked or clogged fuel/water separator filter can
TRATE THE S K I N A N D C A U S E P E R S O N A L INJURY, cause starting problems and prevent the engine from
WEAR SAFETY GOGGLES A N D ADEQUATE PRO revving up. It can also cause engine miss under load,
TECTIVE CLOTHING. AVOID C O N T A C T WITH F U E L low power and blue or white fog like exhaust.
S P R A Y W H E N B L E E D I N G HIGH P R E S S U R E F U E L The maximum allowable fuel pressure drop across
LINES. the fuel/water filter separator is 21 kPa (3 psi).
There is a drain at the bottom of the separator fil C A U T I O N : D o not operate the fuel system with a
ter (Fig. 13). Place a drain pan under the drain tube. suction restriction of more than 95 M M Hg (3.75
With t h e e n g i n e n o t r u n n i n g , hold t h e drain open inch Hg). Refer to Lift Pump Test.
until all water and contaminants have been removed
and clean fuel exits the drain. Dispose of mixture in
drain pan according to applicable regulations.
If excess water gathers in separator/filter in a short
time, the fuel t a n k must be removed, drained and
cleaned.
HIGH PRESSURE FUEL LINE RESTRICTIONS

High pressure fuel line leaks can cause starting
problems, poor engine performance and engine miss
under load. Restricted high pressure lines can cause
starting problems, poor engine performance, engine
miss under load and black smoke from exhaust.
W A R N I N G : U S E E X T R E M E CAUTION W H E N IN
SPECTING FOR HIGH P R E S S U R E FUEL L E A K S . IN
S P E C T F O R HIGH P R E S S U R E F U E L L E A K S W I T H A Fig. 15 Lift Pump
SHEET OF C A R D B O A R D . HIGH FUEL INJECTION Low lift pump output can be caused by a worn ec
P R E S S U R E C A N C A U S E P E R S O N A L I N J U R Y IF centric on the engine camshaft. A properly operating
C O N T A C T I S M A D E WITH T H E S K I N . lift pump will pump a minimum volume of 0.75 liter
(0.70 U.S. quart) of fuel in 30 seconds at engine
Start the engine. Move the cardboard over the high cranking speed.
pressure fuel lines and check for fuel spray onto the
The maximum allowable pressure drop across the
cardboard. If a high pressure line connection is leak
fuel filter is 21 Kpa (3 psi). As the filter removes
ing, bleed the system and tighten the connection. Re
contaminants in the fuel, the pressure drop across
fer to the 5.9L Diesel Service Procedures section for
the fuel separator filter will increase. Frequent re
air bleeding procedures. Replace damaged, restricted
placement of the separator filter can indicate a worn
or leaking high pressure fuel lines with the correct
lift pump. Refer to the Maintenance Schedule at the
replacement line.
front of this manual for recommended replacement
intervals.
C A U T I O N : The high pressure fuel lines must be
clamped securely in place in the holders. The lines
LIFT PUMP TEST
cannot contact each other or other components. Do
(1) Disconnect fuel inlet tube at the lift pump.
not attempt to weld high pressure fuel lines or to
(2) Install T-fitting between disconnected fitting
repair lines that are damaged. Only use the recom
and lift pump inlet. Connect vacuum gauge to T-fit
mended lines when replacement of high pressure
ting.
fuel line is necessary.
WARNING: U S E EXTREME CAUTION WHEN E N
G I N E I S O P E R A T I N G . D O N O T S T A N D IN D I R E C T
KSB SOLENOID
LINE WITH F A N . D O N O T PUT H A N D S N E A R PUL
The KSB solenoid will click when it is energized
LEYS, BELTS OR F A N . DO NOT WEAR LOOSE
and de-energized.
CLOTHING.
If the solenoid does not click when 12 volts is sup
plied to it, replace the solenoid. The vacuum gauge will not indicate a vacuum un
til the lift pump begins to operate at full capacity.
(3) Operate engine at approximately 1500 rpm for
An improperly operating lift pump can cause low
30 seconds. Vacuum should not exceed 12.7 kPa (3.75
engine power. Inspect the fuel supply line to the
in. Hg).
pump for restrictions, kinks or leaks. Fuel leaking
(4) If vacuum exceeds 12.7 kPa (3.75 in. Hg) check
from the weep hole (Fig. 15) in the pump casing in
fuel tube for restriction. A partially clogged in-tank
dicates a leaking pump diaphragm. The lift pump is
fuel filter can also cause excess vacuum.
not repairable and must be replaced as an assembly.
THROTTLE POSITION SENSOR TEST It is possible t h a t a DTC for a monitored circuit
may not be entered into memory even though a mal
C A U T I O N ; Before checking the T P S , the throttle function has occurred. This may happen because one
linkage must be checked for correct adjustment. of the DTC criteria for the circuit has not been met.
The throttle lever must contact the low idle speed
screw. The throttle lever must reach breakover when ACCESSING DIAGNOSTIC TROUBLE CODES
the throttle is wide open. Refer to the Accelerator Pedal A stored diagnostic trouble code (DTC) can be dis
and Throttle Cable section of Group 14, Fuel Systems. played by cycling the ignition key On-Off-On-Off-On
The throttle position sensor (TPS) can be tested within three seconds and observing the malfunction
with the DRB II or a digital voltmeter (Fig. 16). The indicator lamp. This lamp was formerly referred to
center terminal of the TPS is the output terminal. as the check engine lamp. The lamp is located on the
instrument panel.
They can also be displayed through the use of the
Diagnostic Readout Box II (DRB II scan tool). The
DRB II connects to the data link connector in the en
gine compartment. For operation of the DRB II, refer
to the appropriate Powertrain Diagnostic Procedures
service manual.
EXAMPLES
• If the lamp flashes 4 times, pauses and flashes 1
more time, a diagnostic trouble code (DTC) number
41 is indicated.
• If the lamp flashes 4 times, pauses and flashes 6
more times, a diagnostic trouble code (DTC) number
J9114-244 46 is indicated.
Refet* to the Diagnostic Trouble Code (DTC) charts
Fig. 16 Throttle Position Sensor (TPS) Testing for DTC identification.
Turn the ignition key to the On position. Check If the problem is repaired or ceases to exist, the
TPS output voltage at the center terminal wire of the powertrain control module (PCM) cancels the DTC
connector. Measure the voltage at idle (throttle lever after 51 engine starts.
contacting low idle speed screw) and at wide open Diagnostic trouble codes indicate the results of a
throttle ( W O T ) . At idle TPS output voltage should be failure, but never identify the failed component di
approximately 1 volt. At wide open throttle, the TPS rectly.
output voltage must be 2.25 to 2.75 volts higher t h a n The circuits of the data link connector are shown
the reading at idle. The output voltage should in in (Fig. 17).
crease gradually as the throttle lever is slowly
opened from idle to WOT. If the TPS is not within D-1
1
GROUND
the proper range, adjust the sensor. Refer to the Die
sel Fuel Injection—Service Procedures section of this D-2 N/C
group.
D-3 SCI TRANS
ON-BOARD DIAGNOSTICS (OBD) D-4 SCI RECEIVE
The powertrain control module (PCM) has been
programmed to monitor many different circuits. If a D-5 IGNITION
problem is sensed in a monitored circuit often
enough to indicate an actual problem, a diagnostic J9214-20 D-6 N O T USED
trouble code (DTC) is stored. The DTC will be stored
in the PCM memory for eventual display to the ser Fig. 17 Data Link Connector Schematic
vice technician. If the problem is repaired or ceases ERASING TROUBLE CODES
to exist, the PCM cancels the DTC after 51 engine The DRB II scan tool must be used to erase a di
starts. agnostic trouble code (DTC). Refer to the appropriate
Certain criteria must be met for a diagnostic trou Powertrain Diagnostic Procedures service manual for
ble code (DTC) to be entered into PCM memory. The operation of the DRB II scan tool.
criteria may be a specific range of engine rpm, en
gine temperature and/or input voltage to the PCM.
DRB II SCAN TOOL cates t h a t the powertrain control module (PCM) h a s

For operation of t h e DRB II scan tool, refer to t h e recognized an abnormal signal in a circuit or the sys
appropriate Powertrain Diagnostic Procedures ser tem. A DTC may indicate t h e result of a failure, but
vice manual. never identify the failed component directly.
DIAGNOSTIC TROUBLE CODE (DTC) SYSTEM SCHEMATICS—5.9L DIESEL ENGINE

On t h e following pages, a list of diagnostic trouble Refer to the following system schematic for t h e
codes is provided for the diesel engine. A DTC indi 5.9L diesel engine.
5.9L DIESEL DIAGNOSTIC TROUBLE CODES (DTC)
Fault C o d e DRBII Display Description o f Fault C o n d i t i o n
11 No Reference Signal No reference signal from Engine Speed Sensor.

During Cranking
15 No Vehicle Speed No speed sensor signal detected during road load conditions.
Signal
22 Coolant Sensor Voltage Coolant temperature sensor input below the minimum acceptable voltage.
Too Low
or
Coolant Sensor Voltage Coolant temperature sensor input above the maximum acceptable voltage.
Too High
23 Charge Air Temperature Charge Air Temperature Sensor input above/below acceptable minimum.
Sensor Voltage High
or
Charge Air Temperature
Sensor Voltage Low
24* TPS Voltage High Throttle position sensor (TPS) input above the maximum acceptable voltage.
or
TPS Voltage Low Throttle position sensor (TPS) input below the minimum acceptable voltage.
33 A/C Clutch Relay Circuit An open or shorted condition detected in the A/C clutch relay circuit.
34 Speed Control An open or shorted condition detected in the speed control vacuum or vent
Solenoid Circuits solenoid circuits.
41 Generator Field Not
Switching Properly Generator field not switching properly.
42 Auto Shutdown Relay

Control Circuit An open or short condition detected in the auto shutdown relay circuit.
or
No ASD Relay Voltage
Sense at PCM No ASD voltage sensed at PCM.
*Automatic Transmission Only
J9314-182
FUEL SYSTEM 14 - 97
5„9L DIESEL DIAGNOSTIC TROUBLE CODES {DTC}-CONTINUED
Fault C o d e DRBII Display Description of Fault Condition
45* Overdrive Solenoid An open or shorted condition detected in overdrive solenoid circuit.
46 Charging System Charging system voltage too high.

Voltage Too High
47 Charging System Charging system voltage too low.

Voltage Too Low
53 Internal PCM Failure Internal failure in the PCM.
62 PCM Failure PCM failure - SRI miles not stored.

SRI Miles Not Stored
63 PCM Failure PCM failure - EEprom write denied.
EEprom Write Denied
*Automatic Transmission Only

J9314-183
OVERDRIVE/OVER-RIDE CO
SWITCH oo
(AUTO ONLY)
c/3
-<
LSTARJERJ^ _ j
J9314-184
5 . 9 1 . DIESEL SYSTEM SCHEMATIC •

WIRE WIRE
CAV C O L O R DESCRIPTION CAV C O L O R DESCRIPTION
1 WT/BK WATER-IN-FUEL SENSOR 37 OVERDRIVE LAMP SIGNAL

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

II 12 13 14 15 16 17 18 19 20 \ \
1 7 3 4 5 6 7 8 9 10 J/^"*\\ o o o o o o o o o o ) }
34 DB/OR WIDE OPEN THROTTLE (A/C) TERMINAL HI
Hi\ \ \ oooooooooo (1 O j ] 31| 32 33 34 35 36 37 38 39 40 1JU

41 42 43 44 45 46 47 48 49 SO 1 ^m^^
35 SHOWN VlX 21o22o 23
oooooooooo J / /
o o24o25o26o27o o28o29 130 \V~V//
1 Li
36 J9314-185
PCM CONNECTOR CAVITY DESCRIPTION

DIESEL FUEL INJECTION SYSTEM DIAGNOSIS
SYMPTOM CAUSE ACTION
Starting problem Improper fuel Drain fuel tank, flush system, fill with proper
fuel. Change filter
Empty fuel tank or fuel tank vent blocked Fill tank, bleed system, check tank vent
Air in fuel system Bleed fuel system
Voltage not supplied to fuel solenoid or Correct voltage supply problem or

fuel solenoid inoperative replace solenoid
Clogged fuel filter Replace fuel filter
Restricted or blocked fuel supply lines Remove restriction or replace lines
Leaking injection lines, damaged lines or Replace damaged lines or tighten

loose connections connections as necessary.
Bleed fuel system
Wax buildup in fuel filter (cold weather Replace fuel filter, use recommended
only) diesel fuel
Incorrect injection pump to engine timing Adjust injection pump timing
Malfunctioning air heating system Repair air heating system
Injection sequence does not correspond Install fuel injection lines in correct order
with firing order
Malfunctioning KSB valve Replace injection pump
Low or uneven engine compression Repair as necessary
Restricted or blocked fuel injection lines Remove restriction or replace lines
Fuel injection pump malfunction or Replace fuel injection pump

not adjustable
Engine Surge at idle Empty fuel tank or fuel tank vent blocked Fill tank, bleed system, check tank vent
Low idle speed Adjust idle speed J9H4-22

DIESEL FUEL INJECTION SYSTEM DIAGNOSIS-CONTINUED
Engine surges at idle Fuel injection pump malfunction or Replace fuel injection pump
not adjustable
Rough idle when engine Is warm Improper fuel Drain fuel tank, flush system, fill with
proper fuel
Low idle speed Adjust idle speed
Injection pump rear support bracket loose Repair as necessary
Restricted or damaged injector nozzle Repair or replace as necessary
Injection sequence does not correspond Install injection lines in correct order
with firing order
Fuel injection pump malfunctioning Replace fuel injection pump

or not adjustable
Engine mines under lead Improper fuel Drain fuel tank, flush system, fill with
proper fuel
Restricted or blocked fuel injection lines Remove restrictions or replace lines
Restricted or blocked fuel supply lines Remove restrictions or replace lines

loose connection connections as necessary.
Bleed fuel system.
1
J9114-23
14 - 102 FUEL SYSTEM —
•
SYMPTOM CAUSI ACTION
l u p i n * mimes under I m 4 Incorrect injection pump timing Adjust injection pump timing
Restricted or damaged injector nozzle Replace or repair as necessary
Restricted or blocked fuel injection lines Install fittings proper positions
Fuel Injection pump malfunction or Replace fuel injection pump

not adjustable
l e w power Improper fuel Drain fuel tank, flush system, fill with
proper fuel
Control lever not going to full throttle Adjust throttle linkage

position
Intercooler internally blocked or leaking Check pressure drop across intercooler.

If pressure drop is more than 4 in. Hg, clean
or replace as necessary.
Injection pump overflow fitting switched with Install fittings in proper positions
inlet fitting

loose connections connections as necessary.
Bleed fuel system
Clogged or restricted air filter Remove restrictions or replace filter if

necessary
Air fuel control tube broken or leaking Repair or replace as necessary
Low manifold pressure Check and repair turbocharger operation.

Check intercooler and air pipes for blockage
Injection sequence does not correspond Install fuel injection lines in correct
with firing order order
Incorrect injection pump to engine timing Check injection pump to engine timing

not adjustable
J9114-253
FUEL SYSTEM 14-103
Excessive fuel consumption improper diesel fuel Use correct fuel for conditions. Refer to
owner's manual
Incorrect injection pump timing Adjust injection pump timing
Clogged or restricted air filter Remove restrictions or replace air filter if

necessary
Injection sequence does not correspond install fuel injection lines in correct order
with firing order

If pressure drop is more than 4 in. Hg,
clean or replace as necessary
Low idle misadjusted Adjust idle stop screw
Malfunctioning KSB valve Replace injection pump
Incorrect injection pump to engine timing Adjust injection pump to engine timing

not adjustable
Unabie to shut engine off Voltage to fuel solenoid interrupted or fuel Correct voltage supply problem or replace
solenoid inoperative solenoid
Either poor performance, black Improper fuel Drain fuel tank, flush system, fill with
m o k e or low power proper fuel for conditions. Refer to owner's
manual

Clogged or restricted air filter Remove restrictions or replace filter if

necessary
Air fuel control tube leaking or broken Repair or replace as necessary
Low manifold pressure Check and repair turbocharger operation
Injection sequence does not correspond Install fuel injection lines in correct order
with firing order

—
J9114-255
14-104 FUEL SYSTEM
•
Injection pump to engine timing Check injection pump to engine timing

Either poor performance,
black smoke or low power Fuel injection pump malfunction or Replace fuel injection pump
not adjustable
White or blue fog-like exhaust Improper fuel Drain fuel tank, flush system, fill with proper
in full-load range fuel, change filter
Restricted or blocked fuel injection lines Remove restriction or replace lines
Restricted or blocked fuel supply lines Remove restriction or replace lines
Wax buildup in fuel filter (cold weather Replace fuel filter, use recommended i
only) diesel fuel. Inspect fuel heater
electrical connector for damage.
Injection pump overflow fitting switched Install fittings in proper positions

with inlet fitting

not adjustable
Incorrect lale speed Low idle misadjusted Adjust idle stop screw

not adjustable
Engine does not rev up Improper fuel Drain fuel tank, flush system, fill with proper
fuel, change filter
Empty fuel tank or fuel tank Fill tank, bleed system, check
vent blocked tank vent
J9114-26
Engine does not rev up Control lever not going to full throttle Adjust throttle linkage
position

Wax buildup in fuel filter (cold weather Inspect fuel heater electrical connector
only) for damage. Replace fuel filter, use
recommended diesel fuel.
Injection pump overflow fitting switched Install fittings in proper sequence

with inlet fitting
Fuel injection pump malfunction or Replace injection pump

not adjustable
Infection pump runs hot Overflow blocked Clean overflow orifice or replace fitting
J9114-254
14 - 106 FUEL S Y S T E i
DIESEL FUEL I N J E C T I O N - S E R V I C E PROCEDURES
INDEX
page page
Air Bleed Procedure 106 Fuel/Water Separator Filter . . . . . . . . . . . . . . . . 115
Air Fuel Control Tube 107 High Pressure Fuel Lines 116
Air Intake Heater 107 Injection Timing 117
Engine Speed Sensor 108 K S B Solenoid 118
Fuel Drain Manifold 109 Mechanical Lift Pump 119
Fuel Heater . 110
Powertrain Control Module ( P C M ) 108
Fuel Injection Pump 110
Fuel Injection Pump Supply Line 114 Throttle Position Sensor ( T P S ) 119
Fuel Injectors 114 Water-ln-Fuel Sensor 121
AIR BLEED PROCEDURE

A certain amount of air becomes trapped in t h e
fuel system when fuel system components a r e ser
viced or replaced. Bleed t h e system after fuel system
service according to t h e following procedures.
WARNING: D O NOT BLEED AIR FROM THE FUEL

S Y S T E M O F A HOT ENGINE. D O NOT ALLOW FUEL
TO S P R A Y ONTO THE EXHAUST MANIFOLD W H E N
BLEEDING AIR FROM THE FUEL S Y S T E M .
MANUAL BLEEDING
Some air enters t h e fuel system when t h e filters or
injection pump supply line are changed. This small
amount of air is vented automatically from t h e injec
tion pump through t h e fuel drain manifold. This is if Fig. 1 Low Pressure Bleed Screw
the filter was changed according to instructions. P U M P . P L A C E T H E T R A N S M I S S I O N IN N E U T R A L
The system will have to be bleed manually if: OR PARK A N D S E T PARKING B R A K E BEFORE E N
• The fuel filter is not filled before installation GAGING THE STARTER MOTOR.
• Injection pump is replaced
• High pressure fuel line connections are loosened or
lines replaced C A U T I O N : D o not e n g a g e the starter motor for more
• Initial engine start-up or start-up after a n ex than 30 s e c o n d s at a time. Allow two minutes b e
tended period of no engine operation. tween cranking intervals.
(1) Open t h e low pressure bleed screw (Fig. 1).
Crank t h e engine for 30 seconds a t a time to allow
(2) Operate t h e hand lever on t h e mechanical lift
air trapped in t h e injection pump to vent out t h e
pump until t h e fuel exiting t h e low pressure bleed
drain manifold. Observe t h e previous WARNING and
screw is free of air.
CAUTION.
If t h e m a n u a l lever feels as if it is not pumping, ro
t a t e (crank) t h e engine approximately 90 degrees. HIGH PRESSURE FUEL LINES
Continue pumping until air is removed.
(3) Tighten low pressure bleed screw to 8 N»m (6 W A R N I N G : T H E INJECTION P U M P S U P P L I E S HIGH
ft. lbs.) torque. P R E S S U R E F U E L O F A P P R O X I M A T E L Y 59,000 K P A
(8,000 P S I ) T O E A C H I N D I V I D U A L INJECTOR
C A U T I O N : T h e manual lever m u s t be returned to
T H R O U G H T H E HIGH P R E S S U R E L I N E S . F U E L U N
the lock position (up) after priming.
DER THIS AMOUNT O F P R E S S U R E C A N P E N E
TRATE THE S K I N A N D C A U S E P E R S O N A L INJURY.
INJECTION PUMP WEAR SAFETY GOGGLES A N D ADEQUATE PRO
TECTIVE CLOTHING A N D AVOID C O N T A C T WITH
WARNING: T H E ENGINE M A Y START WHEN F U E L S P R A Y W H E N B L E E D I N G HIGH P R E S S U R E
C R A N K I N G T O B L E E D AIR FROM T H E INJECTION FUEL LINES.
WARNING; DO NOT BLEED AIR FROM THE FUEL INSTALLATION

SYSTEM OF A HOT ENGINE. DO NOT ALLOW FUEL (1) Connect tube to intake manifold. Tighten fit
TO SPRAY ONTO THE EXHAUST MANIFOLD WHEN ting to 8 Nnn (6 ft. lbs.) torque.
BLEEDING AIR FROM THE FUEL SYSTEM. (2) Connect tube to injection pump using new
seals. Tighten fitting screw to 12 Nnn (9 ft. lbs.)
Bleed air from one injector at time. torque.
(1) Loosen the high pressure fuel line fitting at the
injector (Fig. 2). AIR INTAKE HEATER
(2) Disconnect the throttle rod from the throttle le
ver on t h e injection pump.
(3) Disconnect electrical connections air intake
heaters (Fig. 4).
Fig. 2 Bleeding High Pressure Fuel Lines

(2) Crank the engine until all air is bleed from the
line. D o n o t o p e r a t e t h e s t a r t e r m o t o r for l o n g e r
t h a n 30 s e c o n d s . W a i t t w o m i n u t e s b e t w e e n
cranking intervals.
(3) Start the engine and bleed one injector at a Fig. 4 Air Intake Heaters—Typical
time until the engine runs smoothly. (4) Remove t h e throttle bracket (Fig. 5).
AIR FUEL CONTROL TUBE

REMOWAL
(1) Disconnect tube from fuel injection pump (Fig.
3).
Fig. 5 Throttle Bracket—Typical

(5) Loosen clamps securing air the crossover tube
hose to the turbo-charger.
(6) Remove air crossover tube mounting screws.
(7) Remove air crossover tube.
Fig. 3 Air Fuel Control Tube Removal/Installation (8) Remove air intake heater.
(9) Clean air intake heater-to-intake manifold
(2) Disconnect tube from intake manifold.
mating surfaces.
(3) Remove tube. Discard seals.
(10) Install air intake heater (with new gasket) in PCM
reverse order of removal. MOUNTING
BOLTS
AIR INTAKE HE A TER RELA YS
(2) Disconnect electrical connections from relays
(Fig. 6).
HEATER
RELAYS
PCM CONNECTOR
CONNECTOR MOUNTING
WHEEL.. BOLT J9314-165
WELL J9114-67
Fig. 8 PCM Mounting
Fig. 6 Air intake Heater Relays—Typical (5) Remove the three PCM-to-mounting bracket
(3) Remove relay mounting screws. Remove relays. bolts (Fig. 8). Do not remove the PCM mounting
(4) Install relays in reverse order of removal. bracket from the fender.
(6) Remove PCM from vehicle.
POWERTRAIN CONTROL MODULE ( P C I )
INSTALLATION
REMOWAL (1) Check pins in 60-way PCM connector for dam
The PCM is located in the engine compartment be age. Repair as necessary.
hind the battery and under the left front fender (Fig. (2) Position PCM and install mounting bolts.
7). Tighten bolts to 4 N*m (35 in. lbs.) torque.
(3) Connect 60-way electrical connector to the
A/C CLUTCH RELAY STARTER RELAY PCM. Tighten connector mounting screw to 4 N m #
TORQUE CONVERTER AUTO SHUTDOWN RELAY (35 in. lbs.) torque.

CLUTCH RELAY
FUEL PUMP RELAY (4) Install battery.
(5) Connect battery cable to battery.
ENGINE SPEED SENSOR

The engine speed sensor (sometimes referred to as
the crankshaft position sensor) is located on the front
of engine (Fig. 9). Two spacers located behind the
sensor are used to position sensor over the vibration
damper.
REMOWAL
POWERTRAIN
DATA LINK CONTROL Before removing the sensor, note the position and
CONNECTOR MODULE J9314-164 routing of the sensor wiring harness. This routing
must be maintained to prevent wiring from contact
Fig. 7 Powertrain Control Module (PCM) Location ing belt or pulleys.
(1) Disconnect the negative battery cable at bat (1) Disconnect the speed sensor pigtail harness
tery. from the main engine wiring harness near the front/
(2) Remove battery holddown clamps. top of engine.
(3) Position battery to gain access to PCM, (2) Remove the clip bolts from the sensor pigtail
(4) Remove 60-way electrical connector from the wiring harness.
PCM (one screw) (Fig. 8). (3) Remove the two speed sensor mounting nuts
(Fig. 9).
SENSOR MOUNTING BOLTS (5) Gently seat (push down) the sensor until it con
tacts the feeler gauge. B e sure the sensor is n o t
n e a r either of the notches (Fig. 9) o n the vibra
tion d a m p e r . If sensor is a d j u s t e d at o r n e a r
t h e s e notches, it will b e d a m a g e d w h e n e n g i n e is
started.
#
(6) Tighten sensor mounting nuts to 24 N m (18 ft.
lbs.) torque.
(7) Remove feeler gauge.
(8) Connect the sensor electrical connector to the
m a i n engine wiring harness.
FUEL DRAIN MANIFOLD

REMOVAL
(1) Remove the fuel drain manifold holddown
clamp mounting screws (Fig. 11).
DRAIN
MANIFOLD
VIBRATION
DAMPER J9214-69
Fig. 9 Engine Speed Sensor

(4) Remove the speed sensor and its two mounting
spacers from the vehicle.
INST ALL A TION/ADJUSTMENT

The engine speed sensor uses a slotted hole on one
side (Fig. 10) to adjust its depth. A brass (non-mag
netic) feeler gauge must be used to adjust the sensor.
J9114-43
Fig. 11 Fuel Drain Manifold

(2) Remove injection pump vent capscrew (Fig. 11).
(3) Remove fuel drain manifold fitting screws and
washers at each fuel injector (Fig. 12).
INJECTOR
Fig. 10 Engine Speed Sensor—Installation

Sensor-to-vibration damper air gap is: 1.25 MM
(.049 in.) minimum to 1.30 MM (.051 in.) maximum.
(2) Position speed sensor, its two mounting spacers
and two mounting n u t s to the engine. Install mount DRAIN MANIFOLD
FITTING
ing nuts finger tight. SCREW J9114-44
(3) Route sensor wiring harness behind engine pul
leys. Install and tighten wiring harness clip bolts. Fig. 12 Fuel Drain Fitting Screws
(4) Place the feeler gauge between the sensor and
(4) Disconnect drain line T-fittings.
the vibration dampener.
INSTALLATION
(1) Using new seals on all fittings, assemble fuel
drain manifold in reverse order of disassembly.
(2) Tighten drain manifold fitting screws at the in
#
jectors to 8 N m (6 ft. lbs.) torque.
(3) Tighten drain manifold holddown clamp screws
to 24 N*m (18 ft. lbs.) torque.
#
(4) Tighten injection pump capscrew to 32 N m (24
ft. lbs.) torque.
FUEL HEATER
The fuel heater is located above the fuel/water sep
arator filter (Fig. 13).
REMOVAL
(1) Thoroughly clean the area around the separa
Fig. 14 Fuel Heater Removal/Installation
tor filter before service is performed.
(2) Disconnect the water-in-fuel (WIF) sensor elec (6) Apply a light film of clean engine oil to sealing
trical connector (Fig. 13). surface of separator filter.
(3) Remove the fuel/water separator filter. Refer to (7) Install a new square cut O-ring to the filter
Fuel/Water Separator Filter removal and installation connector on the bottom of the fuel heater.
in this group. (8) Install separator filter. Tighten separator filter
(4) Disconnect electrical connector from the fuel one half t u r n after it makes contact.
heater (Fig. 13). (9) Connect electrical connector to WIF sensor and
Fuel Heater.
FUEL INJECTION PUMP

REMOVAL
(2) Disconnect throttle linkage.
(3) Remove throttle bracket (Fig. 15).
SENSOR J9114-39

(5) Remove the filter adapter from the fuel heater
(Fig. 14).
(6) Remove fuel heater.
(7) Remove seals from fuel heater. Clean the fuel
heater and cylinder block mating surfaces.
INSTALLATION Fig. 15 Throttle Bracket

(1) Install new seals in fuel heater and adapter. (4) Remove injection pump supply line. Refer to
(2) Install fuel heater and adapter. Tighten Fuel Injection Pump Supply Line.
adapter to 32 N r n (24 ft. lbs.) torque. (5) Remove high pressure fuel lines. Refer to High
(3) Apply a light film of clean engine oil to sealing Pressure Lines.
surface of WIF sensor. (6) Disconnect electrical connector from fuel sole
(4) Install WIF sensor into new fuel/water separa noid.
tor filter. (7) Disconnect electrical connector from KSB Sole
(5) Fill separator filter with clean fresh fuel. noid.
(8) Remove the air control tube (Fig. 16).

(9) Remove fuel pump vent line and capscrew (Fig.
16).
Fig. 18 Oil Fill Tube and Bracket

(13) Place a shop towel below the retainer n u t in
the gear housing cover opening to prevent the n u t or
washer from falling into the gear housing. Remove
Fig. 16 Fuel Solenoid, Air Control Tube, Pump Vent the gear retaining n u t and washer.
Line The engine can be rotated with a barring tool such
The control lever is indexed to the shaft during cal as Snap-On No. SP371, MTE No. 3377462 (Cummins
ibration. D o not remove the control lever from in Tool Division), or an equivalent.
jection pump. (14) Insert the barring tool into the flywheel hous
(10) Remove bolt attaching the injection pump sup ing opening. The opening is located in rear flange of
port bracket to the vacuum pump. Remove the upper the engine, on the exhaust manifold side (Fig. 19).
and lower bolts attaching the support bracket to the
engine block. Loosen the middle bolt and pivot the
bracket towards the rear of the engine (Fig. 17).
Fig. 19 Rotating Engine with Barring Tool

(15) Rotate engine with the barring tool until the
fuel injection pump key-way is in the position shown
Fig. 17 Injection Pump Support Bracket in Fig. 20.
(11) Remove oil fill tube bracket mounting screw The engine has a timing pin (Fig. 21). The pin en
(Fig. 18). gages a hole in the camshaft gear when cylinder No.
(12) Remove oil fill tube from and adapter from 1 is at TDC on the compression stroke.
front cover.
C A U T I O N : During engine assembly by the manufac
C A U T I O N : If gear retainer nut or washer drops into turer, the timing pin is positioned to correspond
gear housing, cover must be removed to retrieve with the compression stroke T D C position of cylin
der number one. If the timing pin or gear housing is
them before engine is started.
removed, the timing pin location will not be correct
when reinstalled.
14 - 112 FUEL SYSTEM
J9114-58
Fig. 22 Injection Pump Timing Marks
J9114-57
Fig. 21 Timing Pin—Cylinder No. 1

Fig. 23 Injection Pump Shaft LockScrew and
(16) Locate TDC position (compression stroke) for Washer
No. 1 cylinder by slowly rotating the engine with the (20) Use a T-bar puller to separate the gear from
barring tool while lightly pushing in on the timing the pump shaft. Use M8 X 1.24 MM (metric) screws
pin. Stop when the timing pin engages the index hole to attach T-bar to shaft. Pull the injection pump gear
in the camshaft gear. forward until it separates from the injection pump
(17) Disengage the timing pin from the camshaft shaft (Fig. 24). The injection pump gear cannot be re
gear. moved from the engine through the oil fill opening in
Check the timing marks on the flange of the injec the timing case cover.
tion pump (Fig. 22). Each pump and engine have
unique marks. It is not possible to exchange pumps C A U T I O N : D o not allow the drive gear key-way to
and use the same marks for alignment. drop into the gear housing cover when removing
The injection pump has a lockscrew. The lockscrew the pump.
is used to hold the injection pump shaft in place once
TDC has been located. New and rebuilt injection (21) Remove the injection pump mounting nuts.
pumps should be received with the shaft locked in (22) Remove injection pump. Clean gasket surfaces
place by the lockscrew. on block and injection pump.
(18) Loosen the injection pump shaft lockscrew. It
is located below the injection pump mounting nut. INSTALLATION
Remove washer from injection pump (Fig. 23). Attach Before installing the injection pump, be sure t h a t
washer to injection pump with wire tag for use dur No. 1 cylinder is at No. 1 position.
ing installation. (1) Locate TDC position (compression stroke) for
(19) Tighten lockscrew. No. 1 cylinder by slowly rotating the engine with the
Fig. 24 Separating Pump Gear from injection Pump

Fig. 25 Marking New or Rebuilt Injection Pump
Shaft
New and rebuilt injection pumps should be re
barring tool while lightly pushing in on the timing
ceived with the shaft locked in place by the lock-
pin. Stop when the timing pin engages the index hole
screw.
in the camshaft gear.
(10) Loosen injection pump lockscrew and install
(2) Disengage the timing pin from the camshaft
washer under lockscrew (Fig. 26). Tighten lockscrew
gear.
to 13 Nnn (10 ft. lbs.) torque.
(3) Install a new injection pump gasket.
The shaft of a new or reconditioned pump is locked
in place. The key is positioned to align with the drive
gear slot when cylinder No. 1 is at TDC on the com
pression stroke.
C A U T I O N : Be sure that the injection pump shaft

key-way does not fall into the gear housing when
installing the injection pump. T h e key-way must be
removed if it falls into the gear housing.
(4) Install the injection pump. Finger tighten the

mounting nuts. The pump must be able to move in
the slot.
(5) Remove the T-bar from the injection pump
gear.
(6) Install pump drive shaft gear retaining nut and
Fig. 26 Installing Lockscrew Washer
spring washer. The injection pump will rotate
slightly if the pump mounting nuts were installed (11) Install injection pump support bracket with
finger tight and the crankshaft does not move. mounting s c r e w s finger tight. Using following the
(7) Tighten injection pump drive shaft gear retain sequence, tighten mounting screws to 24 Nnn (18 ft.
ing nut to 15-20 N t h (11-15 ft. lbs.) torque. Do not lbs.) torque.
over tighten. This is not the final tightening • Tighten bracket to vacuum pump screw.
torque. • Tighten bracket to block mounting screws.
(8) If installing original injection pump, rotate • Tighten bracket to injection pump mounting
pump to align timing marks. If installing a new or screws.
rebuilt pump without a timing mark, take up gear • Tighten throttle support bracket mounting screws.
lash by rotating pump counterclockwise towards cyl (12) Tighten injection pump drive shaft gear re
inder head. taining nut to 65 N*m (48 ft. lbs.) torque.
(9) Tighten injection pump mounting nuts to 24 (13) Install oil filler assembly to gear housing.
Nnn (18 ft. lbs.) torque. Tighten clamp screw to 43 Nnn (32 ft. lbs.) torque.
If installing a new or rebuilt pump, permanently (14) Install high pressure fuel lines. Refer to High
m a r k the injection pump flange in line with the Pressure Lines. Tighten high pressure fuel lines to
m a r k on the gear housing (Fig. 25). 24 Nnn (18 ft. lbs.) torque.
(15) Install fuel injection pump supply line. Refer
to Fuel Injection Pump Supply Line.
(16) Connect electrical connector to fuel solenoid.
(17) Connect electrical connector to KSB solenoid.
(18) Install fuel pump vent line and capscrew.
(19) Install air fuel control tube.
(20) Install throttle bracket (Fig. 15). Tighten
mounting bolts to 24 N»m (18 ft. lbs.) torque.
(21) Install throttle linkage. When connecting the
cable to the control lever, adjust the length so the le
ver has stop-to-stop movement. Refer to Accelerator
Pedal and Throttle Controls section of Group 14,
Fuel Systems.
(22) Install and adjust throttle position sensor. Re
fer to Service Adjustments.
(23) Bleed air from fuel system. Refer to High Fig. 28 Supply Line to Injection Pump Connection
Pressure Fuel Lines in the Air Bleeding portion of
the Diesel Fuel Injection section of Group 14, Fuel (2) Tighten the supply line connections to 24 Nnn
Systems. (24 ft. lbs.) torque.
(24) Adjust the low idle speed if required. Refer to (3) Manually bleed the system of air. Refer to
Service Adjustments near the end of this group. Manual Bleeding in this section.
(25) Inspect throttle linkage to be sure that the (4) Connect negative cable to battery.
control lever breaks over the full throttle position.
Adjust as necessary. Refer to Accelerator Pedal and FUEL INJECTORS
Throttle Cable section of Group 14, Fuel Systems.
REMOVAL
FUEL INJECTION PUMP SUPPLY LINE (1) Disconnect negative cable from battery.
(2) Remove throttle linkage.
REMOVAL (3) Remove high pressure fuel lines. Refer to High
(1) Disconnect negative cable from battery. Pressure Fuel Lines in this section.
(2) Disconnect supply line at fuel/water separator (4) Remove the fuel drain manifold. Refer to Fuel
filter (Fig. 27). Drain Manifold in this section.
(5) Thoroughly clean the area around the injector.
C A U T I O N : U s e a deep well socket to remove the

fuel injector (Fig. 29).
(6) Remove injector (Cummins injector nozzle

puller tool 3823276 or an equivalent). Discard copper
seal.
Fig. 27 Supply Line to Separator Filter Connection

(3) D o not allow the injection p u m p inlet fit
ting to m o v e w h e n loosening supply line. U s e
t w o w r e n c h e s w h e n removing line. Disconnect
supply line from injection pump (Fig. 28).
INSTALLATION
(1) Install low pressure fuel supply line in reverse
order of removal. Fig. 29 Fuel Injector Removal/Installation
FUEL SYSTEM 14 - 115
(7) Clean injector nozzle bore with wire brush

(Cummins tool number 3822509 or equivalent—Fig.
30).
Fig. 32 Injector Installation

(10) Bleed air from t h e high pressure lines. Refer
to High Pressure Lines in the Air Bleeding section.
Fig. 30 Cleaning Cylinder Head Injector Bore
INSTALLATION FUEL/WATER SEPARATOR FILTER
(1) Install new copper seal on injector (Fig. 31).
REMOVAL
(1) Disconnect electrical connector from water-in-
fuel (WIF) sensor at the bottom of the separator filter
(Fig. 33).
J9114-50
Fig. 31 Injector Seal

(2) Apply a coating of anti-seize compound to t h e
threads of the injector holddown n u t and between the
top of the nut and injector body.
C A U T I O N : Align the tab on the side the injector C A U T I O N : When removing the fuel/water separator
with the notch in the cylinder head injector bore filter, be sure that the fuel heater electrical connec
(Fig. 32). tor is not turned against the engine. The connector
could be opened or damaged.
(3) Install injector.
(4) Tighten injector n u t to 60 N«m (44 ft. lbs.) (2) Remove fuel/water separator filter. The fuel
torque.
heater assembly should not move when removing or
(5) Position O-ring into groove on injector.
installing t h e fuel/water separator.
(6) Connect fuel drain manifold. Refer to Fuel
(3) Remove the square cut O-ring from the filter
Drain Manifold in this section.
connector a t t h e bottom of the fuel heater (Fig. 34).
(7) Connect high pressure fuel lines. Refer to High
Pressure Fuel Lines in this section. (4) Drain t h e fuel/water separator filter. Remove
(8) Install throttle linkage. the water-in-fuel sensor, O-ring and fuel/water drain
(9) Connect negative cable to battery. valve assembly from separator filter (Fig. 34).
14 • 116 FUEL SYSTEM
Fig. 34 WIF Sensor, Drain Valve Assembly Fig. 35 Injection Pump Bracket— Typical
INSTALLATION (4) Disconnect high pressure lines from fuel injec
(1) Install new O-ring on WIF sensor. tors.
(2) Install WIF sensor into new separator filter. (5) Remove high pressure line holders mounting
If the new fuel/water separator filter is not filled screws.
with clean fuel before it is installed, manual air
bleeding of the fuel system may be necessary. C A U T I O N : Be sure that the high pressure fuel lines
(3) Fill separator filter with clean fuel. are installed in the same order that they were re
(4) Apply a light film of clean unused engine oil to moved. Prevent the injection pump delivery valve
the separator filter seal. holders from turning when removing or installing
(5) Install a new square cut O-ring to the filter high pressure lines from injection pump (Fig. 36).
connector on the bottom of the fuel heater.
C A U T I O N : When installing the Fuel/Water separator

filter, be sure that the fuel heater electrical connec
tor is not turned against the engine. The connector
could be damaged or opened.
(6) Install separator filter. Tighten separator filter

one half t u r n after it makes contact.
(7) Connect electrical connector to WIF sensor.
HIGH PRESSURE FUEL LINES

All high pressure fuel lines are of the same length
and inside diameter. Correct high pressure fuel line
usage and installation is critical to smooth engine
operation.
Fig. 36 Injection Valve Holder
C A U T I O N : The high pressure fuel lines must be
(6) Disconnect high pressure lines from fuel injec
clamped securely in place in the holders. The lines
cannot contact each other or other components. D o tion pump. Remove high pressure lines.
not attempt to weld high pressure fuel lines or to
INSTALLATION
repair lines that are damaged. Only use the recom
(1) Install high pressure fuel lines in the correct
mended lines when replacement of high pressure
order and positioned in holders.
fuel line is necessary.
(2) Tighten high pressure fuel line connections.
(3) Tighten holder screws to 24 N-m (18 ft. lbs.)
REMOVAL torque.
(1) Disconnect negative cable from battery. (4) Install injection pump bracket. Tighten mount
(2) Remove throttle linkage. ing screws to 24 N*m (18 ft. lbs.) torque.
(3) Remove injection pump bracket (Fig. 35).
(5) Bleed air from the fuel system. Refer to High C A U T I O N : During engine a s s e m b l y by the manufac
Pressure Fuel Lines in the Air Bleeding portion of turer, the timing pin is positioned to c o r r e s p o n d
this section. with the c o m p r e s s i o n stroke T D C position of cylin
der n u m b e r one. If the timing pin or gear h o u s i n g i s
INJECTION TIMING r e m o v e d , the timing pin location will not be correct
If incorrect injection timing is suspected, injection w h e n reinstalled.
pump-to-engine timing or injection pump timing may
be the cause. Check injection pump timing before (1) Locate TDC position (compression stroke) for
checking injection pump-to-engine timing. cylinder number one by slowly rotating the engine
with the barring tool while lightly pushing in on the
INJECTION PUMP TIMING timing pin. Stop when the timing pin engages the in
dex hole in the camshaft gear.
CAUTION; W h e n setting injection p u m p timing, re (2) Once TDC has been located, pull the timing pin
fer to the engine identification plate attached to the out of the camshaft gear to the normal run position.
timing c a s e flange for the correct specification (Fig. (3) Remove plug and copper washer from the rear
37). of the injection pump (Fig. 39).
PLUG J9114-63
Fig. 37 Engine identification Plate Fig. 39 Timing Indicator Plug
The engine can be rotated with a barring tool such Dial gauges and dial gauge holders used to check
as Snap-On No. SP371, MTE No. 3377462 (Cummins injection pump timing are commercially available.
Tool Division), or an equivalent. Snap-On dial gauge and gauge holder YA83300,
The engine has a timing pin (Fig. 38). The pin en MTE (Cummins Tool Division) dial gauge 3377259
gages a hole in the camshaft gear when cylinder No. and dial gauge holder 2066 or an equivalent can be
1 is at TDC on the compression stroke. used. Whichever dial gauge is used, note the range of
gauge and also what one revolution of needle travel
equals. On gauge shown in Fig. 40, one revolution of
the needle equals 0.50 MM.
It may be necessary to remove one or more high
pressure fuel line(s) from the pump to install the
gauge (Fig. 40). If a high pressure fuel line is re
moved, the system must be bled of air after reinstall
ing the fuel line. Refer to High Pressure Fuel Lines
in the Air Bleeding portion of the Diesel Fuel Injec
tion section of Group 14, Fuel Systems.
(4) Install the gauge holder and gauge in the injec
tion pump (Fig. 40). Be sure gauge travel is at least
2.0 MM.
The engine can be rotated with a barring tool such
as Snap-On No. SP371, MTE No. 3377462 (Cummins
J9114-57 Tool Division), or an equivalent.
(5) Insert barring tool into the flywheel housing
Fig. 38 Timing Pin—Cylinder No. 1 opening. The opening is located in the rear flange of
correct amount of plunger lift is obtained at TDC
(TDC pin engages hole in camshaft gear). Set timing
to 1 . 2 5 MM lift.
( 9 ) If the injection pump does not have the correct
lift, rotate the injection pump on the mounting studs
while noting the reading on the dial gauge. Rotate
the pump to obtain the correct amount of injection
pump plunger lift.
( 1 0 ) Tighten mounting stud nuts to 2 4 N*m ( 1 8 ft.
lbs.) torque.
( 1 1 ) Remove dial gauge and holder.
( 1 2 ) If removed, install high pressure fuel lines.
( 1 3 ) Install plug tod washer into injection pump.
J9114-64
Tighten plug to 1 0 Nnn ( 7 ft. lbs.) torque.
( 1 4 ) If high pressure fuel lines were removed,
Fig. 40 Checking injection Pump Timing bleed air from the fuel system. Refer to High Pres
sure Fuel Lines in the Air Bleeding section.
the engine, on the exhaust manifold side (Fig. 4 1 ) .
INJECTION PVMP*>TO*ENGINE TIMING
( 1 ) With the gear housing cover off, be sure t h a t
the crankshaft gear and camshaft gear are correctly
timed. Correct as necessary. Refer to Group 9 , En
gines.
The engine can be rotated with a barring tool such
as Snap-On No. S P 3 7 1 , MTE N o . 3 3 7 7 4 6 2 (Cummins
Tool Division), or an equivalent.
The engine has a timing pin (Fig. 3 8 ) . The pin en
gages a hole in the camshaft gear when cylinder No.
1 is at TDC on the compression stroke.
C A U T I O N ; During engine a s s e m b l y by the manufac

turer, the timing pin is positioned to c o r r e s p o n d
with the c o m p r e s s i o n stroke T D C position of cylin
Fig. 41 Rotating Engine with Barring Tool der number one. If the timing pin or gear h o u s i n g is
removed, the timing pin location will not be correct
( 6 ) Rotate the engine in t h e direction opposite en when reinstalled.
gine rotation until the needle on the dial gauge stops
moving. Adjust the face of the gauge to read zero at ( 2 ) Locate TDC position (compression stroke) for
the needle. No. 1 cylinder by slowly rotating the engine with the
(7) Rotate the engine (in normal direction) back to barring tool while lightly pushing in on the timing
TDC on the No. 1 cylinder compression stroke. pin. Stop when the timing pin engages the index hole
in the camshaft gear.
C A U T I O N : T h e dial g a u g e needle s h o u l d m o v e ( 3 ) Once TDC has been located, pull the timing pin
smoothly w h e n the engine i s rotated. If the needle out of the camshaft gear to the normal r u n position.
j u m p s or b o u n c e s , replace the injection p u m p . ( 4 ) With the gear housing cover off, inspect the
alignment of the timing marks on the camshaft gear
( 8 ) Taking note of dial gauge travel (number of
and injection pump gear. The letter E on the injec
revolutions), rotate the engine in the normal direc
tion pump gear should be aligned with the m a r k on
tion until cylinder No. 1 is again at TDC on the com
the camshaft gear (Fig. 4 2 ) .
pression stroke. Use the timing pin to locate TDC. ( 5 ) If necessary check and adjust injection pump
The reading on the dial gauge when the timing pin timing. Refer to Injection Pump Timing.
indicates TDC is the amount of plunger lift the pump
has at t h a t point. Refer to t h e specification on the KSB SOLENOID
engine identification plate for the correct amount of
lift. The injection pump is properly timed when the REMOVAL
The KSB Solenoid is not serviceable. It must be re
placed as a complete unit.
Fig. 42 Injection Pump-to-Engine Timing Fig. 44 Lift Pump Removal/Installation

(1) Disconnect electrical connector from KSB sole INSTALLATION
noid (Fig. 4 3 ) . (1) Install lift pump with new gasket. Tighten
(2) Remove KSB solenoid. #
mounting screws to 24 N m (18 ft. lbs.) torque.
A i r d o e s n o t h a v e to b e M e d from t h e fuel in (2) Install low pressure fuel lines.
j e c t i o n p u m p a n d fuel s y s t e m after r e p l a c i n g t h e (3) Manually bleed the system of air. Refer to
K S B solenoid. Manual Bleeding in this section.
(4) Connect battery cable to battery.
THROTTLE POSITION SENSOR (TPS)

The TPS is used on vehicles equipped with an au
tomatic transmission only. The TPS is adjustable and
m u s t be adjusted after installation.
REMOVAL
(1) Remove the electrical connector from the TPS
(Fig. 45).
Fig. 43 KSB Solenoid—Removal/installation

INSTALLATION
(1) Install the KSB solenoid in the injection pump.
Tighten the solenoid to 43 N*m (32 ft. lbs) torque.
(2) Connect harness connector to KSB solenoid.

The lift pump is attached to the drivers side of the
engine block towards the rear of the engine (Fig. 44).
REMOVAL Fig. 45 Throttle Position Sensor

(1) Disconnect negative battery cable at battery. (2) Remove the two TPS mounting screws. Do not
(2) Disconnect low pressure fuel lines from pump remove the TPS mounting bracket screws from the
(Fig. 44). injection pump. Lift the TPS straight up for removal.
(3) Remove lift pump mounting screws. (3) If the nylon adapter (Fig. 46) has remained on
(4) Clean mating surfaces on lift pump and engine the TPS mounting bracket after removal of TPS, it
block. must also be removed. To remove adapter, slightly
move the throttle lever (by hand) from the idle posi TPS MOUNTING
tion and lift adapter for removal. BRACKET
Fig. 46 Nylon Adaptor—TPS to Injector Pump

INSTALLATION TANG NYLON ADAPTOR
The bottom of the nylon adapter (on the TPS) has a
hex head. The hex head on this adapter fits into a Fig. 48 Positioning Nylon Adapter
hex opening in the injection pump throttle shaft (Fig. (2) Position the TPS to nylon adapter. Refer to the
47). previous CAUTION.
(1) Install the nylon adapter to the TPS mounting (3) The TPS is spring loaded. After positioning the
bracket. The t a n g on the nylon adapter (Fig. 48) TPS on the adapter, be certain to rotate the TPS in a
should be within the notch area on the TPS mount clockwise direction to allow installation of its two
ing bracket (Fig. 48). If adapter will not drop into mounting screws.
hex opening on injector pump, open the throttle (4) Install and tighten both TPS mounting screws.
slightly. This will cause the throttle shaft to rotate If the TPS bracket mounting screws were removed,
and allow the adapter to be positioned. tighten them to 7 N»m (60 in. lbs.) torque.
(5) Connect the electrical connector to the TPS.
CAUTION: Do not allow the tang on the nylon
(6) Adjust the TPS. Refer to the following Adjust
adapter to be outside of notch area on TPS mount
ment procedure.
ing bracket (Fig. 48). Damage to adapter and im
proper TPS operation will occur. ADJUSTMENT
CAUTION: Before adjusting the TPS, the throttle

linkage must be checked for correct adjustment.
The throttle lever must contact the low idle speed
screw. The throttle lever must reach breakover
when the throttle is wide open. Refer to the Accel
erator Pedal and Throttle Cable section of Group
14, Fuel Systems.
A digital voltmeter (Fig. 49) or the DRB II scan

tool is needed to adjust the throttle position sensor.
(1) Turn the ignition key to the On position.
(2) Connect the negative probe of the voltmeter to
a good ground source such as the negative post of t h e
battery.
(3) Probe the throttle position sensor output wire
Fig. 47 Throttle Position Sensor Installation at the TPS electrical connector. The center wire on
The hex drive on the TPS nylon adapter should be the connector is the output circuit.
flush with the top of the throttle lever hex opening
or just above it.
Fig. 49 Throttle Position Sensor (TPS) Testing Fig. 51 Adjusting Throttle Position Sensor
(4) With the fuel injection pump throttle lever con
tacting the low idle speed screw (Fig. 50), TPS output
should be 1 volt or slightly above. If not, the TPS
must be adjusted.
(5) The TPS nylon adapter (Fig. 51) is machined to
accept a 10 MM open end wrench. To adjust, gently
rotate the nylon adapter with a 10 MM open end
wrench to until correct voltage is obtained.
Fig. 52 Correct Breakover Spring Position

WATER-IN-FUEL SENSOR
REMOVAL
(1) Remove fuel/water separator filter. Refer to Fu
el/Water Separator Filter Removal.
J9114-261 (2) Remove the square cut O-ring from the filter
connector at the bottom of the fuel heater (Fig. 53).
Fig. 50 Throttle Lever Contacting Low Idle Speed (3) Drain the fuel/water separator filter. Remove
Screw the water-in-fuel sensor, O-ring and fuel/water drain
(6) Open throttle to the wide open position. The valve assembly from separator filter (Fig. 53).
spring load breakover lever should have moved off
the stop and rest against the breakover spring (Fig. INSTALLATION
52). If not, the throttle actuation rod must be ad (1) Apply a light film of clean engine oil to sealing
justed before adjusting TPS. Refer to Accelerator surface of WIF sensor.
Pedal and Throttle Cable section of Group 14, Fuel (2) Install WIF sensor into new fuel/water separa
Systems. tor filter.
(7) With throttle held in wide open position, check (3) Fill separator filter with clean fresh fuel.
TPS output voltage. It should be 2.25 to 2.75 volts (4) Apply a light film of clean engine oil to sealing
higher t h a n the output voltage is at closed throttle surface of separator filter.
position. If not, gently rotate nylon adapter to obtain (5) Install a new square cut O-ring to the filter
correct voltage. connector on the bottom of the fuel heater.
(6) Install separator filter. Tighten separator filter
one half turn after it makes contact.
(7) Connect electrical connector to WIF sensor and
fuel heater.
SERVICE ADJUSTMENTS—DIESEL
GENERAL INFORMATION
The low idle speed adjustment is the only adjust
ment that can be made to the injection pump. The
fuel solenoid is the only component that can be ser
viced on the injection pump. Refer to Service Proce
dures section for fuel solenoid service. All other
injection p u m p service must b e performed b y
authorized personnel.
LOW IDLE SPEED

Use an optical tachometer such as Snap-on No.
MT139 or MTE (Cummins tool division) No. 3377462
to read engine rpm.
(1) If necessary, adjust low idle speed at the low
idle speed screw (Fig. 54). If the vehicle has an auto
matic transmission, with the air conditioning on, set
low idle speed to 700 rpm. If the vehicle has a man Fig. 54 Adjusting Low Idle Speed
ual transmission, with the air conditioning on, set to obtain specified rpm. Refer to the Specification
low idle speed to 750 rpm. section at the end of this group for idle speeds.
(2) Loosen idle screw lock nut using Cummins tool
number 3823750 or an equivalent. Adjust idle screw
SPECIFICATIONS
GENERAL INFORMATION FUEL TANK CAPACITIES
The following specifications are published from t h e
latest information available a t t h e time of publica
tion. If a n y t h i n g differs b e t w e e n t h e specifica TANK: LITERS GALLONS
tions found on the Vehicle Emission Control Standard 83.0 22
I n f o r m a t i o n (VECI) l a b e l a n d t h e following s p e c Optional 114 30
ifications, u s e s p e c i f i c a t i o n s o n V E C I label. Ramcharger 120.9 34
Nominal refill capacities are shown. A variation may be observed

from vehicle to vehicle due to manufacturing tolerances and refill
procedures.
J9014-182
FUEL SOLENOID-5.9L DIESEL
Current Draw 2 Amps

Minimum Voltage 10 Volts
Operating Voltage 12 Volts
Resistance 6.9-7.9 Ohms
J9114-214
ENGINE SPEED—5.9L DIESEL
Full Throttle Stop Speed (No Load) 2925 RPM (Max)
Full Throttle Stop Speed (No Load) 2824 RPM (Min)
Low Idle Stop Speed (A/C On—Auto Trans) 700 RPM
Low Idle Stop Speed (A/C On—Man Trans) 750 RPM
J9114-215
FUEL SYSTEM—5*9L DIESEL
Fuel Pressure Drop Across Filter 21 kPa (3 psi) Max
Fuel Return Line Restrictions 20.4 in. Hg. Max
Injector Operating Pressure (Pop Off Pressure) 3550 psi
Mechanical Lift Pump Inlet Restriction 3.75 in. Hg. Max
Mechanical Lift Pump Output (Flow) 0.75 L (0.70 qt) per 30 seconds Max
Mechanical Lift Pump Output (Pressure) 21-35 kPa (3-5 psi)
J9114-216
14-124 FUEL SYSTEM
TORQUE-EXCEPT DIESEL
DESCRIPTION TORQUE
Accelerator Pedal Bracket

Mounting Nuts . 7 N m (55 in. lbs.)
Coolant Temperature Sensor . . 11 N« m (8 ft. lbs.)
Crankshaft Position Sensor
Mounting Bolts . 8 N« m (70 in. lbs.)
Fuel Filter Mounting Bolts . . . . 8 N- m (75 in. lbs.)
Fuel Hose (Tube) Clamps . . . . 1 N- m (10 in. lbs.)
IAC Motor-To-Throttle Body . . . 7 N- m (60 in. lbs.)
Intake Manifold Charge
Air Temperature Sensor . . . . 28 N •m (20 ft. lbs.)
MAP Sensor Mounting Screws. . 3 N •m (25 in. lbs.)
Oxygen Sensor . 30 N •m (22 ft. lbs.)
PCM 60-Way Connector
Mounting Screw . 4 N •m (35 in. lbs.)
Throttle Body Mounting Bolts. . . 23 N •m (200 in. lbs.)
Throttle Position Sensor
Mounting Bolts . . . . . . . . . . 7 N« m (60 in. lbs.)
• — _ — _ FUEL SYSTEM 14 - 125
TORQUE—5.9L DIESEL
Component N-m ft. l b s . / I n . l b s .
Air Fuel Control Tube 12 N-m 9 ft. lbs.
Fuel Line Clamp to Intake Manifold Mounting Screws 24 N-m 18 ft. lbs.
Fuel Line Fittings at Injector—High Pressure 24 N-m 18ft. lbs.
Fuel Line Fittings at Injection Pump—High Pressure 24 N-m 18ft. lbs.
Fuel Solenoid 43 Nm 32 ft. lbs.
Injection Pump Mounting Nuts 24 N-m 18ft. lbs.
Injection Pump Lockscrew (Locked Position) 30 Nm 22 ft. lbs.
Injection Pump Lockscrew (Unlocked Position) 13 Nm 10ft. lbs.
Injection Pump Gear Retaining Nut 65 Nm 48 ft. lbs.
* Injection Pump Support Bracket 24 Nm 18 ft. lbs.
Injection Pump Timing Plug 10Nm 7.5 ft. lbs.
Injector Drain Screw 8 N-m 6 ft. lbs.
Injector Retainer Nut 60 Nm 44 ft. lbs.
Low Pressure Bleed Screw on Filter Head 8 Nm 6 ft. lbs.
Mechanical Lift Pump Mounting Screws 24 Nm 18ft. lbs.
Throttle Linkage Rod Lock Nuts 9 N-m 7 ft. lbs.
Throttle Control Bracket Mounting Screws 24 Nm 18 ft. lbs.
Throttle Rod to Throttle Rod Ball Stud Nut 10 Nm 7.5 ft. lbs.
* Mounting bolts must be tightened in specified sequence. J9114-205

PROPELLER SHAFTS 16-1
PROPELLER SHAFTS
CONTENTS
page page
GENERAL INFORMATION 1 TORQUE SPECIFICATIONS 15

PROPELLER SHAFT REPLACEMENT 8 UNIVERSAL JOINT REPLACEMENT 10
SERVICE DIAGNOSIS/PROCEDURES 3
GENERAL INFORMATION
PROPELLER SHAFTS operating angles. This is accomplished through uni
The basic function of a propeller shaft is to trans versal joints. The U-joints permit the propeller shaft
mit power from one point to another. The shaft is de to operate at different angles. The slip joints (or
signed to send torque through an angle from the yokes) permit contraction or expansion.
transmission (transfer case on 4WD vehicles) to the Tubular propeller shafts are balanced by the man
axle (Fig. 1). ufacturer with weights spot welded to the tube.
The propeller shaft must operate through con The propeller shaft is designed and built with t h e
stantly changing relative angles between the trans yoke lugs in line with each other. This is called phas
mission and axle. It also must be capable of changing ing. This design produces the smoothest running con
length while transmitting torque. The axle rides sus dition. An out of phase shaft can cause a vibration.
pended by springs in a floating motion. This means Before undercoating a vehicle, the propeller
the propeller shaft must contract, expand and change shaft a n d the U-joints should b e covered. This
S
LP
I Y
OKEB
OOT
FRONT
PROPELLER
SHAFT
REAR
PROPELLER SHAFT
J9216-23
Fig. 1 Front and Rear Propeller Shafts (4 WD)

16-2 PROPELLER SHAFTS •
will prevent the undercoating from c a u s i n g an
u n b a l a n c e d condition and vibration.
CAUTION: Use exact replacement hardware for at

taching the propeller shafts. Exact replacement will
ensure safe operation. The specified torque must
always be applied when tightening the fasteners.
UNIVERSAL JOINTS
The front prop shaft uses the 7260 series universal
joint. The rear prop shaft uses the 7290 series uni
versal joint on all but the Dana 70 axle. The 1410 se
ries is used with the Dana 70 axle.
Two different types of universal joints systems are
used:
• Single cardan universal joint (Fig. 2)
• Double cardan universal joint (Fig. 3)
LUBRICATION
The slip yoke on the front shaft is equipped with a RETAINER J9216-20
zerk type lubrication fitting. Use a multi-purpose
NLGI Grade 2 E P lubricant. Refer to Group 0, Lubri Fig. 2 Single Cardan Universal Joint (Typical)
cation and Maintenance for additional information. U-joints should be inspected for leakage and damage
The factory installed U-joints are lubricated for the each time the vehicle is serviced. If seal leakage or
life of the vehicle and do not need re-lubrication. All damage exists, the U-joint should be replaced.
1. LINK YOKE 6. SEAL 11. FRONT SPIDER

2. SOCKET SPRING 7. BEARING CAP 12. NEEDLE BEARINGS
3. SOCKET BALL RETAINER 8. REAR SPIDER 13. THRUST WASHER
4. THRUST WASHER 9. SOCKET YOKE 14. DRIVE SHAFT YOKE
5. NEEDLE BEARINGS 10. SOCKET BALL 15. RETAINING CLIP
Fig. 3 Double Cardan (CV) Universal Joint

• PROPELLER SHAFTS 16 - 3
SERVICE DIAGNOSIS/PROCEDURES
INDEX
page page
Precautions . 3 Universal Joint Angle Measurement ............ 4
Runout 4 Vibration 3
Unbalance 3
PRECAUTIONS a specific speed range is not caused by propeller

Propeller shafts are balanced by the manufacturer shaft unbalance. Defective U-joints or an incorrect
to prevent vibration. Before undercoating a vehicle, propeller shaft angle are usually the cause.
the propeller shaft and the U-joints should be cov
ered. This will prevent the undercoating from caus UNBALANCE
ing an unbalanced condition and vibration. If propeller shaft unbalance is suspected, it can be
Use exact replacement hardware for attaching the verified with the following procedure.
propeller shafts. Exact replacement will ensure safe R e m o v i n g and re-indexing the propeller shaft
operation. The specified torque must always be ap 180° m a y eliminate some vibrations.
plied when tightening the fasteners. (1) Raise and support the vehicle.
(2) Clean all foreign material from propeller shaft
VIBRATION and U-joints.
Tires t h a t are out-of-round or wheels t h a t are un (3) Inspect propeller shaft for missing balance
balanced will cause a low frequency vibration. Refer weights, broken welds, and bent areas. If the pro
to Group 22, Tires And Wheels for service informa peller shaft is bent, it must b e replaced.
tion.
(4) Ensure the U-joints are not worn and are prop
Brake drums t h a t are unbalanced will cause harsh,
erly installed.
low frequency vibration. Refer to Group 5, Brakes for
(5) Check the U-joint clamp screws torque.
service information.
(6) Remove wheels and tires. Install wheel lug
Driveline vibration can also result from loose or
damaged engine mounts. Refer to Group 21, Trans nuts to retain brake drums in place.
missions for additional information. (7) Mark and number the shaft at four positions
Propeller shaft vibration will increase as the vehi 90° apart, six inches from the yoke weld end.
cle speed is increased. A vibration that occurs within
DRIVELINE VIBRATION
Drive Condition Possible C a u s e Correction
PROPiLLlR SHAFT a. Undercoating or other foreign material a. Clean exterior of shaft and wash with
on shaft. solvent.
b. Loose U-joint clamp screws. b. Tighten screws properly.
c. Loose or bent U-joint yoke or excessive c. Install replacement yoke.
runout.
d. Incorrect drive line angularity. d. Correct angularity
e. Rear spring center bolt not in seat. e. Loosen spring U-bolts and seat center
bolts.
f. Worn U-joint bearings. f. Replace U-joint.
g. Propeller shaft damaged (bent tube) or g. Install replacement propeller shaft.
out of balance.
h. Broken rear spring. h. Replace rear spring.
i. Excessive runout or unbalanced i. Reindex propeller shaft 180°, test and
condition. correct as necessary.
j. Excessive drive pinion gear shaft yoke j. Reindex propeller shaft 180° and
runout. evaluate.
UNIVERSAL J O I N T NOISE a. U-joint clamp screws loose. a. Tighten screws with specified torque.
b. Lack of lubrication. b. Replace U-joint.
J9216-7
(8) Run and accelerate the vehicle until vibration
occurs. Note the intensity and speed the vibration oc
curred. Stop the engine.
(9) Install a screw clamp at p o s i t i o n I (Fig. 1).
RF4B9
Fig. 3 Clamp Screws Separated

(16) If the amount of vibration remains unaccept
able, apply procedures at the front end of propeller
shaft.
Fig. 1 Clamp Screw At Position 1
(10) Start the engine and re-check for vibration. If RUNOUT
there is little or no change in vibration, move the (1) Remove dirt, rust, paint, and undercoating
clamp to one of the other three positions. Repeat the from the propeller shaft surface. Areas where the
vibration test. dial indicator will contact the shaft must be clean.
(11) If there is no difference, the vibration may not (2) The dial indicator must be installed perpendic
be caused by propeller shaft unbalance. ular to the shaft surface.
(12) If the vibration decreased, install a second (3) Measure runout at the center and ends.
clamp (Fig. 2) and repeat the vibration test. (4) Refer to Runout Specifications chart.
(5) Replace the propeller shaft if the runout ex
ceeds the limit.
RUNOUT SPECIFICATIONS
Front of shaft 0.010 in. (0.25 mm)

Center of shaft . 0.015 in. (0.38 mm)
Rear of shaft . 0.010 in. (0.25 mm)
NOTE: Measure front/rear runout approximately 3 inches
(76 mm) from the weld seam at each end of the shaft tube
for tube lengths over 30 inches. Under 30 inches the max.
runout is 0.20 inch for full length of the tube.
J9116-15
UNIVERSAL JOINT ANGLE MEASUREMENT

Fig. 2 Two Clamp Screws At The Same Position
(13) If vibration increased, separate the clamp INFORMATION
screws (1/4 inch above and 1/4 inch below the mark). When two shafts intersect, the bend t h a t is formed
Repeat the vibration test (Fig. 3). is called the working angle. The larger the angle, the
(14) Increase distance between the clamp screws. larger the amount of acceleration and deceleration of
Repeat the test until the amount of vibration is at the joint. This speeding up and slowing down of the
the lowest level. Bend the slack end of the clamps so joint must be cancelled. This will produce a smooth
the screws will not loosen. power flow. This is done through phasing and proper
(15) Install t h e wheel and tire. Remove supports universal joint working angles.
and lower the vehicle.
• PROPELLER SHAFTS 16-5
A propeller shaft is properly phased when the yoke (2) Place Inclinometer on yoke bearing (A) parallel
ends are on the same plane or in line. A twisted to the shaft (Fig. 5). Center bubble in sight glass and
shaft will throw the yokes out of phase and cause a record measurement.
noticeable vibration. This m e a s u r e m e n t will give y o u the transmis
When t a k i n g universal joint angle measurements s i o n o r O U T P U T YOKE A N G L E (A).
or checking phasing with two piece shafts, consider
each shaft separately. On 4WD vehicles, the front
shaft input (pinion shaft) angle has priority over the
caster angle.
Ideally the driveline system should have:
• A n g l e s that are in equal or opposite within 1
degree of e a c h other
• H a v e a 3 degree m a x i m u m operating angle
• H a v e at least a 1/2 degree continuous operat
ing (propeller shaft) angle
Engine speed (R.P.M.) is the main factor though in
determining maximum allowable operating angles.
As a guide to maximum normal operating angles re
fer to the chart listed (Fig. 4).
PROPELLER SHAFT M A X * NORMAL

R«P*JVi* OPERATING ANGLES
5000 3°
4500 3°
4000 4°
3500 5°
3000 5° Fig. 5 Front (Output) Angle Measurement (A)
2500 7°
2000 8° (3) Rotate propeller shaft 90 degrees. Place Incli
1500 11° nometer on yoke bearing parallel to the shaft (Fig.
J9316-4
6). Center bubble in sight glass and record measure
ment. This measurement can also be taken at the
Fig. 4 Maximum Angles and R.P.M. rear end of the shaft.
INSPECTION This measurement will give y o u the PROPEL
Before m e a s u r i n g universal joint angles, the LER S H A F T A N G L E (C).
following must done.
• Inflate all tires to correct pressure.
• Check angles in the same l o a d e d or u n l o a d e d
condition as w h e n the vibration occurred. P r o p
shaft angles will change according to the
amount of load in the vehicle. A l w a y s c h e c k an
gles in l o a d e d a n d unloaded conditions.
• Check the condition of all suspension components
and verify all fasteners are torqued to specifications.
• Check the condition of the engine and transmis
sion mounts and verify all fasteners are torqued to
specifications.
MEASUREMENT
To accurately check driveline alignment, raise and
support the vehicle at the axles as level as possible.
Allow the wheels and propeller shaft to turn. Remove
any external bearing snap rings (if equipped) from
universal joint so protractor base sits flat.
(1) Rotate the shaft until transmission/transfer J9216-9
case output yoke bearing is facing downward.
A l w a y s m a k e m e a s u r e m e n t s from front to Fig. 6 Propeller Shaft Angle Measurement (C)
rear.
16 - 6 PROPELLER SHAFTS •
(4) Subtract smaller figure from larger (C minus
A) to obtain transmission OUTPUT OPERATING
ANGLE.
(5) Rotate propeller shaft 90 degrees and place In
clinometer on pinion yoke bearing parallel to the
shaft (Fig. 7). Center bubble in sight glass and record
measurement.
T h i s m e a s u r e m e n t will give y o u t h e p i n i o n
shaft o r I N P U T YOKE A N G L E (B).
(6) Subtract smaller figure from larger (C minus
B) to obtain axle INPUT OPERATING ANGLE.
Refer to rules given below and the example in (Fig.
8) for additional information.
• Good cancellation of u-joint operating angles (with
in 1°)
• Operating angles less than 3°
• At least 1/2 of one degree continuous operating
(propeller shaft) angle
7663
(J-23498A) J9216-12
Fig. 7 Rear (input) Angle Measurement (B)
Horizontal Level
(A) Output Yoke = 3.0° 4.9° (B) Axle Input Yoke = 3.2° Q r 4.9°
r
(C) Prop. Shaft = 4.9° ° -3.0° (C) Prop. Shaft = 4.9° -3.2°
Transmission Output 1.9° Axle Input 1.7°
Operating Angle Operating Angle
Trans. Output Operating Angle 1.9°

Axle Input Operating Angle -1.7°
Amount of U-Joint Cancellation 0.2° J9316-3
Fig. 8 Universal Joint Angle Example

ADJUSTMENT AT AXLE WITH LEAF SPRINGS two-piece prop shaft. Shudder can be decreased by
Adjust the pinion shaft angle a t the springs with lowering the center bearing in 1/4 inch increments
tapered shims (Fig. 9). Install tapered shims between with shim stock or fabricated plates (Fig. 10). Plate
the springs and axle pad to correct the angle. Refer stock must be used to maintain compression of the
to Group 3, Rear Suspension and Axle for additional rubber insulator around the bearing. Do not use
information. washers. Replace t h e original bolts with the appro
priate increased length bolts.
Fig. 9 Angle Adjustment at Leaf Springs

ADJUSTMENT AT CENTER BEARING WITH
TWO-PIECE SHAFT
Drive away shudder is the vibration t h a t occurs at
first acceleration from a stop. Shudder vibration usu
J9316-25
ally peaks at the engines highest torque output.
Shudder is a symptom associated on vehicles using a Fig. 10 Angle Adjustment at Center Bearing
PROPELLER SHAFT REPLACEMENT
PRECAUTIONS TRANSFER
Use exact replacement hardware for attaching the
propeller shafts. Exact replacement will ensure safe
operation. The specified torque must always be ap
plied when tightening the fasteners.
Mark the propeller shaft yoke and axle or trans
mission yoke before service (Fig. 1). This will assure
correct phasing and eliminate possible vibration.
REFERENCE MARKS
J9316-2
Fig. 1 Reference Marks on Yokes
C A U T I O N : D o not allow the propeller shaft to drop
or hang from either universal joint during removal.
Attach it to the vehicle underside with wire to pre Fig. 2 Front Propeller Shaft
vent damage to the universal joints. INSTALLATION
(1) Position the propeller shaft with the yoke ref
erence m a r k s aligned. Install the propeller shaft
C A U T I O N : Protect the machined, external surface of
(Fig. 2).
the slip yoke from damage after propeller shaft re
Replacement U-joint straps and bolts must be
moval. If damaged, the transmission extension seal
installed.
could be damaged.
(2) Tighten the U-joint strap bolts at the pinion
shaft to;
FRONT • Gasoline engines — to 19 N*m (14 ft. lbs.) torque.
• Diesel engines — to 29 N*rri (21 ft. lbs.) torque.
REMOVAL Tighten the transfer case bolts to 88 Nnn (65 ft.
(1) Shift the transmission and transfer case (if ap lbs.) torque.
plicable) to their Neutral positions. Raise the vehicle. (3) Install skid plates (if equipped), refer to Group
Remove skid plates (if equipped) from frame, refer to 13, Frames. Lower the vehicle.
Group 13, Frames.
(2) Scribe alignment marks on the yokes at the REAR
transfer case. Place m a r k s at the pinion shaft and at REMOVAL
each end of the propeller shaft. These m a r k s will be (1) Shift the transmission and transfer case (if ap
used for installation reference (Fig. 2). plicable) to their Neutral positions. Raise the vehicle.
(3) Remove the U-joint strap bolts at the pinion (2) Scribe alignment marks at the pinion yoke and
shaft yoke. at each end of the propeller shaft.
(4) Remove bolts from transfer case yoke and re (3) Remove the U-joint strap bolts at the pinion
move the propeller shaft. shaft yoke (and transfer case).
(4) Slide the slip yoke off of the transmission/
transfer case output shaft and remove the propeller
shaft (Fig. 3).
• PROPELLER SHAFTS 16-9
SLIDING (4) Scribe alignment marks at t h e frame cross-

member for reference. Remove the bolts t h a t attach
the center bearing to the support bracket (Fig. 4).
SCREW
19 N-m
(14 ft-lbs). CLAMP J9216-6
Fig. 3 Rear Propeller Shaft

INSTALLATION
(1) Slide the slip yoke on the transmission/transfer
case output shaft. Align the installation reference Fig. 4 Center Bearing Support
marks at the axle yoke and install the propeller (5) Slide the slip yoke off of the transmission/
shaft (Fig. 3). transfer case output shaft and remove the propeller
R e p l a c e m e n t U-joint s t r a p s a n d b o l t s m u s t b e shaft.
installed.
(2) Tighten the U-joint strap bolts to 19 Nnn (14 ft. INSTALLATION
lbs.) torque. (1) Slide t h e slip yoke on the transmission/transfer
(3) Lower the vehicle. case output shaft. Align the installation reference
m a r k s a t the axle yoke. Install the propeller shaft.
R E A R - T W O PIECE (2) Align and install the center bearing to the sup
port bracket. Install the bolts and tighten to 68 Nnn
REMOVAL (50 ft. lbs.) torque.
(1) Shift the transmission and transfer case (if ap R e p l a c e m e n t U-joint s t r a p s a n d b o l t s m u s t b e
plicable) to their Neutral positions. Raise the vehicle. installed.
(2) Scribe alignment m a r k s at t h e pinion yoke and (3) Tighten the U-joint strap bolts to;
at each end of the propeller shaft. • Gasoline engine — to 19 Nnn (14 ft. lbs.) torque.
(3) Remove the universal joint strap bolts at the • Diesel engine — to 34 Nnn (25 ft. lbs.) torque.
pinion shaft yoke. (4) Lower the vehicle.
UNIVERSAL JOINT REPLACEMENT
PRECAUTIONS (5) Set the yoke in an arbor press or vise with a large
It is very important to p u t reference marks on t h e socket beneath it. Position the yoke with the lube fit
yokes before removal or component service (Fig. 1). ting pointing up (if equipped). Place a smaller socket on
This will ensure correct phasing. the upper bearing assembly and press it through to re
lease the lower bearing assembly (Fig. 3).
REFERENCE MARKS
J9316-2
Fig. 1 Reference Marks on Yokes

SINGLE CARDAN
REMO VAL/DISASSEMBL Y
Single cardan universal joints a r e not serviceable.
If worn or leaking, they must be replaced as a unit. J9316-2V
(1) Remove t h e propeller shaft. Refer to Propeller
Shaft Replacement in this group. Fig. 3 Press Out Bearing
(2) Paint or score alignment marks o n t h e (6) If the bearing assembly will not pull out by hand
y o k e s a n d propeller shaft for installation refer after pressing, tap the base of the lug near it to dis
ence. lodge.
(3) Using a soft drift, t a p t h e outside of the bear (7) To remove t h e opposite bearing, t u r n t h e yoke
ing assembly to loosen snap ring. over and straighten t h e cross in t h e open hole. Then
(4) Remove snap rings from both sides of yoke carefully press the end of the cross until the remain
(Fig. 2). ing bearing can be removed (Fig. 4).
C A U T I O N : If the c r o s s or bearing assembly are

cocked when being pressed, the bearing assembly
will score the walls of the yoke bore and ruin the
yoke.

(1) Clean all t h e universal joint yoke bores with
cleaning solvent and a wire brush.
(2) Inspect t h e yokes for distortion, cracks and
worn bearing assembly bores.
ASSEMBL Y/INSTALLA TION

(1) Apply extreme pressure (EP) N.L.G.I. Grade 1
or 2 grease to aid in installation.
(2) Position t h e cross in t h e yoke with its lube fit
J9316-19 ting (if equipped) pointing up (Fig. 5).
(3) Place a bearing assembly over t h e trunnion
Fig. 2 Remove Snap Ring and align it with t h e cross hole (Fig. 6). Keep t h e
BEARING
J9316-24
(7) Install the propeller shaft. Refer to Propeller
Fig. 4 Press Out Remaining Bearing Shaft Replacement in this group.
CROSS
DOUBLE CARDAN (CV)
REMOVAL/DISASSEMBL Y
Single cardan universal joints are not serviceable.
If worn or leaking, they must be replaced as a unit.
(1) Remove the propeller shaft. Refer to Propeller
Shaft Replacement in this group.
(2) Paint or score alignment m a r k s on the
y o k e s a n d propeller shaft for installation refer
ence.
(3) Remove all the bearing assembly snap rings
(Fig. 7).
J9316-22
Fig. 5 Install Cross In Yoke

needle bearings upright in the bearing assembly. A
needle roller lying at the bottom will prevent proper
assembly.
(4) Press the bearing assembly into the cross hole
enough to install a snap ring. Install a snap ring.
(5) Repeat steps 3 and 4 to install the opposite
bearing assembly. If the joint is stiff, strike the yoke
with a soft hammer to seat tjie needle bearings. In
stall a snap ring.
(6) Add grease to lube fitting (if equipped).
J9316-5
Fig. 7 Remove Snap Rings
16 - 12 PROPELLER SHAFTS •
(4) Press the bearing assembly partially from the (6) Flip assembly and repeat steps 4 and 5 for re
outboard side of the center yoke, enough to grasp by moving the opposite side bearing. This will then al
vise jaws (Fig. 8). Be sure to remove any lube fittings low removal of the cross centering kit assembly and
t h a t may interfere with removal. spring (Fig. 10).
f — ^ Fig. 10 Remove Centering Kit

J9316-8
J9316-6
Fig. 8 Press Out Bearing (7) Press the remaining bearing assemblies out the
other cross as described above to complete the disas
(5) Grasp the protruding bearing by vise jaws. Tap sembly.
the tube yoke with a mallet and drift to dislodge
from the yoke (Fig. 9). CLEANING AND INSPECTION
(1) Clean all the U-joint yoke bores with cleaning
solvent and a wire brush.
(2) Inspect the yokes for distortion, cracks and
worn bearing assembly bores.
ASSEMBLY/INSTALLATION
During installation, ensure that the spiders
a n d y o k e s are aligned to the reference marks.
(1) Fit a cross into the tube yoke (Fig. 11).
J9316-7
Fig. 9 Remove Bearing From Yoke
J9316-9
Fig. 11 Install Cross In Yoke
(2) Place a bearing assembly in a tube yoke hole (4) Flip the tube yoke and bearing assembly instal
and over a trunnion. Keep the needle bearings up lation on the opposite trunnion. Install a snap ring
right in the bearing assembly (Fig. 12). A needle (Fig. 14).
roller lying at the bottom will prevent proper assem
bly. Be sure to remove any lube fittings t h a t may in
terfere with removal.
J
931
6-
12
Fig. 14 Press In Bearing Assembly

(5) Fit the center yoke on the remaining two trun
Fig. 12 Install Bearing Assembly nions and press bearing assemblies in place, both
(3) Press the bearing assembly in place and install sides (Fig. 15). Install a snap ring.
a snap ring (Fig. 13).
J
931
6-
13
Fig. 15 Install Center Yoke
Fig. 13 Press in Bearing Assembly

16-14 PROPELLER SHAFTS
(6) Install the centering kit assembly inside the (8) Press the remaining two bearing assemblies
center yoke making sure the spring is in place (Fig. into place and install snap rings (Fig. 18).
16). Align the lube fitting on the centering kit with
the lube fitting on the installed cross.
1
I J9316-16
J9316-14 Fig. 18 Press In Bearing Assembly

(9) Tap the snap rings to allow them to set into the
Fig. 16 Instail Centering Kit
grooves (Fig. 19).
(7) Place two bearing assemblies on the remaining
cross (opposite sides). Fit the open trunnions into the
center yoke holes and the bearing assemblies into
the centering kit (Fig, 17). Align the lube fitting on
the cross with the other two lube fittings.
J9316-17
J9316-15 Fig. 19 Seat Snap Rings In Groove
Fig. 17 Install Remaining Cross

PROPELLER SHAFTS 16 - 15
(10) Check for proper assembly. Flex t h e CV joint

beyond center, it should snap over-center in both di
rections when correctly assembled (Fig. 20).
(11) Add grease to all three lube fittings.
(12) Install the propeller shaft. Refer to Propeller
Shaft Replacement in this group.
J9316-18
Fig. 20 Check Assembly
PROPELLER SHAFTS A N D U - J O I N T S
DESCRIPTION TORQUE
Center Bearing to Support
Bracket (Two Piece Shaft) 68 N-m (50 ft. lbs.)
Double Cardan to Transfer
Case Yoke Bolts 88 N-m (65 ft. lbs.)
Prop Shaft to Axle Yoke
Screws (Gas Engine) 19 N-m (14 ft. lbs.)
Prop Shaft to Axle Yoke
Screws (Diesel Engine) 29 N-m (21 ft. lbs.)
J9216-24
• STEERING 19-1
STEERING
CONTENTS
page page
GENERAL INFORMATION 1 STEERING COLUMN 3i

POWER STEERING PUMP 11 STEERING LINKAGE 17
POWER STEERING SYSTEM DIAGNOSIS . . . . . 2 TORQUE SPECIFICATIONS 40
RECIRCULATING BALL POWER STEERING GEAR . 20
GENERAL INFORMATION
STEERING SYSTEM COMPONENTS RECIRCULA TING-BALL POWER STEERING
Dodge T r u c k s use a p o w e r assisted recirculating- GEARS
ball t y p e s t e e r i n g g e a r (Fig. 1). T h e g e a r i s u s e d w i t h The recirculating ball system acts as a rolling
four w h e e l d r i v e a n d t w o w h e e l drive v e h i c l e s . thread between t h e worm shaft and rack piston. The
Power steering systems u s e ; worm shaft is supported by a thrust bearing a t t h e
• S t e e r i n g gear lower end and a bearing assembly a t t h e upper end.
• Steering linkage When t h e worm shaft is turned t h e rack piston
• Pressure and return fluid hoses and fittings moves. The rack piston teeth mesh with t h e pitman
• Belt driven hydraulic steering pump with fluid (sector) shaft. Turning the worm shaft turns t h e pit
reservoir man shaft, which turns the steering linkage.
The steering gears can be adjusted and internally
serviced.
An identification code on the upper adjustment
cover designates t h e ratio.
• Code XS designates 13-16:1 ratio used in Dodge
Ram Truck vehicles
POWER STEERING PUMP

Hydraulic pressure is provided by a belt driven
power steering pump. The power steering pump is a
constant flow rate and displacement, vane-type
pump. The internal parts t h a t are inside the housing
operate submerged in fluid. The flow control orifice is
part of the pressure line union. The pressure relief
valve inside t h e flow control valve limits t h e pump
pressure.
The power steering pump is connected to the steer
ing gear via t h e pressure hose and t h e return hose.
The pump shaft h a s a pressed-on pulley t h a t is belt
driven by t h e crankshaft pulley.
J9219-65 Trailer tow option vehicles are equipped with a
power steering pump oil cooler. The oil cooler is
Fig. 1 Power Steering Systems mounted to t h e engine block under t h e steering
The steering linkage consists of a pitman a r m , pump cast aluminum mounting bracket.
idler arm, tie rods, and center link. Adjustment The power steering pump on t h e D O D G E T U R B O
sleeves are used on t h e tie rods for toe and steering D I E S E L engine is bolted onto t h e rear of t h e vac
wheel alignment. For additional wheel alignment in u u m pump. The pump is driven by t h e accessory
formation refer to Group 2, Front Suspension. drive through a common shaft.
19 - 2 STEERING •
Dodge R a m T r u c k p o w e r s t e e r i n g p u m p s a r e
not interchangeable with p u m p s installed i n
o t h e r vehicles.
The Saginaw P-Series pump (Fig. 2) is used in
Dodge Ram Truck vehicles.
STEERING COLUMNS
Two general types of steering columns are installed
on Dodge Ram Truck vehicles: a fixed, non-tilt col
umn and a tilt column.
The ignition key/lock cylinder and the ignition
switch are located in the steering column. When in
the LOCK position, the ignition switch and the steer
ing shaft cannot be operated. The lock mechanism
also prevents operation of the automatic trans, gear
shift mechanism.
Fig. 2 Saginaw P-Series Pump
The intermediate shaft is attached to t h e gear and
Both types of steering columns have anti-theft pro
column shaft with universal joints.
visions. They are energy-absorbing (collapse from im
pact in the event of a front-end collision).
POWER STEERING S Y S T E M D I A G N O S I S
PUMP PRESSURE TEST (7) Gauge should read below 862 k P a (125 psi), if
The following procedure can be used to test the op above, inspect the hoses for restrictions and repair as
eration of the power steering system on t h e vehicle. necessary. The initial pressure should be in the
(1) Check belt tension and adjust as necessary. range of 345-552 k P a (50-80 psi).
(2) Disconnect high pressure hose at gear or pump. C A U T I O N : The following test procedure involves
Use a container for dripping fluid. testing maximum pump pressure output and flow
(3) Connect Gauge C-3309-E to both hoses using control valve operation. D o not leave valve closed
adapter fitting (Fig. 1). Connect spare pressure hose for more than five seconds a s the pump could be
to gear or pump. damaged.
SPECIAL
(8) Close valve fully three times and record high
est pressure indicated each time. All three readings
must b e a b o v e specifications a n d within 345 k P a
(50 psi) of e a c h other.
9 Pressures above specifications but not within 345
kPa (50 psi) of each other, replace pump.
• Pressures within 345 k P a (50 psi) of each other
but below specifications, replace pump.
C A U T I O N : D o not force the pump to operate against

the stops for more than 2 to 4 seconds at a time be
cause, pump damage will result.
1 Pressure Hose to Steering Gear
2 Shut-Off Valve (9) Open the test valve, t u r n steering wheel ex
3 Pressure Hose From Pump J9219-44 treme left and right positions against the stops.
Record the highest indicated pressure at each posi
Fig. 1 Pressure Test Gauge tion. Compare readings to specifications. If highest
(4) Open t h e test valve completely. output pressures are not the same against either
(5) Start engine and let idle. stop, the gear is leaking internally and must be re
(6) Check fluid level, add fluid as necessary. paired.
The steering p u m p relief pressure for all en
gines is 1400 p.s.i. ± 50.
• STEERING 19 - 3
PUMP LEAKAGE DIAGNOSIS
9119-1
19 - 4 STEERING
POWER STEERING SYSTEM DIAGNOSIS
P U M P NOISI
There is some noise in all power steering systems. One of the most common is a hissing sound evident at standstill parking. Hiss is
a high frequency noise similar to that experienced while slowly closing a water tap. The noise is present in every valve and results
from high velocityfluidpassing valve orifice edges. There is no relationship between this noise and performance of the steering.
Hiss may be expected when steering wheel is at end of travel or when slowly turning at standstill.
CONDITION POSSIBU CAUSI CORRICriON
OBJECTIONALHISSOR 1. Noisy valve in gear 1. Check for proper seal between steering
WHISTLE column coupling and dash seal.
Ensure steering column lower coupling
has no metal-to-metal contact
within the coupling by performing an
electrical continuity check. (Remove
coupling for check.)
If hiss is still extremely objectionable,
replace steering gear.
RATTLE OR CLUNK 1. Gear loose on front crossmember 1. Check gear-to-crossmember mounting

bolts. Tighten to specification.
2. Crossmember-to-frame bolts or studs loose 2. Torque bolts and studs to specifications.
3. Tie rod looseness (outer or inner) 3. Check tie rod pivot points for wear.
Replace if necessary.
4. Pressure hose touching other parts of vehicle 4. Adjust hose to proper position by
loosening, repositioning, and retightening
fitting. Do not bend tubing.
5. Noise internal to gear 5. Replace gear.
CHIRP OR SQUEAL (IN 1. Loose belt 1. Adjust belt tension to specification.

THE AREA OF PUMP)
PARTICULARLY
NOTICEABLE AT FULL
WHEEL TRAVEL A N D
DURING STANDSTILL
PARKING
9119-2
• STEERING 19-5
PUMP GROWL
Pump growl results from the development of high pressure fluid flow. Normally this noise should not be high enough to be
objectionable. Abnormal situations, such as a low oil level causing aeration or hoses touching the vehicle body, can create a noise
level that could bring complaints.
WHINE OR GROWL 1. Low fluid level 1. Fill to proper level and perform leakage
(PUMP NOISE) diagnosis. (Recheck after system is free
of aeration.)
2. Hose touching vehicle body or frame 2. Reposition hose. Replace hose if tube
ends are bent.
3. Extreme wear of pump internal parts 3. Replace pump andflushsystem.
SUCKING AIR SOUND 1. Loose return line clamp 1. Tighten or replace clamp.
2. Inspect connection and replace o-ring as
2. Missing O-ring on hose connection required.
3. Fill to proper level and perform leakage
3. Low fluid level diagnosis.
4. Inspect and replace reservoir as required.
4. Air leak between reservoir and pump
SQUEAK OR RUB SOUND 1. Sound from steering column 1. Check for squeak in steering column.
Inspect for contact between shroud
intermediate shaft, column, and wheel.
(Realign if necessary.)
2. Sound internal to steering gear 2. Replace gear.
SCRUBBING/KNOCKING 1. Incorrect tire size 1. Verify tire size is the same as originally
supplied.
2. Check clearance between tires and other
vehicle components, through full travel 2. Correct as necessary.
3. Check for interference between steering gear
and other components 3. Correct as necessary.
4. Incorrect gear supplied
4. Replace gear.
9119-3
19 - 6 STEERING •
B I N D S STICKS S E I Z E D
CATCHES, STICKS IN 1. Low fluid level 1. Fill to proper level and perform leakage
CERTAIN POSITIONS OR diagnosis.
DIFFICULT TO TURN 2. Tires not properly inflated 2. Inflate tires to proper pressure.
3. Lack of lube in ball joints 3. Lubricate where possible.
4. Lack of lube in outer tie rod ends 4. Lubricate where possible.
5. Loose pump belt 5. Tighten or replace belt.
6. Faulty pump flow control (Verify cause using 6. Replace pump.
Pump Test Procedure)
7. Excessive friction in steering column or 7. Correct condition. (See Steering Column
intermediate shaft Service Procedure.)
8. Steering column coupling binding 8. Realign as necessary.
9. Excessive friction in gear 9. Replace gear.
SHAKE SHUDDER VIBRATION
VIBRATION OF THE 1. Air in the power steering system 1. Steering shudder can be expected in new
STEERING WHEEL A N D / vehicles and vehicles with recent steering
OR DASH DURING DRY system repairs. Shudder should improve
PARK OR LOW SPEED after the vehicle has been driven several
STEERING MANEUVERS weeks.
2. Tires not properly inflated 2. Inflate tires to proper pressure.
3. Excessive engine vibration 3. Make sure that engine is running properly.
4. Faulty accessory drive belt tensioner. 4. Check dynamic belt tensioner for
(Poly-V belt systems only) abnormal vibration. (See Drive Belt
Adjustments.)
5. Overcharged air conditioner 5. Check air conditioning pump head
pressure. (See Air Conditioning
Refrigerant System Diagnosis.)
9119-4
• STEERING 19 - 7
L O W ASSIST, N O ASSIST, O R H A R D STEERING
STIFF, HARD TO TURN, 1. Tires not properly inflated 1. Inflate tires to proper pressure.
SURGES, MOMENTARY 2. Low fluid level 2. Add power steering fluid as required and
INCREASE IN EFFORT perform leakage diagnosis.
WHEN TURNING
3. Loose belt 3. Tighten or replace belt.
4. Lack of ball joint lubrication 4. Lubricate or replace as required.
5. Low pressure pump (Verify using Pump Test 5. Verify cause using Pump Test Procedure.
Procedure) Replace pump if necessary.
6. High internal leak gear 6. Check steering system using test
procedure. If steering gear is at fault,
replace steering gear.
P O O R RETURN T O CENTER
STEERING WHEEL DOES 1. Tires not properly inflated 1. Inflate tires to proper pressure.
NOT WANT TO RETURN 2. Improper front wheel alignment 2. Check and adjust as necessary.
TO CENTER POSITION
3. Lack of lubrication in ball joint 3. Replace as required or lubricate.
4. Steering column U-joints misaligned 4. Realign steering column U-joints.
5. Mispositioned dash cover 5. Reposition dash cover.
To evaluate items 6 and 7, disconnect the
intermediate steering shaft. Turn the steering
wheel and listen for internal rubbing in
column.
6. Steering wheel rubbing 6. Adjust covers.
7. Tight steering shaft bearings 7. Replace bearings.
8. Excessive friction coupling universal joint 8. Replace U-joints.
9. High friction in the steering gear 9. Replace steering gear.
91195
19 - 8 STEERING
LOOSE STEERING
EXCESSIVE WHEEL 1. Air in system 1. Add fluid.

KICKBACK OR TOO 2. Gear loose on crossmember 2. Check gear to crossmember mounting
MUCH STEERING WHEEL bolts. Tighten to specification,
PLAY
3. Worn/broken intermediate shaft 3. Check for worn universal joint ond broken
isolator. Replace intermediate shaft if
worn.
4. Free play in steering column 4. Check and replace as required.
5. Loose ball joints 5. Check and replace as required.
6. Front wheel bearings loose or worn 6. Tighten hub nut or replace with new parts
as necessary.
7. Loose outer tie rod ends 7. Check and replace as required.
8. Loose inner tie rod ends 8. Replace gear.
9. Defective steering gear rotary valve 9. Replace gear.
V E H I C L E L E A D S T O THE S I D E
WHEEL DOES NOT 1. Radial tire lead 1. Rotate tires as recommended in Tire
WANT TO RETURN TO Service.
CENTER POSITION 2. Alignfrontend as recommended in
2. Front end misaligned
Wheel Alignment Service Procedure.
3. Wheel braking 3. Check for dragging brakes as directed in
Brake Service Procedure.
4. Unbalanced steering gear valve. (If this is the 4. Checking for pull with outer tie rod end
cause, the steering efforts will be very light in disconnected. If verified, replace gear.
direction of lead and heavier in the opposite
direction)
9119-6
• STEERING 19-9
FLUID LEAK
LOW FLUID LEVEL WITH: 1. Overfilled reservoir 1. Adjust fill level.

• N O VISIBLE SIGNS OF 2. Hose connections at pump or gear 2. Check for loose fittings and tighten to
LEAKS O N THE specifications. If fittings are tight, examine
STEERING GEAR, for damaged or missing O-ring and
PUMP, O N FLOOR, OR replace as required.
ANYWHERE ELSE 3. Identify location of leak and repair or
3. Pump or gear leak
LOW FLUID LEVEL WITH: replace as indicated in Power Steering
• VISIBLE LEAK O N
Pump and/or Gear sections of this
STEERING GEAR,
service manual.
PUMP, FLOOR, OR
ANYWHERE ELSE
F O A M Y O R MILKY FLUID
AERATION A N D 1. Air leaks 1. Check for air leak as described under

OVERFLOW O F FLUID sucking air and correct.
2. Low fluid level 2. Extremely cold temperatures may cause
system aeration if the oil level is low.
Add fluid as required.
3. Cracked pump housing 3. Remove pump from vehicle and separate
reservoir from housing. Check expansion
plug and housing for cracks. Replace
pump as required.
4. Water contamination 4. Drain and refill fluid if there is evidence
of contamination.
9119-7
19 - 10 STEERING •
GEAR LEAKAGE DIAGNOSIS
1. SIDE C O V E R LEAK - T O R Q U E SIDE 3 . PRESSURE LINE FITTING - TOR

C O V E R B O L T S T O 6 0 N T T I (45 FT. QUE THE HOSE FITTING NUT TO
LBS.). R E P L A C E T H E S I D E C O V E R 2 7 N.m ( 2 0 FT. LBS.). IF LEAKAGE
SEAL IF T H E L E A K A G E PERSISTS. PERSISTS, REPLACE THE SEAL.
2. ADJUSTER P L U G SEAL - REPLACE 4. PITMAN SHAFT SEALS - REPLACE
T H E ADJUSTER P L U G SEALS. THE SEALS.
5. T O P C O V E R SEAL - REPLACE T H E
SEAL. J9219-29
• STEERING 19 - 11
POWER STEERING PUMP
INDEX
page page
Power Steering Hose 11 Pump Replacement—Gasoline Engine . . . . . . . . . 14
Power Steering Pump—Initial Operation 15 Pump Reservoir 15
Pump Pulley 15 Service Information . . . . . . . . . . . . . . . . . . . . . . . 11
Pump Replacement—Diesel Engine 12
SERVICE INFORMATION
The power steering pump internal components are
not serviced or adjusted. If a malfunction or an inter
nal fluid leak occurs, the complete unit must be re
placed.
POWER STEERING HOSE

Max. cool, vehicles are equipped with a power
steering auxiliary fin oil cooler. The oil cooler is
mounted to the engine block under the steering
pump (Fig. 2).
Cap hose open ends and pump/steering gear fit
tings to prevent entry of foreign material.
WARNING; P O W E R STEERING F L U I D ( A N D P U M P
COMPONENTS) A N D T H E E X H A U S T S Y S T E M C A N
BE EXTREMELY H O T IF T H E E N G I N E H A S B E E N
RECENTLY OPERATING. D O NOT S T A R T THE E N
GINE WITH A N Y L O O S E O R D I S C O N N E C T E D
H O S E S . DO N O T A L L O W T H E H O S E S T O T O U C H A
HOT EXHAUST M A N I F O L D OR T H E C A T A L Y T I C
CONVERTER.
Fig. 1 Power Steering Hose Diesel Engine
REMOWAL
SCREW
(1) Remove fasteners from hose retaining brackets
at all locations.
(2) Disconnect pressure and return hose from the
steering gear. Drain the fluid from pump and reser
voir (Fig. 1, 2).
(3) If applicable, remove cooler bracket fasteners
from block.
(4) Disconnect pressure and return hose from the
pump. Remove hoses from vehicle (Fig. 1, 2).
INSTALLATION
(1) Wipe hose ends, pump and gear unions clean.
(2) Connect hose at steering gear and pump. Route
hose while avoiding extreme bends or kinks. T h e
h o s e m u s t b e k e p t a w a y from e x h a u s t s y s t e m
c o m p o n e n t s . Do not distort hose tube ends by bend
ing, kinking or over tightening.
(3) Tighten cooler bracket fasteners to 41 N»m (30
ft. lbs.) torque (Fig. 1, 2).
(4) When used, the protective foam sleeves must be
properly positioned on the hose to prevent chafing.
Fig. 2 Power Steering Hose V/6, V/8
(5) Tighten fittings at pump and gear to 35 Nnn
(6) Install clamps on return hose on gear and
pump.
(7) After installation, inspect and test for fluid
leaks.
PUMP REPLACEMENT—DIESEL ENGINE

REMOVAL
(1) Place a drain pan under the power steering
pump.
(2) Disconnect and cap the vacuum and steering
pump hoses.
(3) Disconnect the electrical connector on the oil
pressure sender unit (Fig. 3). Remove sender unit
from engine block and plug hole in block.
Fig. 4 Oil Feed Line Removal/Installation
PUMP ENGINE BLOCK
Fig. 3 Oil Pressure Sending Unit

(4) Disconnect and cap the oil feed line from the
bottom of the vacuum pump (Fig. 4).
(5) Remove the lower bolt t h a t attaches the vacu
um/steering pump assembly to the engine block. Re
move the n u t from the steering pump attaching
bracket (Fig. 4).
Fig. 5 Pump Assembly Upper Bolt
(6) Remove upper bolt from the pump assembly
(Fig. 5). Remove the assembly from the engine (Fig. (11) Remove the two pump body spacers (Fig. 8),
6). for pump installation.
(7) Remove the gasket from the mounting surfaces
on engine block and pump assembly. INSTALLATION
(8) Drain the fluid from the steering pump. (1) Install the two pump body spacers (Fig. 8).
(9) Remove the steering pump to vacuum pump (2) Rotate the drive gear until the steering pump
bracket attaching nuts (Fig. 7). and vacuum pump drive dogs align. Install the steer
(10) Slide the steering pump from the bracket. Use ing pump onto the vacuum pump bracket. Use care
care not to damage the internal oil seal in the vac to avoid damaging the oil seal in the vacuum pump
u u m pump (Fig. 8). during installation. T h e s t e e r i n g p u m p h o u s i n g
PUMP BRACKET
SPACERS J9119-69
Fig. 8 Steering Pump Removal/Installation

Fig. 6 Pump Assembly Removal/Installation
PUMP
Jf 119-78
Fig. 9 Steering/Vacuum Pump Assembly
Fig. 7 Bracket Nut Removal/Installation
the block bracket. Tighten the pump-to-engine block
a n d spacers m u s t mate completely with the vac
attaching bolts to 77 N*m (57 ft. lbs.) torque.
u u m p u m p b r a c k e t (Fig. 9).
(6) Install the steering pump to attaching bracket
(3) Install the three (3) vacuum pump bracket to
n u t and tighten to 24 N*m (18 ft. lbs.) torque.
steering pump nuts. Tighten to 24 N«m (18 Ft. lbs.)
(7) Remove plug and install the oil pressure send
torque.
ing unit and electrical connector.
(4) Position a new gasket on the vacuum pump as
(8) Install the oil feed line to the vacuum pump.
sembly, use sealer if necessary to retain the gasket.
Tighten the oil line connection to 7 N»m (60 in. lbs./
(5) Align and install the pump assembly on the en
5 ft. lbs.) torque.
gine. Ensure the steering pump stud is inserted into
(9) Install the fluid hoses to the power steering lower bracket to engine block bolts. Pivot the pump
pump, Tighten the pressure fitting at the pump to 30 assembly past the coolant tube. Remove the upper
N*m (22 ft. lbs.) torque. stud. Remove upper bolt from cylinder head. The
(10) Install and clamp the hose on the vacuum steering pump and mounting bracket will be re
pump. moved from engine as an assembly.
(11) Fill the reservoir with power steering fluid (4) Remove the pump pulley, refer to the procedure
only. If necessary, refer to P u m p Initial O p e r a t i o n below. This will allow access to the pump attaching
for detailed instructions. screws.
(12) Start and r u n the engine. Check the operation (5) Remove the bracket to pump attaching screws
of the brakes, if necessary refer to Group 5, Brakes (Fig. 11).
for additional information.
PUMP REPLACEMENT—GASOLINE ENGINE

REMOVAL
WARNING: D O NOT REMOVE THE WATER PUMP

COOLANT TUBE UNLESS THE COOLANT SYSTEM
HAS B E E N DEPRESSUR1ZED A N D DRAINED*
WARNING: D O NOT ATTEMPT TO REMOVE THE

PUMP WITHOUT REMOVING T H E BELT FIRST. T H E
AUTOMATIC T E N S I O N E R I S U N D E R A HIGH
SPRING LOAD.
(1) Remove the serpentine drive belt. Rotate ten

sioner clock-wise and hold in place, and remove belt
(Fig. 10).
Fig. 11 Pump Removal/Installation

INSTALLATION
(1) Install the bracket to pump mounting screws
(Fig. 11). Tighten to 54 N-m (40 ft. lbs.).
(2) Install the pump pulley, refer to the procedure
below.
(3) Position the steering pump (with pulley) and
mounting bracket on the engine block (Fig. 11). In
stall the upper stud and bolt in bracket. Pivot the
pump down past the coolant tube. Install the lower
bolts in bracket (Fig. 11).
(4) Install the bracket to engine block attaching
bolts (Fig. 11). Tighten the bolts and n u t to 41 N*m
(30 ft. lbs.).
(5) Connect the fluid hoses to the pump.
(6) Install the serpentine drive belt. Rotate ten
sioner clock-wise and hold in place, slip the belt over
the pulleys. Refer to Group 7, Cooling for belt rout
Fig. 10 Serpentine Belt Removal/Installation ing.
(2) Clamp the fluid return hose and disconnect the C A U T I O N : D o not use automatic transmission fluid
hoses from t h e power steering pump. Cap the fit to fill the reservoir.
tings.
(3) Remove battery ground cable and nut at stud. (7) Fill the reservoir with power steering fluid
Unthread stud from cylinder head, do not remove only. If necessary, refer to P u m p Initial O p e r a t i o n
from bracket. Loosen upper bracket bolt. Remove the for detailed instructions.
# _ , STEERING 19-15
PUMP PULLEY
REMOVAL
(1) Remove the pulley with Puller C-4333 (Fig.
12).
Fig. 13 Pulley Installation (Typical)

(3) Remove O-ring seals from housing and reser
voir (Fig. 14).
(4) Remove flow control valve and spring from
housing.
Fig. 12 Pulley Removal (Typical)
INSTALLATION
D o n o t hammer o n pulley b e c a u s e t h i s will Clean all parts before installation. Lubricate
damage it a n d the pump. n e w O-ring seals with MOPAR® P o w e r Steering
(2) Replace pulley if bent, cracked, or loose. Fluid or a n equivalent product.
(1) Install flow control valve and spring (Fig. 15).
INSTALLATION
(2) Install new O-ring seals in housing (Fig. 15).
(1) Install the pulley with Installer C-4063-A (Fig. Tighten mounting studs to 48 N«m (35 ft. lbs.)
13). Do not use the tool adapters. torque.
(2) Ensure t h a t the tool and the pulley remain (3) Install fitting in flow control valve bore.
aligned with the pump shaft. Prevent the pulley from Tighten the fitting to 75 N-m (55 ft. lbs.) torque.
being cocked on the shaft.
(3) Force pulley flush with the end of the shaft. POWER STEERING PUMP-INITIAL OPERATION
With Serpentine Belts; Run engine until warm (5
min.) and note any belt chirp. If chirp exists, move C A U T I O N : The fluid level should be checked with
pulley outward approximately 0.5 mm (0.020 in.). If engine off to prevent injury from moving compo
noise is increases, press on 1.0 mm (0.040 in.). Be nents. U s e only M O P A R ® Power Steering Fluid. D o
careful that pulley does not contact mounting not use automatic transmission fluid. D o not over
fill.
bolts.
Wipe filler cap clean, then check the fluid level.
PUMP RESERVOIR The dipstick should indicate FULL COLD when the
REMOVAL fluid is at normal temperature.
Discard all O-ring seals during disassembly, (1) Fill the pump fluid reservoir to the proper level
and let the fluid settle for at least two (2) minutes.
they are not re-usable.
(2) Start the engine and let r u n for a few seconds.
(1) Remove the filler cap and drain the fluid from
The turn the engine off.
reservoir before removing parts.
(3) Add fluid if necessary. Repeat the above proce
(2) Remove mounting studs and pressure fitting
dure until the fluid level remains constant after run
(Fig. 14). Rock reservoir by hand or use a soft face ning the engine.
mallet to remove. (4) Raise the front wheels off the ground.
EXPANSION PLUG - D O N O T REMOVE; RESERVOIR
IF DEFORMED OR DISLODGED,
REPLACE HOUSING CAP
HOUSING
FITTING
75 N-m
SEAL (55 FT. LBS.) 9119-9
Fig. 14 Pump and Reservoir

(5) Start the engine. Slowly t u r n the steering VALVE A N D
wheel right and left, lightly contacting the wheel SPRING
stops.
(6) Add power steering fluid if necessary.
(7) Lower the vehicle and t u r n the steering wheel
slowly from lock to lock.
(8) Stop the engine. Check the fluid level and refill
as required.
(9) If the fluid is extremely foamy, allow the vehi
cle to stand a few minutes and repeat the above pro
cedure.
J8919-101
Fig. 15 Flow Control Valve/Spring Installation

STEERING L I N K A G E
SERVICE INFORMATION IDLER
The tie-rod end ball stud seals should be inspected ARM
during all oil changes.
A damaged ball stud seal requires removal of the
seal. Inspect the tie-rod end ball stud at the throat
opening. Check for lubricant loss, contamination, ball
stud wear or corrosion. If these conditions exist, re
place the tie-rod. A replacement seal can be installed
if lubricant is in good condition. Otherwise, a com
plete replacement tie-rod end should be installed. Lu
bricate the tie-rod end with MOPAR® Multi-Mileage
Lubricant, or equivalent.
Use Puller C-3894-A for tie rod removal. Fail
ure to use this tool c o u l d d a m a g e the tie rod a n d
seal (Fig. 1).
DUTY
TIE ROD J9119-66
Fig. 2 Steering Linkage—2WD Vehicles
Fig. 1 Ball Stud Removal

STEERING LINKAGE—2WD
REMOWAL
(1) Remove the cotter pin and nut from the tie-rod.
(2) Remove the tie-rod end ball studs from steering
knuckle arms (Fig. 1 and 2),
Use care to avoid damaging the seals.
(2) Remove inner tie-rod ends (Fig. 1 and 2) from
center link.
(3) Remove idler arm ball stud from center link
(Fig. 2). Remove idler a r m bolts from frame side rail
(Fig. 2).
(4) Remove pitman arm ball stud from center link. Fig. 3 Pitman Arm Removal
(5) Mark the pitman arm and shaft positions for (2) Center steering gear to alignment m a r k s and
reference. Remove pitman arm with Puller C-4150 install pitman arm.
(Fig. 3). (3) Install the washer and retaining n u t on the pit
man shaft. Tighten the n u t to 251 N-m (185 ft. lbs.)
INSTALLATION
torque.
Replace all damaged or worn steering linkage com
(4) Install center link to ball studs (Fig. 2). Install
ponents.
(1) Position idler arm on the frame side rail. In and tighten retaining nuts to 88 N-m (65 ft. lbs.)
stall bolts/nuts and tighten to 88 N-m (65 ft. lbs.) torque. Install new cotter pins.
torque.
CAUTION: It i s possible to install the center link r e STEERING NUT
versed position. T h i s w i l l result i n i n c o r r e c t geome
try and interferences during vehicle jounce. Viewed
from t h e front of the vehicle, the c e n t e r l i n k ends
s h o u l d turn u p w a r d . Viewed from the s i d e of the v e
hicle, the ends s h o u l d t u r n toward the front of t h e
vehicle. The t i e - r o d ball s t u d s enter the center link
bores from the rear.
(5) Install tie-rod ends into center link (Fig. 2).

Tighten the nuts to 54 N»m (40 ft. lbs.) torque. In
stall new cotter pins.
(6) Insert tie-rod ends into steering knuckle arm
torque. Install new cotter pins. LINK FITTING J9119-12
(7) Remove the supports and lower the vehicle to
the surface. Adjust the wheel toe position (refer to Fig. 5 Drag Link
the Alignment Specifications chart within Group 2,
Front Suspension).
Position the clamp on the sleeve s o retaining
bolt is located o n the bottom side of the sleeve.
(8) After adjustment, tighten the tie-rod adjust
ment sleeve clamp bolt;
• Standard Duty— 25.4 N-m (225 in. lbs.) torque
• Heavy D u t y - 34 N-m (25 ft. lbs.) torque
STEERING LINKAGE—4WD VEHICLES

U s e Puller C-4150 to remove a drag link or pit
m a n arm. Failure to use this tool could c a u s e
d a m a g e to the seals (Fig. 4).
Fig. 6 Steering Arm Removal— Model 44 Axle

(3) Mark the pitman arm and shaft positions for
reference. Remove the nut and washer from the pit
m a n arm. Remove the pitman arm with Puller
C-4150 (Fig. 7).
(4) Remove the cotter pin and n u t from the tie-rod.
(5) Remove the tie-rod end ball studs from steering
knuckle arms (Fig. 1 and 2).
TOOL C-4150 U s e care to avoid damaging the seals.
R H 4 0 4
Fig. 4 Drag-Link Removal INSTALLATION

Replace all damaged or worn steering linkage com
REMOVAL ponents.
(1) Remove drag link tie-rod end ball studs from (1) Center steering gear to alignment marks and
steering arm and pitman arm (Fig. 4 and 5). install pitman arm.
U s e care to avoid damaging the seals. (2) Install the washer and retaining nut on the pit
(2) Remove the steering arm nuts and washers m a n shaft. Tighten the nut to 251 N-m (185 ft. lbs.)
(Fig. 6). Tap the steering arm to loosen it from the torque.
knuckle. Pry the steering arm upward and remove. (3) Position the steering arm on the knuckle. In
stall the washers and attaching nuts. Tighten the
nuts to 122 N-m (90 ft. lbs.).
POINT J9102-62
Fig. 8 Correct Drag Link installation

(5) Insert tie-rod ends into steering knuckle arm
torque. Install new cotter pins.
(6) Remove the supports and lower the vehicle to
the surface. Adjust the wheel toe position (refer to
the Alignment Specifications chart within Group 2,
Front Suspension).
Fig. 7 Pitman Arm Removal Position the clamp o n the sleeve so retaining
(4) Connect the drag-link ball studs to the steering bolt is located on the bottom side of the sleeve.
knuckle arm and pitman arm (Fig. 8). Install the re (7) After adjustment, tighten the tie-rod adjust
taining nuts and tighten to 81 N»m (60 ft. lbs.) ment sleeve clamp bolt to 34-41 N-m (25-30 ft. lbs.)
torque. Install new cotter pins. torque.
19-20 STEERING •
RECIRCULATING BALL POWER S T E E R I N G GEAR
INDEX
page page
Adjuster Plug Assembly Replacement 26 Pitman Shaft Seals and Bearing Replacement . . . 31
Check Valve Replacement 32 Rack Piston and Worm Shaft Replacement . . . . . 29
Gear Disassembly Information 23 Service Information 20
Housing End Plug 25 Steering Gear Adjustments 22
Pitman Shaft and Side Cover Replacement 25 Steering Gear Replacement 32
Pitman Shaft Seals — in Car Replacement . . . . . 20 Valve Replacement 27
SERVICE INFORMATION • Stop the engine.

A recirculating-ball steering gear is used with the (5) Remove backup washer and single lip seal with
power (assisted) steering system. The power steering screwdriver.
gear can be adjusted and internally serviced. (6) Inspect t h e housing for burrs and remove if
necessary. Inspect the pitman shaft seal surface for
PITMAN SHAFT SEALS - IN CAR REPLACEMENT roughness and pitting. If pitted replace shaft.
(1) Remove pitman a r m from gear. Refer to Pit (1) Install single lip seal with Installer or a suit
man Arm Removal in Steering Linkage. able size deep socket (Fig. 2).
(2) Clean exposed end of pitman shaft and housing. SPECIAL TOOL
Use a wire brush to clean the shaft splines. C4171
(3) Remove retaining ring with snap ring pliers TOP OF TOOL
(Fig. 1). FLUSH WITH
HOUSING
RETAINING RING
SPECIAL TOOL
BACKUP WASHER G4328
DOUBLE-UP SEAL
BACKUP WASHER
SINGLE-LIP SEAL
NEEDLE BEARING
J9119-42
Fig. 2 Pitman Shaft Seal Installation
(2) Coat the double lip seal and washer with
J8919-39
grease.
(3) Install the backup washer.
Fig. 1 Pitman Shaft Seals (4) Install the double lip seal.
C A U T I O N : U s e care not to score the housing bore (5) Install the backup washer.
when prying out seals and washers. (6) Install the retainer ring with snap ring pliers.
(7) Center the steering gear.
(4) Remove backup washer and double lip seal (8) Install t h e pitman arm. Refer to Pitman Arm
with screwdriver. Installation in Steering Linkage.
• Start t h e engine and t u r n the steering wheel fully (9) Add power steering fluid. Refer to Power Steer
to the LEFT to force out t h e seals and washers. ing Initial Operation.
19 - 22 STEERING — — — — •
STEERING GEAR ADJUSTMENTS
SERVICE INFORMATION
Adjusting the steering gear in the vehicle is NOT
recommended. Remove the gear from the vehicle
(Fig. 3) and mount in a vise. Drain the power steer
ing fluid and make the following adjustments in this
order:
• FIRST - worm thrust bearing preload
• SECOND - over-center preload adjustment
WORM THRUST BEARING PRELOAD

ADJUSTMENT
(1) Remove adjuster plug locknut (Fig. 4).
J8919-58
Fig. 5 Alignment Marking On Housing
Fig. 4 Loosening the Adjuster Plug Locknut

(2) Turn the adjuster in with Spanner Wrench
C-4381. Tighten the plug and thrust bearing in the
housing until firmly bottomed in housing.
(3) Place an index m a r k on the housing even with
one of the holes in adjuster plug (Fig. 5).
Fig. 6 Remarking The Housing
(4) Measure back (counterclockwise) 13 mm (0.50
in) and mark housing (Fig. 6). (3) Turn the pitman shaft adjuster screw back
(5) Rotate adjustment cap back (counterclockwise) (COUNTERCLOCKWISE) until extended, then t u r n
with spanner wrench until hole is aligned with the back in (CLOCKWISE) one full turn.
second mark (Fig. 7). (4) Place the torque wrench in the vertical position
(6) Install and tighten locknut to 109 N-m (80 ft. on the stub shaft. Rotate the wrench 45 degrees each
lbs.) torque. Be sure adjustment cap does not t u r n side of the center and record the highest rotational
while tightening the locknut. torque on center (Fig. 9).
(5) Turn the adjuster in until torque to t u r n stub
OVER-CENTER ADJUSTMENT
shaft is 0.6 to 1.2 N-m (6.0 to 10.0 in. lbs.) more t h a n
(1) Rotate the stub shaft from stop to stop and
reading in Step 4.
count the number of turns.
(6) Prevent the adjuster screw from turning while
(2) Starting at either stop t u r n the stub shaft back
tightening adjuster lock nut. Tighten the adjuster
1/2 the total number of turns. This is the center of
the gear travel (Fig. 8). lock n u t to 49 N-m (36 ft. lbs.).
FIRST
MARK
J9219-30
Fig. 7 Aligning To The Second Mark Fig. 8 Steering Gear Centered
GEAR DISASSEMBLY INFORMATION

C A U T I O N : Cleanliness is extremely important when
repairing a power steering gear. Keep the bench,
tools and components clean at all times. Thor
oughly clean the exterior of the gear with cleaning
solvent before disassembly. Drain a s much of the
fluid a s possible. Use protective vise jaws at all
times when clamping components. During a s s e m
bly, lubricate all components with power steering
fluid except when instructed otherwise (Fig. 10).
Fig. 9 Checking Over-center Rotation Torque

TO
4^
m
rn
z
o
1 - HOUSING, STEERING GEAR 25 - BEARING ASSY., NEEDLE (PITMAN SHAFT)

2 - RACE, THRUST BEARING (WORM) 26 - SEAL, PITMAN SHAFT (SINGLE LIP)
3 - BEARING ASSY., ROLLER THRUST (WORM) 27 - WASHER, SEAL BACK-UP (PITMAN SHAFT)
4 - RACE, THRUST BEARING (WORM) 28 - SEAL, PITAAAN SHAFT (DOUBLE LIP)
5 - WORM, STEERING 29 - WASHER, SEAL BACK-UP (PITMAN SHAFT)
6 - SEAL "O" RING (STUB SHAFT) 30 - RING, RETAINING (PITMAN SHAFT SEAL)
7 - SHAFT, STUB 31 - WASHER, PITMAN SHAFT LOCK
8 - SPOOL, VALVE 32 - NUT, PITMAN SHAFT
9 - SEAL, "O" RING (SPOOL) 33 - NUT, RACK PISTON
10 - BODY, VALVE 34 - BALL
11 - RING, VALVE BODY (3) 35 - GUIDE, BALL RETURN (2)
12 - SEAL, "O" RING (VALVE BODY) (3) 36 - CLAMP, BALL RETURN GUIDE
13 - RETAINER, BEARING (ADJUSTER) 37 - SCREW ASSY., LOCKWASHER & (2)
14 - SPACER, THRUST BEARING 38 - PLUG, RACK PISTON
15 - RACE, UPPER THRUST BEARING (SMALL) 39 - SEAL, "O" RING (RACK PISTON)
16 - BEARING, UPPER THRUST 40 - RING, RACK PISTON
17 - RACE, UPPER THRUST BEARING (LARGE) 41 - SEAL, "O" RING (HOUSING END PLUG)
18 - SEAL, "O" RING (ADJUSTER) 42 - PLUG, HOUSING END
19 - PLUG, ADJUSTER 43 - RING, RETAINING (HOUSING END PLUG)
20 - BEARING, NEEDLE 44 - GEAR ASSY., PITMAN SHAFT
21 - SEAL, STUB SHAFT 45 - SEAL ASSY., GASKET
22 - SEAL, STUB SHAFT DUST 46 - COVER ASSY., HOUSING SIDE
23 - RING, RETAINING 47 - BOLT, HEX. HEAD (SIDE COVER) (4)
24 - NUT, ADJUSTER PLUG LOCK 48 - NUT, LASH ADJUSTER
J9219-64
Fig. 10 Power Steering Gear

PITMAN SHAFT AND SIDE COVER REPLACEMENT (3) Install gasket to side cover and bend tabs
around edges of side cover.
REMOVE (4) Install pitman shaft assembly and side cover to
(1) Remove steering gear from vehicle. Refer to housing.
Power Steering Gear Replacement in this section. (5) Install side cover bolts and tighten to 60 N»m
(2) Remove pitman a r m from steering gear. Refer (44 ft. lbs.).
to Pitman Arm Removal in the Steering Linkage sec (6) Adjust pitman shaft, refer to Over-Center Ad
tion. justment.
(3) Rotate stub shaft back and forth to drain power
steering fluid. INSTALL
(1) Install steering gear. Refer to Power Steering
DISASSEMBLE Gear Replacement in this section.
• Clean exposed end of pitman shaft and housing. (2) Install pitman arm onto steering gear. Refer to
• Clean pitman shaft spline with a wire brush. Steering Linkage in this group.
(1) Remove preload adjuster nut.
(2) Rotate stub shaft with socket to center gear. HOUSING END PLUG
Remove side cover bolts.
(3) Remove side cover, gasket and pitman shaft as REMOVE
an assembly. (1) Remove steering gear from vehicle. Refer to
(4) Remove pitman shaft from the side cover (Fig. Power Steering Gear Replacement in this section.
11). (2) Remove pitman a r m from steering gear. Refer
to Steering Linkage in this group.
(3) Rotate stub shaft back and forth to drain power
steering fluid.
DISASSEMBLE
• Rotate stub shaft back and forth to drain fluid.
(1) Rotate retaining ring until one end is under
the hole in the housing. Unseat and force ring from
groove (Fig. 12).
Fig. 11 Side Cover and Pitman Shaft

ASSEMBLE
Fig. 12 End Plug Retaining Ring
(1) Install pitman shaft to side cover by screwing
shaft in until it fully seats to side cover. (2) Rotate stub shaft slowly COUNTER-CLOCK
(2) Install preload adjuster nut. D o not tighten WISE to remove end plug out from housing (Fig. 13).
nut until after pitman shaft adjustment h a s b e e n
made.
19 - 2 6 STEERING •
C A U T I O N : D o not turn stub shaft a n y further than (2) Install pitman arm onto steering gear. Refer to
necessary. T h e recirculating balls will drop out of Steering Linkage in this group.
the rack piston circuit a n d fall inside the rack pis
ton chamber. ADJUSTER PLUG ASSEMBLY REPLACEMENT
(3) Remove O-ring seal (Fig. 13). REMOWE

(1) Remove steering gear from vehicle. Refer to
Power Steering Gear Replacement in this section.
DISASSEMBLE
(1) Remove adjuster plug lock n u t from housing.
(2) Remove adjuster plug from housing with Span
ner Wrench C-4381 (Fig. 15).
SPECIAL TOOL
C-4381 OR J-7624
HOUSING END PLUG

O-RING SEAL
HOUSING END PLUG
RETAINING RING J9319-30
Fig. 13 End Plug Components

ASSEMBLE
• Lubricate O-ring seal with power steering fluid.
(1) Install O-ring into housing.
(2) Install plug, tap lightly with a plastic mallet to
seat it.
(3) Install retaining ring with open end 25 m m (1 Fig. 15 Remove/Install Adjustment Plug
inch) from access hole (Fig. 14). (3) Remove thrust washer bearing retainer from
adjuster plug with screwdriver (Fig. 16).
BEARING RETAINER
Fig. 14 Installing The Retaining Ring

Fig. 16 Remove Retainer
INSTALL
Gear Replacement in this section.
(4) Remove bearing spacer, races and thrust bear (1) Install needle bearing into adjuster plug with
ing (Fig. 17). an appropriate tool.
(2) Install lip seal and dust seal into adjuster plug
LARGE
RETAINING THRUST with an appropriate tool.
SNAP RING WASHER (3) Install retainer snap ring.
f
STUB SHAFT
DUST SEAL (4) Install O-ring seal to adjuster plug.
SMALL
THRUST WASHER (5) Install large bearing race, thrust bearing, small
bearing race and bearing spacer to adjuster plug.
(6) Install thrust washer bearing retainer to ad
juster plug (Fig. 19).
PUNCH
NEEDLE
BEARING
NEEDLE
SEAL
BEARING
RETAINING
SPACER RING
ADJUSTMENT RETAINER
CAP J8919-42 ADJUSTER PLUG
Fig. 17 Adjustment Plug (Cap) Components

(5) Remove O-ring seal.
(6) Remove retaining snap ring.
(7) Remove needle bearing, dust seal and lip seal
J9219-10
with an appropriate tool (Fig. 18).
Fig. 19 Install Retainer
C A U T I O N : When installing adjuster plug, care
should be taken NOT to cut the seals.
(7) Install adjuster plug into housing with Spanner

Wrench C-4381.
(8) Adjust bearing preload, refer to Thrust Bearing
Preload Adjustment.
(9) Install adjuster plug lock nut, and using a
NEEDLE punch (drift) in a notch, tighten securely (Fig. 20).
BEARING
REMOVAL Hold adjuster plug to maintain alignment of the
TOOL marks.
(10) Adjust pitman shaft. Refer to Over-Center Ad
justment.
INSTALL
(1.) Install steering gear. Refer to Power Steering
VALVE REPLACEMENT
J8919-43
REMOVE
Fig. 18 Needle Bearing Removal (1) Remove steering gear from vehicle. Refer to
ASSEMBLE Power Steering Gear Replacement in this section.
C A U T I O N : Needle bearing must be installed with DISASSEMBLE

identification on bearing facing tool to prevent dam (1) Remove adjuster plug, refer to Adjuster Plug
age to bearing. Assembly Replacement.
19 - 28 STEERING
J9319-36
Fig. 22 Remove and Install Stub Shaft

Fig. 20 Tighten Lock Nut
(2) Remove stub shaft and valve assembly (Fig.
GEAR, MAKE SURE ANGLE O F Fig. 23 Remove and Install Spool

THRUST RACES ARE AS SHOWN. J9319-32
ASSEMBLE
(1) Install valve spool O-ring seal to valve spool.
Fig. 21 Bearing, Worm and Valve Assembly
(2) Lubricate valve spool and O-ring seal with
(3) Remove stub shaft from valve assembly, if nec power steering fluid.
essary. (3) Install valve spool to valve body by pushing
• Tap stub shaft lightly on a block of wood to loosen and rotating. Hole in valve spool for stub pin must
shaft cap. be accessible from opposite end of valve body.
• Pull cap and valve body and disengage stub shaft (4) Assemble stub shaft to valve spool, if necessary
pin from hole in valve body (Fig. 22). and insert pin (Fig. 25).
(4) Remove valve assembly if necessary. • Notch in stub shaft cap MUST fully engage valve
• Remove valve spool by pulling and rotating from body pin and seat against valve body shoulder.
valve body (Fig. 23). (5) Install O-ring seals and teflon rings to valve
• Remove valve spool O-ring seal. body.
• Remove valve body teflon rings and O-ring seals (6) Lubricate O-ring seals and teflon rings with
(Fig. 24). power steering fluid.
RACK PISTON AND WORM SHAFT REPLACEMENT

REMOVE
Power Steering Gear Replacement in this section.
DISASSEMBLE
(1) Remove pitman shaft and side cover. Refer to
Side Cover and P i t m a n Shaft Replacement in this
section.
(2) Remove housing plug end. Refer to Housing
End Plug Replacement in this section.
(3) Turn stub shaft COUNTERCLOCKWISE until
the rack piston begins to come out of the housing.
(4) Remove rack piston plug (Fig. 26).
EXTENSION E N D PLUG
J8919-48
Fig. 24 Remove and install Valve Seals

NOTCH IN CAP
VALVE BODY PIN
RACK J9219-9
PISTON
Fig. 26 Remove and Install Rack Piston End Plug

liHiiiiiim (5) Insert Arbor C-4175 into bore of rack piston
(Fig. 27). Hold tool tightly against worm shaft while
turning the stub shaft COUNTERCLOCKWISE.
The rack piston will be forced onto the tool and
J9319-38 hold the rack piston balls in place.
(6) Remove the rack piston, rack balls, and tool to
Fig. 25 Stub Shaft Installation gether from housing.
(7) Remove valve. Refer to Valve Replacement in
(7) Install stub shaft and valve assembly to worm
this section.
shaft. Line up worm shaft to slot in the valve assem
(8) Remove worm shaft.
bly. (9) Remove thrust bearing and races.
(8) Adjust Thrust Bearing Preload Adjustment and (10) Remove tool from rack piston.
Over-Center Adjustment. Refer to Steering Gear Ad (11) Remove rack piston balls.
justments in this section. (12) Remove screws, clamp and ball guide.
(13) Remove teflon ring and O-ring seal (Fig. 28).
INSTALL
(1) Install steering gear. Refer to Power Steering CLEAN AND INSPECTION
Gear Replacement in this section. (1) Wash all components in clean solvent and dry
with compressed air.
11-30 STEERING w
INSTALL BALLS IN THIS HOLE

WHILE SLOWLY ROTATING
W O R M COUNTERCLOCKWISE
J9319-39
Fig. 27 Remove and install Rack Piston Fig. 29 Installing Balls in Rack Piston
rack piston balls are smaller than the silver
balls. THE BLACK AND SILVEE BALLS MUST
B E I N S T A L L E D A L T 1 E N A T E L Y INTO T H E
RACK PISTON AND BALL GUIDE. This proce
d u r e will maintain w o r m shaft preload.
(3) Lubricate and install rack piston balls through
return guide hole while turning worm shaft COUN
TERCLOCKWISE.
(4) Install remaining balls to guide using grease or
petroleum jelly at each end to hold in place (Fig. 30).
(5) Install guide onto rack piston and return with
GUIDE
J92T9-12
Fig. 28 Remove and Install Seal on Rack Piston

(2) Check for scores, nicks or burrs on the rack pis
ton finished surface. Slight wear is normal on the
worm gear surfaces.
ASSEMBLE
(1) Install O-ring seal and teflon ring and lubricate
with power steering fluid.
(2) Install worm shaft to rack piston outside of
housing. Fully seat worm shaft to rack piston. Align
worm shaft spiral groove with rack piston ball guide
BALLS J9319-40
hole (Fig. 29).
Fig. 30 Balls in the Return Guide
WARNING: MAKE S U R E A L L RACK PISTON BALLS
#
A R E REINSTALLED IN THE RACK PISTON. IM clamp and screws. Tighten screws to 58 N m (43 in.
P R O P E R INSTALLATION MAY R E S U L T IN P E R lbs.) torque.
S O N A L INJURY. (6) Insert Arbor C-4175 into bore of rack piston.
Hold tool tightly against worm shaft while turning
T h e r e a r e 24 b a l l s in t h e r a c k p i s t o n circuit, 12 the stub shaft COUNTERCLOCKWISE.
a r e M a c k a n d 12 a r e silver ( C h r o m e ) . T h e b l a c k
The rack piston will be forced onto the tool and PITMAN SHAFT SEALS AND BEARING
hold the rack piston balls in place. REPLACEMENT
(7) Install the races and t h r u s t bearing to worm
shaft (Fig. 31). REMOVE
WORM SHAFT THRUST RACES Power Steering Gear Replacement in this section.
DISASSEMBLE
(1) Remove p i t m a n arm from gear. Refer to Pit
m a n Arm Removal in Steering Linkage.
(2) Clean exposed end of pitman shaft and housing.
Use a wire brush to clean the shaft splines.
(3) Remove retaining ring with snap ring pliers
(Fig. 32).
RETAINING RING
BACKUP WASHER
DOUBLE-UP SEAL
BACKUP WASHER
SINGLE-LIP SEAL
MAKE SURE ANGLE OF THRUST NEEDLE BEARING

RACES ARE AS SHOWN
J9319-41
Fig. 31 Worm Shaft and Bearing

(8) Install worm shaft to housing.
(9) Install valve. Refer to Valve Replacement in
this section.
(10) Install rack piston to worm shaft from tool,
compress seals.
Hold Arbor tightly against worm shaft and turn
J8919-39
stub shaft CLOCKWISE until rack piston is seated
on worm shaft.
Fig. 32 Pitman Shaft Seals
WARNING: M A K E S U R E A L L R A C K PISTON B A L L S C A U T I O N : U s e care not to score the housing bore
A R E R E I N S T A L L E D IN T H E R A C K P I S T O N . I M when prying out seals and washers.
P R O P E R I N S T A L L A T I O N M A Y R E S U L T IN P E R
S O N A L INJURY. (4) Remove backup washer and double lip seal
with screwdriver.
(11) Install rack piston plug and tighten to 150 (5) Remove backup washer and single lip seal with
N»m (111 ft. lbs.) torque. screwdriver.
(12) Install housing end plug. Refer to Housing (6) Inspect the housing for burrs and remove if
End Plug Replacement in this section. necessary.
(13) Install pitman shaft and side cover. Refer to (7) Remove needle bearing from side cover area of
Side Cover and Pitman Shaft Replacement in this housing (Fig. 33).
section.
ASSEMBLE
(14) Adjust steering gear. Refer to Steering Gear
(1) Install needle bearing into housing (Fig. 34).
Adjustments in this section.
(2) Install single lip seal with Installer or a suit
able size socket (Fig. 35).
INSTALL
(3) Coat t h e double lip seal and washer with
grease.
(5) Install the double lip seal.
19 - 32 STEERING
REMOVER SIDE COVER SPECIAL TOOL

AREA C-4171
TOP OF TOOL
FLUSH WITH
HOUSING
SPECIAL TOOL
C4328
J9319-42 J9119-42
Fig. 33 Needle Bearing Removal Fig. 35 Pitman Shaft Seal Installation

SPECIAL TOOL CHECK VALVE REPLACEMENT
C-4171
REMOVE
DO NOT (1) Remove steering gear from vehicle. Refer to
BOTTOM BEARING
IN HOUSING Power Steering Gear Replacement in this section.
WHEN TOOL
BOTTOMS ON DISASSEMBLE
HOUSING, BEARING IS
FULLY INSTALLED C A U T I O N : Use care not to damage the threads of
the housing when prying out check valve.
(1) Remove valve by prying from housing with a

SPECIAL TOOL small screwdriver.
C-4178
ASSEMBLE
(1) Install the valve into the housing with a 3/8-
inch diameter piece of tubing 100 m m (4 inches)
long.
INSTALL
\ J9119-4 Gear Replacement in this section.
Fig. 34 Pitman Shaft Bearing Installation STEERING GEAR REPLACEMENT

(7) Install the retainer ring with snap ring pliers. REMOVAL
(8) Install the pitman shaft and side cover. Refer (1) Place the front wheels in a straight-ahead posi
to Side Cover and Pitman Shaft Replacement in this tion.
section. (2) Disconnect and cap the fluid hoses from steer
ing gear.
INSTALL (3) Remove the coupler roll pin and disconnect a t
(1) Install steering gear. Refer to Power Steering the steering gear (Fig. 36).
Gear Replacement in this section. (4) Mark the pitman shaft and pitman a r m for in
stallation reference. Remove t h e pitman a r m from
the shaft with Puller C-4150 (Fig. 37).
(6) Remove the steering gear retaining bolts and
• STEERING 11-33
SCREW REINFORCEMENT
Fig. 36 Column Shaft Removal Fig. 38 Steering Gear Removal/Installation (2WD)
Fig. 37 Pitman Arm Removal Fig. 39 Steering Gear Removal/Installation (4 WD)

nuts. Remove the steering gear from the vehicle (Fig. finger-tight (Fig. 38). Center the steering gear and
38, 39). align the steering column shaft and the stub shaft.
9 2WD vehicles; remove the steering gear retaining • 4WD vehicles; install the steering gear to the
bolts from the frame rail and remove the gear (Fig. frame reinforcement bracket (Fig. 39). Tighten the
40). screws to 176 N»m (130 ft. lbs.) torque. Install t h e as
• 4WD vehicles; remove the steering gear and rein sembly as above, finger tight.
forcement bracket from the frame rail. Remove the A special knurled shoulder bolt is used for the
gear from the reinforcement bracket (Fig. 39). lower bracket to frame bolt. The bolt is available for
service to eliminate bracket shift t h a t produces an off
INSTALLATION center condition. The tight fit between the frame and
(1) Align the column coupler shaft to steering bracket will eliminate any movement between the
gear. Install the roll pin in shaft coupling (Fig. 38). two parts.
(2) Position the steering gear on the frame rail and
(3) Re-position gear at frame to eliminate any
install the bolts (Fig. 38, 39). Tighten the bolts to
binding, tighten attaching bolts/nuts;
• 2WD vehicles; tighten gear to frame bolts to 136
• 2WD vehicles; position the steering gear at the
frame rail. Install and tighten the attaching bolts
• 4WD vehicles; tighten gear frame reinforcement
bracket to frame bolts/nuts to 223 N-m (165 ft. lbs.)
torque.
(4) Align and install the pitman arm.
(5) Install the washer and retaining nut on the pit
man shaft. Tighten the nut to 251 N-m (185 ft. lbs.)
torque.
(6) Connect fluid hoses to steering gear, tighten to
28 N-m (21 ft. lbs.). Add fluid, refer to Power Steer
ing Pump Initial Operation.
POWER STEERING GEAR SPECIFICATIONS
Steering Gear Type . . . . . . . . . . . . . Recirculating ball with Steering Gear Adjustments:

hydraulic assist. Wormshaft Bearing Preload Torque 0.45-1.13 N m
(4 to 10 in-lbs)
Ratio Code (Top of Gear)
BH,NZ 14:1 Pitman Shaft Overcenter Drag Torque:
BF, XS 13-16:1 New Gear
(less than 400 miles/640 km) . . . . . . . . . 0.45-0.90 N m
Steering Gear Hydraulic Fluid Use Mopar Power (4 to 8 in-lbs) in addition to wormshaft
Steering Fluid, or equivalent. bearing preload but not to exceed
combined total of 2 N m (18 in-lbs).
Steering Gear Lubricants Lubricate pitman shaft
seals, bearings races, and rack Used Gear
piston recirculating balls with (over 400 miles/640 km) 0.5-0.6 Nm (4 to 5 in-lbs)
petroleum jelly. Lubricate all other in addition to wormshaft bearing
parts with power steering fluid. preload but not to exeed
combined total of 2 N-m (18 in-lbs).
C a u t i o n : Gears must be adjusted exactly as outlined in
Steering Gear Adjustments-On Bench. Failure to
adhere to the recommended procedures may result
in gear damage or improper steering response.
J9219-36
• STEERING 19 - 3 i
S T E E R I N G COLUMN
SERVICE INFORMATION STEERING WHEEL
The Acustar columns ( F i g . l ) have been designed to
be serviced as an assembly; less wiring, switches, REMOWAL
shrouds, steering wheel, etc. Also most steering col (1) Make sure the front wheels are in the straight
umn components can be serviced without removing a h e a d position.
the column from the vehicle. For additional informa (2) Disconnect the negative (ground) cable from
tion refer to Group 8H, Electrical. the battery.
(3) Remove the horn pad components (Fig. 2).
C A U T I O N : Bumping, jolting and hammering on the
steering column shaft and gear shift tube must be (4) Remove the steering wheel retaining nut. Score
avoided during all service procedures. or paint alignment marks on the column shaft and
steering wheel (if none exist) for installation refer
ence.
C A U T I O N : Disconnect negative (ground) cable from
the battery before servicing any component on the HORN PAD
column.
C A U T I O N : D o not attempt to remove the pins to dis

semble the tilting mechanism. Damage will occur.
Safety g o g g l e s should be w o r n at all times

w h e n involved w i t h steering column service.
Fig. 2 Horn Pad Removal/installation
STEERING TILT UPPER PANEL TOE COUPLER ROLL
Fig. 1 Acustar Steering Column

19-36 STEERING •
(5) Remove the steering wheel with Puller (6) Pull clockspring assembly from column by lift
C-3428-B (Fig. 3). D o not h a m m e r or j o l t t h e ing locking fingers as necessary. The clockspring
steering c o l u m n o r shaft during r e m o v a l of t h e cannot be repaired, and must be replaced if faulty.
wheel.
INSTALLATION
S
P E
CAIL
TOOL (1) Snap clockspring assembly onto column. If
C3
-4
28B- clockspring is not properly positioned, follow the cen
tering procedures before installing steering wheel.
(2) Connect the wire connector to the clockspring.
WARNING: ENSURE CLOCKSPRING WIRE CON

NECTION IS C O M P L E T E L Y S E A T E D . T H E LATCH
ING C L I P A R M S M U S T B E P R O P E R L Y E N G A G E D
ON THE MODULE.
(3) Install upper and lower steering column

shrouds. Be sure wiring is inside of shrouds and not
pinched.
(4) Install the steering wheel and air bag module,
refer to Steering Wheel Installation.
CENTERING PROCEDURE
If the rotating tape within the clockspring is not
positioned properly, the clockspring may fail during
S
TEE
RN
IG use. The following procedures MUST BE USED to
W H
EEL J
921
9-
56 center the clockspring.
Fig. 3 Steering Wheel Removal (1) Place the front wheels in the straight ahead po
sition before starting the procedure.
INSTALLATION (2) Depress the 2 locking tabs to disengage the
(1) Install the steering wheel with the scored locking mechanism (Fig. 4).
marks or master splines aligned.
(2) Pull the speed control wires through the lower,
larger hole in the steering wheel. Pull the horn wire
through the smaller hole at the top. Ensure the
wires a r e N O T pinched.
(3) Install the retaining n u t and tighten to 61 N«m
(45 ft. lbs.) torque. Force the s t e e r i n g w h e e l d o w n
on the shaft w i t h the r e t a i n i n g nut only. D o not
hammer or s h o c k the c o l u m n w i t h s u d d e n im
pact to install the wheel.
(4) Connect the wire feed to the horn buttons.
(5) Connect the wire feeds to the speed control
switch (Fig. 2).
(6) Connect the battery ground (negative) cable.
CLOCKSPRING
REMOVAL
(1) Place the front wheels in the straight ahead po
sition before starting the repair.
(2) Disconnect battery negative cable and isolate.
(3) Remove the steering wheel, refer to Steering
Wheel Removal. Fig. 4 Clockspring (Auto-Locking)
(4) Remove upper and lower steering column (3) Keeping the mechanism disengaged, rotate the
shrouds to gain access to the clockspring wiring. clockspring rotor in the CLOCKWISE DIRECTION
(5) Release wire connector at clockspring. to the end of the travel. Do not apply excessive
torque.
• STEERING 19 • 37
(4) From the end of travel, rotate the rotor 2 1/2 D

ASH S
CR
EW S
P R N
IG
full t u r n s in the COUNTER CLOCKWISE direction. P
"A
NEL PN
I
The horn wire should end up at the top and t h e squib S
TEE
RN
IG
GE
AR
wire at the bottom (Fig. 4).
(5) Install the steering wheel, refer to Steering
Wheel Installation.
COLUMN— REMOVAL/INSTALLATION
C A U T I O N : Bumping, jolting and hammering on the
steering column shaft and gear shift tube must be
avoided during all service procedures.
S
TEER
NIG
COL
UM N
REMOVAL R
WA
SH
ER N U T J
?N" J9119-15
(1) Make sure the front wheels are in the s t r a i g h t
a h e a d position.
Fig. 6 Coupler Screw Removal
(2) Disconnect the negative (ground) cable from
the battery.
(3) Remove steering wheel from column, refer to
Steering Wheel-Removal.
(4) For vehicles equipped with a column shift, dis
connect the link rod by prying it out of the grommet
in the shift lever (Fig. 5).
STEERING
COLUMN
COVERS
J908K-33
PRYING TOOL
Fig. 7 Steering Column Cover
RN829 S
TEER
NIG
COL
UM N
Fig. 5 Link Rod Removal ASSY.
(5) Paint installation alignment marks on the col

u m n shaft-to-coupler. This will aid in column shaft to
wheel alignment. Remove the steering column shaft-
to-coupler screws (Fig. 6).
(6) Remove the dash panel column and fuse block
cover (Fig. 7).
(7) For column shift vehicles, make sure shift lever
is in Park position and remove PRNDL driver cable.
(8) Remove tilt lever (if equipped) from column. T
URNS G
IN AL
MUL
TI SWT
IC
H AND
(9) Remove the upper and lower lock housing ^
FUNCTO
IN L
EVE
R
shroud (Fig. 1). Remove the lower fixed shroud. SWT
IC
H
(10) Remove the t u r n signal multi-function switch J918J-1 CO
NNEC
TOR
with a 7mm socket (Fig. 8).
(11) Loosen the upper Support Bracket nuts to al Fig. 8 Multi-function Switch Wiring
low some slack. This will aid in removal of the upper (13) Remove the wiring harness from the column
fixed shroud. by prying out the plastic retainer buttons (Fig. 8).
(12) Remove the electrical connections from Key-in (14) Remove the lower dash panel and support
light, Main Ignition Switch, Horn connection or bracket standoff fasteners (Fig. 1).
Clock Spring (Speed Control) (Fig. 9). (15) Remove the column out through the passenger
19 - 38 STEERING
KEY-IN SWITCH & MULTI F U N C T I O N
RN832
Fig. 11 Ground Clip & Spacer Installation
Fig. 9 Steering Column Wiring
(7) Clip the wiring harness on the steering column.
compartment. Use care to avoid damaging the paint Connect the multi-function switch wiring and tighten
or trim. with 7mm socket (Fig. 8).
(8) Install the upper fixed shroud.
INSTALLATION
(9) Be sure both breakaway capsules are fully
C A U T I O N : Bumping, jolting and hammering on the seated in the slots in the column support bracket.
steering column shaft and gear shift tube must be Tighten the two upper bracket nuts to 12 N-m (105
avoided during all service procedures. in. lbs.) torque.
(10) Tighten the toe plate to floor pan attaching
(1) Column shift vehicles, install a new grommet nuts to 22.5 N-m (200 in. lbs.) torque.
(Fig. 10). Use MOPAR® Multipurpose Lubricant, or (11) Install the wiring connections to the column
equivalent, to aid installation of the grommet. A (Fig. 10). Install the lower fixed shroud.
n e w grommet should be u s e d w h e n ever the rod (12) Column shift vehicles, install the PRNDL
is disconnected from the lever. driver cable.
(13) Install the lock housing shrouds. Install the
D I R E C T I O N O F INSTALLATION
tilt lever (if equipped).
(14) Install the lower dash panel column cover
(Fig. 7).
(15) Install steering wheel on column, refer to
Steering Wheel-Installation.
(16) Column shift vehicles, connect the shift link
rod to the transmission shift lever. Use MOPAR®
Multipurpose Lubricant, or an equivalent product, to
aid the installation.
(17) Check operation of the transmission shift link
age and adjust as necessary. Refer to Group 21,
RN830 Transmission for the shift linkage adjustment.
(18) Connect the battery ground (negative) cable.
Fig. 10 Grommet Installation
(2) Install the ground clip on the left spacer slot COLUMN COMPONENT SERVICE
(Fig. 11). The Acustar tilt and standard columns (Fig.l) have
(3) Remove the shipping lock pin (Fig. 1), if neces been designed to be serviced as an assembly; less
sary. wiring, switches, shrouds, steering wheel, etc. Most
(4) Install column through floor pan. steering column components can be serviced without
(5) Position the column bracket shear pins on the removing the column from the vehicle. For additional
attaching studs. Install, but loose assemble the two information, refer to Group 8H, Electrical.
upper bracket washers and nuts. (1) The gear shift lever (if equipped) can be ser
(6) With t h e front wheels in the straight-ahead po viced. Use a drift and a suitable size socket to drive
sition. Align the steering column shaft-to-coupler out the pin (Fig. 12).
screws (Fig. 6). Tighten the screws to 22.5 N*m (200 (2) The P R N D L driver can be removed by drilling
in. lbs.) torque. out the rivets. Use care from bending when install-
• STEERING 19-39
Fig. 14 Do Not Remove Retainer

19-40 STEERING •
TORQUE S P E C I F I C A T I O N S
STEERING COLUMN STEERING LINKAGE
Description Torque DESCRIPTION TORQUE
Steering Wheel to Shaft Center Link to Ball Stud Nuts..., 88 N®m (65 ft. lbs.)
Retaining Nut 61 N»m (45 ft. lbs.) Drag Link Ball Stud Nuts (4WD-AII) 81 N®m (60 ft. lbs.)
Coupler Bolt 47 N»m (35 ft. lbs.) Idler Arm to Frame Bolts... 88 N*m (65ft.lbs.)
Upper Column Bracket Pitman Shaft Nut 251 NTn(185ft. lbs.)
Support Nuts 12N*m(105in. lbs.) Steering Arm to Knuckle
Nuts (4WD-Model 44) 122 N*m (90ft.lbs.)
Toe Plate Attaching
Tie-Rod Clamp Nut (Standard
Bolts/Nuts 23 N«m (200 in. lbs.) Duty 2WD).... 25 N^m (225 in. lbs.)
J9319-61 Tie-Rod Clamp Nut (Heavy Duty 2WD). 34 N«m (25ft.lbs.)
Tie-Rod Clamp Nut (4WD) 34-41 N«m
STEERING GEAR (25-30 ft. lbs.)
tie-Rod End to Center Link Nut. 54 N«m (40ft.lbs.)
Tie-Rod End Nut to Steering
DESCRIPTION TORQUE Knuckle Arm (2WD).. 54 N*m (40ft.lbs.)
Tie-Rod End Nut to Steering
Adjustment Cap Locknut 108 N»m (80 ft. lbs.) Knuckle Arm (4WD) 61 N«m(45ft. lbs.)
Adjustment Screw Locknut.... 27 N®m (20 ft. lbs.) J9219-91
Gear to Frame Bolts (2WD) 136 N®m (100 ft. lbs.)
Gear to Frame Bracket (4WD) 176 N®m (130 ft. lbs.)
Gear Frame Bracket to Frame (4WD)... 223 N*m (165 ft. lbs.) STEERING PUMP
Gear to Frame Bolts (4WD) 203 N*m (150 ft. lbs.)
High Pressure Fluid Line. 35 N*m (25 ft. lbs.)
DESCRIPTION TORQUE
Intermediate Shaft Pinch
Bolt (Upper and Lower) 47 N»m (35 ft. lbs.) Flow Control Valve 75 N®m (55ft.lbs.)
Pitman Shaft Nut 251 N»m (185 ft. lbs.) High Pressure Fluid Line 35 N«*m (25 ft. lbs.)
Return Pressure Fluid Line 35 N*m (25 ft. lbs.) Oil Cooler to Block Screws 41 N*m (30ft.lbs.)
Return Guide Clamp Bolt 5 N*m (4 ft. lbs.) Pump Bracket to Engine
(3.9 and 5.2 L).. 41 N*m (30ft.lbs.)
Rack-Piston Plug 102 N®m (75 ft. lbs.) 54 N®m (40ft.lbs.)
Pump to Bracket (3.9 and 5.2 L)....
Side Cover Bolts 61 N*m (45 ft. lbs.) Pump to Front Bracket Bolt (5.9 L). 41 N*m (30ft.lbs.)
J9219-90 Pump to Rear Bracket Nut (5.9 L) 54 N*m (40ft.lbs.)
Pump to Vacuum Pump Nuts
(Diesel Engine) 24 N®m (18ft.lbs.)
Pump Assembly to Engine
Block (Diesel Engine) 77 N*m (57ft.lbs.)
Pump to Support Bracket Nut
(Diesel Engine) 24 N T H (18ft.lbs.)
Remote Reservoir to Acc,
Drive Bracket (5.9 L) 23 N*m (200 in. lbs.)
Reservoir to Body Bolts 48 N«m (35ft.lbs.)
J9219-92
• TRANSMISSION AND TRANSFER CASE 21 - 1
TRANSMISSION AND TRANSFER CASE
CONTENTS
page page
AUTOMATIC T R A N S M I S S I 0 N - 3 2 R H / 3 6 R H / NP241 TRANSFER CASE 350

37RH/42RH/46RH 73 NV4500 MANUAL TRANSMISSION 1
G360 MANUAL TRANSMISSION 46 NV4500 TRANSMISSION OVERHAUL . . . . . . . . . 6
6360 TRANSMISSION OVERHAUL . . . . . . . . . . 53 TRANSMISSION/TRANSFER CASE
NP2Q5 TRANSFER CASE . . . . . . . . . . . . . . . . 342 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 364
NV4300 MANUAL TRANSMISSION
INDEX
page page
Gear Ratios 1 Transmission Identification 1
General Information 1 Transmission Installation—2-Wheel Drive 4
Recommended Lubricant—Capacity—Fill Level ...1 Transmission Installation—4-Wheel Drive ........ 5
Shift Pattern 1 Transmission Removal—2-Wheel Drive 3
Transmission Diagnosis 2 Transmission Removal—4-Wheel Drive 4
GENERAL INFORMATION I.D. t a g if removed during service. The information

The NV4500 is a five-speed, constant mesh manual on the t a g is essential to correct parts ordering.
transmission (Fig. 1). All gear ranges including re
verse a r e synchronized. Fifth gear is a n overdrive RECOMMENDED LUBRICANT-CAPACITY-FILL
range with a ratio of 0.74:1. The transmission has a LEVEL
cast iron gear case and aluminum shift cover. Recommended lubricant for the NV4500 is Castrol
The NV4500 is a top loader style transmission. The Syntorq. This is a SAE 75W-90 synthetic gear lubri
shift lever is located in t h e shift cover and operates cant with a n API grade rating of GL 4. Syntorq is
the shift forks and rails directly. The shift forks and t h e o n l y lubricant recommended for use in NV4500
rails a r e all located within t h e aluminum cover transmissions.
Dry fill lubricant capacity is approximately 3.78 li
which is bolted to t h e top of the gear case.
ters (8 pints).
A reverse gear inhibitor mechanism prevents re
Correct lubricant fill level is to the bottom edge of
verse gear engagement when shifting into forward
t h e fill plug hole (Fig. 3). Check fill level only when
gear ranges. The inhibitor mechanism is located in
t h e transmission is level.
the shift cover.
Tapered roller bearings support t h e drive gear, GEAR RATIOS
mainshaft a n d countershaft in t h e gear case. Pilot NV4500 gear ratios are:
roller bearings in the drive gear hub support the for First gear: 5.61:1
ward end of the mainshaft. The mainshaft gears are Second gear: 3.04:1
all supported on caged type roller bearings. Drive Third gear: 1.67:1
gear t h r u s t reaction is controlled by a needle type Fourth gear: 1.00:1
thrust bearing. The bearing is located a t the forward Fifth gear: 0.74:1
end of t h e mainshaft. Reverse gear: 5.61:1
TRANSMISSION IDENTIFICATION SHIFT PATTERN

The NV4500 transmission identification t a g is at The NV4500 shift pattern is in a modified H pat
tached to the driver side PTO cover (Fig. 2). tern (Fig. 4). Overdrive fifth and reverse gears are in
The t a g provides t h e transmission model number, line and outboard of the first through fourth gear po
build date and part number. Be sure to reinstall t h e sitions.
21 - 2 NV4500 MANUAL TRANSMISSION •
2WD
VERSION
4WD
VERSION
J9221-15
Fig. 1 NV4500 Manual Transmission

TRANSMISSION DIAGNOSIS mon causes of hard shifting. If hard shifting is also
accompanied by gear clash, synchronizer clutch and
COMMON PROBLEM CAUSES stop rings, or mainshaft gear teeth may be worn or
The majority of transmission malfunctions are a re damaged.
sult of: Hard shifting may also be caused by a loose, or
• insufficient lubricant misaligned shift cover, or alignment dowels. Worn, or
• incorrect lubricant damaged shift cover components will also cause hard
• misassembled or damaged internal components shifting. Any of the foregoing faults will cause com
• improper operation. ponent bind and high shift efforts.
Misassembled synchro components will also cause
HARD SHIFTING
shift problems. Incorrectly installed synchro sleeves,
A low lubricant level, loose or worn shift lever, or struts, or springs will all cause shift problems.
loose, damaged shift housing components are com
• NV4500 MANUAL TRANSMISSION 21 - 3
PTO SLIPS OUT OF GEAR

COVER Transmission disengagement may be caused by
misaligned or damaged shift components, or worn
teeth on the mainshaft gears or synchro components.
Incorrect assembly will also contribute to gear disen
gagement.
LOW LUBRICANT LEWEL

Insufficient transmission lubricant is usually the
result of leaks, or inaccurate fluid level check or re
fill method.
Leaks will be evident by the presence of gear oil
around the leak point. If leakage is not evident, the
condition is probably the result of an underfill condi
tion.
If air powered lubrication equipment is used to fill
a transmission, be sure the equipment is properly
calibrated. Equipment out of calibration can lead to
an underfill condition.
J9221-14
CLUTCH PROBLEMS
Fig. 2 NV4500 identification Tag Location Worn, damaged, or misaligned clutch components
can cause difficult shifting, gear clash and noise.
A damaged pilot bearing will cause noise. If bear
ing damage is severe, drive gear misalignment and
hard shifting can also occur.
A worn or damaged clutch disc, pressure plate, or
release bearing can cause hard shifting and gear
clash.
Damaged or worn clutch hydraulic components, or
leaks in the fluid lines or cylinders will cause hard
DRAIN shifting and gear clash. Failure of one of the clutch
PLUG J9221-80
hydraulic cylinders can result in incomplete clutch
release or engagement.
Fig. 3 NV4500 Drain And Fill Plug Locations
Verify that clutch components are all in good con
o 0 © dition before removing the transmission for repair.
TRANSMISSION REMOVAL—2-WHEEL DRIVE

(2) Shift transmission into Neutral.
(3) Remove screws attaching shift boot to floorpan.
Then slide boot upward on lever.
(4) Loosen nut t h a t secures shift lever on transmis
0 0 © J9221-13
sion stub lever. Then remove shift lever from stub le
ver.
Fig. 4 NV4500 Shitt Pattern (5) Raise and support vehicle.
(6) Mark propeller shaft and axle yokes for align
NOISY OPERATION ment reference. Use paint, scriber, or chalk to mark
Transmission noise is most often a result of worn yokes.
or damaged components. Chipped, broken gear or (7) Remove U-joint clamp strap screws and remove
synchronizer teeth and brinnelled, spalled bearings clamps.
all cause noise. (8) Remove propeller shaft.
Abnormal wear and damage to internal compo (9) Disconnect and remove exhaust system Y-pipe.
nents is frequently the end result of insufficient lu (10) Disconnect wires at speed sensor and backup
bricant, non-recommended lubricants, or improper light switch.
operation. (11) Support engine with adjustable safety stand
and wood block.
21 - 4 NV4500 MANUAL TRANSMISSION
(12) If transmission is to be disassembled for re (15) Fill transmission with required lubricant, if
pair, remove drain plug and drain lubricant from necessary.
transmission. (16) Lower vehicle.
(13) move bolts/nuts attaching transmission to rear (17) Install shift lever on transmission stub lever.
mount. (18) Install shift boot and bezel.
(14) Support transmission with a transmission (19) Connect battery negative cable.
jack. Secure transmission to jack with safety chains.
(15) Remove rear crossmember, TRANSMISSION REMOVAL—4-WHEEL DRIVE
(16) Remove bolts attaching clutch slave cylinder (1) Disconnect battery negative cable.
to clutch housing. Then move cylinder aside for (2) Shift transmission into Neutral.
working clearance. (3) Remove shift lever boot and bezel.
(17) Remove transmission harness wires from clips (4) Loosen nut attaching shift lever to transmis
on transmission shift cover. sion stub lever and remove shift lever from stub le
(18) Remove bolts attaching transmission to clutch ver.
housing. (5) Raise- vehicle.
(19) Slide transmission and jack rearward until (6) Remove skid plate if equipped.
drive gear clears clutch housing. (7) If transmission will be disassembled for repair,
(20) Lower transmission jack and remove trans remove drain plug and drain lubricant from trans
mission from under vehicle. mission.
(21) If transmission will be overhauled, clean (8) Mark propeller shafts and yokes for assembly
transmission exterior with solvent or with steam reference.
gun. (9) Disconnect propeller shafts and remove propel
ler shafts.
TRANSMISSION INSTALLATION—2-WHEEL DRIVE (10) Disconnect and remove exhaust system
(1) Apply light coat of Mopar high temperature Y-pipe. Then disconnect and lower remaining ex
bearing grease to contact surfaces of following com haust pipes for clearance as necessary.
ponents: (11) Support engine with adjustable safety stand.
• drive gear splines and pilot bearing hub (12) Disconnect speed sensor wires and disconnect
• release bearing slide surface of front retainer speedometer cable, if equipped.
• pilot bearing (13) Disconnect backup light switch wires.
• release bearing bore (14) Disconnect transfer case shift linkage at
• release fork transfer case range lever.
• release fork ball stud (15) Remove bolts/nuts attaching transmission to
• propeller shaft slip yoke rear support.
(2) Fill transmission with recommended lubricant. (16) Remove crossmember bolts/nuts and remove
Correct fill level is bottom edge of fill plug hole. crossmember.
(3) Mount transmission on jack and position trans (17) Support transfer case with transmission jack.
mission under vehicle. Secure transfer case to jack with safety chains.
(4) Raise transmission until drive gear is centered (18) Remove transfer case attaching nuts.
in release bearing and clutch disc hub. (19) Move transfer case rearward until input gear
(5) Move transmission forward and start drive gear clears transmission mainshaft.
in release bearing, clutch disc and pilot bushing. (20) Lower transfer case assembly and move it
(6) Work transmission forward until seated against from under vehicle.
clutch housing. Do not allow transmission to remain (21) If transmission is being removed for repair,
unsupported after drive gear has entered clutch disc. remove drain plug and drain lubricant from trans
(7) Install and tighten transmission-to-clutch hous mission.
ing bolts to 108 N*m (80 ft. lbs.) torque. (22) Support transmission with transmission jack.
(8) Install clutch slave cylinder. Secure transmission to jack with safety chains.
(9) Connect speed sensor and backup light switch (23) Remove transmission harness from retaining
wires. clips on transmission shift cover.
(10) Position transmission harness wires in clips (24) Remove bolts/nuts attaching transmission
on shift cover. mount to rear crossmember.
(11) Install transmission mount on transmission or (25) Remove rear crossmember.
rear crossmember. (26) Remove clutch slave cylinder splash shield, if
(12) Install rear crossmember. equipped.
(13) Remove transmission jack and engine support (27) Loosen clutch slave cylinder attaching nuts
fixture. until cylinder piston rod is clear of release lever.
(14) Align and connect propeller shaft. This reduces pressure on lever and release bearing
1 . NW4500 MANUAL TRANSMISSION 21 - 5
making transmission removal/installation easier. (9) Position transmission harness wires in clips on
Cylinder does not have to be removed completely. shift cover.
(28) Remove bolts attaching transmission to clutch (10) Tighten slave cylinder attaching nuts and in
housing. stall slave cylinder shield, if equipped.
(29) Move transmission rearward until drive pin (11) Install transmission mount on transmission or
ion clears clutch disc and release bearing. rear crossmember.
(30) Lower transmission and remove it from under (12) Install rear crossmember.
vehicle. (13) Remove transmission jack and engine support
(31) If transmission will be overhauled, thoroughly fixture.
clean transmission exterior with solvent or steam (14) Install transfer case on transmission jack. Se
gun. cure transfer case to jack with safety chains.
(15) Install new gasket on transmission adapter, or
TRANSMISSION INSTALLATION-4-WHEEL DRIVE
coat adapter sealing surface with Mopar Gasket
(1) Apply light coat of Mopar high temperature
Maker, or silicone adhesive sealer.
bearing grease to contact surfaces of following com
ponents: (16) Raise jack and align transfer case input gear
• drive gear splines and pilot bearing hub with transmission mainshaft.
• release bearing slide surface of front retainer (17) Move transfer case forward and seat it on
• pilot bearing adapter.
• release bearing bore (18) Install and tighten transfer case attaching
• release fork nuts to 47 N«m (35 ft. lbs.) torque.
• release fork ball stud (19) Connect transfer case shift lever to range le
• propeller shaft slip yoke ver on transfer case.
(2) Fill transmission with recommended lubricant. (20) Align and connect propeller shafts. Tighten
Correct level is to bottom edge of fill plug hole. U-joint clamp strap bolts to 19 N*m (170 in. lbs.)
(3) Mount transmission on jack and position trans torque.
mission under vehicle. Secure transmission to jack (21) Check lubricant levels in transmission and
with safety chains. transfer case. Add lubricant if necessary.
(4) Raise transmission until drive gear is centered (22) Install transfer case skid plate and crossmem
in release bearing and clutch disc hub. ber. Tighten attaching bolts/nuts to 41 N»m (30 ft.
(5) Move transmission forward and start drive gear lbs.) torque.
in release bearing and clutch disc. (23) Install exhaust system components.
(6) Work transmission forward until seated against (24) Lower vehicle.
clutch housing. Do not allow transmission to remain (25) Install transmission shift lever, boot and be
unsupported after drive gear has entered clutch disc.
zel.
(7) Install and tighten transmission-to-clutch hous
ing bolts to 108 N*m (80 ft. lbs.) torque.
(8) Connect speed sensor and backup light switch
wires.
21 - i NV4500 TRANSMISSION OVERHAUL
NV4500 T R A N S M I S S I O N OVERHAUL
INDEX
page page
Shift Cover Service . . . . . . . . . . . . . . . . . . . . . . . 4 3 Transmission Cleaning and Inspection . . . . . . . . . 21
Transmission Assembly and Adjustment . . . . . . . 26 Transmission Disassembly 6
TRANSMISSION DISASSEMBLY (5) Set cover assembly aside for inspection. If cover
components are damaged, refer to shift cover service
SHIFT COVER REMOVAL information.
(1) Remove shift cover bolts (Fig. 1). SHIFT
COVER
Fig. 3 Shift Cover Removal/installation

Fig. 1 Shift Cower Bolt Removal/installation EXTENSION/ADAPTER HOUSING REMOVAL
(2) Loosen shift cover with pry tool. To avoid dam (1) Remove bolts attaching extension/adapter hous
aging cover seal surface, insert pry tool only in slots ing to gear case (Fig. 4). Use 10 mm, 12 point socket
provided in cover (Fig. 2). to remove housing bolts. Loosen bolts 4-5 threads
with socket and ratchet first. An air wrench can then
SHIFT be used to complete removal but only after bolts are
COVER
SLOT loose.
C A U T I O N : Spline head bolts are used to attach the

extension or adapter housing to the gear case. The
bolt splines are easily damaged if the wrong tool is
used to loosen and remove them. U s e a 10 m m , 12
point socket or box end wrench only.
(2) Remove extension/adapter housing (Fig. 5). Tap

housing with rubber mallet to loosen it. Then break
sealer bead with putty knife and work housing off
alignment dowels with two pry tools. One alignment
dowel is in case. Other dowel is in housing.
(3) Remove spline seal from end of mainshaft (Fig.
6). The seal can b e reused or discarded as de
Fig. 2 Loosening Shift Cover sired. The seal is not an essential part and c a n
(3) Raise cover enough to disengage it from align b e reused or discarded a s desired. The seal is
ment dowels in gear case (Fig. 3). mainly u s e d to prevent lubricant loss during
(4) Raise front of shift cover and lift cover up and shipping and d o e s not h a v e to be replaced if
off gear case (Fig. 3). damaged.
NV4500 TRANSMISSION OVERHAUL 21 - 7
EXTENSION (4) On 2-wheel drive models, remove extension

HOUSING housing seal (Fig. 7). Seal can be removed by collaps
ing one side with punch then prying seal out with
suitable tool.
(5) Note that 4-wheel drive adapter h o u s i n g
d o e s not h a v e a seal (Fig. 8).
2-WHEEL-DRIVE
EXTENSION
HOUSING
SEAL
SPLINE J9221-87
HEAD
BOLTS (8) Fig. 7 Extension Housing And Seal (2-Wheel Drive
Models)
J9221-84 4-WHEEL-DRIVE
ADAPTER
Fig. 4 Extension/Adapter Housing Bolts HOUSING
EXTENSION
HOUSING
J9221-88
GEAR
Fig. 8 Adapter Housing (4-Wheel Drive Models)
CASE J9221-85
MAINSHAFT AND COUNTERSHAFT FIFTH
Fig. 5 Extension/Adapter Housing GEAR REMOWAL
Removal/Installation The fifth gear c o m p o n e n t s c a n b e removed in
dividually or as an assembly. If the fifth gear
MAINSHAFT RUBBER c o m p o n e n t s are only b e i n g r e m o v e d for a c c e s s
SPLINE to another component, r e m o v e them as a n as
SEAL
sembly. H o w e v e r , if any of the fifth gear compo
nents require service, remove them individually.
P r o c e d u r e s for both removal methods are pro
vided below.
Removing Countershaft Fifth Gear Components As Assembly

(1) Remove snap ring t h a t secures fifth speed
J9221-86 clutch gear on countershaft (Fig. 9).
(2) Remove roll pins t h a t secure countershaft fifth
Fig. 6 Mainshaft Spline Seal gear shift fork to shift rail with pin punch (Fig. 10).
Roll pins are driven out from bottom of fork and
not from top.
21 - 8 NV4500 TRANSMISSION OVERHAUL — — — — ^ _ _ _ _ - #
CLUTCH
GEAR J9221-89
Fig. 9 Removing Countershaft Fifth Speed Clutch

Gear Snap Ring
J9221-90 GEAR
Fig. 11 Removing Countershaft Fifth Gear Synchro

Components
against workbench. Purpose of socket wrench and
breaker bar is to prevent mainshaft from turning
while n u t is loosened.
(c) Position small end of Nut Wrench 6443 at ap
proximately 10 o'clock position (Fig. 12).
(d) Strike small end of Nut Wrench 6443 with
heavy copper hammer to break nut loose. N u t is se
FIFTH GEAR cured by interference fit thread plus Loctite adhe
SHIFT FORK J9221-94 sive and will require several firm blows to loosen it
(nut torque is in 300 ft. lb. range).
Fig. 10 Removing Fifth Gear Shift Fork Roil Pins
(e) Once n u t is loose, it can be removed by hold
(3) Remove shift fork and fifth gear components as ing n u t wrench with breaker bar and rotating out
assembly. Rotate mainshaft as needed to allow coun put shaft with socket wrench and ratchet.
tershaft fifth gear to clear mainshaft fifth gear. (f) Remove fifth gear n u t and coned washer from
shaft (Fig. 14). Note position of washer for assem
Removing Countershaft Fifth Gear Components Individually bly reference (coned side of washer faces rear).
(1) Remove snap ring t h a t secures fifth speed
SPECIAL STRIKE
clutch gear on countershaft (Fig. 9).
(2) Remove countershaft fifth speed clutch gear,
stop ring and bearing spacer (Fig. 11).
(3) Remove three struts and strut springs from
countershaft fifth gear hub and sleeve (Fig. 11).
(4) Remove mainshaft fifth gear nut and washer as
follows:
(a) Install N u t Wrench 6443 on fifth gear n u t
(Fig. 12). Note t h a t wrench only fits one way on
nut. Be sure wrench is fully engaged in n u t slots
and is not cocked.
(b) On 2-wheel drive models, install Socket
Wrench 6441 on mainshaft splines. On 4-wheel
NUT J9221-91
drive models, install Socket Wrench 6442 on main-
shaft splines. Then install breaker bar in socket Fig. 12 installing Nut Wrench On Mainshaft Fifth
wrench (Fig. 13). Wedge breaker bar handle Gear
NV4500 TRANSMISSION OVERHAUL 21 - I
SPECIAL FIFTH PLASTIC FIFTH
Fig. 15 Fifth Gear Shift Fork And Sleeve Removal
RATCHET
WRENCH J9221-92
Fig. 13 Removing Mainshaft Fifth Gear Nut From

Shaft Threads
FIFTH NUT
Fig. 16 Removing Countershaft Fifth Gear And

Synchro Hub Assembly
washer bore has notch for locating pin.
(10) Remove and retain thrust washer locating pin
from countershaft (Fig. 19).
Fig. 14 Mainshaft Fifth Gear Nut And Washer

Removal
(5) Remove roll pins t h a t secure countershaft fifth
gear shift fork to shift rail with pin punch (Fig. 10).
Roll p i n s a r e d r i v e n o u t from b o t t o m o f fork a n d
n o t from t o p .
(6) Remove fifth gear shift fork and sleeve as as
sembly (Fig. 15). Remove fork by tapping it off rail
with plastic mallet. L e a v e sleeve e n g a g e d in fork
o r n o t e p o s i t i o n o f sleeve for a s s e m b l y refer
ence.
(7) Remove countershaft fifth gear and hub assem
bly (Fig. 16).
(8) Remove countershaft fifth gear needle bearing
assemblies (Fig. 17).
(9) Remove cone shaped rear bearing thrust Fig. 17 Countershaft Fifth Gear Needle Bearing
washer from end of countershaft (Fig. 18). Note posi Removal
tion of washer for assembly reference. Also note t h a t
21 - 10 NV4500 TRANSMISSION OVERHAUL
SPECIAL TOOL SPECIAL TOOLS

6459 6444-3 (3 REQD.)
THRUST THRUST
WASHER WASHER
J9221-100
PIN (CONE SHAPED) J9221-98
nr m
Fig. 18 Countershaft Rear Bearing Thrust Washer Fig. 20 Seating Puller Flange In First Puller Jaw
Removal SPECIAL TOOL
(11) Remove mainshaft fifth gear with Puller Tool 6444-8
Set 6444 as follows:
(a) Position first Puller J a w 6459 on gear (Fig.
19).
J9221-101
Fig. 21 Installing Retaining Collar Over Puller Jaws

SPECIAL TOOL
6444-8
1 MAINSHAFT J9221-99
SPECIAL TOOL
6459
Fig. 19 Installing First Puller Jaw On Mainshaft Fifth
Gear
(b) Assemble Puller Flange 6444-1 and Puller
Rods 6444-3 (Fig. 2 0 ) . SPECIAL TOOL
6444
(c) Slide assembled puller flange and rods onto
output shaft. Then seat flange in notch of puller
jaw (Fig. 2 0 ) .
(d) Position second Puller J a w 6459 on gear and
in notch of puller flange (Fig. 21).
(e) Slide Retaining Collar 6444-8 over puller
jaws to hold them in place (Fig. 21).
(f) Install Puller and Bolt 6444 on puller rods. MAINSHAFT
Then secure puller to rods with retaining nuts (Fig.
22). SPECIAL TOOL
(g) Tighten puller bolt to remove gear from shaft 6444-3 HOLDING
splines (Fig. 22). WRENCH J9221-190
Fig. 22 Removing Fifth Gear From Mainshaft Splines

• NV4500 TRANSMISSION OVERHAUL 21 - 11
(12) Remove bolts attaching mainshaft rear bear

ing plate to gear case and remove fifth gear, plate,
end play shims and bearing cup (Fig. 28),
. MAINSHAFT REAR BEARING BEARING
BEARING CUP SHIMS PLATE
FIFTH GEAR
SEAL
J9221-102
Fig. 23 Removing Mainshaft Fifth Gear, Bearing FRONT BEARING

Plate, Bearing Shims And Rear Bearing Cup RETAINER
FRONT RETAINER REMOWAL AND Fig. 25 Removing Bearing Retainer Seal

DISASSEMBLY
(1) Remove front retainer bolts (Fig. 24). SPECIAL
TOOL
6444-4
SPECIAL
TOOL
6444-1
FRONT BEARING
J9221-103
RETAINER
SPECIAL
Fig. 24 Removing Front Bearing Retainer Bolts TOOL
6453-1 J9221-178X
(2) Remove front retainer by lightly tapping it
back and forth with plastic mallet to loosen it. Then
rock retainer back and forth by hand to work it out Fig. 26 Assembling Puller Rods, Flange And Jaws
of gear case. Note t h a t retainer flange extends into SPECIAL SPECIAL
and is fairly snug fit in case bore. TOOL TOOL
6453 6453-2
(3) Remove seal from front retainer (Fig. 25). Use
small chisel to collapse one side of seal then pry it
out with suitable tool.
(4) Remove bearing cup from front retainer as fol
lows:
(a) Assemble Puller Flange 6444-1 and Puller
Rods 6444-6 (Fig. 2 6 ) .
(b) Insert Puller J a w s 6453-1 in puller flange
(Fig. 26). Narrow lip of puller jaws will go under
bearing cup.
(c) Install assembled tools in front retainer (Fig.
27). Be sure puller jaws are seated under bearing cup. FRONT
(d) Place Insert Tool 6453-2 in center of puller RETAINER J9221-179
jaws (Fig. 27). Insert tool is used to hold puller
jaws in place. Fig. 27 Installing Puller Tools In Front Retainer
21-12 NV45Q0 TRANSMISSION OVERHAUL •
(e) Install Puller 6444 on puller rods (Fig. 28).
Then install retaining nuts on puller rods.
(f) Tighten puller bolt to draw bearing cup out of
retainer (Fig. 28). Use holding wrench on puller DRIVE GEAR
and t u r n puller bolt with adjustable wrench.
TIGHTENING HOLDING
WRENCH WRENCH
MAINSHAFT
PILOT BEARING
J9221-106
Fig. 30 Pilot Bearing Removal/Installation

(a) Note t h a t puller tool assembly and setup is
similar to t h a t used for removing fifth gear from
SPECIAL mainshaft (Figs. 19-23).
TOOL
6453-2 (b) Assemble Puller Flange 6444-1 and Puller
Rods 6444-4. Then position first Puller J a w 6447
on gear (Fig. 31).
(c) Slide assembled puller flange and rod tools
onto output shaft. Then seat flange in notch of
FRONT puller jaw (Fig. 31).
RETAINER J922M80 (d) Position second Puller J a w 6447 on gear and
in notch of puller flange (Fig. 31).
Fig. 28 Removing Bearing Cup From Front Retainer
DRIVE GEAR REMOVAL AND DISASSEMBLY SPECIAL TOOL
(1) Remove drive gear. Tilt gear downward and out 6444
of case (Fig. 29).
(2) Remove pilot bearing from drive gear (Fig. 30).
(3) Remove bearing from drive gear as follows:
SPECIAL
TOOLS
6444-6 (3)
DRIVE GEAR
SPECIAL TOOLS
6447 (2)
SPECIAL
TOOL
6444-1
SPECIAL TOOL
6444-8
J9221-105
J9221-115X
Fig. 29 Drive Gear Removal
Fig. 31 Removing Front Bearing From Drive Gear
+ N¥4S0O TRANSMISSION OVERHAUL 21 - 13

jaws to hold them in place (Fig. 31).
(f) Install Puller 6444 on puller rods. Then se
cure puller to rods with retaining nuts (Fig. 31).
(g) Tighten puller bolt to remove bearing cone
from drive gear (Fig. 31).
MAINSHAFT AND GEARTRAIN REMOVAL

(1) Remove countershaft rear bearing plate (Fig.
32).
Fig. 34 Removing Reverse Idler Shaft
Fig. 32 Removing Countershaft Rear Bearing Plate

(2) Remove countershaft end play shim and rear
bearing cup (Fig. 33). Fig. 35 Drive Gear Thrust Bearing Removal
Fig. 36 Fourth Speed Clutch Gear Stop Ring

Removal
(7) Roll gear case onto left side (Fig. 37).
(8) Reach into gear case and push reverse idler
Fig. 33 Countershaft End Play Shim And Rear gear away from mainshaft gears.
Bearing Cup Removal (9) Remove mainshaft assembly as follows (Fig.
37):
(3) Remove reverse idler shaft. Thread a shift
cover bolt into shaft and withdraw shaft from case (a) Lift front end of mainshaft slightly.
(Fig. 34). (b) Grasp mainshaft rear splines. Then t u r n
(4) Move 1-2 and 3-4 synchro sleeves into Neutral, spline end of mainshaft in counterclockwise direc
if necessary. tion to rotate shaft and geartrain out of case.
(5) Remove drive gear thrust bearing from forward (c) Once mainshaft gears roll clear of counter
end of mainshaft (Fig. 35). shaft gears, shaft and gear assembly can be tilted
(6) Remove fourth speed clutch gear and synchro outward and removed from gear case (Fig. 37).
stop ring from mainshaft (Fig. 36).
21 - 14 NV4500 TRANSMISSION OVERHAUL •
J922M14
Fig. 37 Mainshaft And Geartrain Removal Fig. 39 Reverse Idler Gear Removal
(10) Refer to mainshaft disassembly procedures if REVERSE
BEARINGS IDLER
any gears or synchro components must be replaced.
REVERSE IDLER GEAR AMD COUNTERSHAFT

REMOVAL/DISASSEMBL ¥
(1) Rotate countershaft outward and push reverse
idler gear away from countershaft and toward front
of case (Fig. 38).
Fig. 40 Reverse Idler Gear Components

(b) Position first Puller J a w 6449 on bearing
cone (Fig. 41).
(c) Seat puller flange in notch of puller jaw just
installed on bearing cone (Fig. 41).
(d) Install second Puller J a w 6449 on bearing
and in notch of puller flange (Fig. 41).
jaws to hold them in place (Fig. 41). Note that re
taining collar has small lip on one end and only
fits one way over jaws.
Fig. 38 idler Gear Moved Away From Countershaft

(2) Remove idler gear through drive gear bore at
front of case (Fig. 39).
(3) Keep reverse idler gear bearings and spacer to
gether for cleaning and inspection (Fig. 40). Insert
idler shaft through gear and bearings to keep them
in place.
(4) Remove idler gear thrust washers from gear
case. Install washers on idler shaft to keep them to
gether for cleaning and inspection.
(5) Remove countershaft r e a r bearing. Shaft can
not be removed from case until rear bearing has been
removed. Bearing removal procedure is as follows:
Rods 6444-6 (Fig. 41). Fig. 41 Removing Countershaft Rear Bearing
(f) Install Puller 6444 on puller rods. Then se (g) Tighten puller bolt to remove bearing from
cure puller to rods with retaining nuts (Fig. 41). shaft (Fig. 43). If bearing is exceptionally tight, tap
(g) Tighten puller bolt to remove bearing from end of puller bolt with mallet to help loosen bear
shaft (Fig. 41). If bearing is exceptionally tight, tap ing.
end of puller bolt with copper mallet to help loosen (9) Remove bearing puller tools.
bearing. (10) Set countershaft and idler gear aside for
(6) Remove bearing puller tools. cleaning and inspection.
(7) Rotate countershaft out of gear case (Fig. 42).
GEAR CASE DISASSEMBL¥
(1) Remove countershaft front bearing cap. Use
mallet or hammer to remove cap from inside case
(Fig. 44).
Fig. 42 Removing Countershaft From Gear Case Fig. 44 Countershaft Front Bearing Cap Removal
(8) Remove countershaft front bearing as follows: (2) Remove countershaft front bearing cup with
(a) Assemble Puller Flange 6444-1 and Puller Remover Tool 6454 and Tool Handle C-4171 (Fig.
Bolts 6444-6 (Fig. 43). 45).
(b) Position first Puller J a w 6451 on bearing.
(c) Seat puller flange in notch of puller jaw.
and in notch of puller flange.
jaws to hold them in place (Fig. 43). Note t h a t re
(f) Install Puller Bridge And Bolt Assembly 6444
on puller bolts. Then secure bridge to bolts with re
taining nuts (Fig. 43).
Fig. 45 Countershaft Front Bearing Cup Removal

(3) Remove roll pin t h a t secures shift lug on shift
rail in case (Fig. 46). A small pin punch can be mod
ified by putting a slight bend in it to drive pin com
pletely out of shift rail (Fig. 46).
(4) Remove shift lug rail by tapping it out of case
and shift lug with tapered punch (Fig. 47). Note po
sition of rail and lug for assembly reference.
(5) Remove lug rail bushings from gear case with
J922M 59X 6444-4 Special Tool 6456 (Fig. 48).
(6) Unclip and remove magnet from bottom of gear
Fig. 43 Removing Countershaft Front Bearing case (Fig. 49).
Fig. 49 Gear Case Magnet Location

chro components can be installed b a c k w a r d s .
To avoid reassembly problems, m a r k the speed
g e a r s , c l u t c h g e a r s , s y n c h r o h u b s , a n d sleeves
for r e f e r e n c e d u r i n g t e a r d o w n . U s e p a i n t o r a
s c r i b e r for m a r k i n g p u r p o s e s . T h e n s t a c k t h e
g e a r t r a i n p a r t s i n o r d e r of r e m o v a l . T h i s p r a c
tice w i l l h e l p a v o i d i n c o r r e c t a s s e m b l y a n d lost
time.
(1) Remove drive gear thrust bearing from end of
Fig. 46 Removing Shift Lug Roii Pin mainshaft, if not previously removed.
(2) Remove fourth gear synchro struts and springs
from 3-4 hub and sleeve (Fig. 50). Three struts and
springs are used. Keep springs and struts together
for inspection and cleaning. Store parts in a paper
cup to avoid losing them.
Fig. 4? Removing Shift Lug Rali
Fig. 50 3-4 Synchro Strut And Spring Removal

(3) Remove 3-4 sleeve from 3-4 synchro hub (Fig.
51).
(4) Remove 3-4 synchro hub from mainshaft
splines with suitable size bearing splitter, or with
two tapered drifts. Position splitter or drifts between
third gear stop ring to start moving hub off shaft.
Fig. 48 Removing Shift Lug Rail Bushings Then complete hub removal by tapping it off shaft
with plastic mallet. Tap hub at 6-8 different points to
MAINSHAFT DISASSEMBLY remove hub evenly.
N o t a l l of t h e m a i n s h a f t g e a r a n d s y n c h r o c o m
p o n e n t s a r e a o n e - w a y fit. S o m e g e a r a n d syn-
THIRD
GEAR
NEEDLE
BEARING
ASSEMBLIES
J922M19
Fig. 51 Removing 3-4 Sieeve From Hub
J922M21
Fig. 53 Third Gear Needle Bearing Removal
SECOND
GEAR THRUST
THIRD WASHER
GEAR
THRUST
WASHER
SNAP RING
THIRD
GEAR
STOP
RING
THIRD GEAR
BEARING
SPACER
3-4
SYNCHRO J9221-122
HUB Fig. 54 Bearing Spacer And Snap Ring Location
SECOND
GEAR
J922M20
Fig. 52 Third Gear, Stop Ring And 3-4 Hub Removal THRUST
WASHER
(5) Remove 3-4 synchro hub, third gear stop ring
and third gear (Fig. 52).
(6) Remove third gear bearing assemblies from
mainshaft (Fig. 53).
(7) Remove third gear bearing spacer (Fig. 54).
(8) Remove snap ring that retains second gear
thrust washer on mainshaft (Fig. 54).
(9) Remove second gear thrust washer (Fig. 55). SECOND
GEAR
Note t h a t washer is notched for locating pin. BEARING J9221-123
Fig. 55 Second Gear Thrust Washer Removal

21-18 NV4500 TRANSMISSION OVERHAUL •
J922M27
Fig. 56 Second Gear Removal Fig. 59 Removing Second Speed Clutch Gear Snap
Ring
Fig. 57 Second Gear Bearing Removal

Fig. 60 Second Speed Clutch Gear, Clutch Ring And
Stop Ring Removal
(13) Remove snap ring t h a t retains second speed
clutch gear (Fig. 59). Snap ring is seated in main-
shaft synchro hub groove.
(14) Remove second speed clutch gear, synchro
clutch ring and synchro stop ring (Fig. 60).
(15) Remove 1-2 synchro hub snap ring (Fig. 61).
(16) Mark position of 1-2 synchro sleeve and hub
for assembly reference. Side of hub with flat hub
spring goes toward front (Fig. 62). Note t h a t tapered
side of sleeve also goes toward front.
(17) Remove 1-2 synchro sleeve, hub, struts and
springs as an assembly (Fig. 62). It is not necessary
to disassemble synchro components unless worn, or
damaged.
Fig. 58 Thrust Washer Locating Pin Removal
(18) Remove first gear synchro stop ring and
(10) Remove second gear (Fig. 56). clutch ring (Fig. 63).
(11) Remove second gear bearing assembly (Fig. (19) Remove first speed clutch gear front snap ring
57). from mainshaft hub (Fig. 64).
(12) Remove t h r u s t washer locating pin (Fig. 58). (20) Remove first speed clutch gear (Fig. 65).
Use needle nose pliers to grip and remove pin.
FIRST
SPEED
CLUTCH
GEAR
CLUTCH
GEAR
SNAP
RING
(FRONT)
J9221-129 J922M32
Fig. 81 Hemming 1-2 Sleeve And Hub Snap Ring Fig. 64 First Speed Clutch Gear Front Snap Ring
Removal
1-2
SLEEVE CLUTCH GEAR
AND HUB SNAP RING (REAR)
(MARK
POSITION FOR
ASSEMBLY
REFERENCE)
FIRST
J9221-130 SPEED
HUB SPRING
CLUTCH
GEAR J9221-133
Fig. 62 Removing 1-2 Synchro Sleeve And Hub
FIRST GEAR Fig. 65 First Speed Clutch Gear Removal
CLUTCH RING
Rods 6444-3 (Fig. 66).
(b) Position first Puller J a w 6445 on bearing
cone (Fig. 66).
(c) Seat Puller Flange 6444-1 in notch of first
puller jaw (Fig. 66).
cone and on puller flange (Fig. 66).
jaws to hold them in place (Fig. 67). Note that re
FIRST GEAR (f) Install Puller 6444 on puller rods. Then se
STOP RING J922M31
cure puller to rods with retaining nuts (Fig. 67).
Fig. 63 First Gear Stop And Clutch Ring Removal (g) Place holding wrench on hex at top of puller
(Fig. 67). Then tighten puller bolt with adjustable
(21) Remove first speed clutch gear rear snap ring
wrench to remove bearing from shaft (Fig. 67). If
from mainshaft hub (Fig, 65). It is not really neces
bearing proves difficult to remove, tap end of puller
sary to remove this snap ring unless it, or the main-
bolt with copper hammer after each t u r n of bolt.
shaft is to be replaced.
This will help loosen bearing on shaft and ease re
( 2 2 ) Remove mainshaft rear bearing as follows:
moval.
Fig. 66 Assembling Rear Bearing Puller Tools

SPECIAL REVERSE
GEAR
J922M35
Fig. 68 Reverse Gear Thrust Washer Removal

(26) Remove reverse gear and synchro components
as assembly (Fig. 70). It is n o t necessary t o re
m o v e or disassemble synchro components unless
they are d a m a g e d and n e e d to be replaced. If
synchro sleeve or struts require service, mark
Fig. 67 Removing Mainshaft Rear Bearing position of sleeve on h u b before removal. Cor
(23) Remove bearing puller tools. rect sleeve position is important a s sleeve c a n be
(24) Remove reverse gear thrust washer (Fig. 68). installed b a c k w a r d s causing shift problems.
(25) Remove reverse gear thrust washer locating (27) Remove reverse gear bearing assembly from
pin (Fig. 69). mainshaft (Fig. 70).
Fig. 69 Removing Thrust Washer Locating Pin Fig. 71 Reverse Gear Bearing Spacer And First Gear
(28) Remove reverse gear synchro stop ring and Snap Ring Removal
clutch gear (Fig. 70).
FIRST REVERSE
J922M51
Fig. 72 Removing Reverse Clutch Gear

FIRST
Fig. 70 Reverse Gear, Bearing And Stop Ring GEAR
Removal
(29) Remove reverse gear bearing spacer from
mainshaft (Fig. 71).
(30) Remove first gear snap ring (Fig. 71). Tension
of this snap ring is considerable. Heavy duty snap
ring pliers will be required to spread the ring far
enough to remove it.
(31) Remove reverse clutch gear (Fig. 72).
(32) Remove first gear from bearing and mainshaft
(Fig. 73).
(33) Remove first gear bearing from mainshaft
(Fig. 74).
J922M52
TRANSMISSION CLEANING AND INSPECTION Fig. 73 Removing First Gear
Clean the gears, bearings shafts, extension/adapter
Inspect the reverse idler gear, bearings, shaft and
housing and gear case with solvent. Dry all parts ex
thrust washers (Fig. 75). Replace the bearings if the
cept the bearings with compressed air. Allow the
rollers are worn, chipped, cracked, flat-spotted, or
bearings to either air dry or wipe them dry with
clean shop towels.
21 - 22 IV4500 TRANSMISSION OVERHAUL •
MAINSHAFT FIRST MAINSHAFT FRONT
DRIVE
GEAR J9221-181
Fig. 76 Drive Gear Components

BEARING OIL FRONT BEARING
CUP SEAL RETAINER
SPACER SHAFT J9221-183

Fig. 77 Front Bearing Retainer Components
Fig. 75 Reverse idler Components
REAR COUNTERSHAFT FRONT
brinnelled. Or if the bearing cage is damaged or dis
torted. Replace the thrust washers if cracked,
chipped, or worn. Replace the gear if the teeth are
chipped, cracked or worn thin.
Inspect the drive gear and bearings (Fig. 76). Mi
nor scratches and burrs on the gear surfaces can be
reduced with an oil stone and 400 grit paper wetted
with oil. Replace either bearing if worn, or damaged.
Replace the gear if any teeth, splines, or bearing sur
faces are also worn or damaged.
Inspect the front bearing retainer and bearing cup
(Fig. 77). Replace the bearing cup if scored, cracked,
brinnelled, or rough. Check the release bearing slide
J922M84
surface of the retainer carefully. Minor corrosion, nicks,
or pitting can be smoothed with 400 grit emery and pol
Fig. 78 Countershaft And Bearings
ished out with crocus cloth. Wet the abrasive paper and
crocus cloth with oil when smoothing/polishing. Replace moved with an oif stone and 400 grit paper wetted
the retainer if worn or damaged in any way. with oil. However, replace the shaft as an assembly
Inspect the countershaft and bearings (Fig. 78). Re if the forward gear is loose, or any of the teeth are
place the bearings if worn, rough, flat spotted, or worn, cracked, broken, or severely chipped.
heat checked. Check the countershaft gear teeth Be sure to check condition of the countershaft bearing
carefully. Small nicks, scratches, or burrs can be re- cups. Replace either bearings cup if worn, or damaged.
Check condition of the mainshaft. Inspect all the GEAR EXTENSION

bearing surfaces, splines and threads. Also check condi CASE HOUSING
tion of the snap ring grooves in the hub area and the (2-WHEEL DRIVE)
speedometer drive gear teeth (Fig. 79). Minor scratches
or burrs can be removed with an oil stone and polished
with crocus cloth. However, replace the shaft if any sur
faces exhibit considerable wear or damage.
BEARING HUB BEARING NUT SPEEDOMETER
SURFACES SURFACES THREADS TEETH
ADAPTER
HOUSING
SPLINES (4-WHEEL
DRIVE) J9221-186
SPLINES SPLINES J922M85
Fig. 80 Gear Case And Extension/Adapter Housings
Fig. 79 Mainshaft Bearing And Spline Surfaces size or damaged. Do not attempt to salvage a worn
Check condition of the gear case and extension or fork. It will cause shift problems later on. Replace
adapter housing (Fig. 80). Be sure the alignment dowels the shift fork roll pins if necessary, or if doubt exists
in the case top surface and in the housing/adapter are about their condition.
tight and in good condition. The bearings should be examined carefully for wear,
Run a tap through the gear case bolt holes if the roughness, flat spots, pitting, or other damage. Replace
threads need minor cleanup. Helicoil inserts can be the bearings if necessary.
used to repair seriously damaged threaded holes if nec Inspect the stop ring and clutch gear, replace ei
essary. ther part if worn or damaged in any way. Also be
Be sure all case and housing/adapter sealing and sure replacement parts fit properly before proceeding
mating surfaces are free of burrs and nicks. This is with assembly.
especially important as gaskets are not used in the Inspect the 1-2 synchro components (Fig. 82). The hub
NV4500. Minor nicks and scratches on the sealing weights and retainer springs are reusable if in good
surfaces can be dressed off with a fine tooth file or oil condition. However, replace the springs if distorted, or
stone. broken and replace the weights if worn or damaged.
Replace the gear case or housing/adapter if cracked Examine the hub and sleeve for wear or damage.
or broken. Do not attempt to repair this type of dam Replace the sleeve and hub if the splines are worn,
age by welding or brazing. chipped or damaged.
Check condition of the countershaft fifth gear com Replace the synchro struts if worn, or chipped. Also
ponents (Fig. 81). This includes the shift lug and rail replace the springs if collapsed, distorted, or broken.
located in the gear case and the rail bushings. Inspect the mainshaft geartrain components (Fig.
Inspect the gear and hub assembly. Minor burrs can 83). Check the teeth on all gears, hubs, clutch gears,
be cleaned up with an oil stone. However, the gear and stop rings and clutch rings. The teeth must be in
hub assembly should be replaced if the teeth or splines good condition and not worn, cracked, or chipped. Re
are excessively worn, or damaged. The synchro sleeve place any component t h a t exhibits wear or damage.
should also be replaced if worn or damaged in any way. Examine the synchro stop rings, clutch rings and
Do not reuse synchro struts that are worn, or springs clutch gears. Replace any part t h a t exhibits wear,
that are collapsed or severely distorted. Replace worn distortion, or damage. Replace the clutch rings if the
distorted synchro parts to avoid shift problems after as friction material is burned, flaking off, or worn.
sembly and installation. Inspect all of the thrust washers and locating pins.
The shift fork should be inspected for evidence of Replace the pins if bent, or worn. Replace the wash
wear and distortion. Check fit of the sleeve in the ers if worn, or the locating pin notches are distorted.
fork to be sure the two parts fit and work smoothly. Check condition of the synchro struts and springs.
Replace the fork if the roll pin holes are worn over- Replace these parts if worn, cracked, or distorted.
- 24 NV4500 TRANSMISSION OVERHAUL •
Fig. 82 1-2 Synchro Components

LEGEND FOR FT GEMRTRAIN
1. MAINSHAFT 25. SYNCHRO HUB SNAP RING
2. FIRST GEAR BEARING 26. FIRST GEAR SYNCHRO STOP RING
3. FIRST GEAR 27. 1-2 SYNCHRO SLEEVE
4. CLUTCH GEAR 28. SYNCHRO STRUTS AND SPRINGS (4 EACH)
5. SYNCHRO STOP RING 29. 1 -2 SYNCHRO HUB (INC. RETAINER SPRINGS AND WEIGHTS)
6. FIRST GEAR SNAP RING 30. SYNCHRO HUB SNAP RING
7. REVERSE GEAR BEARING SPACER 31. SECOND GEAR SYNCHRO STOP RING
8. REVERSE GEAR BEARING 32. SECOND SPEED CLUTCH GEAR
9. REVERSE SYNCHRO SLEEVE 33. SECOND GEAR SYNCHRO CLUTCH RING
10. SYNCHRO STRUTS AND SPRINGS (3 EACH) 34. CLUTCH GEAR SNAP RING
11. REVERSE GEARLINES 35. SECOND GEAR BEARING
12. THRUST WASHER 36. SECOND GEAR
13. THRUST WASHER LOCATING PIN 37. THRUST WASHER AND LOCATING PIN
14. MAINSHAFT REAR BEARING 38. THRUST WASHER SNAP RING
15. MAINSHAFT REAR BEARING CUP 39. THIRD GEAR BEARING SPACER
16. MAINSHAFT END PLAY SHIMS 40. THIRD GEAR
17. MAINSHAFT REAR BEARING PLATE 41. THIRD GEAR BEARING ASSEMBLIES (2)
18. MAINSHAFT FIFTH GEAR 42. THIRD GEAR SYNCHRO STOP RING
19. THRUST WASHER 43. 3-4 SYNCHRO SLEEVE
20. FIFTH GEAR NUT 44. SYNCHRO STRUTS AND SPRINGS (3 EACH)
21. MAINSHAFT SPLINE SEAL 45. 3-4 SYNCHRO HUB
22. CLUTCH GEAR SNAP RING 46. FOURTH GEAR SYNCHRO STOP RING
23. FIRST SPEED CLUTCH GEAR 47. FOURTH SPEED CLUTCH GEAR
24. FIRST GEAR SYNCHRO CLUTCH RING 48. DRIVE GEAR THRUST BEARING
J9321-98
TRANSMISSION ASSEMBLY AND ADJUSTMENT GEAR CASE ASSEMBLY

(1) Install countershaft front bearing cup in case
Assembly Information with Tool Handle C-4171 and Installer Tool 6061-1
Gaskets are not u s e d in the NV4500 transmis or C-4340 (Fig. 84).
sion. U s e Mopar Gasket Maker, silicone adhe (2) Install new bushings in shift lug rail bores
sive/sealer, or Loctite 518 on all gear case and with Tool 6456 (Fig. 85). Seat bushings flush with
extension h o u s i n g sealing surfaces. bores.
Adjustment Specifications
• Countershaft End Play: 0.051-0.15 mm (0.002-
0.006 in.)
• Mainshaft End Play: 0.051-0.15 mm (0.002-0.006 in.)
Fig. 85 Installing Shift Lug Rail Bushings

(3) If case magnet was removed, install and secure
magnet in clip at bottom of case (Fig. 86).
Fig. 84 Installing Countershaft Front Bearing Cup Fig. 86 Gear Case Magnet Installation
NV450I TRANSMISSION OVERHAUL 21 - 27
COUNTERSHAFT AND REVERSE IDLER GEAR (6) Install idler gear front t h r u s t washer on boss in
INSTALLATION gear case (Fig. 89). Coat t h r u s t washer with liberal
(1) Install front bearing on countershaft with In quantity of petroleum jelly to hold it in place.
staller Tool 6446 (Fig. 87).
POSITION
IDLER
GEAR
Fig. 89 Positioning Idler Gear Front Thrust Washer

Fig. 87 Countershaft Front Bearing installation In Case
(2) Lubricate countershaft front bearing cup and (7) Install reverse idler gear in case (Fig. 90).
cone with petroleum jelly. (8) Install idler gear rear thrust washer between
(3) Position gear case on end with rear of case fac idler gear and case boss (Fig. 90).
ing up (Fig. 88). REAR
(4) Install countershaft in gear case (Fig. 88). D o THRUST
not install rear bearing o n countershaft rear at
this time.
Fig. 90 Idler Gear And Thrust Washer Installation

(9) Align idler gear bearings and thrust washers
with drift.
(10) Install reverse idler shaft (Fig. 91). Be sure
notched end of shaft is facing countershaft as shown.
Use shift cover bolt to hold and insert shaft in case
bore.
(11) Lift countershaft upward and position wood
block between front of shaft and case (Fig. 92).
(12) Install rear bearing cone on countershaft with
Installer Tool C-4040 or 6446 (Fig. 93).
Fig. 88 Positioning Countershaft In Gear Case
(13) Remove wood block from under countershaft
(5) Lubricate reverse idler gear bearings with pe and lower countershaft front bearing into front bear
troleum jelly and install first bearing, bearing spacer ing cup.
and second bearing (Fig. 89). (14) Install new front bearing cap in gear case
(Fig. 94). Apply Mopar silicone adhesive/sealer to
21 - 28 N¥4500 TRANSMISSION OVERHAUL
COUNTERSHAFT SHIFT REVERSE

SPECIAL
COVER IDLER
TOOL
BOLT SHAFT
6446
COUNTERSHAFT REAR
BEARING
_ J9221-166
Fig. 91 Reverse idler Shaft Installation Fig. 93 Installing Countershaft Rear Bearing
FRONT
BEARING
CAP
(SEAT
WITH
WOOD
BLOCK)
^ , ( / J9221-172
COUNTERSHAFT
Fig. 94 Countershaft Front Bearing Cap Installation
COUNTERSHAFT
REAR
BEARING
CUP
WOOD,
BLOCK
J9221-165
Fig. 92 Supporting Countershaft With Wood Block

flange and lip of new cap. Then seat cap in case bore
with wood block and mallet.
(15) Lubricate countershaft rear bearing cup and
cone with petroleum jelly.
J9221-167
(16) Install countershaft rear bearing cup in gear
case and over rear bearing (Fig. 95). Tap cup into Fig. 95 Countershaft Rear Bearing Cup Installation
place with plastic mallet if necessary.
(4) Raise countershaft with screwdriver and note
ADJUSTING COUNTERSHAFT END PLAY end play reading on dial indicator. End play should
(1) Install countershaft rear bearing plate (Fig. be 0.051 - 0.15 mm (0.002 - 0.006 in.).
96). Be sure plate is seated in notch in reverse idler (5) Remove countershaft rear bearing plate.
shaft before tightening bearing plate bolts. (6) Select and install end play shim t h a t will pro
vide minimum countershaft end play. Position shim
(2) Rotate countershaft 4-5 times to seat bearings.
on rear bearing cup (Fig. 98).
(3) Mount dial indicator on case. Then position in
(7) Reinstall countershaft rear bearing plate (Fig.
dicator plunger on end of countershaft and zero indi
96). Be sure plate is seated in reverse idler shaft
cator dial needle (Fig. 97). notch before installing bolts. Also be sure end play
COUNTERSHAFT REAR (8) Apply 1-2 drops Mopar Loc N' Seal or Loctite
BEARING 242 to threads of rear bearing plate bolts. Then in
PLATE
stall and tighten bearing plate bolts to 23 Nnn (200
IDLER in. lbs.) torque.
SHAFT
SHIFT LUG AND RAIL INSTALLATION

(1) Lubricate shift lug, rail and bushings with Cas-
trol Syntorq.
(2) Insert shift lug rail part way into case.
(3) Install shift lug on rail. Note position of
(4) Position shift rail so roll pin notches are at ap
proximately 5 o'clock position (Fig. 99).
(5) Install roll pin t h a t secures lug to rail (Fig. 99).
J9221-168 NOTCHES LUG SHIFT

(FOR 5TH GEAR RAIL LUG
SHIFT FORK
Fig. 96 Countershaft Rear Bearing Plate installation ROLL PINS)
DIAL
INDICATOR
INDICATOR
MOUNTING
ARM
AND
BASE
J922M71
Fig. 99 Shift Lug And Rail Installation

MAINSHAFT AND GEARTRAIN ASSEMBLY
C A U T I O N : The reverse, 1-2 and 3-4 synchro compo

nents can be assembled and installed incorrectly if
care is not exercised. S o m e components can be in
stalled backwards resulting in shift problems. Refer
J922M69 to the assembly procedures for component identifi
cation and location.
Fig. 97 Measuring Countershaft End Play
(1) Lubricate mainshaft bearing surfaces and all
REAR END bearing assemblies with Castrol Syntorq or with pe
BEARING PLAY
CUP SHIM troleum jelly.
(SELECTIVE) (2) Install first snap ring in rearmost groove of
mainshaft hub (Fig. 100). This snap ring locates first
speed clutch gear on shaft. A total of 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.
(3) Install first gear bearing assembly on main-
shaft (Fig. 100).
(4) If desired, mainshaft can be placed in upright
Fig. 98 Installing Countershaft End Play Shim
(vertical) position and supported with wood blocks
shims are still in position before tightening bearing (Fig. 101). Reverse gear components are easier to in
plate bolts. stall with shaft upright.
(5) Install first gear and bearing on shaft (Fig.
101). Clutch hub side of gear faces front of shaft.
SNAP FIRST REVERSE GEAR
RING -GEAR STOP RING
BEARING
W O O D BLOCKS XLUTCH GEAR
-FIRST GEAR
MAINSHAFT
SYNCHRO
HUB J9221-176 \- -• ~ • - - x
J9221-191
i
Fig. 100 First Gear Bearing and Snap Ring
Installation Fig. 102 Clutch Gear Stop Ring Installation
(6) Install clutch gear on first gear (Fig. 101). Be REVERSE GEAR
sure clutch gear is seated on shaft splines. BEARING
(7) Install first gear snap ring (Fig. 101). Use
BEARING
heavy duty snap ring pliers to install this snap ring SPACER
as ring tension is considerable. D o not overspread
s n a p ring a n d make sure it is fully seated in
groove. Reverse gear will not fit properly if s n a p FIRST
GEAR
ring is n o t fully seated.
FIRST FIRST
GEAR GEAR J9221-192
SNAP
RING
Fig. 103 Reverse Gear Bearing And Spacer
Installation
C A U T I O N : The reverse sleeve will fit either way o n
the hub. This means the sleeve can be installed
backwards if care is not exercised. Be sure the ta
pered side of the sleeve faces rearward after instal
REVERSE
lation.
CLUTCH
GEAR
(a) Position sleeve on hub so tapered side of
sleeve faces rearward. Sleeve will fit either way
but will cause shift problems if installed backwards
J9221-177
(Fig. 104).
(b) Rotate sleeve to align teeth on sleeve and
Fig. 101 First Gear, Clutch Gear And Snap Ring hub. Sleeve will slide easily into place on hub
Installation
when properly aligned.
(8) Install stop ring on clutch gear (Fig. 102). Be (c) Install springs in gear hub (Fig. 104). Use pe
sure stop ring is fully seated on gear taper. troleum jelly to hold springs in place if desired.
(9) Install reverse gear bearing spacer on main- (d) Compress first spring with flat blade screw
shaft (Fig. 103). Bearing spacer seats against first driver and slide strut into position in hub slot.
gear snap ring. Then work spring into seat in strut with small
(10) Install reverse gear bearing on mainshaft hooked tool, or screwdriver.
(Fig. 103). (e) Install second and third struts in same man
(11) If reverse gear sleeve and struts were disas ner as described in step (d).
sembled for service, reassemble sleeve, struts and (f) Work sleeve upward on hub until struts are
springs as follows: centered and seated in sleeve. Sleeve should be in
neutral position after seating struts.
• NV4I00 TRANSMISSION OVERHAUL 21 - 31
Fig. 106 Thrust Washer Pin Installation
HUB J922M89
Fig. 104 Reverse Gear Synchro Assembly

(12) Install reverse gear and synchro assembly on
mainshaft (Fig. 105). Rotate assembly until stop ring
lugs engage in hub slots and gear drops into fully
seated position.
Fig. 107 Reverse Gear Thrust Washer Installation
Fig. 105 Reverse Gear Installation

(13) Install reverse gear thrust washer pin in main-
shaft (Fig. 106). Use needle nose pliers to install pin.
(14) Install reverse gear thrust washer (Fig. 107).
Be sure locating pin is seated in thrust washer notch.
(15) Install rear bearing on mainshaft. Use In
staller Tool 6446 to seat bearing on shaft and against
thrust washer (Fig. 108). If bearing is not fully Fig. 108 Installing Mainshaft Rear Bearing
seated on shaft, seat bearing by tapping inner race
hub to secure clutch gear (Fig. 110). Be sure snap
with small brass punch and hammer. Bearing inner
race should be flush with shaft. ring is fully seated in hub groove and against clutch
(16) Turn mainshaft over and place it in horizontal gear. Note t h a t this is second of four snap rings used
position on workbench. to secure synchro components on shaft hub.
(17) Install first speed clutch gear on mainshaft (19) Assemble first speed clutch ring and stop ring
1-2 synchro hub (Fig. 109). Recessed side of gear (Fig. 111).
faces front. Be sure gear is seated against snap ring (20) Install assembled first speed clutch and stop
previously installed on hub. rings on clutch gear (Fig. 112). B e s u r e tabs o n
(18) Install snap ring on mainshaft 1-2 synchro c l u t c h ring are aligned and seated in first gear
Fig. 109 installing First Speed Clutch Gear Fig. 112 First Speed Clutch And Stop Ring
Installation
MAINSHAFT
GEAR
CASE
Fig. 110 installing First Speed Clutch Gear Snap

Ring
J9221-222
Fig. 113 Mainshaft Positioned For Gear And

Synchro Installation
(22) If 1-2 synchro hub and sleeve were disassem
bled for service, reassemble hub, sleeve, struts and
springs as follows:
(a) Install weights in hub (Fig. 114). Use petro
leum jelly to hold weights in place if desired.
Fig. 111 Assembling First Speed Clutch And Stop
(b) Install weight retainer springs. Flat spring
Rings
goes at front side of hub (Fig. 115). Be sure re
h u b . 1-2 s y n c h r o h u b will n o t s e a t p r o p e r l y if tainer spring ends are securely engaged in weight
clutch ring t a b s are misaligned. slots as shown.
(21) Support mainshaft in upright position (Fig. (c) Place synchro hub on bench so side of hub
113). Remaining gears, snap rings and synchro com with square spring is facing up (Fig. 116).
ponents are easier to install with shaft in upright po (d) Align and install sleeve on hub. Be sure ta
sition. Shaft can be supported in gear case as shown, pered side of sleeve faces upward (toward front).
or hole can be cut in workbench to support shaft. Rotate sleeve until it slides onto hub. Sleeve only
HUB SYNCHRO
Fig. 114 Installing Weights In 1-2 Synchro Hub
Fig. 116 installing 1-2 Synchro Sleeve On Hub
STRUTS AND
SPRINGS (4 EACH) J9221 -209
J9221 -207 Fig. 117 Installing 1-2 Synchro Struts And Springs
(23) Install first speed stop ring in 1-2 synchro hub
Fig. 115 Installing Weight Retainer Springs In 1-2
and sleeve (Fig. 118). Be sure stop ring is fully
Synchro Hub
seated and engaged in hub and sleeve.
fits one way and will easily slide onto hub when
long slot in sleeve, aligns with long shoulder on
hub (Fig. 116).
(e) Place wood blocks under hub t h a t will raise
hub about 3.5 cm (1-3/8 in.) above surface of work
bench. Then allow sleeve to drop down on h u b (Fig.
117).
(f) Install springs and struts in hub (Fig. 117).
Use lots of petroleum jelly to hold them in place.
Then compress struts with your fingers and move
sleeve upward until struts are started in sleeve.
Verify t h a t struts are engaged in sleeve before pro
ceeding.
(g) Turn synchro assembly upright. Then move
sleeve into neutral position on hub and work struts
into sleeve at same time. Be sure struts are seated
and springs are not displaced during assembly. Fig. 118 Installing First Speed Stop Ring In Synchro
Hub
(24) Install 1-2 synchro assembly and stop ring on

mainshaft. Rotate sleeve to align it with stop ring lugs SYNCHRO
SNAP
if necessary. Then seat assembly on shaft (Fig, 119). RING
MAINSHAFT
HUB
SYNCHRO
SYNCHRO ASSEMBLY
ASSEMBLY
TAPERED
SIDE
OF
SLEEVE
J9221-212
Fig. 121 Installing 1-2 Synchro Snap Ring
(28) Reinstall flat weight spring in 1-2 synchro
J9221-211
hub (Fig. 122). Be sure spring ends are securely en
Fig. 119 1-2 Synchro Installation gaged in weight slots.
(25) Check position of 1-2 and reverse synchro FLAT 1-2
sleeves. Be sure tapered side of 1-2 sleeve faces front WEIGHT SYNCHRO
and tapered side of reverse sleeve faces rear (Fig. SPRING HUB
120). Also be sure square spring is visible at forward
side of 1-2 synchro hub. D o not skip this check as
transmission will not shift properly if either syn
chro sleeve is installed b a c k w a r d s .
1-2
SLEEVE
TAPER
TO fll^ \ \ V ^221-213
FRONT
Fig. 122 Reinstalling Flat Weight Spring
(29) Assemble second speed clutch gear, clutch
ring and stop ring (Fig. 123).
REVERSE
STOP RING
SLEEVE
TAPER
TO
REAR CLUTCH RING
CLUTCH GEAR
J9221-216
Fig. 120 Correct Position Of Reverse And 1-2

Synchro Sleeves
(26) Temporarily remove flat weight spring from
front side of 1-2 synchro hub. Removing spring
makes installation of 1-2 hub snap ring easier.
(27) Install snap ring t h a t secures 1-2 synchro on
mainshaft hub (Fig. 121). Be sure snap ring is fully J9221-200
seated in ring groove in mainshaft hub. If s n a p ring

Fig. 123 Assembling Second Speed Clutch Gear,
will not seat in groove, r o u n d weight spring at
Clutch Ring And Stop Ring
rear of 1-2 synchro h u b is probably not seated i n
recess a t front of first s p e e d clutch gear. Or first
s p e e d clutch gear is slightly misaligned. Realign
as n e e d e d to fully seat s n a p ring.
NV450Q TRANSMISSION OVERHAUL 21 - 35
(30) Install assembled second speed clutch gear

and rings on mainshaft and in 1-2 synchro h u b (Fig.
124).
Fig. 126 Second Gear Bearing Installation
1 SECOND
GEAR
Fig. 124 Second Speed Clutch Gear, Clutch Ring
And Stop Ring Installation
(31) Install snap ring that secures second speed
clutch gear on mainshaft (Fig. 125). Use narrow
blade screwdriver to work snap ring into hub groove
as shown. Be sure snap ring is fully e n g a g e d in
mainshaft groove before proceeding. If s n a p
ring will not fit in groove, clutch gear is slightly
misaligned. Or, flat weight spring at front of 1-2
synchro h u b is probably not s e a t e d in recess in
front of s e c o n d s p e e d clutch gear.
Fig. 127 Second Gear Installation
Fig. 125 Installing Second Speed Clutch Gear Snap

Ring
(32) Install second gear bearing on mainshaft (Fig.
126).
(33) Install second gear on mainshaft and bearing. Fig. 128 Thrust Washer Pin Installation
Rotate gear until tabs of second speed clutch ring are
fully seated in tab slots in gear (Fig. 127).
(34) Install thrust washer pin in shaft (Fig. 128).
Use needle nose pliers to insert pin in shaft hole.
21 - 36 NV4500 TRANSMISSION OVERHAUL -
(35) Install second gear thrust washer. Be sure

washer is seated on gear and pin (Fig. 129).
SECOND SECOND
Fig. 131 Third Gear Bearing Installation
J9221-224
Fig. 129 Second Gear Thrust Washer installation

(36) Install second gear thrust washer snap ring
(Fig. 130). Be sure snap ring is fully seated in main-
shaft groove.
(37) Install third gear bearing spacer on shaft and
seat it against thrust washer snap ring (Fig. 130).
Fig. 132 Third Gear Installation
SYNCHRO THIRD
THRUST
WASHER
SNAP RING
HIRD GEAR
BEARING
SPACER
Fig. 133 Third Gear Stop Ring Installation
(b) Insert all three synchro struts in slots ma
J922M22
chined in sleeve and hub (Fig. 134).
Fig. 130 Installing Snap Ring And Third Gear (c) Install and seat synchro springs (Fig. 134).
Bearing Spacer Use flat blade or phillips screwdriver to compress
springs and seat them in struts and hub as shown.
(38) Install third gear bearings on mainshaft (Fig.
(42) Remove mainshaft and geartrain from gear
131). Upper bearing should be flush with mainshaft
hub. If upper bearing is not flush w i t h h u b , ei case or from workbench.
ther bearing spacer or s n a p ring w a s not in (43) Start 3-4 synchro assembly on mainshaft. Tap
stalled. Check and correct if necessary. assembly onto shaft splines until hub is about 3 mm
(39) Install third gear over bearings and on main- (1/8 in.) away from third speed stop ring. Then align
shaft (Fig. 132). stop ring with synchro sleeve and hub and seat syn
(40) Install synchro stop ring on third gear (Fig. chro assembly with Tool C-4040 (Fig. 135).
133). Be sure stop ring is fully seated on gear taper. (44) Verify t h a t 3-4 synchro hub is fully seated on
(41) If 3-4 synchro was disassembled for service, shaft. Approximately 3 mm (1/8 in.) of shaft spline
reassemble synchro components as follows: should be visible. If hub is not seated, stop ring lugs
(a) Align and install synchro sleeve on hub (Fig. are misaligned. Rotate ring until lugs are fully en
134). Front side of h u b h a s a narrow groove gaged in 3-4 hub slots.
m a c h i n e d in it.
• IV4500 TRANSMISSION OVERHAUL 21 - 37
Fig. 137 Fourth Speed Clutch Gear Installation

(3) Continue holding front of shaft but switch grip
at rear to shaft output splines. Lift mainshaft assem
bly slightly, align gears and seat assembly in case.
Fig 134 3-4 Synchro Assembly Be sure fourth speed clutch gear and stop ring were
not displaced during installation (Fig. 138).
MAINSHAFT
Fig. 135 Seating 3-4 Synchro Assembly On

Mainshaft
(45) Install fourth speed stop ring in 3-4 synchro
sleeve (Fig. 136).
Fig. 138 Mainshaft And Geartrain Installed In Case
(4) Install drive gear thrust bearing on mainshaft
(Fig. 139). Use plenty of petroleum jelly to hold bear
ing in place.
(5) Check alignment and mesh of mainshaft gears.
If gears are not aligned, roll case on side and realign
shaft and gears in case.
Fig. 136 Fourth Speed Stop Ring Installation

(46) Install fourth speed clutch gear in stop ring
(Fig. 137).
MAINSHAFT AND GEARTRAIN INSTALLATION

(1) Position gear case so case opening is facing up
(Fig. 138).
(2) Grip mainshaft at pilot bearing hub and just
Fig. 139 Drive Gear Thrust Bearing Installation
behind rear bearing. Then lift assembly and guide
rear of shaft through bearing bore at rear of case.
21 - 38 NV45U0 TRANSMISSION OVERHAUL
DRIVE GEAR AND RETAINER INSTALLATION

SPECIAL TOOL
(1) Install bearing on drive gear with Installer 6052
Tool 6448 (Fig. 140).
SPECIAL
-TOOL
6448
RETAINER
BEARING
DRIVE GEAR W O O D BLOCK J9221-202
Fig. 142 Installing Bearing Retainer Oil Seal

J9221-204 (9) Start front bearing retainer in gear case. Ver
ify that retainer lube channel is at top-center (12
Fig. 140 installing Front Bearing On Drive Gear O'clock) position (Fig. 143). Adjust retainer posi
(2) Lubricate pilot bearing with petroleum jelly tion before proceeding, if necessary.
and install it in drive gear bore.
LUBE
(3) Install drive gear on mainshaft. Work gear CHANNEL
rearward until mainshaft hub is fully seated in pilot (INSTALL AT
bearing. 12 O'CLOCK
POSITION)
(4) Install bearing cup in front retainer with
Driver Handle C-4171 and Installer C-4308 (Fig.
141).
SPECIAL SPECIAL
TOOL TOOL
C-4308 C-4171
FRONT
APPLY RETAINER
GASKET
MAKER
HERE J9221-231
WOOD
BLOCKS
Fig. 143 Location Of Front Retainer Lube Channel
(10) Align front bearing retainer bolt holes and tap
retainer into place with plastic mallet. Install and
RETAINER tighten retainer bolts to 30 N-m (265 in. lbs.) torque
(Fig. 144).
J9221-203
Fig. 141 Installing Front Bearing Cup In Retainer

(5) Install new oil seal in front bearing retainer
with Tool C-4595 or 6052 (Fig. 142). Use one or two
wood blocks to support retainer as shown. Lubricate
seal lip with petroleum jelly after installation.
(6) Clean contact surfaces of gear case and front
bearing retainer with a wax and grease remover.
(7) Apply Mopar Gasket Maker to flange surface of FRONT BEARING
RETAINER 9 J9221-103
front bearing retainer (Fig. 143).
(8) Install front bearing retainer over drive gear Fig. 144 Installing Front Bearing Retainer
and start it into case.
MAINSHAFT END PLAY ADJUSTMENT BEARING MAINSHAFT

(1) Install mainshaft rear bearing cup in case a n d PLATE REAR
over bearing. Tap bearing cup into place with plastic OIL HOLE BEARING
(AT TOP) PLATE
mallet.
(2) Install rear bearing plate to hold mainshaft
and rear bearing in position (Fig. 145). Do not install
any end play shims at this time.
(3) Tighten rear bearing plate bolts securely.
(4) Place gear case in upright position on bench.
Either cut hole in bench to accept drive gear a n d
front retainer, or use C-clamps to secure transmis
sion on bench. Do not leave transmission unsup
ported.
(5) Mount dial indicator on rear of gear case and
J9221-233
position indicator plunger against inner race of rear
bearing (Fig. 145).
Fig. 146 Rear Bearing Plate Installation
(6) Move mainshaft forward to remove all play.
Then zero dial indicator. MAINSHAFT
FIFTH
(7) Move mainshaft upward and observe dial indi
GEAR
cator reading. Move mainshaft with pry tool posi
tioned between drive gear and case.
(8) End play should be 0.051-0.15 m m (0.002-0.006
in.). Select fit shims are available to adjust end play
if necessary.
DIAL REAR
INDICATOR BEARING
AND
BASE
SPECIAL
TOOL
6446 J9221-220
Fig. 147 Installing Mainshaft Fifth Gear

(4) Install fifth gear n u t on mainshaft (Fig. 148).
FIFTH NUT
(j POSITION
GEAR WASHER
J INDICATOR
'(CONED)
(J PLUNGER .
L/L-ON BEARING-
(/ INNER RACE J9221-232 FIFTH
GEAR
NUT
Fig. 145 Checking Mainshaft End Play
(9) If end play adjustment is required, remove
bearing plate and install necessary shim.
(10) Reinstall rear bearing plate (Fig. 146).
Tighten rear bearing plate bolts to 23 N*m (200 in.
lbs.) torque. B e sure oil hole in bearing plate is at
top a s s h o w n .
MAINSHAFT FIFTH GEAR INSTALLATION J9221-93

(1) Install mainshaft fifth gear. Use Installer Tool
6446 to seat gear on shaft (Fig. 147). Gear is seated Fig. 148 Installing Fifth Gear Nut And Washer
when it contacts rear bearing. (5) Tighten fifth gear n u t as much as possible with
(2) Install fifth gear n u t washer (Fig. 148). Coned
Nut Wrench 6443, long handle ratchet, breaker bar
side of washer faces end of shaft.
and Socket Wrench 6441 or 6442 (Fig. 149).
(3) Apply 3-4 drops Mopar Lock N ' Seal, or Loctite
242 to n u t threads on mainshaft.
SPECIAL FIFTH
TOOL GEAR
6443 NUT
SPECIAL
TOOL
6441
OR
6442
J9221-235
Fig. 151 installing Fifth Gear Thrust Washer

(3) Lubricate and install fifth gear bearings on
countershaft (Fig. 152).
(4) Install bearing spacer on countershaft and seat
it against bearings (Fig. 152). Coat spacer with pe
BREAKER
BAR troleum jelly to hold it in place.
RATCHET
WRENCH J9221-92
Fig. 149 Fifth Gear Nut installation

.BEARING
(6) Lock mainshaft gears by shifting all synchro SPACER
sleeves into engaged position,
(7) Position Spline Socket Wrench 6441 or 6442 on
mainshaft splines. Then install breaker bar in socket
wrench and wedge b a r against workbench.
(8) Tighten fifth gear n u t with N u t Wrench 6443
and high capacity torque wrench. Required torque on
n u t is 339-475 N*m (250-350 ft. lbs.). Have helper
hold transmission steady if necessary. N u t can also FIFTH
GEAR
be tightened by striking Wrench 6443 with heavy- BEARINGS J9221-236
copper mallet then checking with torque wrench.
Fig. 152 Countershaft Fifth Gear Bearing And
COUNTERSHAFT FIFTH GEAR AND SYNCHRO Spacer Installation
INSTALLATION (5) Install synchro sleeve on hub of countershaft
(1) Install t h r u s t washer pin in countershaft (Fig. fifth gear. Tapered side of sleeve faces front and flat
150). side faces rear (Fig. 153).
GEAR SYNCHRO
SLEEVE
COUNTERSHAFT
FIFTH
GEAR
0 / COUNTERSHAFT J9221-234
J9221-237
Fig. 150 Installing Fifth Gear Thrust Washer Pin Fig. 153 Installing Synchro Sleeve On Countershaft
(2) Install t h r u s t washer on countershaft. Turn Fifth Gear Hub
washer until pin engages in washer notch (Fig. 151). (6) Install shift fork in synchro sleeve (Fig. 154).
Flat side of washer faces rear and cone side to front (7) Install assembled fifth gear, synchro sleeve and
as shown. shift fork (Fig. 155). Align fork with shift lug rail
and align gear with bearings and countershaft. Start
SYNCHRO
' SLEEVE
SHIFT
FORK
V ^ .LS J9221-238
Fig. 154 Installing Fifth Gear Shift Fork In Synchro

Sleeve
components onto shaft and rail. Then tap gear and
fork into place with plastic or rawhide mallet.
(8) Align roll pin holes in shift fork with notches Fig. 156 installing Fifth Gear Synchro Struts And
in shift lug rail. Then install roll pins from top side Springs
of fork (Fig. 155). Note that roll pins are one way fit
due to small shoulder at one end of each pin.
Fig. 157 Fifth Synchro Clutch Gear And Stop Ring

Installation
CLUTCH
Fig. 155 Installing Assembled Countershaft Fifth

Gear, Shift Fork And Synchro Sleeve
(9) Install synchro struts and springs in fifth gear
hub (Fig. 156). Install struts in hub slots first. Then
install springs by compressing them with screwdriver
and working springs into hub and struts.
(10) Assemble and install fifth synchro clutch gear
and stop ring in fifth gear hub (Fig. 157). Make sure
both parts are seated in fifth gear hub.
(11) Install clutch gear snap ring (Fig. 158).
GEAR J9221-89
EXTENSION/ADAPTER HOUSING
Fig. 158 Installing Fifth Synchro Clutch Snap Ring
INSTALLATION
(1) If extension housing seal needs replacement, (3) Remove any burrs from housing bushing bore
remove it collapsing with a punch and chisel. Then with a file and emery cloth.
pry seal out of housing with crowfoot pry bar. (4) Install new bushing in extension housing (Fig.
(2) If extension housing bushing must be replaced, 160). Use Tool Handle C-4171 and Installer Tool
collapse old bushing with tapered drift (Fig. 159). Po SP5559 to install bushing. Note t h a t installer tool
sition drift in slot provided at end of housing. Then SP5559 is part of tool set C-4469.
tap drift into slot and against bushing to collapse (5) Install extension housing seal with Tool
and remove it. C-4660-3 (Fig. 161).
TAPERED SPECIAL TOOL

PUNCH C-4660-3
BUSHING
EXTENSION
HOUSING
EXTENSION HOUSING
J9221-251
Fig. 159 Removing Extension Housing Bushing
SPECIAL
-TOOL
C-4171 J9221-201
Fig. 161 Installing Extension Housing Seal

SPECIAL
•TOOL EXTENSION
C-4660-3 HOUSING
EXTENSION
HOUSING
J9221-252
Fig. 160 Installing Extension Housing Bushing

(6) Clean mating surfaces of extension/adapter
housing and gear case with a wax and grease re GEAR
mover. CASE J9221-85
(7) Check alignment dowels in gear case and hous
ing or adapter. Be sure dowels are in position and Fig. 162 Installing Extension/Adapter Housing
seated. SHIFT COVER INSTALLATION
(8) Apply Mopar Gasket Maker to gear case and (1) Clean mating surfaces of shift cover and gear
housing mating surfaces. case with a wax and grease remover.
(9) Align and install extension/adapter housing on (2) Apply Mopar Gasket Maker, or Loctite 518 to
gear case (Fig. 162). sealing surface of shift cover or gear case. Do not
(10) Apply Mopar Lock N' Seal or Loctite 242 to overapply sealer material. Excess can be squeezed
threads of extension/adapter housing bolts. into gear case and could block lubricant feed holes in
(11) Install and tighten housing bolts to 54 N» (40 time.
ft. lbs.) torque. U s e a twelve point 10 m m socket, (3) Lubricate synchro sleeves with Castrol Syntorq
a ratchet w r e n c h a n d n e c e s s a r y extensions to in gear lubricant. Then apply light coat of petroleum
stall bolts. D o not use any other type of socket jelly to shift fork contact surfaces.
a n d do not u s e an impact w r e n c h . Splines o n (4) Verify t h a t 1-2 and 3-4 synchro sleeves are in
bolt h e a d s c a n b e d a m a g e d if impact w r e n c h or neutral position. Also verify t h a t forks in shift cover
w r o n g type of socket is u s e d for tightening pur are in neutral position.
poses.
• NV4500 TRANSMISSION OVERHAUL 21 • 43
(5) Align and install shift cover (Fig. 163). If cover rails in the cover. Replace the cover assembly if the
will not seat, it is either not aligned on gear case rails are loose in the cover bores.
dowels, or shift forks are not aligned with sleeves Inspect and replace the pads on the fifth-reverse
and shift lug. shift fork if worn. The reverse inhibitor should also
SHIFT
be replaced if worn, or faulty. The expansion plugs at
the rear of the cover can be replaced if loose or leak
ing.
A gasket is not u s e d b e t w e e n the shift cover
a n d gear case. U s e Mopar Gasket Maker, or Loc
tite 518 to seal the cover.
Procedures for the serviceable components in the
shift cover as follows:
Fifth-Reverse Shift Fork Pad Replacement

The plastic shift fork pads are held in place by a
combination of tension and a small locating tang.
Three pads are used on the fork (Fig. 164).
The pads can be removed either by hand or with a
narrow blade screwdriver. To remove the pads by
Fig. 163 Installing Shift Cover Assembly hand, grasp each pad and tilt it out and off the fork.
If the pads prove difficult to remove by hand, insert a
(6) Apply Mopar Lock N' Seal or Loctite 242 to screwdriver blade between the pad and fork and pry
threads of shift cover bolts. the pad off.
(7) Install and tighten shift cover bolts to 30 Nnn
(8) Install backup light switch and vent in shift
cover. Apply sealer to switch threads before installa
tion and tighten switch to 30 Nnn (265 in. lbs.).
(9) On 2-wheel drive models, install and index
speedometer adapter in extension housing.
(10) Install and tighten drain plug to 40 Nnn (30
ft. lbs.) torque.
(11) Fill transmission to bottom edge of fill plug
hole with Castrol Syntorq gear lubricant.
(12) Install and tighten fill plug to 40 N-m (30 ft.
lbs.) torque.
SHIFT COVER SERVICE

The only serviceable shift cover components are:
• fifth-reverse shift fork pads
Fig. 164 Shift Fork Pad Locations
• reverse inhibitor
• vent components Reverse Inhibitor Replacement
• backup light switch The reverse inhibitor mechanism should be
• expansion plugs checked for wear or damage whenever diagnosis in
• shift lever components dicates this is necessary.
The shift cover, shift forks, shift rails and detent The inhibitor mechanism is attached to the cover
components are not serviced individually. The cover with two screws (Fig. 165). Attaching screw torque is
must be replaced as an assembly if the cover, or any 8-14 N-m (75-115 in. lbs.).
shift components are worn or damaged.
Vent Component Replacement
Shift Cover Inspection The shift cover vent assembly consists of the vent
Inspect the cover and shift components whenever tube, connecting hose, hose clamps, and vent valve
the cover is removed from the gear case. Or, when (Fig. 166).
ever diagnosis indicates inspection is necessary. If the vent tube is removed for replacement or ser
Check the forks for wear, distortion, cracks, or be vice access, apply Mopar silicone adhesive/sealer to
ing loose on the shift rails. Also check fit of the shift the tube to help secure it in the cover.
21 - 44 NV450Q TRANSMISSION OVERHAUL
REVERSE (3) Clean all chips from shift cover and plug bores.
INHIBITOR Then clean plug bores with solvent and dry with
clean shop towel.
(4) Apply small bead of sealer to outer edge of each
new plug. Use Mopar silicone adhesive/sealer, or
equivalent.
(5) Position each new plug in bore and tap into
place with hammer and suitable size punch or socket.
Shift Lever Replacement

J9221-255
Fig. 165 Reverse Inhibitor Mounting

HOSE
VENT
VALVE
EXPANSION
PLUGS J9221-258
VENT Fig. 168 Expansion Plug Location

TUBE CLAMP J9221-256
(1) If transmission is in vehicle, remove shift lever
Fig. 166 Shift Cover Vent Components extension, upper boot and bezel. If transmission is
out of vehicle, temporarily mount cover on gear case.
Backup Light Switch Replacement (2) Remove shift lever lower boot. Unseat boot
The backup light switch is located at the left (driv from shift tower and slide it off shift lever.
er) side of the cover (Fig. 167). The switch plunger is (3) Unlock shift lever retainer with two long
operated by the fifth-reverse shift rail. screwdrivers for leverage. Press lever retainer down
The switch can be replaced with the transmission ward with screwdrivers. Then t u r n retainer counter
in, or out of the vehicle. A gasket may, or may not be clockwise to release retainer from locking pins in
used with the switch. shift tower (Fig. 169).
Apply sealer to the switch threads before installa
tion. Tightening torque for the switch is 22-34 N m #
RETAINER
(192-300 in. lbs.).
BACKUP
LIGHT
SWITCH
J9221-257
Fig. 167 Backup Light Switch Location

Expansion Plug Replacement
The expansion plugs at the rear of the shift rail
bores (Fig. 168) can be replaced if loose and/or leak
ing. Replacement procedure is as follows:
Iff^r J9221-253
(1) Drill 6 mm (1/4 in.) diameter hole in each plug
to be removed. Fig. 169 Unlocking Shift Lever Retainer
(2) Pry plug out of cover with tapered punch.
(4) Lift shift lever upward and remove lever, re SHIFT
tainer and spring as assembly (Fig. 170). COVER
SLOT
SHIFT SPRING RETAINER

LOWER
BOOT
J9221-259
Fig. 170 Shift Lever Components

(5) Lubricate shift lever and retainer contact sur Fig. 172 Loosening Shift Cover
faces with petroleum jelly or Castrol Syntorq.
(6) If transmission is out of vehicle, temporarily SHIFT
mount shift cover on gear case.
(7) Position lever assembly in shift tower.
(8) Lock lever retainer in shift tower with two long
screwdrivers. Use screwdrivers to push and turn re
tainer until it engages both locking pins in tower.
(9) Install lower boot on shift lever. Seat boot se
curely on shift tower.
(10) If transmission is in vehicle, install upper
boot, bezel and shift lever extension.
Shift Cover Replacement

(1) Remove transmission from vehicle.
(2) Remove shift cover bolts (Fig. 171).
Fig. 173 Shift Cover Removal/Installation

(7) Clean mating surfaces of shift cover and gear
case with wax and grease remover.
(8) Apply Mopar Gasket Maker, or Loctite 518 to
sealing surface of shift cover or gear case. Do not
overapply sealer material. Excess can be squeezed
into gear case and could block lubricant feed holes in
time.
(9) Lubricate synchro sleeves with Castrol Syntorq
gear lubricant. Then apply light coat of petroleum
jelly to shift fork contact surfaces.
(10) Verify t h a t 1-2 and 3-4 synchro sleeves are in
neutral position. Also verify that forks in shift cover
are in neutral position.
(11) Align and install shift cover (Fig. 173). If
Fig. 171 Shift Cover Boit Removal/Installation cover will not seat, it is either not aligned on gear
case dowels, or shift forks are not aligned with
(3) Loosen shift cover with pry tool. To avoid dam sleeves and shift lug.
aging cover seal surface, insert pry tool only in slots (12) Apply Mopar Lock N' Seal or Loctite 242 to
provided in cover (Fig. 172). threads of shift cover bolts.
(4) Raise cover enough to disengage it from align (13) Install and tighten shift cover bolts to 27-31
ment dowels in gear case (Fig. 173). N*m (216-276 in. lbs.) torque.
(5) Raise front of shift cover and lift cover up and (14) Install backup light switch in cover. Apply
off gear case (Fig. 173). sealer to switch threads before installation and
(6) Set cover assembly aside for inspection. If cover tighten switch to 22-34 N*m (193-265 in. lbs.).
components are damaged, refer to shift cover service (15) Install vent assembly, if removed. Apply an
information. adhesive/sealer to vent tube to help secure it in
cover.
21 - 46 G360 MANUAL TRANSMISSION
G360 MANUAL T R A N S M I S S I O N
INDEX
page page
Gear Ratios 46 Transmission Installation—4-Wheel Drive . . . . . . . 52
General Information 46 Transmission Removal—2-Wheel Drive . . . . . . . . 47
Recommended Lubricant 46 Transmission Removal—4-Wheel Drive 51
Transmission Identification 46 Transmission Serviceability 47
Transmission Installation—2-Wheel Drive . 50
GENERAL INFORMATION Lubricant capacity is 3.3 liters (3.5 qts.). The trans
The Getrag G360 transmission is used exclusively mission drain and fill plugs are both accessible from
with the Cummins turbo diesel engine. It is a heavy the passenger side of the transmission case (Fig. 2).
duty, 5-speed, fully synchronized manual transmis
sion (Fig. 1). Fifth gear is an overdrive range with a TRANSMISSION IDENTIFICATION
ratio of 0.77 to 1. The transmission identification/part number is im
The G360 is a top loader style transmission (Fig. printed on a metal t a g attached to t h e passenger side
1). The shift lever, shift rails and shift forks are of the case (Fig. 2).
mounted in t h e transmission shift cover. The shift le
ver operates t h e shift rails and forks directly. GEAR RATIOS
G360 gear ratios are:
RECOMMENDED LUBRICANT First gear : 5.531:1
Recommended lubricant for t h e Getrag G360 trans Second gear: 3.017:1
mission is SAE 5W-30 engine oil. The oil should Third gear : 1.60:1
meet A.P.I, service classifications SG or SG-CD. Fourth gear: 1.00:1
Fig. 1 G360 Manual Transmission

G360 MANUAL TRANSMISSION 21 - 47
on lower boot. Then slide boot upward on lever (Fig.

3).
(3) Remove screws attaching lower boot and plate
assembly to floor pan (Fig. 4).
IDENTIFICATION
PLATE
LOWER
.BOOT
AND
PLATE
Fig. 2 G360 identification Plate And Drain/Fill Plug
Locations
Fifth gear : 0.77:1 PLATE J9121-255
SCREW (4)
Reverse : 5.029:1
Fig 4 Removing/Installing Lower Boot And Plate
TRANSMISSION SERVICEABILITY
Attaching Screws
The G360 transmission can be serviced when nec
essary. Replacement parts are available for overhaul. (4) Remove shift lever extension by either un
The transmission gear case, rear retainer, counter threading, or unbolting it from shift lever (Fig. 5).
gear and countershaft are not serviceable parts. If
LOWER
these components become damaged to the point of re BOOT AND
placement, the transmission must be replaced as an PLATE
assembly.

(2) Shift transmission into Neutral and remove
screws attaching shift lever upper boot to metal plate
J9121-256
Fig. 5 Removing/Installing Shift Lever Extension

(5) Slide lower boot and plate upward and off shift
lever (Fig. 6).
UPPER
BOOT
BOOT
SCREW (4) LOWER
BOOT AND
PLATE J9121-254
Fig. 3 Removing/Installing Shift Lever Upper Boot

21 - 48 G360 MANUAL TRANSMISSION •
Fig. 8 Removing Shift Lever Snap Ring

ment slots in lever color and pivot ball (Fig. 9).
These slots align with shoulder bolts in shift
tower.
J9121-257
Fig. 6 Removing/Installing Lower Boot And Plate

(6) Remove transmission shift tower boot. Loosen
clamp securing boot to shift tower. Then slide boot
up and off shift lever and shift tower (Fig. 7).
Fig. 9 Removing/Installing Shift Lever

(10) Mark propeller shaft U-joints and axle yokes
for assembly alignment reference (Fig. 10).
(11) Remove propeller shaft. Remove clamp strap
bolts at front of shaft first. Remove center bearing
Fig. 7 Removing/Installing Shift Tower Boot
bracket bolts and support shaft on tool box or stand.
(7) Remove snap ring securing shift lever in shift Then remove rear clamp strap bolts and remove
tower (Fig. 8). shaft.
(8) Remove shift lever (Fig. 10). If lever does not (12) Spread clamps t h a t secure switch wires to
come out readily, press lever downward and quickly transmission top cover and remove wires from
release it two or three times. Or lightly tap side of clamps. Move wires aside to protect them and pro
lever with plastic mallet to loosen it. Note align- vide working clearance.
• G360 MANUAL TRANSMISSION 21 - 49
SAFETY
Fig, 12 Transmission Supported On Jack
Fig. 11 Transmission Rear Mount Bolt Locations

(14) Support transmission with transmission jack
(Fig. 12). Secure transmission to jack with safety
chains as shown.
(15) On some models it may be necessary to re
move screws attaching fuel line clamps to driver side
frame rail (Fig. 13). Three clamps must be removed
so fuel lines can be moved for access to crossmember
bolts on this side of frame rail. Fig. 13 Removing/installing Fuel Line Clamps
(16) Remove left and right crossmember-to-frame
braces (Fig. 14) and remove crossmember.
SLAVE
CYLINDER
PISTON
ROD
CLUTCH
RELEASE
FORK
CROSSMEMBER
FRAME
RAIL DRIVER SIDE
BRACKET
CROSSMEMBER LOOSEN CYLINDER NUTS
TO RELIEVE TENSION
ON FORK AND BEARING J9121-270
Fig. 16 Loosening Slave Cylinder Nuts

(19) Remove bolts attaching transmission to clutch
housing and remove transmission. Rock transmission
slightly to help free input shaft from clutch disc and
release bearing.
(20) Support engine with wood block and adjust
able jack stand (Fig. 17).
PASSENGER.
SIDE
BRACE J9221-65
Fig. 14 Crossmember And Braces

(17) Remove clutch slave cylinder shield (Fig. 15).
J9106-22
Fig. 17 Typical Method Of Supporting Engine
SLAVE TRANSMISSION INSTALLATION—2-WHEEL DRIVE

CYLINDER (1) Mount transmission on jack stand. Secure
HEAT SHIELD transmission to jack with safety chains.
(2) Apply light coat of Mopar high temperature
bearing grease to contact surfaces of input shaft (Fig.
18) and following components:
J9121-269
C A U T I O N : D o not use an excessive amount of
Fig. 15 Removing/Installing Slave Cylinder Shield grease. Excessive amounts of grease could result
in grease contamination of the clutch disc.
(18) Loosen clutch slave cylinder attaching nuts
until cylinder piston rod is clear of release lever (Fig. • input shaft splines and pilot bearing hub
16). This reduces pressure on lever and release bear • release bearing slide surface of front retainer
ing making transmission removal/installation easier. • pilot bushing
Cylinder does not have to be removed completely. • release bearing bore
• release fork
• G360 MANUAL TRANSMISSION 21 - 51
• release fork ball stud notch is forward t h e n install lower boot attaching
• propeller shaft slip yoke screws.
(20) Thread or bolt shift lever extension to shift le
ver. Slide upper boot down extension. Position boot
on plate and install boot attaching screws.
(21) Install shift knob on extension (if removed).

(2) Remove screws attaching shift lever upper boot
to metal plate on lower boot. Then slide boot upward
on lever (Fig. 3).
(3) Remove screws attaching lower boot and plate
assembly to floor pan (Fig. 4).
(4) Remove shift lever extension by unthreading it
A
PPL
Y L
G
IHTC
OAT OF from shift lever (Fig. 5).
HI-TEMP GREASE TO THESE (5) Slide lower boot and plate upward and off shift
SURFACES BEFORE INSTALLATION J9106-15 lever (Fig. 6).
(6) Remove transmission shift tower boot. Loosen
Fig. 18 input Shaft Lubrication Points (Typical) clamp securing boot to shift tower. Then slide boot
(3) Align transmission and clutch housing. Move up and off shift lever and shift tower (Fig. 7).
transmission forward and start input shaft into re (7) Remove snap ring securing shift lever in shift
lease bearing and clutch disc hub. Rotate output tower (Fig. 8).
shaft with socket or yoke to align input shaft and (8) Remove shift lever (Fig. 9). If lever does not
clutch disc splines if necessary. come out readily, press lever downward and quickly
(4) Move transmission forward and seat transmis release it two or three times. Pressure from spring
sion against housing. under lever should push it out of housing. Note
(5) Install and tighten transmission mounting alignment slots in lever cover and pivot ball
bolts to 68 N-m (50 ft-lbs). (Fig. 9). These slots align with shoulder bolts in
(6) Install rear crossmember and crossmember shift tower.
brackets. Start all crossmember bolts/nuts before (9) Raise and support vehicle.
tightening to final torque of 68 N»m (50 ft-lbs). (10) Mark front and rear propeller shafts for in
(7) Remove transmission jack. stallation reference (Fig. 10). Then disconnect and re
(8) Install screws t h a t attach fuel line clamps to move both shafts.
driver side frame rail. (11) Remove transfer case skid plate and cross-
(9) Align clutch slave cylinder in housing and member (Fig. 19).
tighten cylinder attaching nuts.
(10) Install clutch slave cylinder shield.
(11) Secure backup light and vehicle speed sensor
wires in clips at top of transmission. Route wires
across top of transmission to sensor and switch and
connect wires.
(12) Align and install propeller shaft. Support
shaft on box or stand. Install shaft front U-joint first.
Next, secure center bearing bracket to frame bracket.
Then install shaft rear U-joint in axle yoke. Final-
@
tighten U-joint clamp bolts to 19 N m (14 ft-lbs) and
center bearing bracket bolts to 68 N»m (50 ft-lbs).
(13) Lower vehicle.
(14) Lubricate shift lever ball and collar with Mo
par all purpose grease.
(15) Align notches in shift lever ball and collar
and insert shift lever in shift tower.
(16) Press shift lever and collar downward and in
stall shift lever snap ring.
(17) Tighten shift lever alignment bolts com
pletely.
(18) Install boot over shift lever and onto shift S
KD
I
tower and tighten boot clamp securely. PLATE J9121-525
(19) Install lower boot and plate assembly over
shift lever and onto floorpan. Position plate so large Fig. 19 Transfer Case Skid Plate Mounting
(12) Disconnect wires at vehicle speed sensor and • propeller shaft slip yoke
backup light switch. (3) Align transmission and clutch housing. Move
(13) Disconnect transfer case shift lever from lever transmission forward and start input shaft into re
on transfer case. lease bearing and hub of clutch disc.
(14) Temporarily support transmission with adjust (4) Rotate output shaft with socket or yoke to align
able jack stand. Then support transfer case with input shaft and clutch disc splines. If input shaft will
transmission jack. not rotate enough in neutral to align splines, it will
(15) Remove nuts attaching transfer case to trans be necessary to shift transmission into third or
mission adapter and move transfer case away from fourth gear with screwdriver.
transmission rear retainer. (5) Seat transmission against clutch housing and
(16) Lower transfer case and move it from under align bolt holes in transmission and housing.
vehicle. Remove transfer case from transmission jack
(6) Install and tighten transmission-to-clutch hous
and place transfer case on workbench.
ing bolts to 68 N-m (50 ft. lbs.).
(17) Support transmission with transmission jack.
Secure transmission to jack with safety chains. Then (7) Install rear crossmember and mount. Start all
remove jack stand previously used to support trans crossmember bolts/nuts then tighten them to 68 N*m
mission. (50 ft. lbs.) torque.
(18) Spread clamps t h a t secure switch wires to (8) Remove transmission jack.
transmission top cover and remove wires from (9) Install screws t h a t attach fuel line clamps to
clamps. Move wires aside to protect them and pro driver side frame rail.
vide working clearance. (10) Align clutch slave cylinder in housing and
(19) Remove bolts attaching transmission rear tighten cylinder attaching nuts.
mount to crossmember. (11) Install clutch slave cylinder shield.
(20) On some models, it is necessary to remove (12) Secure backup light and vehicle speed sensor
screws attaching fuel line clamps to driver side wires in clips at top of transmission. Route wires
frame rail. Three clamps must be removed to so fuel across top of transmission to sensor and switch and
lines can be moved for access to crossmember bolts at connect wires.
this side of frame rail. (13) Install gasket and transfer case on transmis
(21) Remove left and right crossmember-to-frame sion rear retainer. Tighten transfer case attaching
braces and remove crossmember. nuts to 47 N-m (35 ft. lbs.) torque.
(22) Remove clutch slave cylinder shield. (14) Check transmission and transfer case lubri
(23) Loosen clutch slave cylinder attaching nuts cant levels. Add lubricant if necessary and install fill
until cylinder piston rod is clear of release lever (Fig. plugs.
20). This reduces pressure on lever and release bear
(15) Connect transfer case shift lever to lever on
ing making transmission removal/installation easier.
transfer case.
Cylinder does not have to be removed completely.
(16) Align and install propeller shafts. Tighten
(24) Remove bolts attaching transmission to clutch
housing and remove transmission. Rock transmission U-joint clamp bolts to 19 N-m (14 ft. lbs.).
slightly to help free input shaft from clutch disc and (17) Install skid plate and crossmember. Tighten
release bearing. skid plate and crossmember bolts/nuts to 41 N—m
(25) Support engine with wood block and another (30 ft. lbs.) torque.
adjustable jack stand. (18) Lower vehicle.
(19) Shift transmission into neutral if necessary.
TRANSMISSION INSTALLATION—4-WHEEL DRIVE (20) Lubricate shift lever ball and collar with Mo
(1) Mount transmission on jack stand. Secure par all purpose grease.
transmission to jack with safety chains. (21) Align notches in shift lever ball and collar
(2) Apply light coat of Mopar high temperature and insert shift lever in shift tower.
bearing grease to contact surfaces of input shaft (Fig. (22) Press shift lever and collar downward and in
20) and following components: stall shift lever snap ring.
(23) Install boot over shift lever and onto shift
C A U T I O N : D o not use excessive amounts of grease. tower and tighten boot clamp securely.
This practice could result in contamination of the (24) Install lower boot and plate assembly over
clutch disc. shift lever and onto floorpan. Position plate so large
notch is forward then install lower boot attaching
• input shaft splines and pilot bearing hub screws.
• release bearing slide surface of front retainer (25) Thread or bolt shift lever extension to shift le
• pilot bushing ver. Slide upper boot down extension. Position boot
• release bearing bore on plate and install boot attaching screws.
• release fork (26) Install shift knob on extension (if removed).
• release fork ball stud (27) Connect battery negative cable.
• G360 TRANSMISSION OVERHAUL 21 - 53
G 3 6 0 TRANSMISSION O V E R H A U L
INDEX
page page
Transmission Assembly and Adjustment . . . . . . . 63 Transmission Disassembly 53
Transmission Cleaning and Inspection 59
TRANSMISSION DISASSEMBLY
SHIFT COVER REMOVAL
(1) Shift transmission into neutral.
(2) Remove shift cover bolts.
(3) Loosen shift cover with two pry tools. Insert
tools in cover slots and pry cover off alignment dow
els (Fig. 1). It is important to remove the cover
evenly to avoid d a m a g e . Do not pry o n e side
loose then the other. This practice could damage
the forks and cover.
SHIFT
COVER
Fig. 2 Shift Cover Removal/Installation
Fig. 1 Loosening Shift Cover

(4) Remove shift cover assembly (Fig. 2). Discard
old shift cover gasket. Note that a gasket w a s not
u s e d o n early production transmissions. It is CHANNELS (4) J9321-268
recommended that a g a s k e t b e u s e d w h e n shift
cover is installed after overhaul. Fig. 3 Front Bearing Retainer Removal
(5) Set shift cover assembly aside for inspection. (c) Remove bolts attaching rear bearing retainer
REARING RETAINER AND SHAFT BEARING to gear case and remove retainer. Use rubber mal
RACE REMOVAL let to loosen retainer if necessary.
(1) Remove front bearing retainer bolts and re (d) Remove speedometer gear and spacers from
move retainer (Fig. 3). Tap retainer with rubber mal output shaft.
let to loosen it if necessary. (e) Remove preload shims from rear retainer, or
(2) On 2-wheel drive models, remove rear bearing bearings.
retainer as follows (Fig. 4): (f) Remove yoke seal from retainer with suitable
(a) Remove n u t attaching yoke to output. pry tool. Do not damage retainer surface while re
Torque on nut is quite high. Best w a y to re moving seal.
move nut is with 350-400 ft. lb. rated high ca (3) On 4-wheel drive transmission, remove rear
pacity impact w r e n c h . bearing retainer bolts and remove retainer from gear
(b) Remove yoke from output shaft splines. case (Fig. 5).
21 - 54 G350 TRANSMISSION OVERHAUL 4-
REAR
BEARING
RETAINER
SPEEDOMETER >YOKE
GEAR NUT
YOKE
YOKE
SEAL
SPACERS J9321-271
Fig. 4 Two Wheel Drive Rear Bearing Retainer And Speedometer Gear Removal
(4) On 4-wheel drive transmission, remove bearing OUTPUT
preload shims from rear bearing retainer (Fig. 6). On SHAFT
2-wheel drive transmissions, remove shims from re- SHIM
tainer and slide output shaft rear bearing shims off \ ,
shaft.
J9321-270
Fig. 6 Shim Locations In Rear Bearing Retainer

(5) Remove output shaft and countershaft bearing
races (Fig. 7 ) . Tap front and rear faces of gear case
with large plastic mallet to loosen and remove races.
D o not strike bearing races. Tap o n case sur
faces only.
REAR
BEARING
RETAINER J9321-267
Fig. 5 Four Wheel Drive Rear Bearing Retainer

Removal
• G360 TRANSMISSION OVERHAUL 21 - ii
Fig. 9 Output Shaft And Gear Assembly Removal

COUNTER GEAR AND SHAFT REMOWAL
(1) Remove countershaft front bearing cap from
case (Fig. 10). Strike cap with punch to unseat it. Ex
ercise care as bearing could be damaged if punch
Fig. 7 Shaft Bearing Race Removal penetrates cap and contacts bearing.
(2) Remove large snap ring retaining counter gear
INPUT SHAFT AND OUTPUT SHAFT REMOWAL shaft front bearing race in gear case (Fig. 10).
(1) Rotate input shaft until flats on shaft clutch (3) Remove counter gear shaft front bearing race
teeth are facing downward toward countershaft (Fig. from gear case (Fig. 10). If race proves difficult to re
8). move, use a slide hammer and blind hole puller tool.
Or, remove rear bearing snap ring and drive counter
gear shaft (and front bearing) out front of case. Pro
cedure is outlined in following steps.
Fig. 8 Location Of Input Shaft Clutch Gear Flats

BEARING
(2) Work input shaft forward until clear of output CAP J9321-274
shaft.
(3) Remove output shaft and gears as assembly Fig. 10 Counter Gear Shaft Front Bearing Cap, Snap
from case (Fig. 9). Ring And Race Removal
(4) Remove input shaft from case (Fig. 9).
(5) If bearing on input shaft is damaged, press (4) Remove small snap ring retaining rear bearing
bearing from shaft. Use hydraulic shop press and on counter gear shaft (Fig. 11).
standard bearing splitter type remover tool.
21 - 56 G360 TRANSMISSION OVERHAUL ^ ^ ^ ^ •
REAR COUNTER
ROTAT
E
BEARING GEAR
CO U
N T
ERG E
AR
S
NAP S
HAF
T PAS
TD IL
ER
RING GEA
R AND
OUT OF C
ASE
R
EA
R
B
EAR
NIG
R
EV
ERS
E
J9321-275 D
IL
ER
GEA
R
Fig. 11 Removing Counter Gear Shaft Front Bearing
Snap Ring
(5) Tap countershaft out of forward end of gear
case (Fig. 12). Use hammer and brass punch to re
move shaft and front bearing.
(6) If countershaft rear bearing is damaged, re
move snap ring and press bearing off shaft.
C
O UN T
ER J9321-277
GEAR
S HA F
T Fig. 13 Counter Gear Removal (With New Style Gear
AND
F
RONTB EA
RN
IG Case)
Reverse Idler Removal (New Style Gear Case)
(1) Remove idler shaft pins (Fig. 14). Use appropri
ate size pin punch only to remove pins. Discard pins
after removal as they are not reusable.
DIL
ER
J9321-276 GEA
R
PN
IS
Fig. 12 Counter Gear Shaft And Front Bearing R(EMOVEWT
IH
Removal PIN P
UNCHONLY
)
(7) Position gear case in upright position (Fig. 13).

(8) Remove counter gear from case as follows:
(a) On transmission with new style gear case,
counter gear can be removed by rotating it past re
verse idler gear and out of case (Fig. 13).
(b) On transmission w i t h early style gear
case, it will be n e c e s s a r y to remove reverse
idler gear before counter g e a r c a n b e removed.
R
EV
ERS
E
Refer to following Reverse Idler Gear Removal D
IL
ER
procedures. GEA
R J9321-279
REVERSE IDLER GEAR REMOVAL Fig. 14 Location Of Reverse Idler Shaft Pins
Two styles of transmission case were used for the (2) Remove bolt t h a t aligns and secures idler shaft
G360 transmission. Early style cases had a partial in case (Fig. 15). Keep bolt with idler gear compo
radius machined in the reverse idler area while later nents. Do n o t i n t e r m i x it with other fasteners.
style cases had a full radius. The different machining
required different methods for removing the reverse
idler gear and shaft.
On early style gear cases, the idler gear must be
removed before the counter gear can be removed.
On new style cases, the counter gear can be re
moved with the idler gear still in place.
G350 TRANSMISSION OVERHAUL 21 - 57
(2) Slide gear and washer forward and remove rear

REVERSE
IDLER pin.
SHAFT (3) Remove bolt securing idler shaft in case.
BOLT (4) Slide idler shaft forward and remove gear and
washer from case. Turn counter gear to help rotate
idler gear out of case.
OUTPUT SHAFT DISASSEMBLY

D o not disassemble the 1-2, 3-4 and fifth-re
verse synchros during overhaul. The c o m p o n e n t
J9321-278 parts in e a c h s y n c h r o are not available sepa
rately. The synchros are serviced as assemblies
Fig. 15 Reverse idler Shaft -Bolt Removal only.
(3) Remove reverse idler shaft (Fig. 16) C A U T I O N : The output shaft and geartrain are quite
heavy. Have a helper support and hold the output
shaft and gear assembly during all press opera
tions. Do not allow the shaft and gear assembly to
fall and strike the s h o p floor.
(1) Press fifth gear and rear bearing off output

shaft. Use standard bearing splitter type remover
tool and shop press to remove gear and bearing (Fig.
18).
REAR
BEARING
REVERSE
IDLER
SHAFT J9321-280
Fig. 16 Reverse Idler Shaft Removal (New Style

Gear Case)
(4) Remove idler gear, thrust washers, bearings
and spacer as assembly (Fig. 17).
STANDARD TYPE
IDLER GEAR REMOVER TOOL
THRUST
WASHERS
PRESS
RAM
OUTPUT
SHAFT
J9321-281
Fig. 17 Reverse Idler Gear Removal (New Style Gear Fig. 18 Removing Fifth Gear And Rear Bearing
Case)
(2) Remove fifth-reverse snap ring and blocker
Reverse Idler Removal (Early Style Gear Case) ring (Fig. 19).
(1) Remove front pin from idler shaft first. (3) Remove two halves of fifth gear bearing from
output shaft (Fig. 20).
21 - 58 G360 TRANSMISSION OVERHAUL •
SNAP BLOCKER SNAP SNAP

RING RING RING RING
PLIERS
FIFTH-REVERSE FIRST
SYNCHRO GEAR
ASSEMBLY J9321-283 J9321-285
Fig. 19 Removing Fifth-Reverse Snap Ring And Fig. 21 First Gear Snap Ring Removal
Blocker Ring
PRESS
(4) Remove reverse gear and fifth-reverse synchro RAM
assembly (Fig. 20). Use two large, flat-blade screw
drivers to pry components up and off mainshaft
splines (Fig. 20). If gear and synchro proves difficult
to remove, use a press and bearing splitter for re
moval. FIRST PRESS
GEAR PLATES
(5) Remove reverse gear bearing from gear or out
put shaft.
FIFTH-REVERSE
FIFTH SYNCHRO
GEAR ASSEMBLY
BEARING
(2-PIECE)
REVERSE
GEAR J9321-286
Fig. 22 First Gear Removal
1-2
SYNCHRO
ASSEMBLY
(NOTE POSITION
BEFORE REMOVAL)
PRY>
TOOLS J9321-284
Fig. 20 Reverse Gear And Fifth-Reverse Synchro

Removal
(6) Remove first gear snap ring (Fig. 21).
(7) Remove first gear (Fig. 22). Use shop press and
two press plates to press gear off shaft. Have helper
hold output shaft while removing gear.
(8) Remove first gear bearing from gear or output J9321-288
shaft.
(9) Mark position of 1-2 synchro assembly for in Fig. 23 Removing 1-2 Synchro Assembly
stallation reference. Then remove synchro assembly shop press to remove these components (Fig. 24). P o
from output shaft (Fig. 23). sition remover tool j a w s under t h i r d g e a r for re
(10) Remove pilot bearing, 3-4 synchro assembly moval purposes. Also h a v e helper support a n d
and third gear as a unit. Use suitable size bearing hold assembly during removal.
splitter type remover tool, press tool and hydraulic
Fig. 24 Pilot Bearing, 3-4 Synchro And Third Gear Fig. 26 Second Gear And Thrust Washer Removal
Removal (1) On first gear, tap pins through blocker ring
and remove ring from gear.
(2) On second gear, remove blocker ring as follows:
(a) Position gear on workbench so first roll pin to
be removed extends over edge of bench (Fig. 27).
(b) Tap each roll pin about three quarters of way
through blocker ring.
(c) Pry blocker ring off gear (Fig. 28). Discard
ring if considerable force was required to remove
THRUST
ring from gear.
WASHER
(d) Remove pins from gear with locking pliers
(Fig. 29).
(3) Discard roll pins after removal. They should
not be reused.
(4) Discard either gear if damaged.
J9321-290
Fig. 25 Second Gear Snap Ring Removal

(11) Remove third gear bearing from gear or shaft.
(12) Remove second gear snap ring with heavy
duty snap ring pliers (Fig. 25). Discard snap ring af
ter removal as it is not reusable.
(13) Remove second gear and thrust washer from
shaft with hydraulic shop press (Fig. 26). Have
helper hold output shaft while gear and washer are
being removed.
(14) Remove second gear bearing from gear or
shaft.
FIRST AND SECOND GEAR BLOCKER RING

REMOVAL Fig. 27 Unseating Blocker Ring Roll Pins
The blocker rings on the first and second gears are
TRANSMISSION CLEANING AND INSPECTION
secured to the gear with roll pins.
Clean the transmission components with solvent.
The pins can either be removed completely, or sim Use shop towels to dry bearings and bearing races.
ply tapped inward to allow blocker ring removal. An Compressed air can be used to dry the other trans
appropriate size pin punch and hammer, or locking mission components.
pliers are the only tools required for removal (Fig. D o not u s e c o m p r e s s e d air to dry the bearings.
27). Procedure is as follows: This practice c a n result in abrading and brinnel-
ling the bearing rollers and races.
BLOCKER SECOND
GEAR
Fig. 28 Removing Blocker Ring From Gear Fig. 29 Removing Roll Pins From Gear
Output Shaft And Gears damaged synchro blocker rings, or worn galled bear
Inspect the shaft and gears for wear, or damage ings. Discoloration or shiny spots on gear teeth are a
(Fig. 30). Check for broken, or chipped gear teeth, normal condition and do not indicate a need for re
placement.
1
I
21 - 62 G360 TRANSMISSION OVERHAUL
Synchronizers And Blocker Rings COUNTER REAR

GEAR BEARING
LEGEND FOR OUTPUT SHAFT AND A N D SNAP
GEARTRAIN RING
Front Bearing
Input Shaft
Blocker Ring (4th Gear)
Output Shan Pilot Bearing
3-4 Synchro Assembly
Blocker Ring (3rd gear)
Third Gear
8 Third Gear Bearing
9 Snap Ring
ho Spacer
11 Second Gear
12 Second Gear Blocker Ring And Retaining Pins (3)
13 Second Gear Bearing
14 Output Shaft (2WD version shown)
15 1 -2 Synchro Assembly
16 First Gear Bearing COUNTER
17 First Blocker Ring And Retaining Pins (3) GEAR
18 First Gear SHAFT
19 Spacer
20' Snap Ring
21 Reverse Gear Bearing
22 Reverse Gear FRONT
23' Blocker Ring (reverse gear) BEARING
24 Fifth-Reverse Synchro Assembly AND
25 Snap Ring SNAP RING J9321-308
'26 Fifth Gear Bearing (2-piece)
27 Blocker Ring (fifth gear)
28 Fifth Gear Fig. 31 Counter Gear Components
29 Rear Bearing
J9321-305 threads are in good condition. The case threads can
be cleaned up with a tap, or repaired with Heli-Coil
Inspect the synchro blocker rings (Fig. 30). Look
stainless steel thread inserts if necessary. Replace
for evidence of wear or damage to the clutch material
the bolt if damaged.
on the rings. Also check the rings for cracks. Place
the rings on a flat surface to check for distortion. THRUST REVERSE BEARINGS
The 1-2, 3-4 and fifth-reverse synchro hubs, WASHER IDLER
GEAR
sleeves, struts and springs are serviced as assem
blies. If wear or damage is evident, it will be neces
sary to replace the complete synchro assembly.
Counter Gear And Shaft

Check the gear, shaft and bearings for wear or THRUST
WASHER
damage (Fig. 31). Minor nicks or scratches on the
gear teeth can be smoothed off with an oilstone. Mi
nor nicks or scratches on the shaft can be reduced
and smoothed off with 320/400 grit emery cloth.
SHAFT
The counter gear and shaft are not serviceable PINS
components. If either part is damaged, it will be nec IDLER SHAFT
essary to replace the complete transmission assem SHAFT BOLT J9321-309
bly.
Fig. 32 Idler Gear Components
Reverse Idler Components Bearings And Races
The reverse idler components consist of the gear, Inspect each bearing and race carefully. Check for
shaft, thrust washers, pins, bearings and the shaft such conditions as spalling, wear, cracks, distortion,
bolt (Fig. 32). or flat spotting of the rollers and races. Replace any
Clean and inspect the idler components. Replace bearing or race if doubt exists about its condition.
the gear if any teeth are chipped, or cracked. Replace
the shaft and bearings if galled, brinnelled, or se Seals And Snap Rings
verely worn. The thrust washers can be reused but
Replace front and rear retainer seals and the coun
only if wear is not excessive and the washer notches
tershaft front bearing cap. Do not reuse these parts.
are in good condition.
Replace the pins during overhaul. The pins should
not be reused. Also be sure the shaft bolt and case
The retainer seals have a small spring around the in troleum jelly can be used to hold parts in place and
ner part of the seal. Be sure each seal is installed prelubricate bearings and seal lips.
with this spring facing the case interior. D o not use chassis grease, or similar products
The snap rings should all be replaced. Eeusing on any c o m p o n e n t during assembly. H e a v y lu
snap rings is not recommended. bricating grease will plug the transmission oil
p a s s a g e s resulting in failure.
Shift Cover Preload adjustments are required for the output
Inspect the shift cover components (Fig. 33). The shaft and countershaft bearings. Preload is accom
only serviceable shift cover components are the shift plished by the use of select fit shims. An accurate
lever, lever retainer ring, snap ring, boot and clamp, vernier style depth gauge, depth micrometer, or dial
and backup light switch. indicator and suitable mounting stand are required
If any of the shift forks, shift rails, or shift rail de for measurement and adjustment. The procedure is
described in the Bearing Preload Adjustment section.
tent parts are worn, or damaged, replace the shift
cover assembly. ASSEMBLING OUTPUT SHAFT AND
COVER 1-2 3-4 GEARTRAIN
(1) Lubricate mainshaft, gears and synchro compo
nents with Mopar 5W-30 engine oil.
(2) Install blocker rings on first and second gears
as follows:
(a) Start roll pins into blocker rings and gears
with hammer (Fig. 34).
(b) Seat roll pins with pin punch (Fig. 35). Be
sure roll pins are seated flush with surface of each
blocker ring. Do not drive pins below surface of
rings.
SHIFT
RAILS J9321-310
Fig. 33 Shift Cover Assembly

TRANSMISSION ASSEMBLY AND ADJUSTMENT
Assembly Information
The only gasket in current G360 transmissions is
the shift cover gasket. All other sealing surfaces are Fig. 34 Starting Roll Pins In First/Second Gear
to be sealed with a coating of Mopar Gasket Maker, Blocker Rings
or Loctite 518. (3) Install bearing in second gear and install sec
Prior production G360 transmissions with the ond gear on output shaft (Fig. 36).
early style gear case, w e r e not equipped w i t h a (4) Install second gear thrust washer on output
shift cover gasket. It is r e c o m m e n d e d that a gas shaft (Fig. 37). Washer is tight fit o n shaft. Heat
ket b e u s e d o n these transmissions during over w a s h e r in o v e n or use suitable tool to seat
haul or w h e n e v e r the shift cover is removed w a s h e r o n shaft.If washer is heated to ease instal
during service. A gasket is available separately lation, heat washer for no more t h a n 5 minutes at
or as part of the basic overhaul kit. 200°F.
Apply Mopar Lock N' Seal, or Loctite 242 to bolt
threads before installation. These products will en
sure proper fastener retention and sealing.
Lubricate the transmission components with Mopar
5W-30 engine oil or equivalent, during assembly. Pe
21 - 64 1360 TRANSMISSION OVERHAUL •
SELECT SECOND
FIT GEAR
SNAP THRUST
RING WASHER
BLOCKER
RING
J9321-300
GEAR
Fig. 38 Second Gear Snap Ring Installation
BLOCKER
J9321-297 RING
Fig. 35 Seating Roil Pins in First/Second Gear

THIRD
Blocker Rings GEAR
OUTPUT
SHAFT-
SECOND J9321-301
GEAR
Fig. 39 Third Gear And Blocker Ring Installation
C A U T I O N : Be sure the third gear blocker ring is
aligned with the synchro hub before seating the
J9321-298 synchro assembly. Failure to align the ring could
result in damage to the blocker ring.
Fig. 36 Second Gear Installation
SYNCHRO
THRUST -INSTALLER
WASHER TOOL
INSTALLER
TOOL
3-4 SYNCHRO
ASSEMBLY
SECOND THIRD GEAR
GEAR BLOCKER
RING
J9321-299
Fig. 37 Second Gear Thrust Washer Installation

(5) Install second gear snap ring (Fig. 38). S n a p
J9321-302
r i n g is select fit part. U s e t h i c k e s t s n a p r i n g t h a t
will fit
Fig. 40 Installing 3-4 Synchro Assembly
(6) Install bearing in third gear. Then install gear
on output shaft (Fig. 39). (9) Install pilot bearing on output shaft (Fig. 41).
(7) Install synchro ring in third gear (Fig. 39). Heat bearing in oven to ease installation, or use suit
(8) Install 3-4 synchro assembly on output shaft able tool to tap bearing into place.
(Fig. 40). Side of synchro h u b with long shoulder (10) Turn output shaft over so rear of shaft is fac
g o e s to front of shaft a n d fits inside third gear. ing upward.
Use suitable size pipe style tool to tap or press syn (11) Install 1-2 synchro assembly (Fig. 42). If n e w
chro assembly into place. synchro is being installed, it c a n b e installed ei-
OUTPUT (13) Install first gear on mainshaft (Fig. 44). Work

SHAFT gear back and forth until blocker ring seats in syn
" PILOT chro assembly.
BEARING
J9321-303
Fig. 41 Output Shaft Pilot Bearing Installation

ther w a y o n shaft. If original s y n c h r o is being
reused, install synchro in same position a s w h e n
removed.
Fig. 44 First Gear Installation

(14) Install first gear thrust washer (Fig. 45).
Washer is tight fit on shaft. Either heat w a s h e r
in o v e n to e a s e installation, or u s e pipe tool or
brass drift to press w a s h e r onto shaft a n d
against gear.
Fig. 42 Installing 1-2 Synchro Assembly

(12) Install first gear bearing on mainshaft (Fig.
43).
FIRST
FIRST
GEAR
GEAR
BEARING
Fig. 45 First Gear Thrust Washer Installation

(15) Install first gear snap ring (Fig. 46). Do not
overspread s n a p ring to install it. Also be sure
s n a p ring is fully seated in shaft groove. Tap ring
into place with punch if necessary.
(16) Install bearing in reverse gear.
(17) Install reverse gear on mainshaft (Fig. 47).
(18) Install blocker ring in reverse gear (Fig. 47).
J9321-306 (19) Install fifth-reverse synchro assembly (Fig.
48). Be sure reverse gear blocker ring is aligned in
Fig. 43 First Gear Bearing Installation synchro before proceeding. Use pipe tool to press syn
chro into place if necessary.
21 - 66 G360 TRANSMISSION OVERHAUL
SELECT s u r e s n a p r i n g is fully s e a t e d in shaft g r o o v e .

Move synchro into reverse position for snap ring se
lection if necessary.
Fig. 46 Installing First Gear Snap Ring
BLOCKER
Fig. 49 Fifth-Reverse Synchro Snap Ring

Installation
(21) Install fifth gear bearing halves on output
shaft (Fig. 50). Use petroleum jelly to hold bearing
halves in place.
(22) Install blocker ring in fifth-reverse synchro
sleeve (Fig. 50).
Fig. 47 Reverse Gear And Blocker Ring Installation (23) Install fifth gear (Fig. 50).
J9321-314 SYNCHRO SLEEVE J9321-316
Fig. 48 Fifth-Reverse Synchro Installation Fig. 50 Fifth Gear, Bearings And Blocker Ring
Installation
(20) Install fifth-reverse synchro snap ring (Fig.
49). T h i s is a select fit s n a p r i n g . U s e t h i c k e s t (24) Install rear bearing on output shaft (Fig. 51).
s n a p r i n g t h a t will fit In shaft g r o o v e a n d b e Use suitable tool to seat bearing on shaft.
(25) Verify correct gear installation. Refer to in
stallation sequence shown in Figure 51.
6360 TRANSMISSION OVERHAUL 21 - 67
3-4 THIRD 1-2 SYNCHRO REVERSE FIFTH

SYNCHRO GEAR ASSEMBLY GEAR GEAR
SECOND FIRST FIFTH-REVERSE

GEAR GEAR SYNCHRO ASSEMBLY J9321-287
Fig. 51 Output Shaft Gea fin Installation Sequence

REVERSE IDLER GEAR INSTALLATION (3) Position t h r u s t washer at each end of idler gear
Different procedures are required for installing the and install gear assembly in case (Fig. 53). B e sure
idler gear in early and new style gear cases. slots in thrust w a s h e r s face outward as idler
The idler gear can be installed before installing the gear roll pins fit in these slots.
counter gear in a new style gear case. However, the (4) Align idler shaft pin holes and push idler shaft
counter gear must be installed before the idler gear into place in gear and washers.
in an early style gear case.
Refer to the appropriate idler gear installation pro IDLER GEAR
cedure during reassembly.
Reverse Idler Installation (With New Style Gear Case)

(1) Install reverse idler shaft part w a y into case
(Fig. 52).
Fig. 53 Idler Gear And Thrust Washer Installation

(5) Partially install idler shaft pins. Insert pins
only far enough to hold thrust washers in place.
(6) Check idler gear thrust washer clearance (Fig.
54) as follows:
(a) Check clearance between each thrust washer
Fig. 52 Idler Shaft Installed Part Way In Case and idler gear with feeler gauge.
(2) Install bearings and spacer in reverse idler (b) Clearance should be 0.05 - 0.25 mm (0.002 -
gear (Fig. 32). Be sure spacer is installed between 0.010 in.).
bearings.
(c) If clearance is not within specified limits, re (3) Assemble and install reverse idler gear and
move idler gear and replace thrust washers. Use thrust washers.
new pins when gear and washers are reinstalled. (4) Install rear pin in idler gear and shaft. Then
install front pin.
THRUST (5) Check idler gear thrust washer clearance (Fig.
WASHER 54) as follows:
(a) Check clearance between each thrust washer
and idler gear with feeler gauge.
(b) Clearance should be 0.05 - 0.25 mm (0.002 -
0.010 in.).
(6) If clearance is not within specified limits, re
INSERT FEELER move idler gear and replace thrust washers. Use new
GAUGE HERE pins when gear and washers are reinstalled.
TO CHECK
CLEARANCE
COUNTER GEAR AND SHAFT INSTALLATION
(1) Place gear case in upright position. Front bear
Fig. 54 Checking Idler Gear Thrust Washer
ing retainer/input shaft bore should be facing up
Clearance
(Fig. 57).
(7) Install idler shaft bolt (Fig. 55). Tighten bolt to (2) Slide counter gear into position in case (Fig.
54 N*m (40 ft. lbs.) torque. 57).
(3) Install front bearing and bearing snap ring on
countershaft (Fig. 57).
(4) Install countershaft in gear and seat shaft front
bearing in case (Fig. 57).
FRONT
BEARING COUNTERSHAFT
J9321-317 COUNTER
GEAR
Fig. 55 Idler Shaft Bolt Installation
(8) Tap idler shaft pins into place (Fig. 56).
J9321-319
J9321-318
Fig. 57 Countershaft And Gear Installation
Fig. 56 Idler Shaft Pin Installation
(5) Install countershaft front bearing race in case
REVERSE IDLER INSTALLATION (WITH and on bearing (Fig. 58).
EARLY STYLE GEAR CASE)
(1) Install counter gear and shaft in case. Refer to
procedure in this section.
(2) Install idler shaft part way into case from
front.
USE SOCKET
AS INSTALLER
TOOL
RETAINER
SEAL SEATED
IN RETAINER
Fig. 58 Countershaft Front Bearing Race Installation

(6) Install snap ring that retains countershaft front
bearing race in case bore (Fig. 59). J9321-327
Fig. 61 Input Shaft Seal Installation

(3) Install input shaft. Rotate shaft so flats on
clutch teeth are facing downward. Then install shaft
in case.
(4) Install output shaft and geartrain assembly in
case (Fig. 62).
Fig. 59 Front Bearing Race Snap Ring Installation

(7) Install countershaft front bearing cap in case
bore (Fig. 60). A p p l y Mopar adhesive/sealant, or
3M industrial sealant # 8 0 0 around outer edge of
bearing c a p before installation.
Fig. 62 Output Shaft And Geartrain Assembly

Installation
(5) Install front bearing race in gear case.
(6) Apply recommended sealer to front bearing re
tainer flange surface. Then apply oil to lip of retainer
Fig. 60 Countershaft Front Bearing Cap Installation oil seal.
(7) Install front bearing retainer on case (Fig. 63).
(8) Install rear bearing on countershaft. Then in It is not n e c e s s a r y to align retainer in any spe
stall bearing retaining snap ring. cial position. Oil channels and bolt holes in re
tainer are symmetrical and c a n b e installed in
OUTPUT AND INPUT SHAFT INSTALLATION
any position.
(1) Install new seal in front bearing retainer (Fig.
(8) Apply Mopar Lock N' Seal or Loctite 242 to
61). Use socket or pipe tool to seat seal in retainer.
front bearing retainer bolts. Then install and tighten
B e sure seal lip f a c e s inward t o w a r d case inte
bolts to 22-30 N«m (16-22 ft. lbs.) torque.
rior.
(9) Before proceeding, verify that countershaft
(2) Install new front bearing on input shaft if nec
front bearing cap has been installed (Fig. 64).
essary. Use shop press to install bearing.
Fig. 65 Measuring Height Of Output Shaft Rear

Bearing Race
Fig. 63 Front Bearing Retainer installation

(10) Install output shaft rear bearing race. Tap
race into position with plastic mallet.
(11) Install countershaft rear bearing race in case
(Fig. 64). Then position race on bearing and tap race
into position with plastic mallet.
Fig. 66 Measuring Height Of Countershaft Rear

Bearing Race
(4) Measure depth of shim bore in rear retainer
with depth gauge (Figs. 67 and 68). Record this mea
surement also as it will be needed for shim selection.
Fig. 64 Countershaft Rear Bearing Race Position

OUTPUT SHAFT AND COUNTERSHAFT
BEARING PRELOAD ADJUSTMENT
Bearing preload adjustment is accomplished by the
use of shims. The shims are installed in the shim
bores machined into the rear retainer.
(1) Place transmission in upright position. Use
wood blocks to support transmission on either side of
front bearing retainer.
(2) Tap output shaft and countershaft rear bearing
races into place. Be sure races are seated on bear
ings.
(3) Measure distance from top e a c h of rear bearing
Fig. 67 Measuring Depth Of Output Shaft Bearing
race to case surface with depth gauge (Figs. 65 and
Shim Bore (In Rear Retainer)
66). Measurements reflect amount of bearing race
t h a t extends above rear surface of case. Record these
measurements as they will be needed for shim selec
tion.
DEPTH
GAUGE
COUNTERSHAFT
REAR
BEARING
RETAINER
SHIM
BORE OUTPUT
SHAFT
BEARING REAR
SHIMS RETAINER
COUNTERSHAFT
BEARING
SHIMS
J9321-332 J9321-325
Fig. 68 Measuring Depth Of Countershaft Bearing Fig. 69 Preload Shim Location

Shim Bore (in Rear Retainer) (2) On 2-wheel drive transmissions, install new
(5) Select preload shims for shaft bearings as fol output shaft seal in retainer. Then install speedome
lows: Subtract height of bearing from depth of shim ter gear and spacers on output shaft (Fig. 70).
bore. Then add extra shim thickness of 0.15 - 0.20 (3) Install rear retainer on gear case. Do not dis
mm ( 0.006 - 0.008 in.) for correct preload. place preload shims when installing retainer.
(6) Assemble and install shim packs in rear re (4) Apply Mopar or Loctite thread locker to rear
tainer (Fig. 69). Use petroleum jelly to hold shim retainer bolts. Then install and tighten bolts to 22-30
packs in place during installation. Position thin N-m (16-22 ft. lbs.) torque.
shims at rear of pack where they will seat in (5) On 2-wheel drive transmissions, lube propeller
rear retainer shim bore. shaft yoke seal surface with petroleum jelly or en
gine oil and install yoke. Then install and tighten
TRANSMISSION FINAL ASSEMBLY new yoke nut to 380 N*m (280 ft. lbs.) torque.
(1) Apply Mopar Gasket Maker, or Loctite 518 to (6) Apply coat of Mopar Perfect Seal, or similar
rear retainer flange surface. sealer to new shift cover gasket. Then position gas
ket on gear case. (Although early production trans-
REAR
BEARING
RETAINER
SPEEDOMETER YOKE
GEAR NUT
YOKE
SPACERS J
932
1-
271
Fig. 70 Two Wheel Drive Rear Bearing Retainer And Speedometer Gear
21 - 72 G36Q TRANSMISSION OVERHAUL
missions were not originally equipped with a cover (11) Fill transmission to bottom edge of fill plug
gasket, a gasket should be installed on these trans hole with Mopar 5W-30 engine oil.
missions). (12) Install and tighten fill plug to 47 N-m (35 ft.
(7) Verify t h a t synchronizer sleeves are in neutral lbs.) torque.
position. Shift cover cannot be installed otherwise. (13) Install backup light switch in shift cover if re
(8) Install shift cover. Align shift forks with syn moved.
chro sleeves and alignment dowels and seat cover on
(14) Mount transmission on jack for installation in
case.
vehicle.
(9) Apply Mopar or Loctite thread locker to shift
cover bolts. Then install and tighten bolts to 22-30 (15) Secure transmission to jack with safety
N-m (16-22 ft. lbs.) torque. chains.
(10) Place transmission in level position and in (16) Apply thin coat of Mopar high temperature or
stall drain plug. Tighten plug to 47 N-m (35 ft. lbs.) multi-purpose grease to pilot hub of input shaft.
• AUTOMATIC TRANSMISSION—32RH/36RH/37RH/42RH/46RH 21 - 73
AUTOMATIC TRANSMISSION-32RH/36RH/37RH/42RH/46RH
CONTENTS
page page
AUTOMATIC TRANSMISSION DIAGNOSIS OVERDRIVE UNIT OVERHAUL—42RH/46RH . 324
AND TESTING 85 TRANSMISSION OVERHAUL—32RH 152
AUTOMATIC TRANSMISSION REMOVAL TRANSMISSION OVERHAUL—36RH/37RH . . 192
AND INSTALLATION 142 TRANSMISSION OVERHAUL—42RH 233
GENERAL INFORMATION-32RH/36RH/37RH . . . 73 TRANSMISSION OVERHAUL—46RH 278
GENERAL INFORMATION-42RH/46RH 78
IN-VEHICLE SERVICE—32RH/36RH/37RH/
42RH/46RH 130
GENERAL IN FORMATION-32RH/36RH/37RH
INDEX
page page
Components Unique to 3 7 R H Diesel Torque Converter 76
Transmission 76 Transmission Hydraulic Control System 76
Description 73 Transmission Identification 76
Recommended Fluid 76
DESCRIPTION The 32RH transmission is used with 3.9L and 5.2L

Chrysler 32RH/36RH/37RH transmissions are engines. The 36RH transmission is used with 5.2IV
three speed, fully automatic units with a planetary 5.9L gas engines. The 37RH is used with the 5.9L
gear system (Figs. 1 and 2). Cummins diesel engine.
«*4
FRONT PLANETARY GEAR SET
FLEXIBLE DRIVE PLATE
PR225
Fig. 1 Automatic Transmission-32RH

21 - 76 AUTOMATIC TRANSMISSION—32RH/36RH/37RH/42RH/46RH •
TORQUE CONVERTER COMPONENTS UNIQUE TO 37RH DIESEL
A three element torque converter is used. The con TRANSMISSION
verter used with 32RH and some 36RH transmis
sions has a modulated converter clutch. The Planetary Gears
converter used with 37RH transmissions is not The transmission and overdrive planetary gear car
equipped with a modulated clutch. riers in the 37RH are heavy duty components. The
The converter used with 1993, 32RH transmissions transmission planetary carriers have four pinion
is new. The converter hub was changed to accept the gears. The carrier in the overdrive compounder has
new style drive flats on the oil pump inner gear. The five pinion gears.
new style converter is not interchangeable with pre
vious designs. Clutch Packs
A 241 or 273 mm (9.5 or 10.75 in.) converter is Front and rear clutch packs used in the 37RH con
used for 3.9L, 5.2L and 5.9L gas engine applications. tain 4 discs and 5 steel plates.
A 310 mm (12.2 in.) converter is used for diesel en
Governor Weight Assembly
gine applications.
The converter impeller is connected to the engine The governor weight assembly is made of alloyed
crankshaft through the front cover which is welded brass. The diesel weight assembly is easily identified
to the impeller. The turbine is splined to the trans by the distinctive gold color of the alloyed material.
mission input shaft and the stator is splined to the The heavier weight assembly provides the shift
transmission reaction shaft. points needed to offset lower operating speeds of a
The converter is a welded assembly. It is not a re diesel engine.
pairable component and is serviced as an assembly. The alloyed weight assembly is unique to the
37RH. It is not interchangeable with the weight as
RECOMMENDED FLUID semblies used in gas engine versions.
The recommended and preferred fluid for Chrysler
automatic transmissions is Mopar ATF Plus, Type TRANSMISSION HYDRAULIC CONTROL SYSTEM
7176. Use Mopar Dexron II only when ATF Plus is The transmission hydraulic control system provides
not readily available. fully automatic operation. The system performs five
basic functions, which are:
TRANSMISSION IDENTIFICATION • pressure supply
The transmission part and identification numbers • pressure regulation
are stamped on the left side of the case just above • flow control
the oil pan gasket surface (Fig. 3). Refer to this in • clutch and band application
formation when ordering replacement parts. • lubrication.
Pressure Supply
The oil pump develops fluid pressure for clutch/
band application and for lubrication. The pump is
driven by the torque converter.
Pressure Regulation
The pressure regulator valve maintains transmis
sion line pressure. The amount of pressure developed
is controlled by throttle pressure. Throttle pressure is
dependent on the degree of throttle opening. The reg
ulator valve is located in the valve body.
The throttle valve determines line pressure and
shift speed. The throttle valve also controls upshift
PART BUILD SERIAL 19191-909 and downshift speeds by regulating pressure accord
J V U I z u z
NUMBER DATE NUMBER
ing to throttle position.
Fig. 3 Transmission Identification Numbers And Pressure developed by the governor valve works
Codes with throttle pressure to determine shift points. Gov
ernor pressure is the speed signal t h a t indicates
when a shift should take place. In operation, gover
nor pressure increases at a rate approximately the
same as vehicle speed.
• AUTOMATIC TRANSMISSION—32RH/3SRH/37RH/42RH/48RH 21 - 77
Flow Control And Lubrication through the converter clutch solenoid. The solenoid is
The manual valve is operated by the gearshift link controlled by and connected to the powertrain control
age and provides the operating range selected by the module through a connector in the transmission case.
driver. Electronic control of converter clutch engagement
The 1-2 shift valve provides automatic 1-2 or 2-1 includes disengagement at closed throttle during
shifts and the 2-3 shift valve provides automatic 2-3 warmup and during part throttle acceleration. Non-
or 3-2 shifts. converter clutch transmissions have a threaded plug
The kickdown valve provides forced 3-2 or 3-1 at the rear of the transmission case in place of t h e
downshifts depending on vehicle speed. Downshifts solenoid wiring connector.
occur when the throttle is opened beyond downshift The fail safe valve restricts feed to the converter
detent position which is just before wide open throt clutch if front clutch pressure drops. It permits clutch
tle. engagement only in direct (third) gear and provides
The 2-3 valve throttle pressure plug provides 3-2 fast clutch release during kickdown.
downshifts with varying throttle openings and de
The switch valve directs apply fluid pressure to the
pending on vehicle speed.
converter clutch in one position and releases it in the
The 1-2 shift control valve transmits 1-2 shift pres
opposite position. It also directs oil to the cooling and
sure to the accumulator piston to control kickdown
lube circuits. The switch valve regulates oil pressure
band capacity on 1-2 upshifts and 3-2 downshifts.
The limit valve determines maximum speed at to the torque converter by limiting maximum oil
which a 3-2 part throttle kickdown can be made. pressure to 130 psi.
Some transmissions do not have the limit valve and
Clutch/Band Application
maximum speed for a 3-2 kickdown is at the detent
position. The front/rear clutch pistons and servo pistons are
The shuttle valve has two functions. First is fast actuated by line pressure. When line pressure is re
front band release and smooth engagement during moved, the pistons are released by spring tension.
"lift foot" 2-3 upshifts. Second is to regulate front On 2-3 upshifts, the front servo piston is released
clutch release and band application during 3-2 down by spring tension and hydraulic pressure. The accu
shifts. mulator controls hydraulic pressure on the apply side
The converter clutch valve applies the converter of the front servo during 1-2 upshifts and at all
modulated clutch when supplied with line pressure throttle openings.
21 - 78 AUTOMATIC TRANSMISSION-32RH/36RH/37RH/42RH/46RH
G1NERAL I N F O R M A T I O N — 4 2 R H / 4 6 R H
INDEX
page page
Components Unique to Diesel Version of 4 6 R H . 81 Hydraulic Controls . 83
Description 78 Recommended Fluid 81
Fourth Gear Overdrive Components 81 Torque Converter 81
Fourth Gear Overdrive Operation . 82 Transmission Identification . 81
Gear Ratios 81
DESCRIPTION clutch. The overdrive clutch is applied in fourth gear

The Chrysler 42RH/46RH are four-speed, auto only. The direct clutch is applied in all ranges except
matic transmissions. Fourth gear is an overdrive fourth gear.
range. The 42RH is used for 3.9L and 5.2L engine The governor and park lock assemblies are located
applications. The 46RH is used with 5.2L/5.9L gas inside the overdrive unit. The unit must be removed
engines. A heavy duty version of the 46RH is used and disassembled for service access to the park lock
with the 5.9L Cummins turbo-diesel engine. and governor components.
The 42RH/46RH is a dual unit design. The assem Fourth gear is controlled by a manually operated
bly consists of a three speed automatic transmission switch in the instrument panel. The switch is in cir
with an overdrive unit attached at the rear (Figs. 1 cuit with the overdrive solenoid (on the valve body)
and 2). First through third gear ranges are provided and the powertrain control module. In the On posi
by the clutches, bands, overrunning clutch and plan tion, current flows through the switch to the solenoid
etary gear set in the transmission. Fourth gear range for the 3-4 shift sequence. The transmission must be
is provided by the overdrive unit. Overdrive ratio is in third gear before a 3-4 upshift will occur.
0.69:1. The overdrive solenoid will not be energized and a
The overdrive unit contains an overdrive clutch, di 3-4 upshift will not occur when the control switch is
rect clutch, planetary gear set and overrunning in the OFF position.
TORQUE
CONVERTER
VALVE
BODY
Fig. 2 46RH Transmission And Overdrive Unit

TORQUE CONVERTER The alloyed weight assembly is unique to t h e diesel

A three element torque converter is used for all ap 46RH. It is not interchangeable with the weight as
plications. The converter consists of the impeller, sta- semblies used in gas engine versions.
tor and turbine. The converter also contains an
overrunning clutch and a modulated converter clutch Diesel Thermo Switch
mechanism. Fourth gear operation in t h e diesel 46RH is also
The converter used with 1993, 42RH transmissions controlled by two temperature sensitive thermo-
is new. The converter hub was changed to accept t h e switches.
new style drive flats on the oil pump inner gear. The The first thermo-switch is t h e engine coolant tem
new style converter is not interchangeable with pre perature switch. This switch prevents overdrive
vious designs. fourth gear operation when engine coolant tempera
The converter modulated clutch consists of a slid ture is below approximately 65° F.
ing clutch piston, clutch springs and the clutch disc The second thermo-switch directly monitors trans
friction material. The clutch provides optimum mission fluid temperature. The switch will either
torque transfer and economy when engaged. downshift t h e transmission to third gear, or prevent
The clutch disc is attached to the converter front a 3-4 upshift when fluid temperature exceeds
cover. The clutch piston and clutch springs are at 270-275° F.
tached to the turbine hub. The springs dampen en
The fluid temperature switch is located in a boss
gine firing impulses and loads during the initial
built into t h e cooler outlet line. The boss and switch
phase of converter clutch engagement.
are located approximately 2-3 inches from t h e outlet
Clutch engagement is controlled by the converter
line fitting in the transmission case.
clutch valve and solenoid. Both are located on t h e
transmission valve body. Clutch engagement occurs The engine coolant and fluid temperature switches
in drive range at speeds above approximately 30-35 are in circuit with the overdrive control switch in t h e
mph. instrument panel.
The clutch provides reduced engine speed and
greater fuel economy when engaged. Clutch engage GEAR RATIOS
ment also provides reduced transmission fluid tem 42RH forward gear ratios are:
peratures. First gear = 2.74:1
Second gear = 1.54:1
COMPONENTS UNIQUE TO DIESEL VERSION OF Third gear = 1.00:1
46RH Fourth gear = 0.69:1.
46RH forward gear ratios are:
Planetary Gears First gear = 2.45:1
The transmission and overdrive planetary gear car Second gear = 1.45:1
riers in t h e diesel version of the 46RH are heavy Third gear = 1.00:1
duty components. The transmission planetary carri Fourth gear = 0.69:1.
ers have four pinion gears. The carrier in the over
drive compounder h a s five pinion gears. The heavy RECOMMENDED FLUID
duty planetary units are unique to the diesel 46RH. The recommended and preferred fluid for 42RH/
46RH transmissions is Mopar ATF Plus, type 7176.
Clutch Packs
Use Mopar Dexron II only when ATF Plus is not
Clutch packs used in the diesel version of t h e readily available.
46RH contain the following number of discs and
plates: TRANSMISSION IDENTIFICATION
• transmission front/rear clutch h a s 4 discs and 5 The transmission part and identification numbers
steel plates and codes are stamped on the left side of the case
• overdrive clutch h a s 5 discs and 6 steel plates just above t h e oil pan gasket surface (Fig. 3).
• overdrive direct clutch has 8 discs and 9 steel The first letter/number group is the assembly part
plates number. The next number group t h e transmission
build date. The last number group is the transmis
Governor Weight Assembly
sion serial number. Refer to this information when
The governor weight assembly in the diesel 46RH ordering replacement parts.
is made of alloyed brass. The diesel weight assembly
is easily identified by the distinctive gold color of t h e FOURTH GEAR OVERDRIVE COMPONENTS
alloyed material. The heavier weight assembly pro 42RH/46RH models have three transmission shafts.
vides the shift points needed to offset lower operating An intermediate shaft is positioned between the in
speeds of a diesel engine. put and output shafts. The output shaft is in the
21 - 82 AUTOMATIC TRANSMISSION—32RH/36RH/37RH/42RH/46RH — — — — — •
The fourth gear shift valves and plugs are located

in the valve body lower housing. The components in
clude:
• a separate housing for the overdrive valves and
plugs
• an overdrive solenoid
• a converter clutch solenoid
• a 3-4 shift valve
• a 3-4 timing valve
• a 3-4 accumulator
• a 3-4 shuttle valve
• an overdrive separator plate.
• a boost valve and connecting tube
PART BUILD SERIAL

NUMBER
J9121-202 FOURTH GEAR OVERDRIVE OPERATION
NUMBER DATE
3-4 Shift Sequence

Fig. 3 Identification Number And Code Location
The overdrive clutch is applied in fourth gear only.
overdrive unit. The intermediate shaft is supported The direct clutch is applied in all ranges except
by the overdrive piston retainer and piloted in the fourth gear.
output shaft. Fourth gear overdrive range is electronically con
The overdrive piston and retainer are located at trolled and hydraulically activated. Various sensor
the rear of the transmission case. The retainer serves inputs are supplied to the powertrain control module
as both the rear support and pressure chamber for to operate the overdrive solenoid on the valve body.
the overdrive piston. The intermediate shaft is The solenoid contains a check ball t h a t opens and
splined to the overdrive direct clutch sliding hub, closes a vent port in the 3-4 shift valve feed passage.
planetary assembly and overrunning clutch. The overdrive solenoid (and check ball) are not en
The governor components and speedometer drive ergized in first, second, third or reverse gear. The
are located on the output shaft in the overdrive unit. vent port remains open diverting line pressure from
Two bearings are used to support the output shaft. A the 2-3 shift valve away from the 3-4 shift valve.
longer park rod assembly is also required. The overdrive switch must be in the On position to
There are no rotating seal rings or pressurized oil transmit signals to the solenoid. A 3-4 upshift occurs
for the direct clutch. The clutch is applied by spring only when the overdrive solenoid is energized by an
pressure and released by movement of the overdrive electrical signal from the powertrain control module.
clutch piston during the 3-4 upshift. The solenoid is energized upon receiving a signal.
The governor is operated by fluid pressure supplied This causes the check ball to close the vent port.
through pressure tubes. The tubes are permanently Closing the vent port allows line pressure from the
attached to the governor support. Governor fluid 2-3 shift valve to act directly upon the 3-4 upshift
pressure is transmitted through the intermediate valve.
shaft to the tubes. Line pressure acting on the 3-4 shift valve over
Governor pressure and overdrive clutch pressure comes valve spring tension moving the valve to the
taps are provided in the transmission case for pres upshift position. This action exposes the feed pas
sure testing purposes. sages to the 3-4 timing valve, 3-4 shuttle valve, 3-4
The overdrive unit contains a direct clutch, an accumulator and ultimately to the overdrive piston.
overdrive clutch and an overrunning clutch. Fourth Line pressure through the timing and shuttle
gear range is provided by an additional planetary valves move the overdrive piston into simultaneous
gear set In the overdrive unit. contact with the overdrive clutch and the direct
The direct clutch is applied by spring pressure. A clutch sliding hub.
high pressure spring rated at approximately 830 The overdrive clutch is engaged and the direct
pounds (5530 kPa) tension, holds the clutch in en clutch is disengaged simultaneously to complete the
gagement. The sun gear, direct clutch sliding hub 3-4 upshift.
and drum are splined to the annulus gear for direct The boost valve provides increased fluid apply pres
drive. For coasting or reverse gear, power flows only sure to the overdrive clutch during the 3-4 upshift
through the direct clutch. and during fourth gear operation. The amount of
A timing valve disengages the torque converter boost is determined by throttle opening and line
clutch prior to a 4-3 downshift. The clutch solenoid, pressure.
engagement valve, and timing valve are actuated in The overdrive piston engages the overdrive clutch
fourth gear range. by pressing directly against the clutch pressure
• AUTOMATIC TRANSiISSIO|-32RH/8iRH/37RH/42RH/4iRH 21 - 83
plate. The overdrive clutch also disengages the direct tion section. The main difference being fourth gear
clutch during 3-4 upshifts. As fluid pressure extends operation which is covered here.
the overdrive piston, the piston contacts the direct
clutch hub pressing it rearward. This action com Pressure Regulation
presses the direct clutch spring relieving spring load The pressure regulator valve maintains line pres
on the clutch pack. The clutch is disengaged once sure. The amount of pressure developed is controlled
spring load is relieved. by throttle pressure which is dependent on the de
The 3-4 accumulator cushions overdrive clutch en gree of throttle opening. The regulator valve is lo
gagement to smooth the transition into fourth gear. cated in the valve body.
The accumulator is charged at t h e same time as ap The throttle valve determines line pressure and
ply pressure acts against the overdrive piston. shift speed. Governor pressure increases in propor
Converter clutch engagement in overdrive fourth tion to vehicle speed. The throttle valve controls up
gear is controlled by sensor inputs to the powertrain shift and downshift speeds by regulating pressure
control module. In third gear above 25 mph, sensor according to throttle position.
inputs to the control module t h a t determine clutch
engagement and shift timing are: Flow Control And Lubrication
• coolant temperature (verifies minimum of 60° F) The manual valve is operated by the gearshift link
• engine speed age and provides the operating range selected by the
• vehicle speed driver.
• throttle position The 1-2 shift valve provides 1-2 or 2-1 shifts and
• manifold vacuum (MAP sensor) the 2-3 shift valve provides 2-3 or 3-2 shifts.
The kickdown valve provides forced 3-2 or 3-1
Gearshift Mechanism downshifts depending on vehicle speed. Downshifts
The gear shift mechanism provides the same shift occur when the throttle is opened beyond downshift
positions used with 3-speed Chrysler transmissions detent position which is just before wide open throt
(P-R-N-D-2-1). tle.
The shift into overdrive fourth gear range occurs The 2-3 valve throttle pressure plug provides 3-2
only after the transmission has completed the shift downshifts at varying throttle openings depending on
into D third gear range. No further movement of the vehicle speed.
shift mechanism is required to complete the 3-4 shift. The 1-2 shift control valve transmits 1-2 shift pres
The fourth gear upshift occurs automatically when sure to the accumulator piston. This controls kick-
the overdrive control switch is in the ON position. down band capacity on 1-2 upshifts and 3-2
Shift timing is determined by sensor inputs to the downshifts.
engine controller. The 3-4 shift valve, shuttle valve, timing valve and
accumulator are only actuated when the overdrive
Overdrive Control Switch solenoid is energized.
The overdrive control switch is located in the in The solenoid contains a check ball t h a t controls a
strument panel. In the On position, automatic shifts vent port to the 3-4 valve. The check ball either di
into fourth gear overdrive will occur. In the Off posi verts line pressure away from or directly to, the 3-4
tion, the switch overrides the engine controller pre shift valve. Energizing the solenoid causes the check
venting a shift to overdrive fourth gear range.
ball to close the vent port allowing line pressure to
The switch has an indicator light t h a t illuminates
act upon the 3-4 upshift valve.
when overdrive is turned off. The switch also resets
The limit valve determines maximum speed at
when the ignition key is turned to the OFF position
which a 3-2 part throttle kickdown can be made.
so t h a t the automatic overdrive feature is restored.
The use of fault codes is employed to help diagnose Some transmissions do n o t have the limit valve and
the electronic components t h a t operate the overdrive maximum speed for a 3-2 kickdown is at t h e detent
unit and converter clutch. position.
The 2-3 shuttle valve has two functions. First is
HYDRAULIC CONTROLS fast front band release and smooth engagement dur
The 42REJ/46RH hydraulic control system provides ing lift-foot 2-3 upshifts. The second is to regulate
fully automatic operation. The system performs five front clutch and band application during 3-2 down
basic functions which are: pressure supply, pressure shifts.
regulation, flow control, clutch/band application, and The 3-4 shuttle valve uses a combination of throt
lubrication. tle and governor pressure to control the rate of over
42RH/46RH system operation is similar to t h a t de drive piston apply and release. This is done to
scribed in the 32RH/36RH/37RH General Informa maintain shift quality at varying throttle openings.
21 - 84 AUTOMATIC TRANSMISSION-32RH/36RH/37RH/42RH/46RH •
The 3-4 timing valve is moved by line pressure The 3-4 upshift causes the boost valve to increase
coming through the 3-4 shift valve. The timing valve line pressure to the overdrive clutch. Pressure also
holds the 2-3 shift valve in an upshift position. The increases with throttle opening. This ensures positive
purpose is to prevent the 2-3 valve from up or down clutch engagement during periods of high throttle
shifting before the 3-4 valve. opening acceleration.
The 3-4 accumulator is mounted on the overdrive
housing. It performs the same function as the 2-3 ac Converter Clutch Control
cumulator. It is used to smooth engagement during The converter clutch valve applies the converter
the 3-4 shift. clutch when supplied with line pressure through the
On models with a converter clutch, the clutch valve converter clutch solenoid. The solenoid is mounted on
applies the converter clutch when supplied with line the valve body and energized by an electrical signal
pressure through the converter clutch solenoid. from the powertrain control module. Electronic con
The converter clutch solenoid is mounted on the trol of converter clutch operation includes clutch re
valve body. It is energized by an electrical signal
lease at closed throttle during warmup and during
from the powertrain control module. Electronic con
part throttle acceleration. The boost valve provides
trol of converter clutch engagement includes disen
additional apply pressure for converter clutch appli
gagement at closed throttle during warmup and
cation.
during part throttle acceleration.
The switch valve directs apply fluid pressure to the The switch valve directs fluid apply pressure to the
converter clutch in one position and releases it in the converter clutch in one position and releases it in the
opposite position. It also directs oil to the cooling and opposite position. It also directs oil to the cooling and
lube circuits. The switch valve regulates oil pressure lube circuits. The switch valve regulates oil pressure
to the torque converter by limiting maximum oil to the torque converter by limiting maximum oil
pressure to 130 psi. pressure to 130 psi.
Boost Valve Function Clutch/Band Application

The boost valve provides increased fluid apply pres The clutch and servo pistons are actuated by line
sure for converter clutch and overdrive clutch en pressure. When fluid pressure is released, the pistons
gagement. are released by spring pressure.
The boost valve is connected to the overdrive clutch On 2-3 upshifts, the front servo piston is released
circuit via a tube connected between the valve body by spring tension and hydraulic pressure. The accu
upper and lower housings. The valve is connected to mulator controls hydraulic pressure on the apply side
the converter clutch circuit via the regulator valve, of the front servo during 1-2 upshifts and all throttle
switch valve and 3-4 shift and timing valves. openings.
Hydraulic circuitry for the boost valve is shown in The overdrive direct clutch is applied by spring
the hydraulic flow diagrams. The diagrams are lo pressure. The direct clutch is applied in all ranges
cated at the end of the transmission diagnosis and except fourth gear.
test section. The overdrive clutch is applied in fourth gear only.
During converter clutch engagement in fourth The clutch is applied by the overdrive piston which is
gear, the valve supplies full line pressure directly to
actuated by line pressure through the 3-4 shift valve.
the clutch. The increased pressure available at the
clutch provides smooth shifting and positive engage
ment.
• AUTOMATIC TRANSiISSiOi-32RH/38RH/37RH/42RH/4eRH 21 - 81
AUTOMATIC TRANSMISSION DIAGNOSIS AND TESTING
INDEX
page page
Air Testing Clutch and Band Operation 91 Gearshift Linkage 87
Analyzing the Road Test 87 General Information 85
Converter Housing Fluid Leak Diagnosis . . . . . . . 92 Hydraulic Pressure Test 88
Converter Stall Test 90 Overdrive Fourth Gear Electrical Controls . . . . . . 86
Diagnosis Charts and Hydraulic Flow Diagrams . . 95 Preliminary Diagnosis 85
Fluid Contamination 86 Road Test 87
Fluid Level and Condition 85 Throttle Valve Cable 86
GENERAL INFORMATION (a) If acceleration is sluggish, or if abnormal

The diagnosis and testing information in this sec throttle opening is needed to maintain normal
tion applies to three and four speed models alike. Di speeds with a properly tuned engine, perform a
agnosis and test procedures apply to all models stall test to check converter clutch operation.
except where indicated. Diagnosis information t h a t (b) On 42RH/46RH, if fourth gear upshift does
only applies to 42RH/46RH models is noted. not occur, check overdrive solenoid and switch wir
Automatic transmission problems can be a result of ing for opens, shorts, grounds.
poor engine performance, incorrect fluid level, incor (c) If slippage and engine flare is noted, perform
rect linkage adjustment, band or hydraulic control hydraulic pressure test and air pressure test to
pressure adjustments, hydraulic system malfunctions check clutch-band-governor operation.
or electrical/mechanical component malfunctions.
Begin diagnosis by checking t h e easily accessible Vehicle Is Disabled
items such as: fluid level and condition, linkage ad (1) Check fluid level and condition.
justments and electrical connections on 4-speed mod (2) Check for broken, disconnected throttle link
els. A road test will determine if further diagnosis is age.
necessary. (3) Check for cracked, leaking cooler lines, or
Procedures outlined in this section should be per loose, missing pressure port plugs.
formed in the following sequence to realize t h e most (4) Raise vehicle, start engine, shift transmission
accurate results: into gear and note following:
• Preliminary diagnosis (a) If propeller shafts t u r n but wheels do not,
• Fluid Level and condition problem is with differential or axle shafts.
• Linkage Adjustment (b) If propeller shafts do not turn and transmis
• Road test sion is noisy, stop engine. Remove oil pan, and
• Hydraulic pressure test check for debris. If pan is clear, remove transmis
• Stall test sion and check for damaged drive plate, converter,
• Air pressure tests oil pump or input shaft.
• Leak Tests (c) If propeller shafts do not turn and transmis
• Analyze test results and consult diagnosis charts sion is not
noisy, perform hydraulic pressure test to deter
PRELIMINARY DIAGNOSIS mine if problem is a hydraulic or mechanical.
Two basic procedures are required. One procedure
for vehicles t h a t are driveable and a n alternate pro FLUID LEVEL AND CONDITION
cedure for disabled vehicles (will not back up or (1) Place vehicle on level surface. This is impor
move forward). t a n t for a n accurate reading.
(2) Do not check level until fluid is a t normal op
Vehicle Is Driveable erating temperature of approximately 82°C (180°F).
(1) Check fluid level and condition. This is necessary to avoid false readings which could
(2) Adjust throttle and gearshift linkage if com produce under or over fill condition,
plaint was based on delayed, erratic, or harsh shifts. (3) Fully apply parking brakes.
(3) On 4-speed models, check electrical connections (4) Start and r u n engine at curb idle speed. Then
at dash switch and transmission case. Turn control shift transmission through all gear ranges and back
switch to ON position before proceeding. to Neutral.
(4) Road test and note transmission operating (5) Clean top of filler tube and dipstick to keep dirt
characteristics. out of tube.
(6) Remove dipstick a n d check fluid l e v e l as fol • internal failure t h a t generates debris
lows: • overheat t h a t generates sludge (fluid breakdown)
(a) Dipstick has three fluid level indicating • failure to reverse flush cooler and lines after re
m a r k s which are a MIN dot mark, an OK m a r k pair
and a MAX fill arrow mark: • failure to replace contaminated converter after re
(b) Correct level is to MAX arrow nark on dip pair
stick. This is correct maximum hot fluid level. Ac The use of non recommended fluids can result in
ceptable level is between OK m a r k and max arrow transmission failure. The usual results are erratic
mark on dipstick. shifts, slippage, abnormal wear and eventual failure
(c) If level is at, or below MIN level dot on dip due to fluid breakdown and sludge formation. Avoid
stick, add only enough fluid to restore correct level. this condition by using recommended fluids only.
Mopar ATF Plus, type 7176 is the preferred fluid. The dipstick cap and fill tube should be wiped
Mopar Dexron II can be used if ATF Plus is not clean before checking fluid level. Dirt, grease and
readily available. other foreign material on the cap and tube could fall
into the tube if not removed beforehand. Take the
C A U T I O N : D o not overfill the transmission. Overfill time to wipe the cap and tube clean before withdraw
ing may c a u s e leakage out the pump vent which ing the dipstick.
can be mistaken for a pump seal leak. In addition, Engine coolant in the transmission fluid is gener
overfilling will also cause fluid aeration and foam ally caused by a cooler malfunction. The only remedy
ing a s the e x c e s s fluid is picked up and churned by is to replace the radiator as the cooler in the radiator
the gear train. This will significantly reduce fluid is not a serviceable part. If coolant has circulated
life. through the transmission for some time, an overhaul
may also be necessary; especially if shift problems
(7) Check and note fluid condition as follows: had developed.
(a) Fluid should be dark to light red in color and The transmission cooler and lines should be reverse
free of particles and sludge. flushed whenever a malfunction generates sludge
(b) If fluid is orange, brown, or smells slightly and/or debris. The torque converter should also be re
burned, flow test and reverse flush cooler and lines. placed at the same time.
Then change fluid and filter and road test again to Failure to flush the cooler and lines will result in
confirm proper operation. re-contamination and a shop comeback. Flushing ap
(c) If fluid is black, dark brown, turned to sludge, plies to auxiliary coolers as well. The torque con
contains extensive amount of metal or friction ma verter should also be replaced whenever a failure
terial particles, transmission will need overhaul. generates sludge and debris. This is necessary be
Main and auxiliary coolers will have to be flow cause normal converter flushing procedures will not
tested and reverse flushed as well. remove al of the contaminants.
Effects Of Incorrect Fluid Level OVERDRIVE FOURTH GEAR ELECTRICAL

A low fluid level allows the pump to take in air CONTROLS
along with the fluid. Air in the fluid will cause fluid The electrical controls governing the shift into
pressures to be low and develop slower t h a n normal. fourth gear consist of the control switch on the in
If the transmission is overfilled, the gears churn strument panel and the overdrive solenoid on the
the fluid into foam, aerating the fluid and causing valve body. The control switch is in circuit with the
the same conditions t h a t occur with a low level. solenoid and must be in the On position to energize
In either case, air bubbles cause fluid overheating, the solenoid. The transmission must also have
oxidation and varnish buildup which interferes with reached third gear range before the shift to fourth
valve, clutch and servo operation. Foaming also gear will occur.
causes fluid expansion which can result in fluid over The control switch, valve body solenoid, case con
flow from the transmission vent or fill tube. Fluid nectors and related wiring can all be tested with a 12
overflow can easily be mistaken for a leak if inspec volt test lamp or a multimeter. Check continuity of
tion is not careful. each component when diagnosis indicates this is nec
essary.
FLUID CONTAMINATION Switch and solejioid continuity should be checked
Transmission fluid contamination is generally a re whenever the transmission fails to shift into fourth
sult of: gear range.
• adding incorrect fluid
• failure to clean dipstick and fill tube when check THROTTLE VALVE CABLE
ing level Throttle valve cable adjustment is important to
• engine coolant entering the fluid proper operation. This adjustment positions the
AUTOMATIC TRANSMISSION—32RH/36RH/37RH/42RH/46RH 21 - 87
throttle valve which controls shift speed, quality and

part throttle downshift sensitivity. Gearshift Lever Position
P R N D 2 1
If cable setting is too short, early shifts and slip DRIVE
ELEMENTS 1 2 3 1 2
page between shifts may occur. If the setting is too
long, shifts may be delayed and part throttle down
shifts may be very sensitive. Refer to the In-Vehicle
FRONT
CLUTCH
• •
Service section for adjustment procedure.
FRONT
BAND • •
GEARSHIFT LINKAGE (KICKDOWN)
Gearshift linkage adjustment is important because
it positions the valve body manual valve. Incorrect REAR
CLUTCH
adjustment will cause creeping in Neutral, prema
ture clutch wear, delayed engagement in any gear, or REAR
a no-start in P a r k or Neutral position. BAND
(LOW-REV.)
• •
Proper operation of the neutral start switch will
provide a quick check of linkage adjustment. Refer to OVER
the In-Vehicle Service section for adjustment proce RUNNING • • •
dure. CLUTCH
ROAD TEST J9021-33

Before road testing, be sure the fluid level and all Fig. 1 Clutch And Band Application—32RH/36RH/
linkage adjustments have been checked and adjusted 37RH
if necessary.
Observe engine performance during the road test. Applying the same method of analysis, note t h a t
A poorly tuned engine will not allow an accurate both clutches are applied in D range third gear only.
analysis of transmission operation. If t h e transmission slips in third gear, either the
Operate the transmission in all gear ranges. Check front clutch or the rear clutch is slipping.
for slippage and shift variations. Note whether the By selecting another gear which does not use both
shifts are harsh, spongy, delayed, early, or if part clutches, the slipping clutch can be determined. For
throttle downshifts are sensitive. example, if the transmission also slips in Reverse,
Watch closely for slippage or engine flare which the front clutch is slipping. If the transmission does
usually indicates clutch, band or overrunning clutch not slip in Reverse, the rear clutch is slipping.
problems. If the condition is advanced, an overhaul If slippage occurs during the 3-4 shift or in fourth
may be necessary to restore normal operation. gear, the overdrive clutch is slipping. Similarly, if
A slipping clutch or band can often be determined the direct clutch were to fail, the transmission would
by comparing which internal units are applied in t h e lose reverse gear and overrun braking in 2 (manual
various gear ranges. Refer to the Elements In Use second gear) position would not occur. If the trans
Charts (Figs. 1 and 2) for clutch and band applica mission slips in any other two forward gears, the
tion. The charts provide a basis for analyzing road transmission front section rear clutch may be slip
test results. ping.
If the transmission will not shift into fourth gear,
ANALYZING THE ROAD TEST the control switch, overdrive solenoid or related wir
Refer to the Clutch And Band Application charts ing may also be the problem cause.
(Figs. 1 and 2). Then note which elements are ap This process of elimination can be used to deter
plied in the various gear ranges. mine the slipping unit and check operation. Proper
The rear clutch is applied in all forward ranges (D, use of the Clutch and Band Application Chart is the
2, 1). The transmission overrunning clutch is applied key.
in first gear (D, 2 and 1 ranges only). Although road test analysis will help determine
The rear band is applied in 1 and R range only. the slipping unit, the actual cause of a malfunction
The overdrive clutch is applied only in fourth gear usually cannot be determined until hydraulic and air
and the overdrive direct clutch and overrunning pressure tests are performed. Practically any condi
clutch are applied in all ranges except fourth gear. tion can be caused by leaking hydraulic circuits or
For example: If slippage occurs in first gear in D sticking valves.
and 2 range but not in 1 range, the transmission Unless the condition is obvious, s u c h a s n o
overrunning clutch is slipping. Similarly, if slippage drive in D range, first g e a r only, or n o f o u r t h
occurs in third and fourth gear, the rear clutch is gear range, the t r a n s m i s s i o n s h o u l d n o t be dis
slipping. However, if slippage only occurs in fourth a s s e m b l e d until hydraulic and air pressure tests
gear, the overdrive clutch is slipping. h a v e b e e n performed.
SHIFT T R A N S M I S S I O N CLUTCH ES A N D B A N D S O V E R D R I V E CLUTCHES

LEVER FRONT FRONT REAR REAR O V E R R U N . O V E R D R I V E DIRECT O V E R R U N .
POSITION CLUTCH BAND CLUTCH BAND CLUTCH CLUTCH CLUTCH CLUTCH
Reverse X X X
Drive Range
First X X X X
Second X X X
Third X X X X
Fourth X X X
2-Range:
(Manual
Second):
Second X X X X
First X X X X
1-Range
(Manual
Low):
First X X X X X
J9221-22
Fig. 2 Clutch And Band Application-42RH/46RH

HYDRAULIC PRESSURE TEST «\ \\
R EAR \\v - LN
IE F
RONT
' M S ER
VO \\ P RES
SU
RE /S—' S
ERV
O
R
T
PRESSURE TEST PORT LOCATIONS \\\ W \ \ \ PO., \ i POR
T
There are pressure test ports at the accumulator,
front servo, rear servo and governor. On 42RH/46RH
transmissions, an additional port for overdrive clutch
pressure is provided at the left-rear of the case.
Line pressure is checked at the accumulator port
on the right side of the case (Fig. 3). The front servo
pressure port is at the right side of the case just be
hind the filler tube opening (Fig. 4).
The rear servo pressure port is at the right rear of Fig. 3 Pressure Test Ports At Side Of Case
the case (Fig. 3). The governor pressure port is at the
G
OVE
RNO
R
left side of the extension housing (Fig. 4). P
RE
SS
URE P
ORT
On 42RH/46RH transmissions, the governor and
overdrive clutch pressure ports are at the rear of the
case (Fig. 5).
Hydraulic test pressures range from a low of one
psi (6.895 kPa) governor pressure, to 300 psi (2068
kPa) at the rear servo pressure port in reverse.
Two gauges are needed for the pressure test. Use
Pressure Gauge C-3292 to check pressure at the ac
cumulator, front servo, governor and overdrive pres
sure ports. Use 300 psi Pressure Gauge C-3293 to
Fig. 4 Pressure Test Ports At Rear Of Case
check pressure at the rear servo. The 300 psi gauge
can also be used to check all other pressures except Test One—Transmission In 1 Range
governor pressure. This test c h e c k s p u m p output, pressure regula
tion, a n d condition of the rear clutch a n d rear
PRESSURE TEST PROCEDURE servo circuits. Pressure Gauges C-3292 a n d
Connect a tachometer to the engine. Position the C-3293 are required for this test.
tachometer so it can be observed from under the ve (1) Connect 100 psi Gauge C-3292 to accumulator
hicle. Raise the vehicle on hoist t h a t will allow the (line pressure) port and connect 300 psi Gauge
wheels to rotate freely.
F
(4) Move transmission throttle lever from full for

ward to full rearward position and read pressure at
both gauges.
(5) Line pressure should be 54-60 psi 372-414 kPa)
with throttle lever forward and gradually increase to
90-96 psi ( 621-662 kPa) as lever is moved rearward.
Test Three—Transmission In D Range

This test c h e c k s pressure regulation and con
dition of the front a n d rear c l u t c h circuits. U s e
both pressure g a u g e s for this test.
(1) Connect gauges to accumulator (line pressure)
and front servo ports (Fig. 3). Either pressure test
gauge can be used at either port.
(2) Start and r u n engine at 1600 rpm for this test.
(3) Move selector lever two detents rearward from
full forward position. This is D range.
(4) Read pressures on both gauges as transmission
throttle lever is moved from full forward to full rear
ward position.
(5) Line pressure should be 54-60 psi (372-414
kPa) with throttle lever forward and gradually in
crease as lever is moved rearward.
(6) Front servo is pressurized only in D range and
should be same as line pressure within 3 psi (21 kPa)
up to downshift point.
Test Four—Transmission In Reverse

Fig. 5 Pressure Test Port Locations—42RH/46RH This test c h e c k s p u m p output, pressure regula
tion and the front clutch and rear servo circuits.
C-3293 to rear servo port (Figs. 3, 4). Be sure 300
Use 300 psi Gauge C-3293 for this test.
psi g a u g e is c o n n e c t e d to rear servo port. (1) Connect pressure gauge to rear servo port
(2) Disconnect throttle and gearshift cable/linkage (Figs. 3 and 4).
at transmission. (2) Start and run engine at 1600 rpm for test.
(3) Start and run engine at 1000 rpm. (3) Move valve body selector lever four detents
(4) Move transmission shift lever (on valve body rearward from full forward position. This is Reverse
manual shaft) all way forward into 1 range. range.
(5) Read pressures on both gauges as transmission (4) Move throttle lever fully forward then fully
throttle lever is moved from full forward to full rear rearward and note gauge readings.
ward position. (5) Pressure should be 145 - 175 psi (1000-1207
(6) Line pressure should be 54-60 psi (372-414 kPa) with lever forward and increase to 230 - 280 psi
kPa) with throttle lever forward and gradually in (1586-1931 kPa) as lever is moved rearward.
crease to 90-96 psi (621-662 kPa) as lever is moved
rearward. Test Five—Governor Pressure
(7) Rear servo pressure should be same as line This test c h e c k s governor operation by mea
pressure within 3 psi. suring governor pressure r e s p o n s e to c h a n g e s in
engine speed. It is usually not n e c e s s a r y to
Test Two—Transmission In 2 Range check governor operation u n l e s s shift s p e e d s
This test c h e c k s p u m p output a n d pressure are incorrect or if the transmission will not
regulation. Use 100 psi Gauge C-3292 for this downshift. U s e 100 psi Gauge C-3293 for this
test. test.
(1) Connect pressure gauge to accumulator (line (1) Position vehicle on hoist t h a t will allow rear
wheels to rotate freely.
pressure) port (Fig. 3).
(2) Connect pressure gauge to governor pressure
(2) Start and run engine at 1000 rpm.
port (Figs. 4 and 5).
(3) Move transmission shift lever (on valve body
(3) Start engine, shift the transmission into drive
manual shaft) one detent rearward from full forward
(D) range and apply brakes to prevent rear wheels
position. This is 2 range. from rotating.
(4) Note pressure with engine at curb idle speed
and rear wheels stopped. Pressure should be zero to 1EST CONDITION INDICATION
1-1/2 psi maximum. If pressure exceeds this figure, Line pressure O K during Pump and regulator valve O K
governor valve or weights are sticking open. any one test
(5) Slowly increase engine rpm and observe speed
Line Pressure O K in R Leakage in rear dutch area (servo,
ometer and pressure test gauge. Governor pressure but low in D, 2, 1 dutch seals, governor support
should increase in proportion to indicated vehicle seal rings)
speed (or approximately 1 psi for every 1 mph). Leakage in front dutch area (servo,
Pressure O K in 1, 2 but
(6) Pressure rise should be smooth and drop back low in D3 and R dutch seals, retainer bore, pump
to 0 to 1-1/2 psi when wheels are braked to a stop seal rings)
and engine returns to curb idle speed. Pressure O K in 2 but low in Leakage in rear servo
(7) Compare results of the pressure tests with the R and 1
Pressure Test Analysis Charts (Figs. 6 and 7).
Front servo pressure in 2 Leakage in servo; broken servo
ring or cracked servo piston
Test Six—42RH/46RH Transmission In Overdrive Fourth
Gear Pressure low in all positions C o g g e d filter, stuck pressure
regulator valve, worn or
This test c h e c k s line pressure at the overdrive
defective pump
clutch in fourth gear range. Use 300 psi Test
G a u g e C-3292 for this test. Governor pressure too high at Governor valve sticking open
idle speed:
(1) Raise vehicle and connect test gauge to over
drive clutch pressure port (Fig. 5). Governor pressure low at all Governor valve sticking dosed
(2) Lower vehicle to enough to allow entry into mph figures
drivers seat. Leave vehicle wheels approximately one Clogged oil cooler or lines, seal
Lubrication pressure low at all
foot off shop floor. throttle positions rings leaking, output shaft
(3) Secure test gauge where it can be viewed from plugged with debris, worn
drivers seat. bushings in pump or dutch
retainer J9021-34
(4) Verify t h a t overdrive control switch is in ON
position.
(5) Start engine and shift into D range. Fig. 6 Pressure Test Analysis Chart (32RH/36RH/
(6) Increase engine rpm gradually until 3-4 shift 37RH)
occurs and note gauge pressure. (3) Start and r u n engine until transmission fluid
(7) Pressure should be 469-496 kPa (68-72 psi) reaches normal operating temperature.
with closed throttle and increase to 620-827 k P a (90- (4) Block front wheels.
120 psi) at 1/2 to 3/4 throttle. Note t h a t pressure will (5) Fully apply service and parking brakes.
increase to 896 k P a (130 psi) or more at full throttle. (6) Open throttle completely for no more t h a n five
(8) Refer to pressure test chart (Fig. 7) for pressure seconds and record maximum engine rpm registered
diagnosis.
on tachometer.
CONVERTER STALL TEST C A U T I O N : Stall testing c a u s e s a rapid increase in
Stall testing involves determining maximum en transmission fluid temperature. D o not hold the
gine rpm obtainable at full throttle with the rear
throttle open any longer than five seconds. If more
wheels locked and the transmission in D range. This
than one stall test is required, run the engine at
test checks the holding ability of the converter over
1000 rpm with the transmission in Neutral for at
running clutch and both of the transmission clutches.
When stall testing is completed, refer to the Stall least 20 s e c o n d s to cool the fluid.
Speed Specifications chart and Stall Speed Diagnosis
(7) If engine speed exceeds maximum shown in
guides.
stall speed chart, release accelerator pedal immedi
WARNING: NEVER ALLOW ANYONE TO STAND ately. This condition indicates transmission clutch
IN FRONT OF THE VEHICLE DURING A STALL slippage is occurring.
TEST. ALWAYS BLOCK THE FRONT WHEELS AND (8) Shift transmission into Neutral. Operate en
APPLY THE SERVICE AND PARKING BRAKES gine for 20 seconds. Stop engine, shift transmission
DURING THE TEST. into P a r k and release brakes.
(9) Stall speeds should be: 1800-2100 rpm with
3.9L engine and 1700-2000 rpm with 5.2L/5.9L en
STALL TEST PROCEDURE gines.
(1) Connect tachometer to engine.
(10) Refer to Stall Test Diagnosis.
(2) Check and adjust transmission fluid level.
AUTOMATIC TRANSMISSION—32RH/36RH/37RH/42RH/46RH 21 - 91
dicate a damaged converter. To confirm t h a t noise is

TEST CONDITION INDICATION
originating from the converter, operate the vehicle at
Line pressure OK during Pump and regulator valve OK light throttle in Drive and Neutral on a hoist and lis
any one test
ten for noise coming from the converter housing.
Line Pressure OK in R Leakage in rear clutch area (servo,
but low in D, 2, 1 clutch seals, governor support AIR TESTING CLUTCH AND BAND OPERATION
seal rings) Air pressure testing can be used to check clutch
Pressure Low in D Overdrive clutch piston seal, or and band operation with the transmission either in
Fourth Gear Range check ball problem the vehicle, or on t h e work bench as a final check af
ter overhaul.
Pressure OK in 1, 2 but Leakage in front clutch area (servo,
low in D3 and R clutch seals, retainer bore, pump Air pressure testing requires t h a t the oil pan and
seal rings) valve body be removed from the transmission. The
servo and clutch apply passages are shown in Figure
Pressure OK in 2 but low Leakage in rear servo
in R and 1 8.
FRONT SERVO APPLY^ FRONT
Front servo pressure low Leakage in servo; broken servo REAR SERVO APPLY SERVO
in 2 ring or cracked servo piston RELEASE
Pressure low in all positions Clogged filter, stuck regulator
valve, worn or faulty pump, PUMP
plugged fluid cooler LINE PRESSURE TO
SUCTION
ACCUMULATOR
Governor pressure too high Governor valve sticking open PUMP
at idle speed PRESSURE
Governor pressure low Governor valve sticking closed FRONT

at all mph figures CLUTCH
APPLY
Lubrication pressure low at Clogged oil cooler or lines, seal
all throttle positions rings leaking, output shaft plugged REAR
with debris, worn bushings in CLUTCH
pump or clutch retainer APPLY
J9321-165 TO TORQUE
GOVERNOR CONVERTOR
PRESSURE I
Fig. 7 Pressure Test Analysis Chart (42RH/46RH) FROM TORQUE
CONVERTER
STALL TEST DIAGNOSIS TO
GOVERNOR TO COOLER ^H252
Stall Speed Too High
If stall speed exceeds specifications by more t h a n Fig. 8 Air Pressure Test Passages
200 rpm, transmission clutch slippage is indicated. Front Clutch Test
Place one or two fingers on the clutch housing and
Stall Speed Too Low apply air pressure through front clutch apply passage
Low stall speeds with a properly tuned engine in (Fig. 8). Piston movement can be felt and a soft thud
dicate a torque converter overrunning clutch prob heard as the clutch applies.
lem. The condition should be confirmed by road
testing prior to converter replacement. Rear Clutch Test
The converter overrunning clutch is slipping when: Place one or two fingers on the clutch housing and
Stall speeds are 250 to 350 rpm below specified min apply air pressure through rear clutch apply passage
imum and the vehicle operates properly at highway (Fig. 8). Piston movement can be felt and a soft thud
speeds but has poor low speed acceleration. heard as the clutch applies.
Stall Speed Normal Front Servo Test

If stall speeds are normal but abnormal throttle Apply air pressure to the front servo apply passage.
opening is required to maintain highway speeds, the The servo rod should extend and cause the band to
converter overrunning clutch is seized and the torque tighten around the drum. Spring tension should re
converter must be replaced. lease the servo when air pressure is removed.
Converter Noise During Test
A whining noise caused by fluid flow is normal
during a stall test. However, loud metallic noises in
Rear Servo Test ing with one a dust shield bolt.
Apply air pressure to the rear servo apply passage. (5) Have helper run engine at 2500 rpm (with
The servo rod should extend and cause the band to transmission in Neutral) for two minutes; then stop
tighten around the drum. Spring tension should re engine.
lease the servo when air pressure is removed. (6) Inspect test probe and converter housing. If
leak is evident, note color of fluid. Transmission fluid
CONVERTER HOUSING FLUID LEAK DIAGNOSIS is red. Engine oil ranges in color from brown to
When diagnosing converter housing fluid leaks, green, or to black when oil is dirty.
two items must be established before repair. First, it (7) If probe upper surface is dry, converter and seal
must be verified t h a t a leak condition actually exists. are OK. However, path of fluid across probe upper
And second, the true source of the leak must be de surface indicates converter or seal leak. Fluid leak
termined. ing u n d e r probe is coming from pump housing area
Some suspected converter housing leaks may not (Fig. 11).
be leaks at all. They may only be the result of resid
(8) Fluid leaking under probe could be from: pump
ual fluid in the converter housing, or excess fluid
seal and/or bushing, pump vent, kickdown lever shaft
spilled during factory fill or refill after repair.
access plug, pump bolts, or porous spots in pump
Converter housing leaks have several potential
body or transmission case (Fig. 11).
sources. Through careful observation, a leak source
can be identified before removing the transmission (9) If porous spots in transmission case or pump
for repair. body are suspected leak source, pressurize transmis
Pump seal leaks tend to move along the drive hub sion as described in Leak Testing With Air Pressure.
and onto the rear of the converter. Pump O-ring or
pump body leaks follow the same path as a seal leak TORQUE CONVERTER LEAK POINTS
(Fig. 9).
Pump vent or pump attaching bolt leaks are gener
ally deposited on the inside of the converter housing
and not on the converter itself (Fig. 9).
Pump seal or gasket leaks usually travel down the
inside of the converter housing.
Front band lever pin plug leaks are generally de
posited on the housing and not on the converter.
,j PUMP PUMP PUMP
SHIELD MATERIAL: 5-1/2" X 1-1/2" X 1/32"

BOLT SHEET METAL RN778
Fig. 10 Leak Test Probe
Fig. 9 Typical Converter Homing Leak Paths

LEAK DIAGNOSIS PROCEDURE
(1) Raise rear of vehicle and allow accumulated
fluid to drain out of converter housing.
(2) Check and adjust transmission fluid level.
(3) Raise vehicle. Remove converter housing dust
cover and wipe as much fluid as possible from con
verter housing.
Fig. 11 Pump Area Inspection Points
(4) Fabricate test probe from steel or aluminum
stock (Fig. 10). Then attach probe to converter hous Possible sources of converter leaks are:
• AUTOMATIC TRANSMISSION-32RH/3IRH/37RH/42RH/48RH 21 - 13
• Leaks at weld joint around outside diameter weld The strap attaching hole positions are approximate
(Fig. 12). only. Measure hole position on the converter housing
• Leaks at converter hub weld (Fig. 12). before drilling.
The pump vent tool is made from 6.35 m m (1/4 in.)
OUTSIDE TORQUE CONVERTER
DIAMETER HUB WELD rod and 4.75 mm (3/16 in.) plate (Figs. 16, 17).
WELD The fabricated tools can all be made from mild
steel or aluminum stock.
WELD BREAK EDGE 1/16" MIN.
OR BRAZE
-«-l/8"
• SEAL THIS END AIR TIGHT

"LUG POLISH
OUTSIDE
STARTER RING GEAR RH254
1-3/4"-*- „ O F OPEN
" E N D FOR
Fig. 12 Typical Converter Leak Points • 5"-
THIS DISTANCE
O N TUBE
LEAK TESTING WITH AIR PRESSURE MATERIAL: 1-1/2 INCH O.D. THIN
This test involves closing off the transmission WALLED STEEL TUBING A N D
1/8 INCH STEEL DISC RN780
openings and pressurizing the transmission to 8 psi
(55 kPa) with air pump tool 7700. Fig. 14 Converter Hub Seal Cup-32RH/42RH
A soapy water solution is applied to suspected leak
points before and during the pressure test. Leaks will 15/32 INCH DRILL 4 HOLES
be indicated by the presence of air bubbles coming
through the solution.
Some transmission openings such as the fill tube
and front cooler line fitting can be closed off with a
rubber plug or similar device. Plugs can secured with
wire or duct tape.
The transmission rear output shaft opening is
closed off simply by leaving the transfer case bolted
in place. However, if the transfer case has been re
moved, a shipping plug can used to close off this
opening.
MATERIAL: 1/4 INCH STEEL STOCK
The torque converter hub opening in the pump and 1-1/4 INCH WIDE RN781
the pump vent require special tools to close them off.
The converter hub seal cup is made from thin wall Fig. 15 Seal Cup Retaining Strap
tube and a 3.18 mm (1/8 in.) thick disc (Figs. 13, 14).
AIR PRESSURE LEAK TEST PROCEDURE
A retaining strap is needed to secure the seal cup
(1) Install vent plug, converter hub seal cup and
for testing. The strap can be made from 31.75 mm (1-
cup retaining strap (Fig. 18).
1/4 in.) wide stock (Fig. 15).
(2) Close off remaining transmission openings with
WELD OR BREAK EDGE 1/16" rubber plugs, or stoppers. D o not close off rear
BRAZE MIN. cooler line fitting as air p u m p will be attached
to this fitting.
(3) Attach Air Pump 7700 to rear cooler line fit
ting. Connect length of copper tube to fitting. Then
attach air pump hose to tube with hose clamp (Fig.
19).
(4) Apply thick soapy water solution to suspected
leak areas.
OUTSIDE OF OPEN C A U T I O N : The recommended test pressure is 8 psi.

END FOR THIS The maximum allowable test pressure is 10 psi
MATERIAL: 1-7/8 INCH O.D. DISTANCE ON TUBE
THIN WALLED STEEL TUBING (68.9 kPa). D o not exceed specified pressure.
AND 1/8 INCH STEEL DISC RN779
(5) Pressurize transmission to 8 psi (55 kPa) with
Fig. 13 Converter Hub Seal Cup-36RH/46RH the hand operated air pump.
Fig. 16 Pump Vent Piug-36RH/46RH

13/32" DRILL 2 HOLES
COOLER LINE FITTING RY254
Fig. 19 Pressurizing Transmission

(4) Inspect pump bushing and converter hub. If
bushing is scored, replace it. If converter hub is
scored, either polish it with crocus cloth or replace
K N / a j
converter if scoring is severe.
(5) Install new pump seal, O-ring, gasket, and
Fig. 17 Pump Vent Plug-32RH/42RH bushing. Replace oil pump if housing is cracked, po
(6) Observe suspected leak areas. Air bubbles ap rous or damaged in any way.
pearing in soapy water solution indicate leak points. (6) Remove kickdown lever pin access plug. Apply
(7) Remove test tools and plugs after test comple Mopar silicone sealer, or Permatex No. 2 to plug
tion and make necessary repairs. Refer to Converter threads and tighten plug to 17 N*m (150 in. lbs.)
Housing Area Leak Correction procedure. torque.
(7) Adjust front (kickdown) band.
CONVERTER HOUSING AREA LEAK (8) Lubricate pump seal and converter hub with
CORRECTION transmission fluid or petroleum jelly and install con
(1) Remove transmission and remove torque con verter.
verter. (9) Install transmission.
(2) Tighten front band adjusting screw until band (10) Install converter housing dust shield
is tight around front clutch retainer. This prevents (11) Lower vehicle and refill transmission with
front clutch from coming out when oil pump is re recommended fluid.
moved.
(3) Remove oil pump and seal. Inspect pump hous
ing drainback and vent holes for obstructions. Clear
holes with solvent and wire.
• AUTOMATIC TRANSMISSION—32RH/36RH/37RH/42RH/46RH 21 - ii
DIAGNOSIS CHARTS AND HYDRAULIC FLOW diagnosis charts apply to all transmission models.
DIAGRAMS The Overdrive Unit charts apply to t h e four speed
The diagnosis charts and hydraulic flow diagrams transmissions only.
provide additional reference for transmission diagno The hydraulic flow diagrams outline transmission
sis. fluid flow and hydraulic circuitry. The flow diagrams
The diagnosis charts provide general information also provide basic working pressures for the various
on a variety of transmission, overdrive unit and con gear ranges.
verter clutch fault conditions. The Transmission Unit
TRANSMISSION DIAGNOSIS
HARSH ENGAGEMENT (FROM 1. Engine idle speed too high 1. Check/adjust idle speed
NEUTRAL TO DRIVE OR
REVERSE) 2. Driver "riding" accelerator pedal during shift 2. Advise owner/operator
3. Throttle cable or linkage misadjusted 3. Adjust cable or linkage; setting is either too
long or too short
4. Band adjustment needed 4. Adjust front/rear bands
5. Loose mounting bolts 5. Check engine, transmission, propeller shaft,
crossmember, and axle bolt torque; tighten
loose bolts and replace missing bolts
6 Worn or damaged U-joints 6. Remove propeller shaft and replace U-joints
7. Loose axle pinion nut 7. Replace nut and check pinion threads before
installing new nut; replace pinion gear if
threads are damaged
8. Hydraulic pressure is incorrect 8. Check pressures; remove, overhaul, or adjust
valve body as needed; repair oil pump if
necessary
Note: The shift from neutral to
reverse is normally quite firm. 9. Accumulator piston spring, or seal worn or 9. Remove valve body and replace piston,
Hydraulic pressure at the rear damaged seal, or spring as needed
servo can approach 300 psi in
10. Faulty converter clutch (if equipped) 10. Replace converter and flush cooler and lines
reverse gear. Do not confuse a
before installing new converter
firm engagement with a truly
harsh engagement 11. Clutch, band, or planetary component is damaged 11. Remove, disassemble, and repair
transmission as necessary
DELAYED ENGAGEMENT 1. Engine idle speed too low 1. Adjust idle speed
(FROM NEUTRAL TO DRIVE
OR REVERSE) 2. Low fluid level 2. Correct level and check for leaks
3. Gearshift linkage but of adjustment 3. Adjust cable or linkage and repair linkage if
worn or damaged
4. Rear band out of adjustment 4. Adjust band
5. Valve body filter plugged 5. Replace fluid and filter. If oil pan and old
fluid were full of clutch disc material and/or
metal particles, overhaul will be necessary
6. Oil pump gears worn or damaged or pump 6. Remove transmission and replace oil pump
body or seal is damaged, allowing pump to
take in air, causing fluid aeration
7. Reaction shaft seal rings worn or broken 7. Remove transmission, remove oil pump, and
replace seal rings
8. Governor valve stuck or valve shaft is loose or 8. Remove and inspect governor components;
damaged replace worn or damaged parts
9. Low hydraulic pressure 9. Perform pressure test, remove transmission,
and repair as needed
10. Clutch, band, or servo damage 10. Remove and disassemble transmission and
repair as necessary
J9321-255
Cenoltfeie Possible Caws® Cowscilon
SHIFTS DELAYED OR ERRATIC 1. Lowfluidlevel 1. Correctfluidlevel and check for leaks

(SHIFTS ALSO HARSH AT
2. Throttle linkage out of adjustment 2. Adjust linkage as described in service section
TIMES)
3. Throttle linkage is binding 3. Disassemble, clean, and adjust linkage; replace
linkage grommets if removed or if worn or
cracked
4. Gearshift linkage out of adjustment 4. Adjust linkage as described in service section
5. Fluid filter partially clogged 5. Replace filter. If filter and fluid contained clutch
material or metal particles, an overhaul may be
necessary
6. Air influiddue to overfill condition or air leakage 6. Drain fluid to correct level if overfilled. Iffluidis
into pump suction passages highly aerated (full of bubbles and foamy), oil
pump gasket or seal may have failed, or pump
body is porous or cracked
7. Clutch or servo problem 7. Remove valve body and air test clutch, band and
servo operation; disassemble and repair
transmission as needed
8. Front band out of adjustment (may cause harsh 8. Adjust band
1-2 shift)
N O REVERSE (D RANGES OK) 1. Gearshift linkage is either out of adjustment or 1. Repair or replace linkage parts as needed
damaged
2. Rear band is out of adjustment 2. Adjust band
3. Valve body malfunction (stuck/damaged manual 3. Remove and service valve body; replace valve
valve, regulator valve, or check ball) body if any valves or valve bores are worn or
damaged
4. Rear servo or front clutch malfunction 4. Remove and disassemble transmission; replace
worn, damaged servo and clutch parts as
necessary
HAS FIRST-REVERSE ONLY 1. Governor valve, shaft, weights, or body damaged 1. Remove governor assembly and repair as
(NO 1-2 OR 2-3 UPSHIFT) necessary
J9121-440
CendSfion Possible Cause Correction
N O DRIVE RANGE 1 . Gearshift linkage either loose, damaged or out of 1. Repair or replace linkage components
(REVERSE OK) adjustment
2. Low fluid level 2. Correct fluid level and check for leaks
3. Valve body malfunction (manual valve or shaft 3. Remove and disassemble valve body; replace as
damaged or 1 -2 shift valve stuck) assembly if any valves or bores are damaged
4. Rear clutch failure 4. Remove and disassemble transmission and rear
clutch; repair/replace worn, damaged parts as
needed
5. Transmission overrunning clutch failure 5. Remove and disassemble transmission; replace
overrunning clutch
6. Input shaft seal rings worn or damaged 6. Remove and disassemble transmission; replace
seal rings and any other worn or damaged parts
N O DRIVE OR REVERSE 1. Low fluid level 1 . Add fluid and check for leaks if drive is restored
(VEHICLE WILL NOT MOVE)
2. Gearshift linkage loose, damaged, or misassembled 2. Inspect, adjust, and reassemble linkage as needed;
replace worn, damaged parts
3. Failure of driveline component, such as U-joint, axle 3. Perform preliminary inspection procedure for
shaft, transfer case component, etc. vehicle that will not move; refer to procedure in
diagnosis section
4. Low fluid pressure due to worn or damaged oil 4. Perform pressure test to confirm low pressure;
pump replace pump body and/or gears if necessary
5. Transmission internal component damaged 5. Remove and disassemble transmission; repair or
replace failed components as needed
6. Valve body malfunction (seized valve, damaged 6. Remove, disassemble, and inspect valve body;
manual lever, valve body screws loose or replace valve body (as assembly) if any valve or
overtightened causing distortion and bind) bore is damaged; clean and reassemble correctly
if all parts are in good condition
J9121-443
• AUTOMATIC TRANSMISSION-32RH/36RH/37RH/42RH/46RH 21 - 99
MOVES IN 2ND OR 3RD 1. Governor valve sticking 1. Remove, clean, and inspect; replace faulty parts
GEAR, ABRUPTLY 2. Valve body malfunction 2. Remove, clean, and inspect; look for stuck
DOWNSHIFTS TO LOW
1 -2 valve or governor plug
SLIPS IN LOW GEAR D ONLY, 1. Overrunning clutch faulty, not holding 1. Replace overrunning clutch
BUT NOT IN 1 POSITION
SLIPS IN FORWARD DRIVE 1. Low fluid level 1. Add fluid and check for leaks
RANGES 2. Check for bad pump gasket or seals, dirt
2. Air in fluid (fluid is foamy, full of bubbles), shifts are
spongy, caused by air getting into pump suction between pump halves, and loose pump bolts or
passages defective O-ring at filler tube
3. Gearshift or throttle linkage out of adjustment 3. Adjust linkage
4. Low hydraulic pressures due to worn pump, 4. Perform hydraulic and air pressure tests to
incorrect control pressure adjustments, valve body determine cause
warpage or malfunction, sticking governor, leaking
seal rings, dutch seals leaking, servo leaks, clogged
filter, or cooler lines
5. Accumulator piston cracked, spring broken or 5. Inspect and repair as necessary
seal worn
6. Clutch or servo malfunction, leaking seals or 6. Air pressure check clutch-servo operation and
worn plates repair as required
7. Overrunning clutch worn, not holding (slips in 7. Replace clutch
1 only)
SLIPS IN REVERSE ONLY 1. Low fluid level 1. Add fluid and check for leaks
2. Aerated fluid; see Slips in Forward Drive Ranges 2. See Slips in Forward Drive Ranges
3. Gearshift linkage out of adjustment 3. Adjust linkage
5. Hydraulic pressure too low due to worn pump, worn 5. Perform hydraulic pressure tests to determine
seal rings, clutch or servo seal leakage cause
6. Worn front clutch, leaking rear servo, or worn 6. Air pressure check clutch-servo operation and
rear band repair as required
7. Band-linkage binding 7. Inspect and repair as required
J9121-444
21-100 AUTOMATIC TRANSMISSION-32RH/36RH/37RH/42RH/46RH •
Condition Possibie Cause Correction
NO KICKDOWN OR 1. Incorrect throttle linkage or cable adjustment 1. Adjust linkage or cable

NORMAL DOWNSHIFT
2. Incorrect gear shift linkage or cable adjustment 2. Adjust linkage or cable
3. Front band out of adjustment 3. Adjust band
4 Hydraulic pressures too high or too low due to 4. Perform hydraulic pressure tests to determine
sticking governor, valve body malfunction, or cause and repair as required. Correct valve
incorrect hydraulic control pressure adjustments body pressure adjustments as required
5. Front servo, band, or linkage malfunction 5. Air pressure test operation and repair as
necessary
6. Clutch or servo malfunction
6. Air pressure test operation and repair as
necessary
STUCK IN LOW GEAR (WILL 1. Gearshift or throttle linkage or cable out of 1. Adjust linkage or cable. Repair linkage of
NOT UPSHIFT) adjustment worn or damaged. Relace damaged cable.
2. Front band out of adjustment 2. Adjust band
3. Governor valve stuck closed; loose output shaft 3. Check line and governor pressures to
support or governor housing bolts, worn pump, determine cause; correct as required
leaking seal rings, or valve body problem (i.e.,
stuck 1-2 shift valve or governor plug)
4. Clutch or servo malfunction 4. Air pressure check operation of clutches and
bands; repair faulty component
N O LOW GEAR (MOVES IN 1. Governor valve sticking in partially open position 1. Remove governor; clean, inspect, and repair
2ND OR 3RD GEAR ONLY) as required
2. Valve body malfunction 2. Remove, clean, and inspect. Look for sticking
1-2 vafve, 2-3 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
5. Incorrect throttle or gearshift linkage or cable 5. Adjust linkage or cable
adjustment
J9321-256
+ AUTOMATIC TRANSMISSION—32RH/36RH/37RH/42RH/46RH 21 - 101
CREEPS I N NEUTRAL 1. Gearshift linkage out of adjustment 1. Adjust linkage

2. Valve body malfunction (warped body, cross 2. Perform hydraulic pressure test to determine
leakage) cause ana repair as required
3. Clutch dragging 3. Air pressure check operation of clutches and
repair as required
4 . Converter lockup clutch dragging 4. Oil pump worn; replace pump
D R A G S O R LOCKS UP 1. Front or rear band out of adjustment 1. Adjust bands

2. Servo band or linkage malfunction (i.e., binding 2. Air pressure check servo operation and repair
linkage, warped band, servo piston stuck) as required
3. Air pressure check clutch operation and repair
3. Dragging clutch (does not release fully) as required
4. Remove, inspect, and repair as required (look
4. Broken or seized planetary gears for debris in oil pan)
5. Remove and inspect clutch, repair as required
5. Overrunning clutch worn, broken, or seized
GROWLING, GRATING, OR 1. Planetary gear set broken or seized 1. Check for debris in oil pan and repair as
SCRAPING N O I S E S required
2. Overrunning clutch worn, seized, or broken 2. Inspect and check for debris in oil pan; repair as
required
3. Oil pump components scored, binding, or broken 3. Remove, inspect, and repair as required
4. Output shaft bearing or bushing damaged 4. Remove, inspect, and repair as required
5. Faulty clutch operation 5. Perform air pressure check and repair as
required
6. Governor support (park gear) binding or seal rings 6. Remove, inspect, and repair as required
broken
7. Front and rear bands out of adjustment 7. Adjust bands
BUZZING N O I S E 1. Low fluid level 1. A d d fluid and check for leaks

2. Air being drawn into pump suction passages 2. Check pump for porous casting, scores on
mating surfaces, and excess rotor clearance;
repair as required
3. Overrunning clutch damaged 3. Replace clutch
4 . Valve body misassembled, bolts loose, weak spring, 4. Remove, disassemble, inspect valve body;
or mispositioned valve or check ball reassemble correctly if necessary; replace
assembly if valves or springs are damaged
J9121-446
21-102 AUTOMATIC TRANSMISSION—32RH/36RH/37RH/42RH/46RH •
OIL COMES OUT FILLER TUBE 1. Transmission overfilled 1. Drainfluidto correct level; remove neutral
switch and drain through switch hole with
suction gun
2. Breather vent in oil pump blocked 2. Inspect and clear blockage
3, Fly id cooler or cooler lines plugged 3. Flush cooler and lines
4. Air influid(aerated) 4. See "Slips In Forward Drive Ranges"
5. Oilfilterclogged 5. Replacefilter;determine the reason for clogged
condition and repair
6. tear servo piston or seal failure 6. Check hydraulic pressure at servo in reverse
(will register low orfluctuaterapidly)
7. Valve body switch valve sticking 7. Remove and clean valve
OIL LEAKS (ITEMS LISTED 1. Speedometer adapter 1. Replace both adapter seals
REPRESENT POSSIBLE LEAK
POINTS AND SHOULD ALL BE 2. Pan gasket 2. Tighten pan screws to 150 inch-pounds; if
CHECKED) leaks persist, replace gasket; do not
overtighten screws
3. Filler tube (where tube enters case) 3. Replace O-ring seal
4. Fluid lines and fittings 4. Tighten fittings; if leaks persist, replace fittings
and lines if necessary
5. Valve body manual lever shaft seal 5. Replace shaft seal
6. Pressure port plug loose 6. Tighten to correct torque; replace plug if leak
persists
7. Rear bearing access plate 7. Replace gasket
8. Gasket damaged or bolts are loose 8. Replace bolts or gasket or tighten bolts
9. Adapter/extension gasket damaged 9. Replace gasket
10. Neutral switch 10. Replace switch and gasket
11. Converter housing area 11. Check for leaks at seal caused by worn seal or
burr on converter hub (cutting seal), worn
bushing, missing oil return, oil in front pump
housing, or hole plugged. Check for leaks past
O-ring seal on pump, or past pump-to-case
bolts; pump housing porous, oil coming out
vent due to overfill or leak past front band shaft
access plug
12. Cooler line fittings and hoses 12. Replace fittings and hoses
13. Pump seal 13. Replace seal
14. Torque converter 14. Replace converter
J9121-448
• AUTOMATIC TRANSMISSION—32RH/36RH/37RH/42RH/46RH 21-103
Condition Possible Couso Correction
OVERHEAT DURING 1. Vehicle not properly equipped for trailer towing or 1. Be sure vehicle is equipped with recommended
C O M M E R C I A L OPERATION commercial use optional components (i.e., H D springs,
OR WHILE TRAILER T O W I N G transmission, axle, larger CID engine, auxiliary
(FLUID DARK A N D BURNED cooler, correct axle ratio, etc.). If vehicle is not so
WITH S O M E SLUDGE equipped, it should not be used for severe
FORMATION) service operation
2. Vehicle not equipped with auxiliary fluid cooler 2. Drain fluid, change filter, and install auxiliary
cooler
3 . Extensive idling time or operation in heavy traffic in 3. Cut down on idling time; shift into neutral every
hot weather so often and run engine at 1000 rpm to help
circulate fluid through cooler
4. Tow vehicle overloaded (exceeding vehicle tow 4. Be sure vehicle is properly equipped to handle
capacity) load; do not tow Class Ill-type loads with a
vehicle that is only rated for Class 1 or II
operation
5. Air flow to auxiliary cooler blocked by snow plow, 5. Remove or reposition item causing air flow
front mounted spare tire, bug screen, or similar item blockage
OVERHEAT DURING N O R M A L 1. Lowfluidlevel 1. A d d fluid and check for leaks

OPERATION (FLUID
2. Fluid cooler, lines blocked, or cooler cracked (oil in 2. Flush cooler and lines and replace radiator if
DISCOLORED, SMELLS
engine coolant) transmission fluid has entered coolant
BURNED)
3 . Switch valve sticking 3. Remove, disassemble, clean valve body
4. Clutch pack clearance incorrect (too tight) 4. Check and correct as required
5. Bands too tight 5. Adjust bands
J9121-450
Condition POMIOSO Ccwse Correction
N O START I N PARK OR 1. Gearshift linkage out of adjustment 1 . Adjust linkage

NEUTRAL
2. Neutral switch wire broken or open 2 . Check continuity with test lamp; repair as
required
3. Faulty neutral switch 3. Refer to service section for test and replacement
procedure
4 . Valve body manual lever assembly bent, worn, 4 . inspect lever assembly and replace if damaged
broken, or not aligned with switch
SLUGGISH ACCELERATION AT 1. Poor engine performance 1 . Check engine and repair as required
L O W SPEEDS O R REQUIRES
EXCESSIVE THROTTLE
2. Gearshift or throttle linkage out of adjustment 2. Adjust linkage
O P E N I N G TO MAINTAIN 3. Transmission clutches slipping 3. Perform stall test and repair as required
H I G H W A Y SPEEDS 4 . Perform stall test and replace converter if clutch
4 . Overrunning clutch in converter not holding
has failed
5. Converter overrunning clutch stuck 5. Replace converter
FLUID C O N T A M I N A T E D 1 . If contamination occurred shortly after overhaul, 1. If contamination is severe, cooler flushing,
(DISCOLORED, FULL OF fluid cooler and lines were not flushed and flow converter replacement, and another overhaul
SLUDGE A N D / O R METAL rested. This is especially true when original overhaul may be necessary; particularly so if shift
A N D FRICTION MATERIAL was to correct a problem that generated a large problems were also present
PARTICULAR) amount of debris, such as a gear failure or a clutch
pack failure
Note: Flushing the cooler and lines is mandatory after
a failure of the converter lockup clutch
2 . Incorrect fluid used in transmission 2 . If transmission is operating properly, drain fluid,
reverse flush cooler and lines, and change fluid
and filter. However, if shift problem has
developed, converter replacement and
transmission overhaul may be required
3. Main cooler in radiator is cracked, allowing engine 3. Replace radiator (and cooler) and flush lines. If
coolant to enter transmission problem was diagnosed early enough, fluid and
filter change may only be necessary. If
contamination perioa was prolonged, overhaul
and converter replacement may be required
4 . Severe overload results in overheat, fluid break 4 . Repair transmission, flush cooler, and lines.
down, and accelerated wear, especially in high Replace converter if necessary. Install auxiliary
ambient temperatures. Most frequent causes are: cooler if needed. Also install H D cooling system
if needed. If tow vehicle and unit being towed
• Vehicle is not properly equipped for heavy duty
are both overloaded, the only repair is to reduce
service the load to rated limits. However, if trailer or
• Tow vehicle and boat or trailer are both boat is too large for tow vehicle, the only option
overloaded is for the owner to move up to properly-
• Trailer or boat are too large for tow vehicle (load equipped and load-rated tow vehicle
exceeds rated capacity of tow vehicle)
J9121-449
• AUTOMATIC TRANSMISSION—32RH/36RH/37RH/42RH/46RH 21-105
42RH/46RH OVERDRIVE DIAGNOSIS
Condition Possible Co use Correction
N O 3-4 U P S H I F T 1.Fourth gear overdrive switch (on dash) in OFF 1. Turn control switch to O N position
position 2. Replace fuse; determine why fuse failed
2. Overdrive circuit fuse blown and repair a s necessary (i.e., shorts,
grounds in circuit)
3. Fourth gear overdrive switch shorted, open, 3. Replace switch if shorted or open a n d
wires loose repair loose or d a m a g e d wires
4. Overdrive solenoid or circuit wire loose, 4. Check wires/connections with 12V test lamp
shorted, open and voltmeter; repair d a m a g e d or loose
wires/connections as necessary
5. Solenoid feed orifice in valve b o d y is blocked 5. Remove, disassemble, clean valve b o d y

thoroughly
6. Fourth gear overdrive solenoid failure 6. Verify solenoid failure with test lamp and
replace solenoid
7. Sensor failure (vehicle speed sensor or coolant 7. Test both sensors with test lamp or volt/
sensor) ohmmeter and replace faulty sensor
8. Park/neutral switch open or shorted or switch 8. Test switch a s described in service section
wire to powertrain control module is d a m a g e d and replace if necessary
(loss of park/neutral input)
9. Powertrain control module faulty 9. Check with D R B II scan tool and replace if
necessary
10. T.P.S. fault 10. Adjust or replace T.P.S.

11. Transmission fluid temperature sensor fault (if 11. Replace sensor
equipped)
12. Replace both seals
12. Overdrive piston seal failure
13. Remove unit, check end play, and install
13. W r o n g overdrive piston spacer correct spacer
14. Pressure test transmission to determine
14. Low hydraulic pressure cause
15. Set-reset module faulty 15. Replace module (if equipped)
S U P S IN OVERDRIVE 1. Low fluid level 1. A d d fluid and check for leaks

FOURTH GEAR
2. Overdrive piston or seal malfunction 2. Remove overdrive unit; replace piston seals
if worn; replace piston if d a m a g e d , if piston
retainer is d a m a g e d , it will be necessary to
remove and disassemble the transmission
3. Overdrive clutch pack w o r n 3. Remove overdrive unit and rebuild clutch pack
4. 3-4 shift valve, timing valve, or accumulator 4. Remove and overhaul valve body. Replace
malfunction accumulator seals. Make sure all valves operate
freely in bores, and do not bind or stick. Make
sure valve body screws are correctly tightened
and separator plates are properly positioned
5. Overdrive piston retainer bleed orifice blown out 5. Disassemble transmission, remove retainer,
and replace orifice
6. Overdrive unit thrust bearing failure 6. Disassemble overdrive unit and replace
thrust bearing ( N o . 1 thrust bearing is
between overdrive piston and clutch hub;
N o . 2 thrust bearing is between the
planetary gear and the direct clutch spring
plate; N o . 3 thrust bearing is between
overrunning clutch hub and output shaft)
J9321-252
21-106 AUTOMATIC TRANSMISSION—32RH/36RH/37RH/42RH/46RH •
D E L A Y E D 3-4 U P S H I F T 1. Low fluid level 1. A d d fluid and check for leaks

(SLOW TO E N G A G E )
2. Overdrive solenoid or wiring is faulty 2. Test solenoid and check wiring for loose/
corroded connections, or shorts/ground; replace
solenoid if faulty and repiar wiring if necessary
3. Overdrive piston spacer too thin 3. Remove unit; measure end play and select
proper spacer
4. Overdrive clutch pack worn 4. Remove unit and rebuild clutch pack
5. T.P.S. faulty 5. Replace T.P.S.

6. Overdrive clutch bleed orifice plugged 6. Disassemble transmission and replace orifice
3-4 U P S H I F T O C C U R S B E F O R E 1. Overdrive solenoid connector or wiring problem 1. Test connector and wiring for loose connections,
C O M P L E T I O N O F 2-3 U P S H I F T shorts, or ground, and repair as needed
2. Overdrive solenoid malfunction 2. Replace solenoid
3. Coolant temperature or T.P.S. malfunction 3. Test each sensor for continuity, short, ground,
and replace as necessary
4. Valve body malfunction 4. 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
5. Powertrain control module malfunction 3. Test with D R B II scan tool and replace
controller if faulty
J9321-253
+ AUTOMATIC TRANSMISSION-32RH/36RH/37RH/42RH/46RH 21-107
N O 4-3 D O W N S H I F T 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 a s required
2. Converter clutch solenoid not venting 2. Remove valve body and replace solenoid if
seized or shorted
3. Overdrive solenoid not venting 3. Remove valve body and replace solenoid if
seized or shorted
4 . 3-4 shift, shuttle, timing v a l v e , or accumulator 4. Remove valve b o d y ; remove a n d disassemble

malfunction lower housing and 3-4 accumulator housing;
replace seals and clean valves as necessary;
be sure all valves slide freely in bores
5. Powertrain control module malfunction 5. Check operation with D R B II scan tool;

replace controller only if faulty
6 . T.P.S. malfunction 6. Replace T.P.S.
7 . Sensor or sensor wiring problem 7 . Check coolant and transmission temperature
sensors, speed sensor, and overdrive control
switch
N O 4-3 D O W N S H I F T W H E N 1. Control switch open-shorted 1. Test and replace switch if faulty

C O N T R O L S W I T C H IS
T U R N E D OFF 2. Overdrive solenoid wiring or connectors faulty 2. Check solenoid wiring and connections for
shorts/grounds; repair as necessary
3. Overdrive or converter clutch solenoid not 3. Test solenoids and replace if seized or shorted
venting
4. Powertrain control module malfunction 4. Test with D R B II scan tool; replace module if
faulty
J9321-254
HARSH 1-2, 2-3, OR 3-2 1. Lockup solenoid failure 1. Remove valve body and replace solenoid
SHIFTS (A500)
TORQUE CONVERTER LOCKS 1. Lockup solenoid, relay, or wiring problem 1. Test solenoid, relay, and wiring for continuity,
UP IN SECOND AND/OR shorts, or grounds; replace solenoid and relay if
THIRD GEAR (A500) faulty; repair wiring and connectors as
necessary
NOISY OPERATION IN 1. Overdrive clutch discs, plates, or snap rings 1. Remove unit and rebuild clutch pack
FOURTH GEAR ONLY damaged
2. Overdrive piston or planetary thrust bearing 2. Remove and disassemble unit; replace either
brinnelled, installed wrong, or damaged thrust bearing if damaged
3. Output shaft bearings brinnelled, scored, damaged 3. Remove and disassemble unit; replace either
bearing if damaged
4. Planetary gears worn, chipped, damaged 4. Remove and overhaul overdrive unit
5. Overdrive unit overrunning clutch rollers rough, 5. Remove and overhaul overdrive unit
scored, or output bushings are worn
J9121 455
+ AUTOMATIC TRANSMISSION—32RH/36RH/37RH/42RH/46RH 21 - 109
NO REVERSE (OR SLIPS IN 1. Direct clutch spring collapsed or broken 1. Remove and disassemble unit; check clutch pack
REVERSE) and replace spring
2. Direct clutch pack worn 2. Disassemble unit and rebuild clutch pack
4. Front clutch malfunction 4. Air pressure test clutch operation; remove and
rebuild if necessary
5. Overdrive thrust bearing failure 5. Disassemble geartrain and replace bearings
NO 1-2 OR 2-3 UPSHIFT (HAS 1. Governor component loose, worn, or damaged 1. Remove and disassemble unit; replace worn or
LOW AND REVERSE ONLY) damaged governor components as needed
J9121-456
TORQUE CONVERTER CLUTCH DIAGNOSIS
POSSIBLE CAUSE
FAULTY OIL PUMP X X X X X
STICKING GOVERNOR VALVE X X X
PLUGGED COOLER, LINES OR FITTINGS X X X
VALVE BODY MALFUNCTION X X X X X X X
STUCK SWITCH VALVE X X X X X X
STUCK CONVERTER CLUTCH VALVE X X X
STUCK CONVERTER CLUTCH SOLENOID X X
SOLENOID WIRING DISCONNECTED X
FAILED CONVERTER CLUTCH SOLENOID X
FAILED CONVERTER CLUTCH RELAY X X
FAULTY TORQUE CONVERTER: X X X X X
OUT OF BALANCE X
FAILED CONVERTER CLUTCH X X X
LEAKING TURBINE HUB SEAL X X
ALIGN EXHAUST SYSTEM X X
TUNE ENGINE X X X
FAULTY INPUT SHAFT OR SEAL RING X X
THROTTLE CABLE MISADJUSTED X X
j
OUT OF FILL TUBE OR PUMP SEAL
DURING CLUTCH ENGAGEMENT
OVERHEATING: OIL COMING

VIBRATION WHEN "REVVED"
LOW A SPEED IN 4th GEAR
CHATTER DURING CLUTCH
VIBRATION AFTER CLUTCH

LOCKS UP OR DRAGS IN
VIBRATION OR SHUDDER
STAYS ENGAGED AT TOO
SHUDDER AFTER CLUTCH

STALLS OR IS SLUGGISH
ENGAGEMENT-(COLD)
CONVERTER CLUTCH
WILL NOT ENGAGE
CLUTCH WILL NOT
LOW OR SECOND
Z
ENGAGEMENT
ENGAGEMENT
IN NEUTRAL
0
DISENGAGE
IN REVERSE
o
z
o
HYDRAULIC FLOW IN D-FIRST GEAR (32RH/36RH/37RH)
GOVERNOR VALVE
REAR SERVO FRONT, SERVO
r ÂCCUMULATOR
LOCK-UP ONLY
FRONT
CLUTCH
UBRICATION
SELECTOR LEVER IN
DRIVE (BREAKAWAY)
HALF THROTTLE U902M61
HYDRAULIC FLOW IN DSEGOND GEAR (32RH/36RH/37RH)
GOVERNOR VALVE
REAR SERVO FRONT M SERVO ACCUMULATOR
FRONT CLUTCH
TO
LUBRICATION
FRONT
^CLUTCH
LUBRICATION
LINE 75 PSI CONVERTER 5-75 PSI
PUMP SUCTION \y>>>\ LUBRICATION 5-30 PSI WMM (j
THROTTLE 40 PSI WMM 1-2 SHIFT CONTROL M
GOVERNOR 6-75 PSI 25-35 PSI ^ (i

3 OIL FILTER
SELECTOR LEVER IN TORQUE C O N V E R T E R - * * !
DRIVE (SECOND) (|
HALF THROTTLE J9021-162
HYDRAULIC FLOW IN D-THIRD GEAR (32RH/36RH/37RH)
GOVERNOR VALVE
X
REAR CLUTCH J^T Î^L FRONT CLUTCH FRONT UJ SERVO
/ ACCUMULATOR
LOCK-UP ONLY
TO
LUBRICATION
FRONT
CLUTCH
LUBRICATION
J9021-163
HYDRAULIC FLOW IN D«THIRD GEAR—AFTER CONVERTER CLUTCH ENGAGEMENT (32RH/36RH/37RH)
GOVERNOR VALVE REAR SERVO
ACCUMULATOR
LOCK-UP ONLY
TO
LUBRICATION
FRONT
.-CLUTCH
IMBRICATION
SELECTOR LEVER IN TORQUE CONVERTER •

DRIVE (LOCK-UP)
J902M64
HYDRAULIC FLOW DURING PART THROTTLE 3-2 KICKDOWN (32RH/36RH/37RH) fs9
GOVERNOR VALVE
ACCUMULATOR
y
LOCK-UP ONLY
33
GO
33
30
4>
m
30
1-2 SHIFT CONTROL

55-70 PSlk%>3
GOVERNOR 6-40 PSI [ ™ ™
SELECTORLEVER IN DRIVE TORQUE CONVERTER-
(PART THROTTLE KICKDOWN)
BELOW 40 M.P.H. J9021-165
HYDRAULIC FLOW DURING FULL THROTTLE 3-2 KICKDOWN (32RH/36RH/37RHJ
GOVERNOR VALVE REAR SERVO FRONT SERVO ACCUMULATOR
I T
LOCK-UP ONLY
1-2 SHIFT CONTROL P 5 r ^ r i
55-70 ?$ir///A
GOVERNOR 30-73 PSI f—"
SELECTOR LEVER IN DRIVE TORQUE CONVERTER"
(FULL THROTTLE KICKDOWN) J902M66
HYDRAULIC FLOW IN 2-POSITION MANUAL SECOND (32RH/36RH/37RH) ro
GOVERNOR VALVE
REAR CLUTCH REAR SERVO FRONT SERVO
FRONT CLUTCH ACCUMULATOR
r
ao
>
oo
00
m
rO
30
c3
o>
30
30
3^
ro
30
30
FRONT
CLUTCH
UBRICATION
l / M - l v X ' X v : - : - - I OIL FILTER

SELECTOR LEVER IN TORQUE CONVERTER*
TWO (MANUAL SECOND) I B U ^ w S S S ^ ^ ^ i
CLOSED THROTTLE J9021-167
HYDRAULIC FLOW IN 1-POSITION MANUAL LOW (32RH/36RH/37RHf
GOVERNOR VALVE REAR SERVO ^„ „, , FRONT SERVO
REAR CLUTCH r r % t m
FRONT CLUTCH ACCUMULATOR
FRONT
2 CLUTCH
LUBRICATION
SELECTOR LEVER IN
ONE (MANUAL LOW)
CLOSED THROTTLE ^21-168
HYDRAULIC FLOW IN REVERSE—32RH/36RH/37RH
G O V E R N O R VALVE R E A R SERVO
REAR CLUTCH FRONT CLUTCH FRONT SERVO
ACCUMULATOR
FRONT
iCLUTCH
UBRICATION
SELECTOR LEVER
IN REVERSE
HYDRAULIC FLOW IN NEUTRAL (42RH/46RH)
GOVERNOR
HYDRAULIC FLOW IN REVERSE (42RH/46RHJ
ACCUMULATOR
J9321-197 IN3
HYDRAULIC FLOW IN MANUAL LOW (42RH/46RH}
FRONT SERVO
ACCUMULATOR
30
>
Z
CO
CO
LENE
PRESSURE
(55-62 psi) f
CO
i»
as
ac
&3
1-2 cn
SHIFT
CONTROL •C
(25-35 pslj c3
ro
as
ac
GOVERNOR
PRESSURE
(C-30 psi) as
CONVERTER/
LUSE PRESSURE
(5-57 p s i |
PUMP SUCTION
SELECTOR LEVER IN MANUAL I

FIRST G E A R
(CLOSED THROTTLE J
J9321-198
HYDRAULIC FLOW IN MANUAL SECOND (42RH/46RHJ
j LINE PRESSURE j
(55-62 psi)
1-2 SHIFT
CONTROL
(25-35 psi)
GOVERNOR
PRESSURE
(6-57 psi)
CONVERTER/
| LUBE PRESSURE |
(5-57 psi)
PUMP
SUCTION
HYDRAULIC FLOW IN DRIVE FIRST GEAR (42RH/46RH)
J9321-200 •
HYDRAULIC FLOW IN DRIVE SECOND GEAR (42RH/46RH) •
LINE
PRESSURE
(57-94 psi)
GOVERNOR
PRESSURE
(0-57 psi)
1-2 SHIFT
CONTROL
(25-70 psi)
THROTTLE
PRESSURE
(0-94 psi)
COVERTER/
LUBE PRESSURE
(5-57 psi)
PUMP
SUCTION
SELECTOR LEVER IN DRIVE (D)

SECOND GEAR
(PART THROTTLE)
J9321-201
HYDRAULIC FLOW IN DRIVE THIRD GEAR (42RH/46RH)
HYDRAULIC FLOW IN DRIVE FOURTH GEAR OVERDRIVE (42RH/46RH)
GOVERNOR
VALVE
J9321-203 r3
21 - 130 IN-VEHICLE SERVICE-~32RH/36RH/37RH/42RH/4iRH •
IN-VEHICLE SERVICE-32RH/36RH/37RH/42RH/46RH
INDEX
page page
Aluminum Thread Repair 141 Park Lock S e r v i c e - 3 2 R H / 3 6 R H / 3 7 R H . 138
Checking Fluid Level 130 Park/Neutral Position Switch 134
Extension Housing Bushing and Output Shaft Rear Band Adjustment 133
Bearing S e r v i c e - 3 2 R H / 3 6 R H / 3 7 R H . . . . 135 Speedometer Service 134
Extension Housing Yoke Seal Replacement . . . . 135 Transmission Cooler Service 140
Fluid and Filter Change 130 Transmission Throttle Cable Adjustment-
Front Band Adjustment 133 Cummins Diesel Engine 132
Gearshift Linkage Adjustment 130 Transmission Throttle Cable Adjustment-
Governor and Park Gear Service— G a s Engines 131
32RH/36RH/37RH 137 Valve Body Control Pressure Adjustments . . . . . 140
Governor and Park Lock Service—42RH/46RH . 138 Valve Body Service 138
CHECKING FLUID LEVEL Severe Usage Change Interval

(1) Position vehicle on level surface. This is ex Under severe usage, t h e fluid and filter should be
tremely important for accurate check. changed and t h e bands adjusted a t 12,000 mile
(2) Apply parking brakes and r u n engine a t curb (19,000 km) intervals.
idle speed. Severe usage is defined as:
(3) Shift transmission momentarily into all gear • More t h a n half of vehicle operation occurs in
ranges. Then shift back to Neutral. heavy city traffic during hot weather a t ambient
(4) Clean top of filler tube and dipstick (to avoid temperatures above 90° F .
dirt entry) a n d check fluid level. Correct level is as • Vehicle is used for Taxi, Police, Limousine, or sim
follows: ilar commercial operations.
(5) Be sure fluid is a t normal operating tempera • Vehicle is used for trailer/boat towing or heavy
ture (180°F). Correct level is between "Maximum load hauling.
Level Hot" a n d " A d d " m a r k s (crosshatched area) on When t h e factory fluid is drained, refill t h e trans
dipstick. mission with Mopar ATF Plus, type 7176 fluid. Mo
(6) If fluid level is low, add only enough fluid to par Dexron II can be used if ATF Plus is not readily
correct level. available.
C A U T I O N : D o not overfill the transmission. Overfill FLUID AND FILTER REPLACEMENT

PROCEDURE
ing will force fluid out the pump vent which can be
(1) Raise vehicle, remove oil pan and drain fluid.
mistaken for a pump seal leak. Overfilling will also
(2) Remove filter screws and remove filter.
cause fluid aeration and foaming when the excess
(3) Position new filter on valve body and install fil
fluid is picked up and churned by the gear train.
ter screws finger tight.
Aeration will reduce fluid life significantly. (4) Tighten filter screws to 4 N*m (35 in. lbs.) with
torque wrench.
(5) Position new gasket on oil p a n and install p a n
FLUID AND FILTER CHANGE
on transmission. Tighten p a n bolts to 17 N»m (150
Normal Change Interval in. lbs.) torque.
The fluid a n d filter should be changed (and t h e (6) Lower vehicle and refill transmission with rec
bands adjusted) a t recommended maintenance inter ommended fluid.
vals. Or whenever t h e transmission h a s been disas
GEARSHIFT LINKAGE ADJUSTMENT
sembled for any reason.
Check linkage adjustment by starting t h e engine
in P a r k and Neutral.
Recommended Fluid
Adjustment is OK if t h e engine starts only in park
The recommended (and preferred) fluid for and Neutral.
Chrysler automatic transmissions is Mopar ATF Adjustment is incorrect if the engine starts in one
Plus, type 7176. Use Mopar Dexron II only when but not both positions.
ATF Plus is not readily available. If t h e engine starts in any position other t h a n P a r k
or Neutral, or if the engine will not start a t all, t h e
park/neutral position switch may be faulty.
• IN-VEHICLE SERVICE-32RH/36RH/37RH/42RH/46RH 21 - 131
Fig. 1 Column Gearshift Linkage

LINKAGE ADJUSTMENT PROCEDURE TRANSMISSION THROTTLE CABLE
Do n o t attempt l i n k a g e adjustment if a n y compo ADJUSTMENT-GAS ENGINES
nents a r e worn or d a m a g e d . If e i t h e r linkage r o d (1) Turn ignition key to OFF position.
must b e disconnected, t h e plastic grommet secur (2) Remove air cleaner.
ing the rod in the torque shaft lever must be re (3) Position 2.8 - 3.04 mm (0.110 - 0.120 in.) thick
placed. Disconnect the rod with a pry tool. Pry spacer between idle stop and throttle lever on throt
only where the grommet and rod attach and not on tle body. Use appropriate thickness feeler gauges, or
the rod itself. Then cut away the old grommet. Use shim stock as spacer (Fig. 2).
pliers to snap the n e w grommet into the lever and
to snap the rod into the grommet.
(1) Shift transmission into Park.
(2) Raise vehicle.
(3) Check condition of shift rods, control lever,
bushings, washers and torque shaft (Fig. 1). Tighten,
repair, or replace worn or damaged parts.
(4) Loosen shift rod adjusting swivel lock screw. Be
sure swivel turns freely on rod.
(5) Verify that valve body shift control lever is in
Park detent. Move lever fully rearward to check.
(6) Adjust swivel position (on the shift rod) to a ob
tain free pin fit in torque shaft lever (Fig. 1). Then
tighten swivel lock screw to 10 N»m (90 in. lbs.)
torque.
(7) Check adjustment by starting engine in Park
and Neutral. Engine should start in these positions
only. If engine starts i n a n y position other than Fig. 2 Positioning Spacer Between Throttle Stop
Park or Neutral, adjustment is incorrect or And Lever (Gas Engine)
park/neutral position s w i t c h is faulty. (4) Press cable lock button to release cable (Fig. 3).
21 - 132 IN-VEHICLE SERVICE-32RH/36RH/37RH/42RH/46RH •
TORQUE CABLE
IDLE STOP SHAFT RETURN
ADJUSTMENT • — / BRACKET. SPRING
SPACER (USE Hk±s
FEELER GAUGES /o)
OR SHIM STOCK)
\
THROTTLE
LEVERBODY RETURN
SPRING /
BRACKET ^
CABLE
TRANSMISSION BRACKET
THROTTLE
CABLE
THROTTLE
VALVE
LEVER
(ROTATE LEVER
IN DIRECTION
OF ARROW
^ CABLE FOR ADJUSTMENT)
CONDUIT
CABLE ^1 THROTTLE
1
BUTTON CABLE \ > VALVE
CABLE J9221-64
WIPER J932M84
Fig. 4 Throttle Cable Attachment At Transmission

Fig. 3 Throttle Cable Attachment At Engine (Gas Engine)
(Gas Engine)
(Fig. 6). Rotation of the throttle cam (by the engine
(5) Pull cable conduit toward rear of vehicle until throttle cable), actuates the cable and throttle valve
wiper is completely retracted into end of conduit fit
lever for downshifts.
ting (Fig. 3). Then release cable lock button.
A 4.57 m m (0.180 in.) diameter g a u g e is n e e d e d
(6) Raise vehicle for access to transmission throttle
to c h e c k and adjust the throttle valve cable o n
valve lever (Fig. 4).
diesel models. U s e a micrometer a n d inside cali
(7) Rotate throttle valve lever toward front of ve
hicle until ratcheting sound (from cable) stops. pers, a drill of the correct diameter, or fabricate
a g a u g e from metal or aluminum stock.
C A U T I O N : D o not rotate the throttle valve lever be (1) Run engine until it reaches normal operating
yond the idle stop. The lever, valve and manual le temperature.
ver shaft will be damaged if rotated too far. (2) Verify t h a t engine hot idle speed is within
specifications. Adjust hot idle rpm if necessary.
(8) Remove spacer and check cable adjustment. (3) Check cable adjustment with gauge as follows:
Throttle valve lever should begin to move at same (a) Verify t h a t throttle lever is seated against
time lever on MPI throttle body moves off idle posi low idle stop screw (with accelerator pedal fully re
tion. leased).
(9) Lower vehicle. (b) Check clearance between rear of cable actuat
(10) Install air cleaner. ing pin and end of slot in throttle valve cable (Fig.
6).
TRANSMISSION THROTTLE CABLE
(c) Clearance should be 4.57 mm (0.180 in.) as
ADJUSTMENT-CUMMINS DIESEL ENGINE
measured with gauge.
A cable is used to operate the transmission throttle
valve on models with a Cummins diesel engine. Ca (d) If adjustment is OK, no further action is re
ble adjustment is controlled by a locking pawl on the quired. However, if clearance is greater or less
cable sheath (Fig. 5). then specified, adjust cable as described in follow
The rear of the cable is connected to the transmis ing steps.
sion throttle valve lever. The forward end of the ca
ble is attached to a pin on the engine throttle cam
(4) Lift and release cable locking pawl (Fig. 7).

(5) Insert gauge between cable actuating pin and
end of slot in cable.
(6) Slide cable forward or rearward to obtain spec
ified clearance between pin and cable slot.
(7) Press cable locking pawl downward until it
snaps into locked position.
(8) Check cable adjustment one more time before
moving vehicle. This avoids misadjustment caused by
a shift in component position during adjustment pro
cedure.
THROTTLE TRANSMISSION
CAM THROTTLE
VALVE i j /\&s/,
CABLE J9121 -535
m
Fig. 7 Transmission Throttle Cable Locking Pawl

Position—Diesel Engine
lbs.) torque. If Adapter Extension C-3705 must b e
u s e d to r e a c h adjuster screw, tighten screw to
only 5 N»m (47-50 in. lbs.) torque.
(4) Back off adjusting screw 2-1/2 t u r n s on all
transmission models.
(5) Hold adjuster screw in position with backup
ENGINE CABLE
THROTTLE LOCK wrench. Then tighten locknut to 41 N»m (30 ft. lbs.)
CABLE PAWL J9121-533 torque.
(6) Lower vehicle.
Fig. 5 Transmission Throttle Cable
Attachment—Diesel Engine TO COOLER KICKDOWN BAND ADJUSTING SCREW
4.57 M M
(0.180 IN.) GAUGE
GEARSHIFT CONTROL LEVER RH256
Fig. 8 Front (Kickdown) Band Adjustment Screw

J9121-534 Location
REAR BAND ADJUSTMENT
Fig. 6 Transmission Throttle Cable
The transmission oil pan must be removed for ac
Adjustment—Diesel Engine
cess to the rear band adjusting screw.
FRONT BAND ADJUSTMENT (1) Raise vehicle.
The front (kickdown) band adjusting screw is at the (2) Remove transmission oil pan and drain fluid.
left side of the case above the manual valve and (3) Loosen band adjusting screw locknut 5-6 turns.
throttle valve levers (Fig. 8). Be sure adjusting screw turns freely in lever. Lubri
(1) Raise vehicle. cate screw threads if necessary.
(2) Loosen band adjusting screw locknut. Then (4) Tighten adjusting screw to 8 Nnn (72 in. lbs.)
back locknut off 4-5 turns. Also be sure adjusting torque (Fig. 9).
screw t u r n s freely in case. Lubricate screw threads if (5) Complete band adjustment as follows:
necessary. • On 32RH/42RH, back off adjusting screw four
(3) Tighten band adjusting screw to 8 Nrm (72 in. turns.
21 - 134 IN-WEHiCLE SER¥iCE-32RH/3IRH/37RH/42RH/46RH •
• On 36RH/37RH746RH, back off adjusting screw (4) Check speed sensor mounting area in speedom
t w o turns. eter adapter. If transmission fluid is found in this
(6) Hold adjusting screw in place with backup area, adapter oil seal is leaking and will have to be
wrench. Then tighten locknut to 34 N*m (25 ft. lbs.) replaced.
torque. (5) Remove bolt and retainer securing pinion gear
(7) Position new gasket on oil pan and install pan adapter to extension housing.
on transmission. Tighten pan bolts to 17 N»m (13 ft. (6) Carefully work adapter and gear out of hous
lbs.) torque. ing.
(8) Lower vehicle and refill transmission with Mo (7) Remove and discard adapter O-ring (Fig. 10).
par ATF Plus, type 7176, or Dexron II™ fluid. (8) Remove adapter oil seal if necessary. Start new
seal in adapter by hand. Then press seal into adapter
with Installer Tool C-4004 until tool bottoms (Fig.
10).
ADAPTER AND PINION INSTALLATION AND

ADJUSTMENT
C A U T I O N : Before installing the pinion and adapter

assembly, make sure the adapter flange and flange
seat in the housing are perfectly clean. Dirt or for
eign material on these surfaces will cause misalign
ment resulting in pinion gear damage.
(1) Thoroughly clean adapter flange and flange

seat in extension housing.
Fig. § Rear Band Adjustment Screw Location (2) Lubricate adapter oil seal and O-ring with
SPEEDOMETER SERVICE transmission fluid.
Rear axle gear ratio and tire size determine speed (3) Count number of teeth on pinion gear before
ometer pinion requirements. If the gear must be re installing gear in adapter.
placed, refer to the parts catalogue information for (4) Note range numbers on adapter face (Fig. 11).
the correct pinion. These numbers correspond to number of teeth on pin
ion.
ADAPTER AND PINION REMOWAL (5) Install adapter in extension housing.
(1) Raise vehicle. (6) Rotate adapter until required range numbers
(2) Disconnect wires from vehicle speed sensor. are at six o-clock position (Fig. 12). Be sure adapter
(3) Remove speed sensor from speedometer adapter range numbers correspond to number of teeth on pin
(Fig. 10). ion.
(7) Seat adapter in housing.
SEAL ADAPTER ADAPTER
(8) Install adapter clamp. Tighten clamp bolt to 11
RETAINING OIL O-RING
(9) Install vehicle speed sensor. Tighten sensor
coupling n u t to 17 N*m (150 in. lbs.) torque and in
stall sensor wires.
(10) Lower vehicle and top off transmission fluid
level.
PARK/NEUTRAL POSITION SWJTCH

The center terminal of the park/neutral position
switch is the starter circuit terminal. It provides the
ground for the starter solenoid circuit through the se
lector lever in Park and Neutral positions only. The
SPEED ADAPTER SPEEDOMETER
SENSOR CLAMP ADAPTER J932M00
outer terminals on the switch are for the backup
lamp circuit.
Fig. 10 Speedometer Components SWITCH TEST
To test the switch, remove the wiring connector.
Then test continuity between the center terminal
• IN-VEHICLE SERVICE-32RH/3eRH/37RH/42RH/46RH 21 - 135
SPEEDOMETER
ADAPTER LOCK RING
SPECIAL
OIL SEAL TOOL
C-4004
J9321-186
Fig. 11 Replacing Speedometer Adapter Seal

RETAINER
SWITCH
RH266
Fig. 13 Park/Neutral Position Switch Contacts

(4) Start new seal in housing. Then tap seal into
place with Installer Tool C-3995 or C-3972 (Fig. 15).
(5) Carefully guide propeller shaft slip yoke into
housing and onto output shaft splines. Align marks
made at removal and connect propeller shaft to rear
-ADAPTER axle pinion yoke.
- 7 ^ 6 O'CLOCK POSITION RH75
SPECIAL
TOOL
Fig. 12 Indexing Speedometer Adapter
and the transmission case. Continuity should exist
only when the transmission is in P a r k or Neutral.
Shift the transmission into reverse and test conti
nuity at the switch outer terminals. Continuity
should exist only when the transmission is in Re
verse. Continuity should not exist between the outer
terminals and the case.
Check gearshift linkage adjustment before replac
ing a switch t h a t tests bad. Fig. 14 Removing Extension Housing Yoke Seal
SWITCH REPLACEMENT SPECIAL TOOL
(1) Raise vehicle and position drain pan under
switch.
(2) Disconnect switch wires.
(3) Remove switch from case.
(4) Move shift lever to Park and Neutral positions.
Verify t h a t switch operating lever fingers are cen
RH78
tered in switch opening in case (Fig. 13).
(5) Install new seal on switch and install switch in Fig. 15 Installing Extension Housing Yoke Seal
case. Tighten switch to 34 Nnn (25 ft. lbs.) torque.
(6) Test continuity of new switch with 12 volt test EXTENSION HOUSING BUSHING AND OUTPUT
lamp. SHAFT BEARING SERVlCE-32RH/3eRH/37RH
(7) Connect switch wires and lower vehicle.
(8) Top off transmission fluid level. EXTENSION HOUSING REMOVAL
(1) Shift transmission into 1 (manual low) position.
EXTENSION HOUSING YOKE SEAL REPLACEMENT (2) Raise vehicle.
(1) Raise vehicle. (3) Mark propeller shaft and axle yokes for align
(2) Mark propeller and axle yokes for alignment ment reference. Then disconnect and remove shaft.
reference. Then disconnect and remove shaft. (4) Remove vehicle speed sensor, speedometer
(3) Remove old seal with Remover Tool C-3985 adapter and speedometer pinion gear (Fig. 10).
(Fig. 14).
21 - 136 IN-VEHICLE SERVICE—32RH/36RH/37RH/42RH/46RH •
(5) Remove bolts attaching extension housing to (3) Install new bearing on shaft. Be sure locating
rear support. ring groove in outer circumference of bearing is to
(6) Raise transmission slightly with jack stand or ward front (Fig. 17).
floor jack. (4) Install rear bearing retaining snap ring (Fig.
(7) Remove crossmember and rear support as as 16). However, do not install the locating ring on the
sembly. bearing. The locating ring goes in the extension
(8) Remove extension housing attaching bolts. housing. The ring is not seated in the rear bearing
(9) Remove access plate and gasket from underside until the housing is installed.
of extension housing. Plate must be removed for ac
cess to rear bearing locating ring. EXTENSION HOUSING BUSHING
(10) Insert parallel jaw snap ring pliers into access REPLACEMENT
plate opening and spread bearing locating ring (Fig. (1) Remove housing oil seal with Remover Tool
16). C-3985 (Fig. 18).
(11) Hold snap ring in a spread position and work
extension housing off rear bearing.
Fig. 18 Removing Extension Housing Seal

(2) On 32RH, remove housing bushing with bush
ing Tool C-4470. On 36RH/37RH, remove bushing
with Tool C-4469 (Fig. 19).
(3) On 32RH, slide new bushing on installing end
of Tool C-4470. On 36RH/37RH, slide bushing on
Tool C-4469 (Fig. 19).
(4) Align bushing oil hole with oil slot in extension
Fig. 16 Releasing Rear Bearing Locating Ring
housing. Then tap bushing into place (Fig. 19).
(12) Carefully pull extension housing rearward to (5) Install new seal in housing (Fig. 20). On 32RH
move park lock rod past sprag and remove housing. use Seal Installer C-3995. On 36RH/37RH, use Seal
Installer C-3972.
OUTPUT SHAFT REAR BEARING
REPLACEMENT
(1) Remove snap ring t h a t retains rear bearing on
output shaft (Fig. 17).
Fig. 19 Extension Housing Bushing Replacement

EXTENSION HOUSING INSTALLATION
(1) Position new gasket on housing. Use petroleum
Fig. 17 Rear Bearing Location jelly to hold gasket in place.
(2) Install locating ring in extension housing, if re
(2) Remove bearing from output shaft. Note t h a t
moved.
36RH/37RH transmissions have a second snap ring
(3) Slide housing onto output shaft.
at front of shaft bearing. 32RH transmissions do not
have this second snap ring.
IN-VEHICLE SERVICE-32RH/38RH/37RH/42RH/46RH 21 - 137
SPECIAL TOOL G O V E R N O R SUPPORT

A N D PARKING GEAR
RH78
Fig. 20 installing Extension Housing Seal

(4) Work park rod past sprag and move housing
into place on shaft.
(5) Spread rear bearing locating ring with parallel
GOVERNOR BODY
jaw snap ring pliers.
(6) Hold locating ring in spread position. Then L O C K I N G BOLTS (4)
push housing forward until locating ring seats in
bearing and housing seats against transmission case. RH269
Be sure locating ring is fully seated in rear bearing.
(7) Install and tighten housing attaching bolts to Fig. 21 Governor Snap Ring Locations- -32RH/36RH/
43 Nnn (32 ft. lbs.) torque. 37RH
(8) Install gasket and access plate on underside of The weights and valves should fall freely in their
housing. bores when clean and dry.
(9) Install crossmember and rear mount assembly. Minor surface scratches and burrs can be removed
(10) Remove jack used to support transmission. with crocus cloth. Inspect the governor weight spring
(11) Install and tighten housing-to-rear mount for distortion. Replace the spring, if damaged.
bolts to 68 Nnn (50 ft. lbs.) torque. Clean the filter in solvent and dry it with com
(12) Install speedometer pinion and adapter. pressed air. Replace the filter if damaged.
(13) Align and install propeller shaft. Inspect the park gear for chipped or worn gear
(14) Lower vehicle. teeth or damaged ring grooves. Replace the gear, if
(15) Top off transmission fluid level if necessary. damaged.
GOVERNOR AND PARK GEAR SERVICE—32RH/ SPRING
3SRH/37RH OUTER WEIGHT
GOVERNOR AND PARK GEAR REMOVAL

(1) Remove extension housing a n d output shaft VALVE T SHAFT
rear bearing. Refer to procedure in this section. SNAP
(2) Carefully remove snap ring from weight end of RINGS VALVE
governor valve shaft (Fig. 21).

INNER WEIGHT
(3) Slide governor valve and shaft out of governor SNAP
RING
body.
(4) Remove large snap ring from weight end of gover
nor body and remove governor weight assembly. FILTER S C R E E N
(5) Remove snap ring from governor weight and
remove inner weight and spring from outer weight
(Fig. 21).
(6) Remove snap ring retaining governor body and
park gear on output shaft (Fig. 22).
(7) Slide governor body and p a r k gear assembly off
output shaft.
(8) Remove bolts attaching governor body to gear
and separate body from gear. J9221-51
(9) Remove filter screen from governor body.
GOVERNOR/PARK GEAR CLEANING AND Fig. 22 Governor Components—32RH/36RH/37RH

INSPECTION GOVERNOR/PARK GEAR ASSEMBLY AND
Thoroughly clean all t h e governor parts in a suit INSTALLATION
able cleaning solution b u t do not use any type of (1) Assemble governor body, filter screen and park
caustic cleaning agents. gear.
21 - 138 IN-VEHICLE SERVSCE-32RH/36RH/37RH/42RH/46RH
(2) Install and tighten gear-to-body bolts finger

tight. Make sure oil passage in governor body aligns
with matching passage in gear.
(3) Install assembled governor body and gear on
output shaft.
(4) Position governor body so valve shaft hole in
body aligns with matching hole in output shaft. Then
slide body and park gear into place.
(5) Install snap ring securing governor and park
gear to output shaft (Fig. 22).
(6) Tighten bolts attaching governor body to park
gear to 11 N»m (95 in. lbs.) torque.
(7) Assemble governor weights and spring. Secure
inner weight and spring in outer weight with snap J9221-249
ring (Fig. 21). Fig. 23 Park Lock Components-32RH/36RH/37RH

(8) Install weight assembly in governor body and
install retaining snap ring (Fig. 21). PARK LOCK COMPONENT INSTALLATION
(9) Place governor valve on valve shaft. Insert shaft (1) Install reaction plug and pin assembly in hous
in governor body, through governor weights and output ing and secure with new snap ring (Fig. 23).
(2) Position sprag and spring in housing and insert
shaft. Be sure valve is properly seated in body.
sprag shaft. Be sure square lug on sprag is toward
(10) Secure valve shaft with small snap ring.
park gear. Also be sure spring is positioned so it
(11) Install output shaft bearing and extension
moves sprag away from gear.
housing. Refer to procedure in this section.
(3) Replace park rod if necessary.
(4) Install extension housing as described in this
GOVERNOR AND PARK LOCK SERVICE—42RH/ section.
46RH
The governor and park lock components are located VALVE BODY SERVICE
within the overdrive unit and cannot be serviced in
the vehicle. GENERAL SERVICE INFORMATION
The overdrive unit must be removed and disassem The valve body can be removed for service without
bled for access to the governor and park lock compo having to remove the entire transmission assembly.
nents. The valve body can be disassembled for cleaning
Refer to the 42RH/46RH overdrive unit service sec and inspection of the individual components. Refer to
tions for repair procedures. the procedures in the Transmission Unit Subassem
bly Overhaul section.
PARK LOCK SERVICE—32RH/36RH/37RH The only serviceable valve body components are
the:
PARK LOCK COMPONENT REMOVAL • manual lever
(1) Remove extension housing as described in this • manual lever washer/seal/E-clip and shaft seal
section. • manual lever detent ball
(2) Slide sprag shaft out of extension housing and • throttle lever
remove sprag and spring (Fig. 23). • fluid filter
(3) Remove snap ring and slide reaction plug and • overdrive solenoid and connector assembly
pin assembly out of housing. • switch valve, spring and adjusting screw bracket
(4) If park rod requires service, it will be necessary • converter clutch solenoid
to remove valve body. Refer to Valve Body Service The remaining valve body components are serviced
procedures in this section. only as part of a complete valve body assembly.
COMPONENT INSPECTION VALVE BODY REMOVAL

Inspect the sprag shaft for scores and free move (1) Raise vehicle.
ment in the housing and sprag. Inspect the sprag and (2) Remove oil pan and drain fluid.
control rod springs for distortion and loss of tension. (3) Loosen clamp bolts and remove throttle and
manual valve levers from manual lever shaft.
Inspect the square lug on the sprag for broken
(4) Remove park/neutral position switch.
edges. Check the lugs on the park gear for damage.
(5) Remove filter from valve body.
Inspect the ball on the end of the control rod for
(6) Disconnect converter clutch solenoid wire from
nicks and burrs. Also be sure the ball rotates freely.
case connector.
(7) Push solenoid connector out of case.

MANUAL CONVERTER
(8) Remove valve body attaching screws. LEVER CLUTCH
(9) Lower valve body enough to remove accumula
tor piston and piston spring (Fig. 2 4 ) .
(10) Pull valve body forward to disengage park rod.
(11) Push manual lever shaft and solenoid case
connector out of transmission case. Lower valve body,
rotate it away from case, pull park rod out of sprag
and remove valve body (Figs. 25 and 26).
ACCUMULATOR OUTER
PISTON SPRING
INNER SEAL
SPRING RINGS J932M87
Fig. 24 Accumulator Piston And Springs (42RH/

46RH Shown) - Fig. 26 Valve Body Assembly—3-Speed
Transmission
move past sprag when valve body is installed. Rotate
output shaft to verify sprag engagement.
(5) Position accumulator spring between accumula
tor piston and valve body.
(6) Position valve body on transmission and work
park rod past sprag. Be sure accumulator piston and
spring remain in position.
(7) Hold valve body in position and install valve
body attaching screws linger tight only.
(8) Install park/neutral position switch in case.
(9) Tighten valve body attaching screws alter
#
nately and evenly to 11 N m (100 in. lbs.) torque.
(10) Install new fluid filter on valve body. Install
and tighten filter screws to 4 N-m (35 in. lbs.) torque.
(11) Connect solenoid wire to case connector.
(12) Install manual and throttle levers on throttle
lever shaft. Tighten lever clamp screws and check for
free operation. Shaft and levers must operate freely
without any bind.
(13) Install oil pan and new gasket. Tighten pan
(
Fig. 25 Valve Body Assembly—4-Speed Transmission bolts to 17 N»m (150 in. lbs.) torque.
VALVE BODY INSTALLATION (14) Connect park/neutral position switch and con
(1) Verify that park/neutral position switch has verter clutch solenoid wires.
N O T been installed. Valve body cannot be installed (15) Install speedometer pinion gear, adapter and
with switch in place. Remove switch if necessary. speed sensor.
(2) Install new seals on accumulator piston and in (16) Lower vehicle.
stall piston in case. (17) Fill transmission with Mopar ATF Plus, Type
(3) Place valve body manual lever in low (1 posi 7176, or Dexron II™ fluid if ATF Plus is not readily
tion) to ease installing park rod in sprag. available.
(4) Use screwdriver to push park sprag into en (18) Adjust gearshift and throttle linkage.
gagement with park gear. This allows knob on rod to
21 • 140 IN-VEHICLE SERVICE-32RH/36RH/37RH/42RH/46RH •
VALVE BODY CONTROL PRESSURE ADJUSTMENTS The k i c k d o w n valve spring must b e fully com
There are two control pressure adjustments on the p r e s s e d a n d the k i c k d o w n valve completely bot
valve body which are: Line pressure and throttle pres tomed to obtain correct adjustment.
sure.
T h e v a l v e b o d y m u s t b e r e m o v e d from t h e HEX
WRENCH
t r a n s m i s s i o n i n o r d e r t o p e r f o r m t h e adjust
m e n t s . Refer t o t h e v a l v e b o d y r e m o v a l / i n s t a l l a
tion p r o c e d u r e s i n t h i s section.
Because line and throttle pressures are interdepen
dent (each affects shift quality and timing), both ad
^ KICKDOWN y L £ _
justments must be performed properly and in the
correct sequence. Adjust line pressure first and throt THROTTLE
tle pressure last. LEVER
LINE PRESSURE ADJUSTMENT SPECIAL

Measure distance from the valve body to the inner " TOOL
edge of the adjusting screw with an accurate steel C-3763
scale (Fig. 27). J9121-542
Distance should be 1-5/16 in. (33.4 mm).
Fig. 28 Throttle Pressure Adjustment
If adjustment is required, t u r n the adjusting screw
in, or out, to obtain required distance setting. TRANSMISSION COOLER SERVICE
The 1-5/16 in. (33.4 mm) setting is an approximate
FLUSHING COOLERS AND LINES
setting only. Because of manufacturing tolerances, it
If a transmission malfunction contaminates the
may be necessary to vary from this dimension to ob
fluid, the cooler and lines must be reverse flushed
tain desired pressure.
thoroughly. This is necessary to prevent sludge and
One complete turn of the adjusting screw changes line
particles from flowing back into the transmission af
pressure approximately 1-2/3 psi (9 kPa). Turning the
ter repair. The flushing procedure applies to stan
adjusting screw counterclockwise increases pressure
dard and auxiliary coolers.
while turning the screw clockwise decreases pressure.
Pressure equipment is preferred for cooler reverse
flushing. However, reverse flushing can be performed
with hand operated equipment as follows.
Flushing Procedure
(1) Identify and disconnect cooler pressure and re
t u r n lines at transmission (Fig. 29).
INLET
FITTING
(RETURN
_ LINE)
COOLER ^
PRESSURE
LINE A N D
HOSE
RH258
Fig. 27 Line Pressure Adjustment
THROTTLE PRESSURE ADJUSTMENT OUTLET
FITTING
Insert Gauge Tool C-3763 between the throttle le (PRESSURE
ver cam and kickdown valve (Fig. 28). LINE)
Push t h e gauge tool inward to compress the kick-
down valve against the spring and bottom the throt
tle valve. COOLER
Maintain pressure against kickdown valve spring. RETURN
LINE
T u r n throttle lever stop screw until the screw head AND J9121-364
touches throttle lever tang and the throttle lever cam HOSE
touches gauge tool. Fig. 29 Transmission Cooler Line Identification
(2) Position drain pan under cooler pressure line to component. If the cooler is damaged in any way, the
catch material flushed through cooler and lines. radiator will have to be replaced.
(3) Reverse flush cooler using hand operated suc
tion gun filled with mineral spirits. Insert gun nozzle AUXILIARY COOLER REPLACEMENT
(or hose) into cooler return line. Then force mineral (1) Remove grille. Also remove A/C condenser for
spirits into line and through cooler. access if necessary.
(4) Continue reverse flushing until fluid exiting (2) Remove brackets securing cooler to radiator
cooler pressure line is clear and free from debris. Re and radiator support (Fig. 30).
place cooler if fluid cannot be p u m p e d through. (3) Tag cooler hoses for installation reference.
(5) Clear flushing materials from cooler and lines
(4) Position drain pan under cooler lines.
with short pulses of compressed air. Insert air gun
(5) Loosen cooler connecting hose clamps and dis
nozzle into cooler r e t u r n line and continue short air
pulses until all fluid is cleared from cooler and lines. connect hoses.
(6) Pump one quart of fresh automatic transmission (6) Remove cooler
fluid through cooler and lines before reconnecting lines. (7) Connect cooler to hoses.
(8) Position cooler on radiator and install cooler
CHECKING COOLER FLUID FLOW support brackets and attaching fasteners.
Cooler flow is checked, by measuring the amount of
(9) Tighten cooler hose clamps securely.
fluid pumped through the cooler in a specified time
(10) Install grille and air conditioning condenser, if
by the transmission oil pump.
(1) Disconnect cooler return line from transmission removed.
and place it in one quart test container. (11) Check and adjust transmission fluid level.
(2) Add extra quart of fluid to transmission.
(3) Use stopwatch to check test time. ALUMINUM THREAD REPAIR
(4) Shift into Neutral.
(5) Start and run engine at curb idle speed and Damaged or worn threads in the aluminum trans
note cooler flow. A minimum of one quart (0.9 liter) mission case and in the valve body can be repaired
of fluid should flow into test container in 20 seconds. with Heli-Coil thread inserts, or equivalent. Stain
less steel inserts are preferred.
(6) If fluid flow is intermittent, flows less t h a n one
quart in 20 seconds, or fails to flow at all, cooler is Essentially, thread repair consists of drilling out
plugged or damaged and should be replaced. the worn or damaged threads, tapping the hole with
a special tap and installing a Heli-Coil, or equivalent
MAIN COOLER REPLACEMENT thread insert into the tapped hole. This procedure re
The m a i n transmission cooler is located in the ra t u r n s the hole threads to original size. Heli-Coil, or
diator lower tank. The cooler is not a serviceable equivalent, tools and inserts are readily available
from most automotive parts suppliers.
CONNECTING HOSE RADIATOR SUPPORT FAN
SHROUD
PRESSURE LINE
AUXILARY
COOLER
CONNECTING PRESSURE RETURN

HOSE LINE HFRONT
LINE J9021-74
Fig. 30 Auxiliary Cooler Mounting
!1 - 142 AUTOMATIC TRANSMISSION REMOVAL AND INSTALLATION •
A U T O M A T I C T R A N S M I S S I O N REMOWAL A N D I N S T A L L A T I O N
INDEX
page page
Dverdrlve Unit Installation 150 Transmission and Torque Converter Installation—
Overdrive Unit R e m o v a l - 4 2 R H / 4 6 R H . . . . . . . . 149 4-Wheel Drive . . .' 148
Pump Oil Seal 146 Transmission and Torque Converter Removal—
Starter Ring Gear Replacement 144 2-Wheel Drive 142
Torque Converter and Drive Plate Service . . . . . 144 Transmission and Torque Converter Removal —
Transmission and Torque Converter Installation— 4-Wheel Drive 143
2-Wheel Drive 146
TRANSMISSION AND TORQUE CONVERTER

REMOVAL—2-WHEEL DRIVE
T h e transmission a n d torque converter should
be r e m o v e d as an a s s e m b l y to avoid component
damage. The converter drive plate, p u m p bush
ing, or oil seal can be d a m a g e d if the converter
is left attached to the driveplate during removal.
Be sure to remove the transmission and con
verter as an assembly.
(1) Raise vehicle.
(2) Disconnect or remove exhaust components as
needed for service access.
(3) Remove engine-to-transmission struts, if
equipped.
(4) Disconnect fluid cooler lines at transmission.
(5) Remove starter motor and cooler line bracket.
(6) Remove torque converter bolt access cover.
(7) Remove transmission oil pan, drain fluid and
reinstall pan.
(8) Remove transmission fill tube bracket bolts and
remove tube and O-ring from transmission case.
(9) Mark torque converter and drive plate for as Fig. 1 Marking Converter And Driveplate For
sembly alignment (Fig. 1). Note t h a t bolt holes in Alignment Reference
crankshaft flange, drive plate and torque converter
all have one offset hole. Secure transmission to jack with safety chains.
(10) Rotate crankshaft in clockwise direction until (18) Raise transmission slightly with jack to re
converter bolts are accessible. Then remove bolts one lieve load on crossmember and insulator.
at a time. Rotate crankshaft with socket wrench on (19) Remove bolts attaching transmission to insu
damper pulley bolt. lator and crossmember and remove crossmember and
(11) Mark propeller shaft and axle yokes for as brackets.
sembly alignment. Then disconnect and remove pro (20) Remove bolts attaching converter housing to
peller shaft (Fig. 2). engine block.
(12) Disconnect wires from park/neutral position (21) Carefully work transmission and converter as
switch and transmission solenoids. sembly rearward until clear of engine block dowels
(13) Disconnect gearshift rod and torque shaft as and crankshaft.
sembly from brackets on transmission and frame (22) Secure converter in housing with small
rail. C-clamp attached to edge of housing.
(14) Disconnect throttle valve rod (or cable) from (23) Lower transmission and remove assembly
transmission throttle lever. from under vehicle.
(15) Disconnect vehicle speed sensor wires. (24) Remove C-clamp and carefully slide converter
(16) Support engine with Fixture C-3487-A and out of pump. Store converter on bench during service
adapters, or a similar tool. operations. Cover converter hub with tape, card
(17) Support transmission with transmission jack. board, or paper to prevent dirt entry.
• AUTOMATIC TRANSMISSION REMOVAL AND INSTALLATION 21 - 143
AXLE PROPELLER switch and transmission solenoids.

YOKE SHAFT (14) Disconnect transmission gearshift rods and
YOKE torque shaft assembly from brackets on transmission
and frame rail.
(15) Disconnect throttle valve cable from transmis
sion throttle lever.
RETAINER (16) Remove transfer case skid plate and skid plate
BOLT crossmember (Fig. 3).
U-JOINT RETAINER (170 IN-LBS)
(17) Disconnect wires from vehicle speed sensor.
(18) Disconnect necessary vacuum harness hoses.
SKID
PLATE
CROSSMEMBER
TRANSMISSION
OUTPUT
SHAFT J9021-146
Fig. 2 Propeller Shaft Attachment

TRANSMISSION AND TORQUE CONVERTER
REMOVAL—4-WHEEL DRIVE
The transmission a n d torque converter should
be r e m o v e d as a n assembly to avoid c o m p o n e n t
damage. The converter drive plate, p u m p bush
ing, or oil seal c a n be damaged if the converter TRANSFER
CASE
is left attached to the driveplate during removal. SKID
Be sure to remove the transmission a n d con PLATE J9121-525
verter as an assembly.
(1) Raise vehicle. Fig. 3 Skid Plate Mounting
(2) Disconnect or remove exhaust components as (19) Disconnect transfer case shift lever from
needed for service access. range lever.
(3) Remove engine-to-transmission struts, if (20) Support transfer case with transmission jack.
equipped. Secure transfer case to jack with safety chains.
(4) Disconnect fluid cooler lines at transmission. (21) Remove nuts attaching transfer case to trans
(5) Remove starter motor and cooler line bracket. mission adapter.
(6) Remove torque converter access cover. (22) Pull transfer case rearward until clear of
(7) Remove transmission oil pan, drain fluid and transmission. Lower jack and move transfer case
reinstall pan.
from under vehicle. Then remove transfer case from
(8) Remove transmission fill tube bracket bolts and
jack and leave on bench until ready for installation.
remove tube and O-ring from transmission case.
(23) Support transmission with transmission jack.
(9) Mark torque converter and drive plate for as
sembly alignment. Note t h a t bolt holes in crankshaft Secure transmission to jack with safety chains.
flange, drive plate and torque converter all have one (24) Remove bolts/nuts attaching transmission in
offset hole. sulator plate to rear crossmember (Figs. 4 and 5).
(10) Rotate crankshaft in clockwise direction until (25) Remove bolts/nuts attaching crossmember and
converter bolts are accessible. Then remove bolts one brackets to frame rails and remove crossmember.
at a time. Rotate crankshaft using breaker bar and (26) Support engine with Fixture C-3487-A and
socket installed on damper pulley bolt. adapters, or a jack stand and wood blocks.
(11) Mark front/rear propeller shaft and axle yokes (27) Remove bolts attaching converter housing to
for assembly alignment. engine.
(12) Disconnect and remove both propeller shafts (28) Carefully work transmission-converter assem
(Fig. 2). bly rearward until clear of crankshaft and engine
(13) Disconnect wires from park/neutral position block dowels.
21-144 AUTOMATIC TRANSMISSION REMOVAL AND INSTALLATION
TRANSMISSION
ADAPTER
BOLT AND
; WASHER (2)
INSULATOR
SPACER (2)
UPPER
INSULATOR (2)
INSULATOR
MOUNTING
PLATE
LOWER
WITH 7" RAIL INSULATOR (2)
(135 " WHEELBASE) J9121-532
Fig. 4 Transmission-To-Crossmember Attachment (Except 46RH)

(29) Secure converter in place with small C-clamp placement should b e c o m e necessary, be sure to
attached to edge of converter housing. use the n e w style converter. The n e w converter
(30) Lower transmission and remove assembly a n d oil p u m p are not interchangeable with pre
from under vehicle. vious style parts.
(31) Remove C-clamp securing converter in hous
ing. STARTER RING GEAR REPLACEMENT
(32) Carefully slide converter out of pump and re
C A U T I O N : T h e starter ring gear on standard torque
move it from transmission. Place converter on bench
converters can be replaced when necessary. How
and cover converter hub with tape, cardboard, or pa
ever, the ring gear on torque converters with a
per to prevent dirt entry.
modulated converter clutch, cannot be replaced.
The heat from welding will d a m a g e the converter
TORQUE CONVERTER AND DRIVE PLATE SERVICE clutch friction material. Converters with a clutch
After the transmission has been removed, the drive
must be replaced a s an assembly if the ring gear is
plate and torque converter can be replaced or re
damaged.
moved for service access.
The torque converter is not a serviceable part. If
the converter is contaminated by a transmission mal RING GEAR REMOWAL
function, or damaged in any way, it must be replaced (1) Cut through weld material at rear side of ring
as an assembly. D o not attempt to flush a con gear with a hack saw or grinding wheel. Be careful
verter contaminated by metal or clutch facing to avoid cutting or grinding into front cover.
particles. Flushing will not r e m o v e these con (2) Scribe heavy line on front cover next to front
taminants. face of ring gear. Line is needed to properly locate
A n e w torque converter a n d oil p u m p are u s e d new gear on converter.
in 1993, 42RH transmissions. The n e w converter (3) Support torque converter on front cover with
h a s a different style drive h u b . The h u b w a s blocks of wood (Fig. 6) Position blocks adjacent to
c h a n g e d to accept the n e w d e s i g n drive flats on converter lugs to avoid altering lug position. The
the oil p u m p inner gear. The drive flats replace torque converter must not rest o n the front
the square lugs u s e d previously. If converter re cover h u b during this operation.
ITEM S E T - T O - T O R Q U E SPECIFICATION TRANSFER

CASE
(§) 203 N»m (150 ft. lbs.)
(D 41 N*m (30 ft. lbs.)
© m N«m (50 ft. lbs.)
W TIH
7" RAIL
Fig. 5 Transmission~To-Cross mber Attachment (With 46RH)

(4) Remove ring gear with drift and hammer. Tap RING GEAR INSTALLATION
downward on gear near welded areas to break any (1) Heat and expand new ring gear for installation
remaining weld material (Fig. 6). on converter. Any of the following methods are ac
(5) Tap around ring gear until it comes off con ceptable:
verter. (a) OVEN: Place gear in oven and set tempera
(6) Smooth weld areas on converter with a mill ture at 200-250° F (93° C) Allow ring gear to re
file. main in oven for 15 to 20 minutes.
(b) BOILING WATER: Place ring gear in shal
low container. Add water and heat for approxi
mately eight minutes after water has come to a
boil.
(c) STEAM: Place ring gear on a flat surface and
direct steam flow around gear for approximately 2
minutes.
(2) After ring gear is expanded by heating, imme
diately place gear in position on converter front
cover.
(3) Quickly t a p gear onto cover evenly with plastic
or rawhide mallet. Continue tapping gear until face
of gear is even with scribe line (made during re
moval) on the front cover.
(4) Before proceeding, make sure gear is even with
scribed line around full circumference of the front
cover.
(5) The following recommendations are provided as
Fig. 6 Removing Starter Ring Gear an aid to successfully welding a new ring gear to the
converter.
• Do NOT weld with oxy-acetylene equipment
21 - 146 AUTOMATIC TRANSMISSION REMOVAL AND INSTALLATION •
• Use a D.C. welder set at straight polarity, or use Seal Installation
an A.C. welder if the proper electrode is available On 32RH/42RH pumps, use Installer Tool C-4193
• Use 1/8 inch diameter welding rod and a welding to install the new seal (Fig. 9).
current of 80 to 125 amps. On 36RH/37RH/46RH pumps, use Installer Tool
• Direct arc at intersection of gear and front cover at C-3860-A (Fig. 9).
an angle of 45° from rear face of gear. To use the tool, place the seal in the pump opening
(6) Weld new ring gear to torque converter front with the seal lip facing inward. Then tap the seal
cover. Take care to place same amount of weld mate into place with the installer tool (Fig. 9). Tool Han
rial (or as nearly as possible) in original weld loca dle C-4171 may be used with the installer tool if de
tions. This is essential in maintaining converter sired.
balance. Position welds alternately on opposite sides
of converter and ring gear to minimize distortion.
(7) Inspect gear teeth and remove any nicks, raised
metal, weld spatter, or rough surfaces.
PUMP OIL SEAL

Seal Removal
On 32RH/42RH pumps, remove the seal with Spe
cial Tool C-3981B (Fig. 7).
On 36RH/37RH/46RH pumps, remove the seal with
Special Tool C-3861 (Fig. 8).
To use the remover tool, First start the tool into
the seal by hand. Next, thread the tool into the seal
as far as it will go. Use a wrench on the tool hex to
turn the tool. Continue tightening until all the tool J932M80
threads firmly grip the metal part of the seal. Then
tighten the tool puller screw to withdraw the seal Fig. 9 Pump Seal Installation
from the pump body. TRANSMISSION AND TORQUE CONVERTER
INSTALLATION—2-WHEEL DRIVE
(1) Mount transmission on jack. Secure transmis
sion with safety chains.
(2) Check converter hub and hub drive notches for
sharp edges, burrs, scratches, or nicks. Polish hub
and notches with 400 grit wet/dry paper or crocus
cloth if necessary. Hub surface must be smooth to
avoid damaging pump seal at installation.
(3) Lubricate converter drive hub and pump seal
lip with transmission fluid.
(4) Install converter in oil pump.
(5) Verify t h a t converter is fully seated. Use
straight edge and steel ruler to check seating (Fig.
10). Surface of converter lugs should be approxi
Fig. 7 Pump Seal Removal—42RH
mately 13 mm (1/2 in.) to rear of straight edge when
converter is fully seated.
(6) Temporarily secure converter with C-clamp at
tached to housing or with metal strap attached
across converter housing.
(7) Mount transmission on jack and secure it with
safety chains.
(8) Check condition of converter driveplate. Re
place plate if cracked, distorted or damaged. If
d r i v e p l a t e replacement w a s necessary, be sure
transmission d o w e l pins are seated in engine
block and protrude far e n o u g h to held transmis
sion in alignment.
(9) Raise transmission and align converter with
Fig. 8 Pump Seal Removal—46RH crankshaft and drive plate.
SENSOR
NEUTRAL START AND
Fig. 10 Checking Torque Converter Seating BACKUP LAMP SWITCH
(10) Move transmission forward. Then raise, lower J9021-76
or tilt transmission to align converter housing with Fig. 11 Transmission Wire Routing—32RH/36RH
dowels in engine block.
(11) Rotate converter until alignment m a r k scribed ENGINE
on converter is aligned with mark on driveplate. Off
set holes in plate are next to 1/8 in. hole in inner cir
cle of plate (Fig. 1).
(12) Carefully work transmission forward until
converter hub is seated.
(13) Install bolts attaching converter housing to
engine block.
(14) Install crossmember and brackets.
(15) Lower transmission onto crossmember and in
sulator. Then install bolts attaching transmission
mount to crossmember.
(16) Remove fixture used to support engine.
(17) Connect wires to vehicle speed sensor.
(18) Install new plastic retainer grommet on any
shift linkage rod or lever t h a t was disconnected. Old
grommets should not be reused. Use pry tool to re
move rod from grommet and cut away old grommet.
Use pliers to snap new grommet into lever and to
snap rod into grommet.
(19) Connect gearshift linkage and transmission
throttle cable to levers on manual valve shaft.
(20) Connect wires to park/neutral position switch,
transmission solenoid(s) and oxygen sensor. Be sure
transmission harnesses are properly routed (Figs. 11
and 12). J9021-75
C A U T I O N : It is essential that correct length bolts be Fig. 12 Transmission Wire Routing—42RH/46RH

used to attach the converter to the driveplate. Bolts (21) Verify converter bolt length. Bolt measure
that are too long will damage the clutch surface in ment is from bottom (underside) of bolt head to end
the converter. If new bolts are required, use the of bolt threads.
bolts specified in this procedure and in the parts • On 9.5 in., 3-lug converter, bolts should be 0.46 in.
b o o k only. (11.7 mm) long.
FILL TRANSMISSION
ITEM TORQUE
TUBE DIPSTICK
A 27-54 N-m (20-40 ft. lbs.)
B 9-14 N-m (80-120 in. lbs.) PLATE BRACKET
C 3-6 N - m (30-50 in. lbs.)
D 4 7 - 8 8 N - m (35-65 ft. lbs.)
E 14-20 N - m (125-175 in. lbs.)
DAMPER
WEIGHT
STRUT
DUST
COVER J9321-232
Fig. 13 Transmission And Fill Tube Attachment

• On 9.5 in., 4-lug converter, bolts should be 0.52 in. (31) Check and adjust gearshift and throttle valve
(13.2 mm) long. linkage if necessary.
• On 10.75 in., 4-lug converter, bolts should be 0.44
in. (11.2 mm) long. TRANSMISSION AND TORQUE CONVERTER
(22) Install torque converter attaching bolts. INSTALLATION—4-WHEEL DRIVE
Tighten bolts as follows:
C A U T I O N : The transmission cooler and lines must
• On models with 9.5 in., 3-lug converter, tighten
bolts to 54 Nnn (40 ft. lbs.) be flushed if repair corrected a problem that gener
• On models with 9.5 in., 4-lug converter, tighten ated sludge, metal particles, or clutch friction mate
bolts to 74 Nnn (55 ft. lbs.) rial. The torque converter should also be replaced
• On models with 10.75 in., 4-lug converter, tighten when contaminated by a malfunction. The transmis
bolts to 31 Nnn (270 in. lbs.) sion, fluid and converter will be contaminated again
• On diesel models, tighten converter bolts to 47 if residue/debris is not flushed from the cooler and
Nnn (35 ft. lbs.) torque lines beforehand.
(23) Install converter housing dust cover.
(24) Install starter motor and cooler line bracket. (1) Check torque converter hub and hub drive
(25) Connect cooler lines to transmission. notches for sharp edges burrs, scratches, or nicks.
(26) Install transmission fill tube (Fig. 13). Install Polish hub and notches with 400 grit paper or crocus
new O-ring seal on tube before installation. cloth if necessary. Hub must be smooth to avoid dam
(27) Install any exhaust components t h a t were re aging pump seal during installation.
moved, or moved for service access. (2) Lubricate converter hub and pump seal lip with
(28) Align and install propeller shaft. Tighten transmission fluid.
shaft U-joint clamp bolts to 19 Nnn (170 in. lbs.) (3) Position converter hub so drive slots will be
torque. aligned with pump gears. Then carefully insert con
(29) Lower vehicle. verter hub into pump and gears.
(30) Fill transmission with Mopar ATF Plus, Type (4) Verify t h a t converter is fully seated. Use
7176, or Mopar Dexron II if ATF Plus is not readily straight edge and steel ruler to check seating (Fig.
available.
10). Surface of converter lugs should be approxi • On 9.5 in., 3-lug converter, bolts should be 11.7
mately 13 mm (1/2 in.) to rear of straight edge when mm (0.46 in.) long.
converter is fully seated. • On 9.5 in., 4-lug converter, bolts should be 13.2
(5) Temporarily secure converter in pump and mm (0.52 in.) long.
housing with C-clamp attached to housing edge, or • On 10.0 in., 4-lug converter, bolts should be 13.2
with metal strap attached across converter housing. mm (0.52 in.) long.
(6) Position transmission on jack. Secure transmis • On 10.75 in., 4-lug converter, bolts should be 11.2
sion to jack with safety chains. mm (0.44 in.) long.
(7) Check condition of converter driveplate. Re (22) Install torque converter bolts. Tighten bolts as
place plate if cracked, distorted or damaged. If follows:
driveplate replacement w a s necessary, be sure • On models with 9.5 in., 3-lug converter, tighten
transmission d o w e l pins are seated in engine bolts to 54 Nnn (40 ft. lbs.).
block a n d protrude far e n o u g h to held transmis • On models with 9.5 in., 4-lug converter, tighten
sion in alignment. bolts to 74 Nnn (55 ft. lbs.).
(8) Coat pilot hub of torque converter with trans • On models with 10.0 in., 4-lug converter, tighten
mission fluid. bolts to 74 Nnn (55 ft. lbs.) torque.
(9) Raise transmission and align converter with • On models with 10.75 in., 4-lug converter, tighten
drive plate and crankshaft. bolts to 31 Nnn (270 in. lbs.).
(10) Move transmission forward. Then raise, lower • On diesel models with 12.2 in. converter, tighten
or tilt transmission to align converter housing with bolts to 47 Nnn (35 ft. lbs.) torque.
dowels on engine block. (23) Install converter housing access cover.
(11) Rotate converter to align marks scribed on (24) Install starter motor and cooler line bracket.
converter and driveplate. Offset holes in plate are (25) Connect cooler lines to transmission.
next to 1/8 in. hole in inner circle of plate (Fig. 1). (26) Install transmission fill tube. Install new
(12) Carefully work transmission forward and over O-ring seal on tube before installation.
engine block dowels until converter hub is seated in (27) Install any exhaust components removed for
crankshaft. service access.
(13) Install bolts attaching converter housing to (28) Support transfer case on transmission jack.
engine. Secure transfer case to jack with safety chains.
(14) Install crossmember. (29) Install gasket on transmission adapter. Coat
(15) Lower transmission onto crossmember and in gasket with Mopar perfect, seal, or silicone sealer be
stall bolts attaching transmission and insulator to forehand.
crossmember (Figs. 4 and 5). (30) Install transfer case on transmission. Tighten
(16) Remove fixture used to support engine. transfer case attaching nuts to 47 Nnn (35 ft. lbs.)
(17) Connect vehicle speed sensor wires. torque.
(18) Install new plastic retainer grommet on any (31) Remove jack supporting transfer case.
shift linkage rod or lever that was disconnected. Old (32) Connect transfer case shift lever to range le
grommets should not be reused. Use pry tool to re ver.
move rod from grommet and cut away old grommet. (33) Align and install propeller shafts. Tighten
Use pliers to snap new grommet into lever and to clamp bolts to 19 Nnn 170 in. lbs.) torque.
snap rod into grommet. (34) Install transfer case skid plate and crossmem
(19) Connect gearshift and throttle linkage to ber.
transmission. (35) Lower vehicle.
(20) Connect wires to park/neutral position switch, (36) Fill transmission with Mopar ATF Plus, Type
transmission solenoids and to oxygen sensor. Be sure 7176, or Mopar Dexron II if ATF Plus is not readily
transmission harnesses are properly routed. available.
(37) Check and adjust gearshift, throttle valve and
C A U T I O N : It is essential that correct length bolts be transfer case shift linkages if necessary.
used to attach the converter to the driveplate. Bolts
that are too long will damage the clutch surface in OVERDRIVE UNIT REMOVAL—42RH/46RH
the converter. If new bolts are required, use the The following removal and installation procedures
bolts specified in this procedure and in the parts apply to the 42RH/46RH overdrive unit only. If the
book only. complete transmission assembly must be removed,
refer to the Transmission And Converter Removal
(21) Verify converter bolt length. Bolt measure and Installation procedures.
ment is from bottom (underside) of bolt head to end (1) Shift transmission into Park.
of bolt threads. (2) Raise vehicle.
(3) Remove transmission oil pan, remove gasket,
drain oil and reinstall pan.
(4) If overdrive unit had malfunctioned, or if fluid
is contaminated, remove entire transmission. If diag
nosis indicated overdrive clutch or governor problems
only, remove overdrive unit only.
(5) Mark propeller shaft universal joint and axle
pinion yoke for alignment reference at installation
(Fig. 14). On 4WD models, m a r k both shafts for ref
erence.
Fig. 15 Removing/Installing Overdrive Attaching

Bolts
(13) Remove and retain overdrive piston thrust
bearing. Bearing may remain on piston or in clutch
hub during removal.
(14) Position drain pan on workbench.
(15) Place overdrive unit over drain pan. Tilt unit
to drain residual fluid from case.
(16) Examine fluid for clutch material or metal
fragments. If fluid contains these items, overhaul
Fig. 14 Marking Propeller Shaft And Axle Yoke For will be necessary.
Alignment Reference
OVERDRIVE UNIT INSTALLATION
(6) Disconnect and remove propeller shaft. On (1) Be sure Alignment Tool 6227-2 is fully seated
4WD models, remove both shafts. in overdrive planetary and overrunning clutch
(7) On 4WD models, disconnect transfer case shift splines before moving unit.
linkage and distance sensor and remove transfer (2) If overdrive piston retainer was not removed
case. during service and original case gasket is in good
(8) Support transmission with transmission jack. condition, proceed to step (6). However, if original
(9) Remove rear crossmember. case gasket is not reusable, trim and install replace
(10) Remove vehicle speed sensor and speedometer ment gasket as described in steps (3) through (5).
adapter. (3) Cut out old case gasket around piston retainer
(11) Remove bolts attaching overdrive unit to with razor knife (Fig. 16).
transmission (Fig. 15). (4) Use old gasket as template and trim new gas
ket to fit.
C A U T I O N : Support the overdrive unit with a jack (5) Position new gasket over piston retainer and on
before moving it rearward. This is necessary to pre transmission case. Use petroleum jelly to hold gasket
vent damaging the intermediate shaft. D o not allow in place if necessary. D o not use any type of sealer
the shaft to support the entire weight of the over to secure gasket. U s e petroleum jelly only.
drive unit. (6) Install selective spacer on intermediate shaft if
removed. Spacer goes in groove just rearward of shaft
(12) Work overdrive unit rearward and off trans rear splines (Fig. 17).
mission intermediate shaft. (7) Install overdrive piston in retainer if removed.
(a) If overdrive unit does not require service, in Lubricate piston seals with Ru-Glyde, Door-Eze or
sert Tool 6227-2 in overdrive unit overrunning petroleum jelly to ease installation. Be sure piston lo
clutch and planetary gear to maintain spline align cating lugs are aligned in piston retainer.
ment. If clutch a n d gear splines rotate out of (8) Install thrust bearing in overdrive unit sliding
alignment, overdrive unit will h a v e to be disas hub. Use petroleum jelly to hold bearing in position.
s e m b l e d in order to realign splines.
(b) If overdrive unit does requires service, refer C A U T I O N : Be sure the shoulder on the inside diam
to Overdrive unit Overhaul section. eter of the bearing is facing forward.
(10) Carefully remove Alignment Tool 6227-2 from

overdrive compounder.
(11) Slide overdrive unit straight onto intermedi
ate shaft. Be sure park rod goes into park lock reac
tion plug at same time.
C A U T I O N : D o not tilt or jounce the overdrive unit

during installation. This could cause the overdrive
planetary and overrunning clutch splines to rotate
out of alignment. If the splines rotate out of align
ment, it will be necessary to disassemble the over
drive unit to realign the splines with Tool 6227-2.
(12) Align slip-fit governor tubes in piston retainer

and work compounder unit forward on intermediate
shaft and seat unit against transmission case.
(13) Install bolts attaching overdrive unit to trans
mission. Tighten bolts in diagonal pattern to 34 N»m
(25 ft-lbs).
(14) Install crossmember.
(15) On 4WD models, install transfer case and con
nect shift linkage and distance sensor.
(16) Install speedometer adapter and vehicle speed
sensor. Be sure to index adapter.
(17) Connect vehicle speed sensor and overdrive so
lenoid wires.
(18) Align and install propeller shaft, or shafts on
4WD models.
(19) If valve body was also removed, adjust bands,
install valve body and install transmission oil pan
and gasket.
Fig. 17 Intermediate Shaft Selective Spacer Location (20) Lower vehicle and refill transmission with
(9) Raise overdrive u n i t on transmission jack and Mopar ATF Plus, Type 7176. Use Mopar Dexron II if
align it with intermediate shaft. ATF Plus is not readily available.
21 - 152 TRANSMISSION OVERHAUL—32RH •
TRANSMISSION OWERHAUL—32RH
INDEX
page page
Extension Housing and Park Lock Component Support Overhaul 158
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 Planetary Gear Train-Output Shaft Overhaul .. 171
Front Clutch Overhaul 165 Rear Clutch Overhaul 168
Front Servo and Band Overhaul 175 Rear Servo and Band Overhaul . . . . . . . . . . . . . 175
Governor and Park Gear Overhaul 160 Transmission Assembly and Adjustment ...... 184
Oil Pump and Reaction Shaft Support Overhaul . 162 Transmission C a s e Cleaning and Inspection ... 158
Overhaul Service Information 158 Transmission Disassembly 152
Overrunning CIutch—Low-Reverse Drum—Rear Valve Body Service and Adjustment ......... 176
(1) Clean transmission exterior with steam gun or
with solvent. Wear eye protection during cleaning
process.
(2) Remove throttle and shift levers from valve
body manual shaft and throttle lever shaft.
(3) Mount transmission in repair stand C-3750-B
or similar type stand (Fig. 1).
Fig. 2 Extension Housing Removal—32RH
Fig. 3 Output Shaft Rear Bearing Position—32RH

(7) Remove oil pan bolts and remove pan and gas
Fig. 1 Transmission Mounted On Repair Stand ket.
(4) Remove bolts attaching extension housing to (8) Remove park/neutral position switch and seal
(Fig. 4).
transmission case. Then remove rear bearing locat
(9) Remove hex head valve body attaching bolts
ing ring access cover from housing (Fig. 2)
(Fig. 5).
(5) Spread rear bearing locating ring with parallel (10) Disconnect solenoid wire from case connector
jaw snap ring pliers (Fig. 2). Then work extension (Fig. 6).
housing off rear bearing and output shaft. Remove (11) Lift valve body upward, guide park rod out of
housing gasket after removing housing. case opening and remove valve body (Fig. 5).
(6) Remove rear bearing and snap ring from out (12) Remove accumulator spring and piston (Fig.
put shaft (Fig. 3). 8).
• TRANSMISSION OVERHAUL—32RH 21-113
VALVE
Fig. 4 Park/Neutral Position Switch Removal/

Installation
Fig. 7 Removing/Installing Valve Body—32RH
Fig. 5 Valve Body Attaching Bolt Locations—32RH
Fig. 8 Removing/Installing Accumulator Piston And

Spring—32RH
Fig. 9 Removing/Installing Front Band Reaction Pin

Fig. 6 Solenoid Wire Connection—32RH Access Plug—32RH
(13) Remove front band reaction pin access plug (15) Remove oil pump bolts.
(Fig. 9). Plug is accessible through converter hous (16) Thread bolts of Slide Hammer Tools C-3752
ing. Use 1/4 inch drive extension to remove plug as into threaded holes in pump body flange (Fig. 10).
shown. (17) Bump slide hammer weights outward to re
(14) Loosen front band adjusting screw locknut 4-5 move pump and reaction shaft support assembly from
turns. Then tighten band adjusting screw until band case (Fig. 10).
is tight around front clutch retainer. This prevents (18) Loosen front band adjusting screw until band
front/rear clutches from coming out with pump and is completely loose.
possibly damaging clutch or pump components.
(21) Remove front band lever (Fig. 13)
Fig. 10 Removing Oil Pump/Reaction Shaft Support

Assembly—32 RH Fig. 13 Removing/Installing Front Band
(19) Squeeze front band together and remove band Lever—32RH
strut (Fig. 11). (22) Slide front band rearward and onto driving
shell. Band will not be removed until after front/rear
clutch removal.
(23) Remove front and rear clutch units as assem
bly. Grasp input shaft, hold clutch units together and
remove them from case (Fig. 14).
Fig. 11 Removing/Installing Front Band Strut—32RH

(20) Remove front band reaction pin with pencil
magnet. Pin is accessible from converter housing side
of case (Fig. 12).
J9121-124
Fig. 14 Removing Front/Rear Clutch

Assemblies—32RH
(24) Lift front clutch off rear clutch (Fig. 15). Set
clutch units aside for overhaul.
(25) Remove output shaft thrust washer from out
Fig. 12 Removing Front Band Reaction Pin—32RH put shaft (or from rear clutch hub).
(26) Remove output shaft thrust plate from output
shaft hub (Fig. 16).
TRANSMISSION OVERHAUL—32RH 21 - 115
FRONT ^ DRIVING
CLUTCH „ SHELL
J9121-127
REAR Fig. 17 Front Band Removal/Installation—32RH

CLUTCH J9121-125
GOVERNOR PARK
BODY GEAR
Fig. 15 Separating Front/Rear Clutch SNAP
Assemblies—32 RH RING
OUTPUT
SHAFT
HUB
OUTPUT
SHAFT Fig. 18 Removing/Installing Governor Body Snap
THRUST Ring-32RH
PLATE J9121-126
E-CLIP (2 REQ'D) GOVERNOR
Fig. 16 Removing/Installing Output Shaft Thrust VALVE
Plate-32RH V SHAFT
(27) Slide front band off driving shell (Fig. 17) and
remove band from case.
(28) Remove governor body snap ring (Fig. 18).
(29) Remove E-clip from one end of governor valve
shaft and remove valve and shaft from governor body
(Fig. 19). Reinstall E-clip on shaft to avoid losing it.
(30) Loosen bolts attaching governor body to park
gear.
(31) Mark position of governor body on park gear
with center punch or scriber.
(32) Remove governor body and park gear as as
sembly (Fig. 20). Work park gear out of rear support
and slide assembly off output shaft.
Fig. 19 Removing Governor Valve And Shaft—32RH
21 - 156 TRANSMISSION OVERHAUL—32RH
GOVERNOR/PARK GEAR ASSEMBLY GOVERNOR
Fig. 20 Removing/Installing Governor And Park

Gear—32RH
(33) Remove planetary geartrain as assembly (Fig.
21). Support geartrain with both hands during re
moval. Do not allow machined surfaces on output
shaft to become nicked or scratched.
Fig. 23 Removing Rear Band Reaction Pins—32RH

support bolts together for assembly reference.
Fig. 21 Planetary Geartrain Removal—32RH
(40) Remove bolts attaching overrunning clutch
(34) Loosen rear band adjusting screw 4-5 turns. cam to case (Fig. 26).
(35) Remove snap ring t h a t secures low-reverse (41) Remove low-reverse drum and overrunning
drum to rear support hub, however do not remove clutch as assembly. Slide drum and clutch through
drum at this time (Fig. 22). rear band and out of case. Set drum and clutch as
(36) Remove rear band upper and lower reaction sembly aside for cleaning and inspection.
pins with parallel jaw snap ring pliers (Fig. 23).
(42) Remove rear band from case.
Spread plier jaws in pin bore to grip pin. Then twist
(43) Compress front servo rod guide about 1/8 in.
and pull pins to remove them as shown.
with valve spring compressor tool C-3422-B (Fig. 27).
(37) Remove rear band lever and strut.
A C-clamp and tool C-4470 can also be used to com
(38) Mark position of rear support for assembly
press rod guide.
reference (Fig. 24). Use scriber or center punch to
m a r k case and support.
(39) Remove rear support bolts and remove support
from low-reverse drum and case (Fig. 25). Keep rear
• TRANSMISSION OVERHAUL—32RH 21 - 157
(44) Remove front servo rod guide snap ring (Fig.

27). E x c e r c i s e c a u t i o n w h e n r e m o v i n g s n a p r i n g .
S e r v o b o r e c a n b e s c r a t c h e d o r n i c k e d if c a r e is
not excercised.
(45) Remove compressor tools and remove front
servo rod guide, spring and servo piston.
Fig. 24 Marking 32RH Rear Support For Assembly

Reference
Fig. 27 Compressing Front Servo Rod Guide—32RH

(46) Compress rear servo spring retainer about
1/16 in. with C-clamp and Tool C-4470 or SP-5560
(Fig. 28). Valve Spring Compressor C-3422-A can
also be used to compress spring retainer.
(47) Remove rear servo spring retainer snap ring.
Then remove compressor tools and remove rear servo
spring and piston.
Fig. 28 Compressing Rear Servo Spring—32RH
Fig. 26 Overrunning Clutch Cam Bolt

Locations—32RH
OVERHAUL SERVICE INFORMATION repaired with Helicoil thread inserts. However, the
Inspect all the transmission bushings during over case will have to be replaced if it exhibits any type of
haul. Bushing condition is important as worn, scored damage or wear.
bushings contribute to low pressures, clutch slip and Lubricate the front band adjusting screw threads
accelerated wear of other components. Do not replace with petroleum jelly and thread the screw part-way
bushings as a matter of course. Replace bushings into the case. Be sure the screw turns freely.
only when actually worn or scored. Remount the case in Repair Stand C-3750-B after
Use recommended tools to replace bushings. The cleaning and inspection.
tools are sized and designed to remove, install and
seat bushings correctly, The bushing replacement OVERRUNNING CLUTCH-LOW-REVERSE
tools are included in Bushing Tool Set C-3887-B. The D R U M - R E A R SUPPORT OVERHAUL
tool set is manufactured by the Miller Tool Co. and is
available through the dealer tool program. DISASSEMBLING OVERRUNNING CLUTCH/
Pre-sized service bushings are available for re LOW-REVERSE DRUM
placement purposes. Only the sun gear bushings are If the clutch assembly came out with the low-re
not serviced. Low cost of the sun gear assembly verse drum, thread two clutch cam bolts into the
makes it easier to simply replace the gear and bush cam. Then lift the cam out of the drum with the bolts
ings as an assembly. (Fig. 29). Rotate the cam back and forth to ease re
Heli-Coil inserts are recommended for repairing moval if necessary. Remove the clutch roller and
damaged, stripped or worn threads in aluminum spring assembly from the race afterward.
parts. These inserts are available from most automo
tive jobbers. Stainless steel inserts are preferred.
The use of crocus cloth is permissible where neces
sary, providing it is used carefully. When used on
valves, use extreme care to avoid rounding off sharp
edges. Sharp edges are vital as they prevent foreign
matter from getting between the valve and valve
bore.
Do not reuse oil seals, gaskets, seal rings, or
O-rings during overhaul. Replace these parts as a
matter of course. Also do not reuse snap rings or
E-clips t h a t are bent or distorted. Replace these parts
as well.
Lubricate transmission parts with Mopar ATF
Plus, Type 7176, or Dexron II™ transmission fluid
during overhaul and assembly.
Use Ru-Glyde or Door Eze to lubricate clutch pis Fig, 29 Removing Overrunning Clutch From Low-
ton seals. Use petroleum jelly to lubricate O-rings Reverse Drum—32RH
and t h r u s t washers. Petroleum jelly can also be used
to hold parts in place during reassembly. CLEANING AND INSPECTION
Clean the overrunning clutch assembly, clutch
TRANSMISSION CASE CLEAN1N8 AND cam, low-reverse drum and rear support in solvent.
INSPECTION Dry them with compressed air after cleaning.
Clean the case in a solvent tank. Flush the case Inspect condition of each clutch part after cleaning.
bores and fluid passages thoroughly with solvent. Replace the overrunning clutch roller and spring as
Dry the case and all fluid passages with compressed sembly if any rollers or springs are worn or dam
air. Be sure all solvent is removed from the case and aged, or if the roller cage is distorted, or damaged.
t h a t all fluid passages are clear. Replace the cam if worn, cracked or damaged.
D o n o t u s e s h o p t o w e l s o r r a g s to d r y t h e c a s e Replace the low-reverse drum if the clutch race,
(or a n y o t h e r t r a n s m i s s i o n c o m p o n e n t ) u n l e s s roller surface or inside diameter is scored, worn or
t h e y a r e m a d e from lint-free m a t e r i a l s . L i n t will damaged. Do n o t r e m o v e t h e c l u t c h r a c e from t h e
readily a d h e r e to case surfaces a n d transmission low-reverse d r u m u n d e r any circumstances. Re
c o m p o n e n t s a n d will c i r c u l a t e t h r o u g h o u t t h e p l a c e t h e d r u m a n d r a c e a s a n a s s e m b l y if e i t h e r
t r a n s m i s s i o n after a s s e m b l y . A sufficient q u a n c o m p o n e n t is d a m a g e d .
tity of lint c a n b l o c k fluid p a s s a g e s a n d i n t e r f e r e Examine the rear support carefully for wear,
with valve body operation. cracks, scoring or other damage. Be sure the support
Inspect the case for cracks, porous spots, worn hub is a snug fit in the case and drum. Replace the
bores, or damaged threads. Damaged threads can be support if worn or damaged.
ASSEMBLING OVERRUNNING CLUTCH/LOW* (e) Check low-reverse drum rotation. D r u m

REVERSE DRUM s h o u l d rotate freely in clockwise direction a n d
(1) Assemble clutch rollers and springs in retainer lock w h e n turned in counterclockwise direc
if necessary (Fig. 30). tion (as v i e w e d from front of case).
RETAINER LOW-REVERSE ^/ CLUTCH
DRUM RACE (ON
HUB OF DRUM)
J9121-139
OVERRUNNING
Fig. 30 Overrunning Clutch Rollers, Springs, CLUTCH
Retainer—32RH J9121-135
(2) Install overrunning clutch roller, spring and re Fig. 32 Temporary Assemby Of Clutch And Drum To
tainer assembly in clutch cam (Fig. 31). Check Operation—32RH
CLUTCH (4) Note component position for assembly refer
ROLLER
ASSEMBLY ence. Bolt holes in clutch cam are countersunk on
one side, Be sure this side of cam will face rearward
when installed (Fig. 33).
(5) Remove rear support, overrunning clutch and
low-reverse drum. Set components aside for final as
sembly. If overrunning clutch will be installed
LOW-REVERSE DRUM OVERRUNNING
CLUTCH
CAM
ROLLER
AND
SPRING ASSEMBLY
CLUTCH CAM
J9121-138
CLUTCH
Fig. 31 Assembling Overrunning Clutch And RACE
Cam-32RH
(3) Temporarily assemble and check overrunning
clutch operation as follows:
(a) Assemble cam and clutch. HUB OF
(b) Install clutch assembly on low-reverse drum LOW-REVERSE
DRUM
with twisting motion (Fig. 32).
(c) Install drum-clutch assembly in case and in
stall clutch cam bolts.
J9121-140
(d) Install rear support and support attaching
bolts. Fig. 33 Assembled Overrunning Clutch
Components—32RH
21-160 TRANSMISSION OVERHAUL—32RH •
b e f o r e final a s s e m b l y , i n s t a l l c a m o n l y a s de
s c r i b e d i n T r a n s m i s s i o n A s s e m b l y A n d Adjust
m e n t section. C l u t c h c a m m u s t b e p r o p e r l y
i n d e x e d in c a s e t o fit a n d o p e r a t e p r o p e r l y .
EXTENSION HOUSING AND PARK LOCK

COMPONENT OVERHAUL
Clean the housing and park lock components in
solvent and dry them with compressed air.
Inspect the housing bushing, seal and bearing snap
ring (Fig. 34). Replace the bushing if scored, worn or
damaged. Replace the seal if cut, torn or distorted.
Replace the snap ring if distorted or broken.
BEARING
SNAP EXTENSION
RING HOUSING BUSHING
Fig. 35 Park Sprag, Shaft And Spring

Removal—32RH
J9121-250
Fig. 34 Extension Housing Components—32RH

Examine the park lock components in the housing.
If replacement is necessary, remove the shaft with
parallel jaw snap ring pliers (Fig. 35) and remove the
sprag and spring. Then remove the spring clip and
reaction plug (Fig. 36).
Compress the reaction plug spring clip only
e n o u g h to r e m o v e or install it. The clip is easily
distorted if overcompressed. Replace the clip if
it b e c o m e s bent or distorted. D o not straighten
a n d reuse the clip if this occurs.
Be sure a replacement sprag is installed so the
sprag locking lug will face the park gear (Fig. 37).
Also be sure the spring is correctly positioned as
shown (Fig. 37). The sprag may not retract if the
spring is improperly installed.
GOVERNOR AND PARK GEAR OVERHAUL

GOVERNOR/PARK GEAR DISASSEMBLY Fig. 36 Park Sprag Reaction Plug And Spring
(1) Loosen bolts attaching governor to park gear. Location—32RH
(2) Remove governor snap ring and locating snap
ring from output shaft (Fig. 38). (7) Remove governor weight snap ring and remove
(3) Remove E-clip securing governor valve shaft weight assembly from governor body. Remove inner
and remove shaft and valve from governor body. snap ring and separate governor weights.
(4) Slide governor and park gear off output shaft.
(5) Remove governor retaining bolts and separate GOVERNOR/PARK GEAR CLEANING AND
governor from park gear. INSPECTION
(6) Remove governor filter from park gear. Keep Clean the governor and park gear components in
filter with governor body. solvent and dry with compressed air.
J9121-47
Fig. 37 Correct Position Of Sprag And

Spring—32RH
Examine the governor components carefully (Fig.
38). Discard any snap rings or E-clips if distorted, or
worn. Be sure the governor weights operate freely in
the bores and do not bind. Also verify t h a t the gov
ernor valve slides freely on the shaft and in the bore.
Minor scratches, or burrs on governor components
can be cleaned up with oil-soaked crocus cloth. How
ever, do not attempt to salvage components t h a t are
severely worn or scored.
There are t w o governor component c h a n g e s
o n current transmissions that affect service pro
cedures. The first c h a n g e involves the governor
valve. The valve is n o w made of aluminum. The
s e c o n d c h a n g e involves the output shaft w h i c h
h a s b e e n spotfaced for governor valve end clear
ance. The n e w aluminum valve must only b e
u s e d with an output shaft that h a s a spotface. In
addition, the governor b o d y a n d spotfaced side
of the valve shaft hole in the output shaft must
b e indexed.
Check condition of the park gear seal rings, ring
grooves and gear teeth (Fig. 39). Replace the gear as
an assembly if the teeth or ring grooves are worn, or
damaged.
Replace the park gear front and rear seal rings if
cracked, or worn. The production style front ring is a
plain type and the rear ring is a hook style. If re
placement rings are both hook-style, be sure the ring Fig. 39 Park Gear And Seal Rings—32RH
ends are properly hooked together.
(2) Assemble governor weights and springs. Then
ASSEMBLING GOVERNOR AND PARK GEAR install weight assembly in governor body but do not
(1) Coat governor body bores and valves with
transmission fluid.
install valve and shaft at this time. These parts are
not installed until after governor and park gear are
in place on output shaft.
(3) Install new seal rings on park gear if neces
sary.
(4) Insert filter screen in park gear and install
governor body on park gear. Tighten attaching bolts
finger tight only. Bolts will not be final tightened
until after governor and park gear are mounted on
output shaft. J9321-213
OIL PUMP AND REACTION SHAFT SUPPORT Fig. 42 Separating Pump Housing From Reaction
OVERHAUL Shaft Support-32RH
PUMP AND SUPPORT DISASSEMBLY

(1) Remove seal from around pump housing (Fig.
40).
J9321-214
Fig. 43 Pump Gear Removal—32RH

OIL PUMP AND REACTION SHAFT SUPPORT
Clean pump and reaction shaft support components
Fig. 40 Removing Pump Housing Seal—32RH
with solvent and dry them with compressed air.
(2) Mark pump housing and support assembly for Inspect the pump housing and support components.
alignment reference. Replace the housing or support if the seal ring
(3) Loosen bolts t h a t attach pump body to support grooves or machined surfaces are worn, scored, pit
(Fig. 41). ted, or damaged.
Replace the pump gears if pitted, worn chipped, or
damaged. Inspect the thrust washer for wear or dam
age. Replace the washer if necessary. N o t e t h a t t h e
i n n e r g e a r u s e d i n 1993 32RH oil p u m p s h a s a
n e w design drive lug. The n e w design incorpo
r a t e s d r i v e flats i n s t e a d of t h e s q u a r e l u g u s e d
p r e v i o u s l y . T h e 1993 t o r q u e c o n v e r t e r h u b h a s
a l s o b e e n r e d e s i g n e d t o a c c e p t t h e n e w d r i v e . If
p u m p g e a r r e p l a c e m e n t is n e c e s s a r y , b e v e r y
s u r e t o o r d e r a n d install t h e n e w style g e a r s .
Inspect the pump and reaction shaft support bush
ings. Minor bushing wear is acceptable. Replace the
Fig. 41 Loosening Pump Support Bolts
bushings only if scored, or severely worn.
(4) Remove pump-to-support bolts and separate Install the gears in the pump housing and measure
support from pump housing (Fig. 42). end clearance with a feeler gauge and straightedge
(5) Remove inner and outer gears from reaction (Fig. 45). Clearance should be 0.010 - 0.06 mm
shaft support (Fig. 43). (0.0004 - 0.0025 in.).
(6) If pump seal was not removed during transmis Measure clearance between the outer gear and the
sion disassembly, remove seal with punch and ham pump body (Fig. 46). Clearance should be 0.08 - 0.19
mer. mm (0.0035 - 0.0075 in.).
(7) Remove front clutch thrust washer from sup Measure gear tooth clearance with a feeler gauge.
port hub (Fig. 44). Align one tooth of the outer gear in inner gear and
TRANSMISSION OVERHAUL—32RH 21 • 163
REACTION SHAFT GASKET

SUPPORT
OIL SEAL
BOLT (6)
O-RING
SEAL
PUMP HOUSING THRUST
WASHER
J
932
1-
207
Fig. 44 Oil Pump And Reaction Shaft Support Components—32RH
STRAIGHT EDGE measure clearance (Fig. 47). Clearance should be

0.08 - 0.19 m m (0.0035 - 0.0075 in.),
FEELER
GAUGE INNER
GEAR
OUTER
J9321-215 GEAR If!
Fig. 45 Measuring Pump Gear End Clearance—32RH
FEELER
GAUGE Fig. 47 Measuring Pump Gear Tooth Clearance
INNER
GEAR
REPLACING OIL PUMP BUSHING
(1) Remove pump bushing with Tool Handle
C-4171 and Bushing Remover SP-3551 (Fig. 48).
(2) Install new pump bushing with Tool Handle
C-4171 and Bushing Installer SP-5117 (Fig. 48).
Bushing should be flush with pump housing bore.
(3) Stake new pump bushing in two places with
J9321-216 blunt punch (Fig. 49). Remove burrs from stake
points with knife blade afterward.
Fig. 46 Measuring Pump Housing-To-Inner Gear
Clearances
SPECIAL BUSHING (7) Position reaction shaft support upright on a
TOOL REMOVAL clean smooth surface.
C-4171
(8) Align bushing in bore. Then tap bushing into
SPECIAL TOOL place until Bushing Installer SP-5325 bottoms.
PUMP HOUSING
SP-3551 (9) Clean reaction shaft support thoroughly after
installing bushing.
BUSHING SPECIAL SPECIAL
TOOL TOOL
SP-1191 C-4171
SPECIAL
TOOL
C-4171 SPECIAL
TOOL SPECIAL
SP-5117 T Q Q L
_ U
SP-5325
BUSHING
BUSHING
INSTALLATION
J9221-242
J9221-243
Fig. 48 Removing OH Pump Bushing—32RH
Fig. 50 Replacing Reaction Shaft Support
Bushing—32RH
ASSEMBLING OIL PUMP AND REACTION
SHAFT SUPPORT
(1) Lubricate gear bore in pump housing with
transmission fluid.
(2) Lubricate pump gears with transmission fluid.
(3) Support pump housing on wood blocks (Fig. 51).
(4) Install outer gear in pump housing (Fig. 51).
Gear can be installed either way (it is not a one-way
fit).
OUTER
GEAR
RH282
PUMP
HOUSING
Fig. 49 Staking Oil Pump Bushing
REPLACING REACTION SHAFT SUPPORT
BUSHING
(1) Assemble Bushing Remover Tools SP-1191,
3633 and 5324 (Fig. 50). D o not clamp a n y part of
reaction shaft or support in vise.
(2) Hold Cup Tool SP-3633 firmly against reaction
shaft and thread remover SP-5324 into bushing as
far as possible by hand. Then thread remover tool 3-4
WOOD
additional turns into bushing with a wrench. BLOCKS
(3) Turn remover tool hex nut down against re J9321-219
mover cup to pull bushing from shaft. Clean all chips
from shaft after bushing removal. Fig. 51 Supporting Pump And Installing Outer
Gear-32RH
(4) Lightly grip old bushing in vise or with pliers
and back remover tool out of bushing. (5) Install pump inner gear (Fig. 52). Gear can be
(5) Assemble Bushing Installer Tools C-4171 and installed either way (it is not a one-way fit).
SP-5325 (Fig. 50). (6) Install new thrust washer on hub of reaction
(6) Slide new bushing onto Installer Tool SP-5325. shaft support. Lubricate washer with transmission
fluid or petroleum jelly.
REACTION
INNER SHAFT
GEAR PUMP SUPPORT
OUTER HOUSING'
GEAR
|lrJ9321-221
Fig. 54 Assembling Reaction Shaft Support And

Pump Housing—32RH
J9321-220 (b) Secure pump assembly in case with 2 or 3
bolts, or with pilot studs.
Fig. 52 Pump Inner Gear Installation—32RH (c) Tighten support-to-pump bolts to 20 N»m (15
(7) If reaction shaft seal rings are being replaced, ft. lbs.).
install new seal rings on support hub (Fig. 53). Lu (d) Remove pump assembly from transmission
bricate seal rings with transmission fluid or petro case.
leum jelly after installation. Squeeze each ring until (12) Install new oil seal in pump with Special Tool
ring ends are securely hooked together. C-4193 and Tool Handle C-4171 (Fig. 55). Be sure
seal lip faces inward.
C A U T I O N : The reaction shaft support seal rings will (13) Install new seal ring around pump housing.
break if overspread, or twisted. If new rings are be Be sure seal is properly seated in groove.
ing installed, spread them only enough for installa (14) Lubricate lip of pump oil seal with petroleum
tion. A l s o be very sure the ring ends are securely jelly. Lubricate pump seal with Ru-Glyde or petro
hooked together after installation. Otherwise, the leum jelly.
rings will either prevent pump installation, or break
during installation.
SPECIAL
SEAL TOOL
RINGS C-4193
PUMP
BODY
PUMP
SEAL
LCC. ,^77/OS J9321-183

SUPPORT S*^
HUB J9321-218
Fig. 55 Pump Oil Seal Installation-32RH
FRONT CLUTCH OVERHAUL
Fig. 53 Hub Seal Ring Position—32RH
FRONT CLUTCH DISASSEMBLY
(8) Install reaction shaft support on pump housing
(Fig. 54). (1) Remove waved snap ring and remove pressure
plate, clutch plates and clutch discs (Fig. 56).
(9) Align reaction support on pump housing. Use
(2) Compress clutch piston spring with Compressor
alignment marks made at disassembly. Or, rotate
Tool C-3575-A (Fig. 57). Be sure legs of tool are
support until bolt holes in support and pump housing
seated squarely on spring retainer before compress
are all aligned (holes are offset for one-way fit).
ing spring.
(10) Install all bolts t h a t attach support to pump
(3) Remove retainer snap ring and remove com
housing. Then tighten bolts finger tight.
pressor tool.
(11) Tighten support-to-pump bolts to required
(4) Remove spring retainer and clutch spring.
torque as follows:
(5) Remove clutch piston from clutch retainer.
(a) Reverse pump assembly and install it in
(6) Remove seals from clutch piston and clutch re
transmission case. Position pump so bolts are fac
tainer hub. Discard both seals as they are not reus
ing out and are accessible.
able.
21 - 116 TRANSMISSION OVERHAUL—32RH
CLUTCH SPRING
> PISTON RETAINER S N A P RING
S N A P RING (WAVED)
FRONT CLUTCH RETAINER
J9121-144 CLUTCH PLATES
Fig. 56 Front Clutch Components—32RH

The steel plates should slide freely in the slots. Re
COMPRESSOR
FRONT
TOOL C-3575-A
place the piston retainer if the grooves are worn or
CLUTCH
damaged. Also check action of the check ball in the
SPRING
piston retainer. The ball must move freely and not
stick.
Replace the retainer bushing if worn, scored, or
there is any doubt about bushing condition.
Inspect the piston and retainer seal surfaces for
nicks or scratches. Minor scratches can be removed
with crocus cloth. However, replace the piston and/or
retainer if the seal surfaces are seriously scored. In
spect the retainer check ball (Fig. 58). Be the check
ball moves freely in its seat.
RETAINER
CHECK BALL
SPRING RETAINER
RETAINER \ ^ S N A P RING ^/J912M47
Fig. 57 Compressing Front Clutch Piston

Spring—32RH
FRONT CLUTCH INSPECTION
Clean the front clutch components in solvent and
dry them with compressed air only. Do not use rags
or shop towels to dry any of the clutch parts. Lint
from such materials will adhere to the component
surfaces and could restrict or block fluid passages af
ter assembly. J9121-368
Replace t h e clutch discs if warped, worn, scored,
burned or charred, or if the facing is flaking off. Re Fig. 58 Front Clutch Retainer Check Ball
place the steel plates if heavily scored, warped, or Location—32RH
broken. Be sure the driving lugs on the plates are in
good condition. The lugs must not be bent, cracked or
damaged in any way.
Replace the clutch spring and spring retainer if ei
ther is distorted, warped or broken.
Check the lug grooves in the clutch piston retainer.
REPLACING FRONT CLUTCH RETAINER

FRONT
BUSHING CLUTCH
(1) Assemble Tool Handle C-4171 and Bushing Re RETAINER
mover SP-3627 (Fig. 59).
(2) Insert remover tool in bushing and drive old
bushing out of retainer (Fig. 59).
(3) Mount Bushing Installer SP-3626 on Tool Han
dle C-4171. Then slide new bushing onto installer
tool.
(4) Align and install new bushing. Tap bushing
into retainer until installer tool bottoms against re
tainer (Fig. 59).
(5) Remove bushing replacement tools and clean
retainer thoroughly.
J9121-146
SPECIAL SPECIAL SPECIAL SPECIAL
TOOL TOOL TOOL TOOL
C-4171 SP-3627 C-4171 SP-3626 Fig. 60 Installing Front Clutch Piston—32RH
(9) Check clutch pack clearance (Fig. 61). Clear
ance should be 1.70 to 3.40 mm (0.067 to 0.134 in.)
FRONT with 4-disc clutch and 1.90 to 3.86 mm (0.075 to
CLUTCH 0.152 in.) with 5-disc clutch. If clearance is incorrect,
RETAINER BUSHING clutch pack components may have to be changed.
\ FEELER GAUGE
BUSHING BUSHING
J9221-246
Fig. 59 Replacing Front Clutch Retainer

Bushing—32RH
ASSEMBLING FRONT CLUTCH
(1) Lubricate clutch plates and soak clutch discs in
transmission fluid.
(2) Install new seals on piston and in hub of re
tainer. Be sure lip of each seal faces interior of clutch
retainer.
(3) Lubricate lip of piston and retainer seals with
liberal quantity of Door Eze, or petroleum jelly. Then
lubricate retainer hub, bore and piston with trans
mission fluid.
(4) Install clutch piston in retainer (Fig. 60). Use
twisting motion to seat piston in bottom of retainer.
Do not attempt to p u s h the piston straight in.
This could fold the seals over causing l e a k a g e FEELER GAUGE RH 288
and clutch slip.
(5) Position spring on clutch piston. Then place Fig. 61 Measuring Front Clutch Pack Clearance
spring retainer on top of spring.
(6) Compress return spring and spring retainer
with Compressor Tool C-3575-A. Then install new
snap ring to secure spring retainer.
(7) Install clutch plates and discs (Fig. 56). Install
steel plate then disc until all plates and discs are in
stalled.
(8) Install pressure plate and waved snap ring
(Fig. 56).
21-168 TRANSMISSION OVERHAUL—32RH
-REAR
INPUT REAR INPUT CLUTCH
OUTPUT CLUTCH SHAFT
SHAFT . THRUST
SHAFT RETAINER
SNAP " / SHAFT WASHER
THRUST
RING / FRONT ('I"")
WASHER
(METAL) SHAFT SEAL
CLUTCH REAR RING r n i T r u
C
PISTON SEAL (TEFLON) ^TCH

REAR SEALS RING PACK
CLUTCH SNAP
PISTON RING
(SELECTIVE)
PISTON
SPRING
TOP
PRESSURE
PLATE
CLUTCH
BOTTOM DISCS (4)
PRESSURE
PLATE
J9121-539
Fig. 62 Rear Clutcl Components—32 RH

REAR CLUTCH OVERHAUL
REAR CLUTCH DISASSEMBLY
(1) Remove fiber t h r u s t washer from forward side
of clutch retainer.
(2) Remove selective clutch pack snap ring (Fig.
62).
(3) Remove top pressure plate, clutch discs, steel
plates, bottom pressure plate and wave spring (Fig.
62).
(4) Remove clutch piston with rotating motion.
(5) Remove and discard piston seals.
(6) Remove input shaft snap ring (Fig. 63).
(7) Press input shaft out of retainer with shop
press and suitable size press tool (Fig. 64).
(8) Remove input shaft front/rear seal rings.
Fig. 63 Removing/Installing Input Shaft Snap
REAR CLUTCH INSPECTION Ring-32RH
Clean the clutch components with solvent and dry
also in good condition. The lugs must not be bent,
them with compressed air. Do not use rags or shop
cracked or damaged in any way.
towels to dry any of the clutch parts. Lint from such
Replace the piston spring and wave spring if either
materials will adhere to component surfaces and
part is distorted, warped or broken.
could restrict or block fluid passages after assembly.
Check the lug grooves in the clutch retainer. The
Replace the clutch discs if warped, worn, scored,
clutch and pressure plates should slide freely in the
burned/charred, the lugs are damaged, or if the fac
ing is flaking off. Replace the top and bottom pres slots. Replace the retainer if the grooves are worn or
sure plates if scored, warped, or cracked. Be sure the
driving lugs on the pressure and clutch plates are
J9121-150
Fig. 64 Pressing input Shaft Out Of Rear Clutch

Retainer—32RH
damaged. Also check action of the check balls in the
retainer and piston. Each check ball must move
freely and not stick.
J9121 -538
Replace the retainer bushing if worn, scored, or
doubt exists about bushing condition.
Fig. 65 Rear Clutch Retainer And input Shaft Seal
Inspect the piston and retainer seal surfaces for Ring Installation—32RH
retainer if the seal surfaces are seriously scored.
Check condition of the fiber thrust washer and
metal output shaft thrust washer. Replace either
washer if worn or damaged.
Check condition of the seal rings on the input shaft
and clutch retainer hub. Replace the seal rings only
if worn, distorted, or damaged. The input shaft front
seal ring is teflon with chamfered ends. The r e a r
ring is metal with interlocking ends.
Check the input shaft for wear, or damage. Replace
the shaft if worn, scored or damaged in any way.
ASSEMBLING REAR CLUTCH

(1) Soak clutch discs and steel plates in transmis
sion fluid.
(2) Install new seal rings on clutch retainer hub
and input shaft (Fig. 65).
(a) Be sure clutch hub seal ring is fully seated in
groove and is not twisted. J912M51
(b) Note t h a t input shaft front seal ring is teflon
and rear seal ring is metal (Fig. 66). Be sure cham Fig. 66 input Shaft Seal Ring Identification—32RH
fered ends of teflon ring are properly joined and (6) Lubricate lip of piston seals with liberal quan
t h a t ends of rear ring are securely hooked together. tity of Door Eze, or petroleum jelly. Then lubricate
Lubricate both rings with light coat of petroleum retainer hub and bore with transmission fluid.
jelly after installation. (7) Install clutch piston in retainer. Use twisting
(3) Lubricate splined end of input shaft and clutch motion to seat piston in bottom of retainer. D o n o t
retainer with transmission fluid. Then press input a t t e m p t t o p u s h t h e p i s t o n s t r a i g h t in. T h i s
shaft into retainer (Fig. 67). c o u l d fold t h e s e a l s o v e r c a u s i n g l e a k a g e a n d
(4) Install input shaft snap ring (Fig. 63). c l u t c h slip.
(5) Install new seals on clutch piston. Be sure lip
of each seal faces interior of clutch retainer.
(13) Install selective snap ring (Fig. 62). Be sure
snap ring is fully seated in retainer groove.
(14) Measure clutch pack clearance (Fig. 69).
Clearance should be 0.64 - 1.14 mm (0.025 - 0.045
in.). If clearance is incorrect, steel plates, discs, snap
ring and pressure plates may have to be changed.
Fig. 67 Pressing input Shaft into Rear Clutch

Retainer—32RH
(8) Install piston spring in retainer and on top of
piston (Fig. 68). Concave side of spring faces down
ward (toward piston).
(9) Install wave spring in retainer (Fig. 68). Be
Fig. 69 Typical Method Of Checking Rear Clutch
sure spring is completely seated in retainer groove.
Pack Clearance
(15) Coat rear clutch fiber thrust washer with pe
troleum jelly and install washer over input shaft and
into clutch retainer (Fig. 70). Use enough petroleum
jelly to hold washer in place.
(16) Set rear clutch aside for installation during fi
nal assembly.
Fig. 68 Piston And Wave Spring Position—32RH

(10) Install bottom pressure plate (Fig. 62). Ridged
side of plate faces downward (toward piston) and flat
side toward clutch pack.
(11) Install first clutch disc in retainer on top of
bottom pressure plate. Then install a clutch plate fol
lowed by a clutch disc until entire clutch pack is in
stalled. Total of 4 discs and 3 plates are required Fig. 70 Installing Rear Clutch Thrust Washer—32RH
(Fig. 62).
(12) Install top pressure plate (Fig. 62).
PLANETARY GEAR TRAIN •OUTPUT SHAFT scored or worn. The bushings are not serviceable. Re
OVERHAUL place the driving shell if worn, cracked or damaged.
Replace planetary gear sets if gears, pinion pins, or
PLANETERY GEARTRAIN DISASSEMBLY (FIG. carrier are damaged in any way. Replace the annu
71) lus gears and supports if either component is worn or
(1) Remove snap ring, tabbed t h r u s t washer and damaged.
thrust plate from front of output shaft. Inspect the geartrain spacers, thrust plates, snap
(2) Remove front annulus gear and support assem rings, and thrust washers. Replace any of these parts
bly. t h a t are worn, distorted or damaged. Do not attempt
(3) Remove front planetary front t h r u s t washer. to reuse these parts.
(4) Remove front planetary gear. Inspect the output shaft carefully. Pay particular
(5) Remove front planetary rear t h r u s t washer. attention to t h e machined bushing/bearing surfaces
(6) Remove sun gear and driving shell. on the shaft and the governor valve shaft bore at the
(7) Remove snap ring t h a t retains sun gear in shaft rear.
driving shell and remove sun gear and thrust plates. Replace the output shaft if the machined surfaces
Note thrust plate position for assembly reference. are scored, pitted, or damaged in any way. Also re
(8) Remove tabbed thrust washer from rear plane
place the shaft if the splines are damaged, or exhib
tary gear.
its cracks at any location (especially at the governor
(9) Remove rear planetary gear from rear annulus
valve shaft bore).
gear and remove annulus gear from output shaft.
(10) Remove snap rings t h a t secure annulus gears ASSEMBLING PLANETARY GEARTRAIN
to supports and separate each gear from the support. (1) Lubricate output shaft and planetary compo
PLANETARY GEARTRAIN INSPECTION nents with transmission fluid. Use petroleum jelly to
Clean the planetary components in solvent and dry lubricate and hold thrust washers and plates in posi
them with compressed air. tion.
Check sun gear and driving shell condition. Re (2) Assemble rear annulus gear and support if dis
place the gear if damaged or if the bushings are assembled. Be sure support snap ring is seated and
SELECT FRONT SUPPORT ANNULUS GEAR FRONT SUN SUN DRIVING SHELL FRONT DRIVING
FIT ANNULUS SNAP RING SUPPORT PLANETARY GEAR GEAR THRUST PLATE SHELL
PLANETARY SNAP THRUST SPACER
SNAP RING WASHERS
RING
FRONT
ANNULUS.
THRUST
WASHER
DRIVING
SHELL
REAR
THRUST
PLATE
OUTPUT
SHAFT
THRUST OUTPUT J9221-17
PLATE SHAFT
Fig. 71 Planetary Gear Train—32RH

t h a t shoulder-side of support faces rearward (Fig.
72).
(3) Install rear thrust washer on rear planetary
gear (Fig. 72). Use enough petroleum jelly to hold
washer in place. Also be sure washer tabs are prop
erly engaged in gear slots.
(4) Install rear annulus over and onto rear plane
tary gear (Fig. 72).
Fig. 74 installing Rear Planetary Front Thrust

Washer-32RH
Fig. 72 Assembling Rear Annulus And Planetary

Gear-32RH
(5) Install assembled rear planetary and annulus
gear on output shaft (Fig. 73). Verify t h a t assembly
is fully seated on shaft.
Fig. 75 Installing Spacer On Sun Gear—32RH
Fig. 73 installing Assembled Rear Annulus And

Planetary Gear On Output Shaft-32RH
(6) Install front thrust washer on rear planetary
washer on gear.
(7) Install spacer on sun gear (Fig. 75). Fig. 76 Installing Driving Shell Front Thrust Plate
(8) Install thrust plate on sun gear (Fig. 76). Note On Sun Gear-32RH
t h a t driving shell thrust plates are interchangeable.
Use either plate on sun gear and at front/rear of
shell.
(9) Hold sun gear in place and install thrust plate

over sun gear at rear of driving shell (Fig. 77). SUN
LOCK GEAR
SUN RING LOCK
DRIVING GEAR GROOVE RING
SHELL
REAR
THRUST
PLATE
DRIVING
SHELL
REAR
THRUST
PLATE J912M62
Fig. 79 Installing Sun Gear Lock Ring—32RH
SUN GEAR/
Fig. 77 Installing Driving Shell Rear Thrust DRIVING SHELL
Piate-32RH ASSEMBLY
(10) Position wood block on bench and support sun

gear on block (Fig. 78). This makes it easier to align
and install sun gear lock ring. Keep wood block
handy as it will also be used for geartrain end play
check.
SUN
GEAR
OUTPUT
SHAFT
J912M65
Fig. 80 Installing Assembled Sun Gear And Driving

Shell On Output Shaft-32RH
FRONT
WOOD PLANETARY
BLOCK GEAR
REAR
TABBED
DRIVING THRUST
SHELL J912M63 WASHER
Fig. 78 Supporting Sun Gear On Wood Block—32RH

(11) Align rear thrust plate on driving shell and
install sun gear lock ring. Be sure ring is fully
seated in sun gear ring groove (Fig. 79).
(12) Install assembled driving shell and sun gear
on output shaft (Fig. 80).
(13) Install rear thrust washer on front planetary
gear (Fig. 81). Use enough petroleum jelly to hold J912M66
washer on gear and be sure washer tabs are all prop
erly seated. Fig. 81 Installing Rear Thrust Washer On Front
(14) Install front planetary gear on output shaft Planetary Gear—32RH
and in driving shell (Fig. 82).
(15) Install front thrust washer on front planetary
washer in place on gear and be sure washer tabs are
seated.
(16) Assemble front annulus gear and support. Be
sure support snap ring is seated.
(17) Position thrust plate on front annulus gear
support (Fig. 83). Use enough petroleum jelly to hold
thrust plate in place.
(18) Install front annulus assembly on front plane
Fig. 84 installing Front Annulus Thrust

Washer-32RH
Fig. 82 Installing Front Planetary And Annulus

Gears—32RH
Fig. 85 Installing Front Annulus Snap Ring—32RH

SELECTIVE
Fig. 83 Positioning Thrust Plate On Annulus

Support—32RH
(19) Install front annulus thrust washer (Fig. 84).
Align flat on washer with flat on planetary hub. Also
be sure washer tab is facing forward.
(20) Install front annulus snap ring (Fig. 85). Use Fig. 86 Installing Planetary Selective Snap
snap ring pliers to avoid distorting ring during in Ring—32 RH
stallation. Also be sure ring is fully seated.
(21) Install planetary selective snap ring with snap driving shell is facing workbench. Then support
ring pliers (Fig. 86). Be sure ring is fully seated. geartrain on wood block positioned under forward
(22) Turn planetary geartain assembly over so
end of output shaft. This allow geartrain components SERVO

to move forward for accurate end play check. PISTON
(23) Check planetary geartrain end play with
feeler gauge (Fig. 87). Gauge goes between shoulder
on output shaft and end of rear annulus support.
(24) Geartrain end play should be 0.12 to 1.22 m m
(0.005 to 0.048 in.). If end play is incorrect, snap ring
(or thrust washers) may have to be replaced. Snap
ring is available in three different thicknesses for ad
justment purposes.
SNAP GUIDE
S E A L
RING J912M72
Fig. 88 Front Servo Components—32RH

ASSEMBLING FRONT SERVO PISTON
(1) Lubricate seal rings and O-rings with petro
leum jelly. Lubricate other servo parts with trans
mission fluid.
(2) Install new O-ring on servo piston rod.
(3) Install new seal on piston rod guide and install
new seal rings on piston.
(4) Assemble rod, piston, servo springs and snap
ring (Fig. 88).
Fig. 87 Checking Planetary Geartrain End REAR SERVO AND BAND OVERHAUL
Play-32RH
REAR SERVO PISTON DISASSEMBLY
FRONT SERVO AND BAND OVERHAUL
(1) Remove seal from servo piston. Note which way
FRONT SERWO DISASSEMBLY (FIG. 88) seal lip faces for assembly reference.
(1) Remove small snap ring from servo piston. (2) Compress cushion spring in vise only enough to
(2) Remove piston, rod, springs and guide. allow piston plug snap ring removal (Fig. 89). Use
(3) Remove and discard servo piston rings and wood block between vise jaws and end of piston plug
to keep plug aligned and in position.
O-ring.
(3) Remove snap ring from end of piston plug (Fig.
FRONT SERWO AND BAND INSPECTION 89).
Clean the servo components with solvent and dry (4) Open vise and remove wood block, piston plug,
them with compressed air. cushion spring and servo piston.
Inspect the servo components. Replace the springs REAR SERVO INSPECTION
if collapsed, distorted or broken. Replace the guide, Clean the servo components with solvent and dry
rod and piston if cracked, bent, or worn. Discard the them with compressed air.
servo snap ring if distorted or warped. Check rear band condition. Replace the band if dis
Replace the front band if distorted, the lining is torted, the lining is burned or flaking off, or the lin
burned or flaking off, or excessively worn. ing is excessively worn.
Check the servo piston bore for wear. Replace the Check the band reaction pins. Replace the O-rings
piston and rod as an assembly if either part is worn on both pins. Minor pin scoring can be cleaned up
or damaged. with crocus cloth. However, replace the pins if worn,
Replace any servo component if doubt exists about severely scored, or cracked.
its condition. Do not reuse suspect parts. Inspect the servo components (Fig. 90). Replace the
SMALL BE SURE
WOOD SEAL LIP
BLOCK IS TOWARD
SERVO BORE
REAR
SERVO
PISTON
SNAP J9121-175
RING
PLIERS
PISTON Fig. 91 Installing Rear Servo Piston Seal—32RH
PLUG
SNAP VALVE BODY SERVICE AND ADJUSTMENT
RING J912M74
VALVE BODY DISASSEMBLY
Fig. 89 Removing/installing Servo Piston Plug Snap
Ring-32 RH C A U T I O N : D o not clamp any part of the valve body
assembly (Fig. 92) in a vise. This practice will dis
servo and cushion springs if collapsed, distorted or tort the valve body and transfer plate resulting in
broken. Replace the plug or piston if cracked, bent, valve bind. Slide valves and plugs out carefully. D o
or worn. Discard the servo snap ring and spring re not use force at any time. The valves and valve
tainer if distorted or warped. body will be damaged if force is used. Also tag or
If doubt exists about the condition of any servo mark the valve body springs for reference a s they
component, replace it. Do not reuse suspect parts. are removed. D o not allow them to become inter
SPRING mixed.
RETAINER
MANUAL CONVERTER
SERVO LEVER CLUTCH
SPRING MODULE
AND TUBE
PISTON
PLUG
SERVO
SNAP
CUSHION
RING
SPRING
PISTON
SEAL
PISTON
PLUG MANUAL
SNAP VALVE
RING
CONVERTER
SERVO SOLENOID CLUTCH
PISTON J9121-173 WIRE SOLENOID
Fig. 90 Rear Servo Components—32RH PARK

ROD J9321-125
ASSEMBLING REAR SERVO PISTON
(1) Assemble piston plug, cushion spring and pis Fig. 92 Valve Body Assembly—32RH
ton (Fig. 90).
(2) Compress cushion spring in vise and install pis (1) Remove screws attaching adjusting screw
ton plug snap ring (Fig. 90). bracket to valve body and transfer plate. Hold
bracket firmly against spring force while removing
(3) Install new seal on piston. Be sure seal lip is
last screw.
toward servo bore (Fig. 91).
(4) Lubricate piston seal with petroleum jelly. Lu (2) Remove adjusting screw bracket, line pressure
bricate other servo parts with transmission fluid. adjusting screw, pressure regulator spring and switch
valve spring (Fig. 93). Do not remove throttle
pressure adjusting screw from bracket a n d d o SHUTTLE

not disturb adjusting screw settings during re VALVE PARK
END PLATE ROD
moval.
SPRING J912M76
Fig. 95 Removing Manual And Throttle Levers
Fig. 93 Adjusting Screw Bracket And Spring
MANUAL
Removal—32RH
(3) Secure detent ball and spring in housing with
Retainer Tool 6583 (Fig. 94).
DETENT BALL AND SPRING HOUSING J9321-121
Fig. 94 Securing Detent Ball And Spring With Fig. 96 Park Rod Removal—32RH
Retainer Tool
(4) Remove manual shaft E-clip and washer (Fig.
95).
(5) Pull manual shaft and park rod assembly up
ward out of valve body and off throttle lever (Fig.
95).
(6) Remove retainer tool and remove detent ball
and spring (Fig. 95).
(7) Remove throttle lever (Fig. 95).
(8) Remove park rod E-clip and separate rod from
J912M78
manual lever (Fig. 96).
(9) Remove screws attaching converter clutch mod Fig. 97 Converter Clutch Module And Connecting
ule to valve body and remove module and connecting Tube Removal/Installation—32RH
tube (Fig. 97). (12) Remove transfer plate and separator plate
(10) Turn valve body over so transfer plate is fac from valve body. Note position of filter and converter
ing upward (Fig. 98). With valve body in this posi clutch solenoid for reference (Fig. 99).
tion, valve body check balls will remain in place and (13) Position transfer plate on bench so separator
not fall out when transfer plate is removed. plate, filter and clutch solenoid are facing up. This
(11) Remove screws attaching transfer plate to will avoid having rear clutch and r e a r servo check
valve body (Fig. 98). balls fall out when plates are separated.
VALVE
BODY
Fig. 100 Removing Converter Clutch

Solenoid—32RH
SEPARATOR
TRANSFER
PLATE J9121-181
Fig. 98 Valve Body- To- Transfer Plate Screw

Locations—32RH
Fig. 99 Transfer Plate Removal/Installation—32RH

(14) Remove screws attaching separator plate to
transfer plate.
(15) Remove converter clutch solenoid from separa
tor plate (Fig. 100). J9121-
(16) Note position of filter, clutch solenoid and rear
clutch/rear servo check balls for assembly reference Fig. 101 Transfer And Separator Plates—32RH
(Fig. 101). (21) Remove throttle valve and spring, kickdown
(17) Remove shuttle valve end plate (Fig. 102). valve and detent and manual valve from valve body
(18) Remove shuttle valve E-clip and remove sec (Fig. 103).
ondary spring and spring guides from end of valve (22) Remove 1-2 and 2-3 shift valve governor plugs
(Fig. 102). from valve body (Fig. 103).
(19) Remove governor valve end plate (Fig. 103). (23) Remove shuttle valve throttle plug, primary
(20) Remove switch valve and pressure regulator spring and shuttle valve from valve body (Fig. 103).
valve from valve body (Fig. 103). (24) Remove 1-2 shift control valve and spring
from valve body (Fig. 104).
E-CLIP SHUTTLE VALVE BODY CLEANING AND INSPECTION

VALVE The only serviceable valve body components are:
• park lock rod and E-clip
• switch valve and spring
• pressure adjusting screw bracket
• throttle valve lever
• manual shaft
• manual shaft seal, washer, E-clip and detent ball
• fluid filter.
• converter clutch solenoid
The remaining valve body components are serviced
only as part of a complete valve body assembly.
Clean the valve body components in a parts clean
ing solution only. Do not use gasoline, kerosene, or
any type of caustic solution. Dry t h e parts with com
pressed air. Make sure all passages are clean and
Fig. 102 Shuttle Valve E-Clip And Secondary Spring free from obstructions.
Location—32RH D o not u s e rags or s h o p towels to w i p e off
valve body components. Lint from these materi
(25) Remove 2-3 shift valve and spring from valve
als will adhere to the valve b o d y components.
body (Fig. 104).
Lint will interfere with valve operation a n d m a y
(26) Remove 1-2 shift valve and spring from valve
clog filters a n d fluid p a s s a g e s .
body (Fig. 104). Inspect the throttle and manual valve levers and
(27) Remove regulator valve end plate (Fig. 104). shafts. Do not attempt to straighten a bent shaft or
(28) Remove regulator valve line pressure plug, correct a loose lever. Replace these components if
pressure plug sleeve, throttle pressure plug and worn, bent, loose or damaged in any way.
spring (Fig. 104). Inspect all of t h e valve body mating surfaces for
scratches, nicks, burrs, or distortion. Use a straight-
SHUTTLE
VALVE
END PLATE
SECONDARY
SPRING & GUIDES
SHUTTLE
VALVE
PRIMARY
SWITCH SPRING
VALVE
SHUTTLE
VALVE
LINE THROTTLE
PRESSURE PLUG
REGULATOR
VALVE
GOVERNOR
PLUG-
END PLATE J9121-50
Fig. 103 Control Valves And Governor Plugs—32RH

REGULATOR
REGULATOR VALVE
VALVE SPRING
THROTTLE
PRESSURE
PLUG
SLEEVE
LINE
PRESSURE
PLUG
REGULATOR
VALVE
END
PLATE
2-3 SHIFT
SHIFT VALVE VALVE AND
SPRING J912M80
END PLATE
Fig. 104 Shift Valves And Pressure Regulator Plugs—32RH
edge to check surface flatness. Minor scratches may minum valves and plugs (Fig. 105). If the coating is
be removed with crocus cloth using only very light damaged or worn through, the valve (or valve body)
pressure. should be replaced.
Minor distortion of a valve body mating surface Aluminum valves and plugs must not be sanded or
may be corrected by smoothing the surface with cro polished under any circumstances. However, minor
cus cloth. The cloth should be in sheet form and be burrs or scratches on steel valves and plugs can be
positioned on a surface plate, sheet of plate glass, or removed with crocus cloth but do not round off the
equally flat surface. However, if distortion is severe valve or plug edges. Squareness of these edges is vi
or any surfaces are heavily scored, the valve body tally important. These edges prevent foreign matter
from lodging between the valves, plugs and bore.
will have to be replaced.
Inspect all the valve and plug bores in the valve
C A U T I O N : The throttle valve, shuttle valve plug, 1-2 body. Use a penlight to view the bore interiors. Re
shift valve and 1-2 governor plug are made of place the valve body if any bores are distorted or
coated aluminum. These components are identified scored. Inspect all of the valve body springs. The
in Figure 105 with the abbreviation (Alum.). Alumi springs must be free of distortion, warpage or broken
num components can be identified by the dark coils.
color of the special coating applied to the surface Trial fit each valve and plug in its bore to check
(or by testing with a magnet). D O NOT polish or freedom of operation. When clean and dry, the valves
sand aluminum valves or plugs with any type of and plugs should drop freely into the bores. Valve
material, or under any circumstances. This practice body bores do not change dimensionally with use. If
will remove the special coating and cause the the valve body functioned correctly when new, it will
valves and plugs to stick and bind. continue to operate properly after cleaning and in
spection. It should not be necessary to replace a
Inspect the valves and plugs for scratches, burrs, valve body assembly unless it is damaged in han
nicks, or scores. Also inspect the coating on the alu dling.
SHIFT VALVE 2-3 SHIFT SHUTTLE VALVE
E N D PLATE VALVE A N D SECONDARY SPRING,
SPRING GUIDES, E-CLIP
1-2 SHIFT
CONTROL VALVE
A N D SPRING
REGULATOR
VALVE
E N D PLATE
SHUTTLE VALVE
COVER
REGULATOR
VALVE
PRESSURE
PLUG
SLEEVE 2-3 SHIFT

VALVE G O V E R N O R
PLUG
REGULATOR
VALVE THROTTLE
PRESSURE PLUG
SHUTTLE VALVE
PLUG (ALUM.)
GOVERNOR
VALVE E N D
PLATE
MODULE
AND
CONNECTING
TUBE
M A N U A L LEVER
DETENT BALL
PRESSURE A N D SPRING
LINE THROTTLE SWITCH REGULATOR
PRESSURE ADJUSTING PRESSURE VALVE VALVE
ADJUSTING SCREW ADJUSTING AND AND
SCREW BRACKET SCREW SPRING SPRING J9121-369
Fig. 105 Valve Body Components—32RH (Alum. Indicates Aluminum Part)

VAL VE BODY ASSEMBL Y 1/4" C
HE
CK B
AL
LS (6)
C A U T I O N : D o not force the v a l v e s or p l u g s into

place during r e a s s e m b l y . If the valve b o d y b o r e s ,
v a l v e s a n d p l u g s are free of distortion or burrs, the
valve b o d y c o m p o n e n t s s h o u l d all slide into place
easily. In addition, d o not overtighten the transfer
plate a n d valve b o d y s c r e w s during r e a s s e m b l y .
Overtightening c a n distort the valve b o d y resulting
in valve sticking, c r o s s leakage a n d unsatisfactory
operation. Tighten valve b o d y s c r e w s to r e c o m
m e n d e d torque only.
(1) Lubricate valve body bores, valves and plugs

with transmission fluid.
(2) Insert rear clutch and rear servo check balls in
transfer plate (Fig. 100).
(3) Install filter screen in separator plate (Fig.
100).
(4) Align and install separator plate on transfer
plate. Verify check ball position before installing sep 11/32" C
HE
CK B
ALL (1) J912M83
arator plate on transfer plate.
(5) Install new O-ring on converter clutch solenoid Fig. 107 Correct Position Of Valve Body Check
and insert solenoid in separator plate (Fig. 106). Baiis-32RH
(10) Install 1-2 and 2-3 shift valves and springs
(Fig. 104).
(11) Install 1-2 shift control valve and spring (Fig.
104)
(12) Install shuttle valve as follows:
(a) Insert shuttle valve in bore.
(b) Insert plastic guides in shuttle valve second
ary spring.
(c) Install spring on end of valve.
(d) Hold shuttle valve in place. Then compress
secondary spring and install E-clip in groove at end
of valve.
(e) Verify that spring and E-clip are properly
seated before proceeding.
(13) Install shuttle valve cover plate (Fig. 103).
Tighten end plate screws to 4 N»m (35 in. lbs.)
Fig. 106 Installing Converter Clutch Solenoid—32RH
torque.
(6) Position valve body so internal passages and (14) Install 1-2 and 2-3 valve governor plugs in
check ball seats are facing upward. Then install valve body (Fig. 103). Then install shuttle valve pri
check balls in valve body (Fig. 107). There are a total mary spring and throttle plug.
of seven check balls; The one large check ball is ap (15) Align and install governor plug end plate on
proximately 11/32 inch in diameter. The remaining valve body and install end plate screws. Tighten
check balls are approximately 1/4 inch in diameter. screws to 4 N*m (35 in. lbs.) torque.
(7) Align and install assembled transfer and sepa (16) Install manual valve (Fig. 103).
rator plates on valve body. Install and tighten valve
(17) Install throttle valve and spring. Then install
body screws alternately in a diagnonal pattern to 4
kickdown valve and detent (Fig. 103).
N»m (35 in. lbs.) torque.
(8) Assemble converter clutch module and valves. (18) Install pressure regulator valve and switch
Then install assembly on valve body (Fig. 108). valve in valve body.
(9) Assemble regulator valve line pressure plug, (19) Install manual lever detent spring in housing.
sleeve, throttle plug and spring (Fig. 104). Insert as Place detent ball on end of spring and push ball and
sembly in valve body and install end plate. Tighten spring into housing. Secure ball and spring with De
end plate screws to 4 N»m (35 in. lbs.) torqe. tent Retainer 7684 or C-3765 (Fig. 94).
MODULE
J932M23
Fig. 108 Converter Clutch Module Components—32RH

(20) Insert line pressure adjusting screw in adjust
ing screw bracket (Fig. 93).
(21) Install spring on end of line pressure regula
tor valve.
(22) Install switch valve spring on tang at end of
adjusting screw bracket (Fig. 94).
(23) Position adjusting screw bracket on valve
body. Align valve springs and press bracket into
place. Install short, upper bracket screws first and
long bottom screw last. Verify t h a t valve springs and
bracket are properly aligned. Then tighten all three
bracket screws to 4 N*m (35 in. lbs.) torque.
(24) Install converter clutch module and connect
ing tube. Be sure long end of tube goes to module
(Fig. 97). Tighten module screws to 4 N r n (35 in.
lbs.) torque.
(25) Install throttle lever in valve body. Then in Fig. 109 Manual And Throttle Lever
stall manual lever over throttle lever and start man Alignment—32RH
ual lever into valve body. (30) If line pressure and/or throttle pressure ad
(26) Align manual lever detent with detent ball justment screw settings were not disturbed, continue
and align lever arm with manual valve. Hold throt with overhaul or reassembly. However, if adjustment
tle lever upward. Then press down on manual lever screw settings w e r e moved or changed, readjust as
until lever is fully seated. described in Valve Body Control Pressure Adjust
(27) Install manual lever seal, washer and retain ment procedure.
ing E-clip.
(28) Lubricate shaft of manual lever with light VALVE BODY CONTROL PRESSURE
coat of petroleum jelly. This will help protect seal lip ADJUSTMENTS
when manual shaft seal is installed. There are two control pressure adjustments on the
(29) Verify t h a t throttle lever is aligned with end valve body which are, line pressure and throttle pres
of kickdown valve stem and t h a t manual lever arm sure.
is engaged in manual valve (Fig. 109).
21 - 184 TRANSMISSION OVERHAUL—32RH - •
The two pressures are interdependent because each
affects shift quality and timing. Each pressure ad
justment must be performed properly and in the cor
rect sequence. The correct sequence is line pressure
adjustment first and throttle pressure adjustment
last.
Line Pressure Adjustment

Measure distance from the valve body to the inner
edge of the adjusting screw with an accurate steel
scale (Fig. 110).
Distance should be 33.4 mm (1-5/16 in.).
in, or out, to obtain required distance setting.
T h e 33.4 m m (1-5/16 in,) s e t t i n g Is a n a p p r o x i
m a t e s e t t i n g . B e c a u s e of m a n u f a c t u r i n g toler
Fig. 111 Throttle Pressure Adjustment—32RH
a n c e s , it m a y b e n e c e s s a r y t o v a r y f r o m t h i s
dimension to obtain desired pressure. TRANSMISSION ASSEMBLY AND ADJUSTMENT
One complete t u r n of the adjusting screw changes
Assembly Tips
line pressure approximately 1-2/3 psi (9 kPa). Turn
ing the adjusting-screw counterclockwise increases Do not allow dirt, grease, or foreign material to en
pressure while turning the screw clockwise decreases ter the case or transmission components during as
pressure. sembly. Keep the transmission case and components
clean. Also make sure the tools and workbench area
used for assembly are equally clean.
Shop towels used for wiping off your hands and ser
vice tools must be made of l i n t free materials. Lint
will adhere to tranmission parts and could interfere
with valve operation, or even restrict fluid passages.
Lubricate the transmission components with ATF
Plus, or Dexron II™ during reassembly. Use petro
leum jelly, Door Eze, or Ru-Glyde on seals and
O-rings to ease installation.
Petroleum jejly can also be used to hold t h r u s t
washers and plates in position during assembly oper
ations. However, d o n o t use chassis grease, bearing
grease, white grease, or similar lubricants on any
transmission part. These types of lubricants can
eventually block or restrict fluid passages and valve
Fig. 110 Line Pressure Adjustment—32RH operation. Use petroleum jelly only.
Throttle Pressure Adjustment Do not force parts into place. Most of the transmis
sion components are easily installed by hand when
Insert Gauge Tool C-3763 between t h e throttle le
properly aligned. If a part seems extremely difficult
ver cam and the kickdown valve stem (Fig. 111).
to install, it is either misaligned or incorrectly as
Push the gauge tool inward to compress the kick-
sembled. Also verify t h a t t h r u s t washers, t h r u s t
down valve against the spring and bottom the throt
plates and seal rings are correctly positioned before
tle valve.
assembly. These parts can interfere with proper as
Maintain pressure against kickdown valve spring.
sembly if mispositioned or "left out" by accident.
Turn throttle lever stop screw until the screw head
touches throttle lever t a n g and the throttle lever cam TRANSMISSION ASSEMBLY PROCEDURE
touches gauge tool. (1) Install rear servo piston, spring and spring re
T h e k i c k d o w n v a l v e s p r i n g m u s t b e fully com tainer. Compress rear servo spring and retainer with
p r e s s e d a n d t h e k i c k d o w n v a l v e c o m p l e t e l y bot Compressor Tool C-3422-A or a large C-clamp.
tomed to obtain correct adjustment. (2) Install front servo piston, spring and rod guide.
Compress front servo rod guide with Valve Spring
Compressor C-3422-B and install servo snap ring.
• TRANSMISSION OVERHAUL—32RH 21-185
(3) Examine bolt holes in overrunning clutch cam. bolts to 17 N»m (150 in. lbs.) torque.
Note t h a t one hole is n o t t h r e a d e d (Fig. 112 This (9) Lubricate overrunning clutch rollers with
hole must align with blank area in clutch cam bolt transmission fluid.
circle (Fig. 113). (10) Install rear band reaction pin (Fig. 105). Be
sure pin is fully seated in case.
Fig. 114 Overrunning Clutch And Rear Band Pin

Installation—32RH
(11) Install rear band in case (Fig. 115). Twin lugs
on band seat against reaction pin and single lug
faces band lever.
(12) Install low-reverse drum as follows (Fig. 115):
(a) Lubricate overrunning clutch race (on hub of
drum) with transmission fluid.
(b) Guide drum through rear band.
(c) Tilt drum slightly and start clutch race into
overrunning clutch rollers.
(d) Rotate drum in clockwise direction and push
drum inward until it seats in overrunning clutch.
Fig. 113 Location Of Blank Area in Clutch Cam Seat

(in Case)-32RH
(4) Mark location of non threaded hole in clutch
cam and blank area of case with paint stripe or
grease pencil (Fig. 114).
(5) Install overrunning clutch roller and spring as
sembly in clutch cam (Fig. 114).
(6) Align and install overrunning clutch in case
(Fig. 114). Be sure c a m is correctly installed. Bolt
holes in c a m are slightly countersunk on o n e
side. This side of c a m faces rearward (toward
rear support).
(7) Verify t h a t non threaded hole in clutch cam is
Fig. 115 Installing Rear Band And Low-Reverse
properly aligned (Fig. 114). Check alignment by
Drum—32RH
threading a clutch cam bolt into each hole. Adjust
cam position if necessary before proceeding. (13) Install rear band lever and pivot pin (Fig.
(8) Install clutch cam bolts. Note t h a t cam bolts 116). Be sure pin is fully seated in case.
are shorter t h a n rear support bolts. Tighten cam
Fig. 116 Installing Rear Band Lever And Pivot Fig. 118 Installing Output Shaft/Planetary
Pin-32RH Geartrain—32RH
(14) Hold low-reverse drum in position and install
rear support. Align support with punch marks made
during disassembly.
(15) Install and tighten rear support bolts to 17
N*m (150 in. lbs. or 13 ft. lbs.) torque.
(16) Install snap ring t h a t retains low-reverse
drum to hub of rear support (Fig. 117).
Fig. 119 Aligning/Seating Rear Planetary In Low-

Reverse Drum—32RH
(21) Install governor filter in park gear and install
governor body on gear (Fig. 120). Align governor
body on gear using marks made at disassembly.
(22) Install new seal rings on hub of park gear
(Fig. 120). Be sure ring (or rings) with hooked ends
Fig. 117 Installing Low-Reverse Drum Snap are properly connected.
Ring—32RH (23) Install governor weight assembly in governor
(17) Lubricate output shaft, rear support bore and body. Be sure governor weight snap rings are se
low-reverse drum hub with transmission fluid. curely seated.
(18) Install assembled output shaft and planetary (24) Align and install governor/park gear assembly
geartrain in case (Fig. 118). on output shaft. Note that output shaft in current
(19) Align drive lugs on rear planetary gear with transmission is spotfaced for governor valve e n d
slots in low-reverse drum (Fig. 119). Then seat plan clearance (Fig. 120). Shaft must be i n d e x e d so
etary assembly in drum. that small end of governor valve will seat in this
(20) Lubricate governor components and park gear spotface. Install governor b o d y and park a s fol
seal rings with transmission fluid. l o w s to ensure proper alignment and operation.
(a) Rotate output shaft until spotface (at gover in valve and in output shaft. If valve shaft binds,
nor valve shaft hole) is facing upward (Fig. 120). governor/park gear is misaligned.
(b) Position valve bore in governor body over
E-CLIP (2 REQ'D) GOVERNOR
spotface on output shaft (Fig. 120). Then align VALVE
valve shaft holes in governor body and output \- SHAFT
shaft.
(c) Align splines in output shaft and park gear
hub.
(d) Carefully push assembly into place in rear
support (Fig. 121).
(e) Verify that governor valve shaft holes in out
put shaft and governor body are still in alignment.
Reposition governor body and park gear if align
ment is not correct.
(f) Tighten bolts attaching governor body to park
gear to 11 N*m (95 in. lbs.) torque.
OUTPUT
SHAFT
GOVERNOR Fig. 122 Installing Governor Valve And Shaft—32RH
BODY
(26) Rotate output shaft until opposite end of gov
ernor valve shaft is facing upward. Then install re-
mainig E-clip on governor valve shaft (Fig. 123). Be
very sure both E-clips are firmly seated on shaft.
GOVERNOR
VALVE
BORE
J9221-52
Fig. 120 Governor Valve And Output Shaft Spotface

Alignment—32RH
GOVERNOR/PARK GEAR ASSEMBLY GOVERNOR
VALVE
SHAFT
BORE GOVERNOR
VALVE
SHAFT J9121-188
Fig. 123 Securing Governor Valve Shaft—32RH

(27) Install snap ring t h a t retains governor body
on output shaft (Fig. 124).
(28) Install output shaft thrust plate on shaft hub
(Fig. 125). Use petroleum jelly to hold thrust plate in
place.
(29) Check input shaft seal rings (Fig. 126). Verify
t h a t diagonal-cut ends of teflon seal ring are properly
joined and ends of metal ring are correctly hooked to
J9121-130
gether. Also be sure rings are installed sequence
Fig. 121 Installing Governor Body And Park shown.
Gear-32RH (30) Check rear clutch thrust washer. Use addi
tional petroleum jelly to hold washer in place if nec
(25) Install first E-clip on governor valve shaft.
essary.
Then install governor valve and shaft in governor
body (Fig. 122). Be sure valve shaft m o v e s freely
Fig. 124 Installing Governor Body Snap Ring—32RH Fig. 127 Assembling Front And Rear Clutch
Units-32RH
(32) Coat output shaft thrust washer with petro
leum jelly. Then install washer in rear clutch hub
(Fig. 128). Use enough petroleum jelly to hold
washer in place. Be sure grooved side of w a s h e r
faces rearward (toward output shaft) as s h o w n .
Also note that w a s h e r only fits one w a y in
clutch hub.
Fig. 125 Installing Output Shaft Thrust PIate-32RH
Fig. 128 Installing Output Shaft Thrust

Washer-32RH
(33) Align drive teeth on rear clutch discs with
small screwdriver (Fig. 129). This will make installa
tion on front planetary easier.
(34) Raise front end of transmission upward as far
as possible and support case with wood blocks. Front/
rear clutch and oil pump assemblies are easier to in
stall if transmission is as close to upright position as
Fig. 126 input Shaft Seal Ring Location-32RH possible.
(35) Install front and rear clutch units as assembly
(31) Align clutch discs in front clutch and install (Fig. 130). Align rear clutch with front annulus gear
front clutch on rear clutch (Fig. 127). Rotate front and install assembly in driving shell. Be sure out
clutch retainer back and forth until completely put shaft thrust w a s h e r and thrust plate are not
seated on rear clutch. displaced during installation.
Fig. 129 Aligning Rear Clutch Disc Lugs—32RH

Fig. 131 Installing Front Band And Reaction
(36) Carefully work assembled clutches back and Pin-32RH
forth to engage and seat rear clutch discs on front
BAND BAND
annulus gear. Verify t h a t front clutch drive lugs are
fully engaged in slots of driving shell after installa
tion.
Fig. 132 Front Band Linkage Installation—32RH

(41) Coat band lever pin access plug with sealer
and install plug in converter housing (Fig. 133).
J9121-124
Fig. 130 Installing Front/Rear Clutch

Assemblies—32RH
(37) Slide front band over front clutch retainer
(Fig. 131).
(38) Insert front band reaction pin part way into
case (Fig. 131). Fig. 133 Installing Front Band Reaction Pin Access
(39) Install front band lever, strut, lever pin and Plug-32RH
adjusting screw (Fig. 132). (42) Check reaction shaft support hub. Verify t h a t
(40) Tighten front band adjusting screw until band seal rings are hooked together and t h a t front clutch
just grips clutch retainer. Verify t h a t front/rear
clutches are still seated before continuing.
thrust washer is properly positioned (Fig. 134). Use
extra petroleum jelly to hold thrust washer in place
if necessary.
SEAL
RINGS J9121-194
Fig. 134 Reaction Shaft Support Seal Rings And Fig. 136 Installing Oil Pump And Reaction Shaft
Front Clutch Thrust Washer Position—32RH Support-32RH
(43) Thread two Pilot Stud Tools C-32S8-B into (48) Measure input shaft end play (Fig. 137). At
bolt holes in oil pump flange (Fig. 135). tach dial indicator to converter housing. Position in
(44) Align and install oil pump gasket (Fig. 135). dicator plunger against input shaft and zero
indicator. Move input shaft in and out and record
reading. End play should be 0.56 - 2.31 mm (0.022 -
0.091 in.). If end play is incorrect, change output
shaft thrust washer and/or thrust plate.
Fig. 135 Installing Pilot Studs And Oil Pump

Fig. 137 Checking Input Shaft End Play-32RH
Gasket-32RH
(49) Make sure neutral switch has n o t been in
(45) Lubricate oil pump seals with transmission
stalled in case. Remove switch if necessary as it will
fluid, petroleum jelly, or Ru-Glyde.
interfere with valve body installation.
(46) Install oil pump (Fig. 136). Align and position
(50) Install new seal rings on accumulator piston
pump on pilot studs. Slide pump down studs and
(Fig. 138). Lubricate accumulator piston, seals and
work it into front clutch hub and case by hand. Then
accumulator bore with transmission fluid.
install two or three pump bolts to hold pump in
(51) Install accumulator piston and spring (Fig.
place.
138) in case.
(47) Remove pilot stud tools and install remaining
(52) Place valve body manual lever in low to move
oil pump bolts. Tighten bolts alternately in diagonal
park lock rod rearward.
pattern to 20 N-m (15 ft-lbs).
• — TRANSMISSION OVERHAUL—32RH 21 - 1S1
(56) Install new filter on valve body. Tighten filter

screws to 4 N»m (35 in. lbs.).
(57) Position new extension housing gasket on
transmission case. Use petroleum jelly to hold gasket
in place.
(58) Install rear bearing and snap ring on output
shaft.
(59) Install extension housing on transmission
case. Tighten housing fasteners to 33 N»m (24 ft.
lbs.). Be sure park lock rod is properly engaged in
sprag before tightening fasteners.
(60) Adjust front/rear bands as follows:
Fig. 138 installing Accumulator Piston And (a) Loosen locknut on each band adjusting screw
Spring—32RH 4-5 turns.
(53) Position valve body on case. Work park rod (b) Tighten both adjusting screws to 8 N*m (72
past sprag and install valve body-to-case bolts finger in. lbs.).
tight. (c) Back off front band adjusting screw 2-1/2
(54) Install neutral switch in case. Tighten switch turns and rear band adjusting screw 4 turns.
(d) Hold each adjusting screw in position and
tighten locknuts to 34 N*m (25 ft. lbs.).
(55) Align valve body on case (Fig. 139). Tighten
(61) Install new pan gasket on transmission and
valve body-to-case bolts alternately and evenly to 12 install oil pan. Tighten pan bolts to 17 N«m (13 ft.
N»m (105 in. lbs.) torque. Start at center and work lbs.).
outward when tightening bolts. D o not overtighten (62) Turn transmission over.
valve b o d y bolts. This could result in distortion (63) Install new manual lever shaft seal in case.
and cross leakage after Installation.. Use 15/16 deep well socket to install seal.
(64) Install throttle valve and manual valve levers
VALVE
on shaft.
(65) Lubricate converter hub with transmission
fluid and carefully install converter. Turn converter
back and forth until seated. Be sure converter hub
slots are fully seated in oil pump gear lugs.
(66) Secure converter in oil pump before mounting
transmission on jack and before moving transmission
back under vehicle. Use metal strapping or small
C-clamp to hold converter in place. Attach strapping
or clamp to converter housing.
C A U T I O N : The transmission cooler a n d lines must

be reverse flushed if overhaul corrected a malfunc
tion that generated sludge, metal particles, or
clutch friction material. The torque converter s h o u l d
also be replaced if contaminated by the s a m e mal
function. Debris a n d residue not flushed from the
cooler a n d lines will flow back into the t r a n s m i s s i o n
and converter. The result could be a repeat failure
Fig. 139 Installing Valve Body—32RH and s h o p comeback.
21 - 192 TRANSMISSION OVERHAUL—38RH/37RH •
TRANSMISSION OVERHAUL—36RH/37RH
INDEX
page page
Extension Housing and Park Lock Components . 202 Rear Clutch Overhaul 212
Front Clutch Overhaul 210 Rear Servo and Band Overhaul 207
Front Servo and Band Overhaul 207 Rear Support and Low-Reverse Drum Service . . 204
Governor and Park Gear Overhaul . 202 Transmission Assembly and Adjustment . . . . . . 224
Oil Pump and Reaction Shaft Support Overhaul . 208 Transmission C a s e Cleaning and Inspection . . . 202
Overhaul Service Information . . 202 Transmission Disassembly . . . . . . . . . . . . . . . . . 192
Overrunning Clutch Overhaul 204
Planetary Gear Train and Output Shaft Overhaul . 214 Valve Body Service and Adjustment 217
solvent. Wear safety goggles while cleaning trans
mission.
(2) Mount transmission on Repair Stand C-3750-B
(Fig. 1).
Fig. 2 Extension Housing Removal—36RH/37RH
Fig. 1 Transmission Mounted On Repair Stand

C-3750-0
(3) Remove bolts attaching extension housing to
transmission case. Then remove rear bearing snap
ring access cover from housing (Fig. 2)
(4) Spread rear bearing locating ring with parallel
jaw snap ring pliers (Fig. 2). Then work extension
housing off bearing and output shaft. Remove hous
ing gasket after removing housing.
(5) Remove rear bearing and snap rings from out
put shaft (Fig. 3). Note t h a t two snap rings a r e used
to retain bearing on 36RH.
(6) Remove throttle and manual valve levers from
valve body manual shaft.
(7) Remove oil p a n bolts and remove p a n (Fig. 4)
and gasket (Fig. 5). Oil p a n magnet can be removed
Fig. 4 Removing/Installing Oil Pan-36RH/37RH
• TRANSMISSION OVERHAUL—36RH/37RH 21-193
or left in pan as needed (Fig. 6). Exercise care when (9) Remove three fluid filter attaching screws and
removing pan to avoid distorting or bending pan remove filter (Fig. 8).
flange.
Fig. 8 Fluid Filter Removal/installation—36RH/37RH

Fig. 5 Removing/installing Pan Gasket—36RH/37RH (10) Remove hex head valve body attaching bolts
(Fig. 9).
Fig. 6 OH Pan Magnet Location—36RH/37RH

(8) Remove neutral switch (Fig. 7). If switch gas
ket is in good condition, retain gasket and keep it Fig. 9 Valve Body Attaching Bolt Locations—36RH/
with switch. 37RH
(11) Lift valve body upward, guide park rod out of
case opening and remove valve body (Fig. 10).
Fig. 7 Neutral Switch Removal/Installation
Fig. 10 Valve Body Removal/Installation—36RH/

37RH
(12) Remove accumulator spring and piston (Fig.
11). Note position of piston and spring for assembly
reference. Remove and discard piston seals if worn or
cut.
Fig. 13 Tightening Front Band To Hold Front Clutch

In PIace-36RH/37RH
Fig. 11 Removing/Installing Accumulator Piston And

Spring-36RH/37RH
(13) Remove front band lever pin access plug (Fig.
12). Square end of 1/4 inch drive extension can be
used to remove plug as shown.
Fig. 14 Installing OH Pump Remover Tools—36RH/

37RH
(d) Remove oil pump and reaction shaft support
by bumping slide hammers outward alternately to
pull pump from case (Fig. 15).
Fig. 12 Removing/Installing Front Band Lever Pin

Access Plug-36RH/37RH
(14) Remove oil pump and reaction shaft support
assembly as follows:
(a) Tighten front band adjusting screw until
band is tight around front clutch retainer (Fig. 13).
This will prevent retainer from coming out with
pump and possibly damaging clutch or pump com
ponents.
(b) Remove oil pump bolts.
(c) Thread Slide H a m m e r Tools C-3752 into
threaded holes in flange of oil pump housing (Fig.
14).
Fig. 15 Removing Oil Pump-36RH/37RH
# , , TRANSMISSION OVERHAUL—38RH/37RH 21 - 115
(15) Remove oil pump gasket (Fig. 16). Note gas

ket position in case for assembly reference.
Fig. 18 Removing Front Band—36RH/37RH

(19) Remove front and rear clutch assemblies as a
Fig. 16 Removing Oil Pump Gasket—36RH/37RH unit (Fig. 19). Set assemblies aside for disassembly
(16) Loosen front band adjusting screw until band and inspection after removal.
is completely loose.
(17) Remove front band strut and anchor (Fig. 17).
(18) Squeeze front band together slightly and slide
band over front clutch retainer and out of case (Fig.
18).
LEVER STRUT
Fig. 19 Removing Front And Rear Clutch

Assemblies—36RH/37RH
J9121-18 (20) Remove front band reaction pin and lever.
Start pin through lever and out of case bore. Use
Fig. 17 Front Band Linkage-36RH/37RH pencil magnet to complete pin removal (Fig. 20).
(21) Remove triangular shaped thrust washer from
output shaft hub if washer remained on hub during
clutch removal (Fig. 21). Or remove washer from in
put shaft hub in rear clutch if washer remained in
hub during removal.
21-118 TRANSMISSION OVERHAUL—36RH/37RH •
(23) If the output shaft or planetary geartrain
components must be disassembled for service,
continue on to step (24). However, if the shaft
and geartrain c o m p o n e n t s do not n e e d servic
ing, the shaft and geartrain c a n be removed as a
unit (Fig. 23). In this case, simply remove the
governor valve shaft, governor a n d park gear
a n d remove the complete assembly.
Fig. 20 Removing Front Band Lever And Pin—36RH/

37RH
Fig. 23 Removing Output Shaft And Planetary

Geartrain-36RH/37RH
(24) Remove planetary gear retaining snap ring
from output shaft (Fig. 24). Retain snap ring if in
good condition (it is reusable).
Fig. 21 Removing Output Shaft Thrust Washer-36RH/37RH
(22) Remove thrust plate from output shaft hub
(Fig. 22).
Fig. 24 Removing Planetary Snap Ring—36RH/37RH

(25) Remove front planetary gear and front annu
lus gear from output shaft as assembly (Fig. 25).
(26) Remove front planetary gear and thrust
washer from front annulus gear (Fig. 26). Note
Fig. 22 Removing Output Shaft Thrust Plate-36RH/ thrust washer position for assembly reference.
37RH
• TRANSMISSION OVERHAUL-36RH/37RH 21 - 197
(27) Remove tabbed t h r u s t washer from driving

shell (Fig. 27). Note washer position for assembly ref
erence.
Fig. 27 Removing Driving Shell Thrust

Washer-36RH/37RH
(28) Remove sun gear and driving shell (Fig. 28).
Fig. 25 Removing Front Planetary And Annulus
Gears—36RH/37RH FRONT
FRONT
Fig. 28 Removing Sun Gear And Driving

Shell-36RH/37RH
Fig. 26 Disassembling Front Planetary And Annulus
Gears—36RH/37RH
21 - 118 TRANSMISSION OVERHIUL-36RH/37RH
(29) Remove tabbed thrust washer from rear plan- (31) Remove rear planetary thrust plate from rear
etary gear (Fig. 29). Note washer position on gear for annulus gear (Fig. 31).
assembly reference.
Fig. 29 Removing Rear Planetary Thrust

Washer-36RH/37RH
(30) Remove rear planetary gear from annulus J9121-31N
gear (Fig. 30).
Fig. 31 Removing Rear Planetary Thrust
Plate-36RH/37RH
(32) Remove rear annulus gear from output shaft
(Fig. 32).
J9121-30
Fig. 30 Removing Rear Planetary Gear—36RH/37RH
J9121-32
Fig. 32 Removing Rear Annulus Gear-36RH/37RH

• TRANSMISSION OVERHAUL-36RH/37RH 21 - 199
(33) Remove output shaft, park gear and governor (36) Slide low-reverse drum off rear support hub
assembly from rear of case (Fig. 33). and out of rear band (Fig. 1).
REAR
BAND
A N D LINK
LOCATING
SNAP RING J9221-7
Fig. 33 Removing Output Shaft, Park Gear And Fig. 35 Removing Low-Reverse Drum—36RH/37RH
Governor Assembly—36RH/37RH (37) Note t h a t overrunning clutch race will remain
(34) Loosen rear band adjusting screw. on splines of low-reverse drum after removal (Fig.
(35) Remove snap ring securing low-reverse drum 36). The race is a permanent press fit o n the h u b
to rear support (Fig. 34). splines. D o not attempt to remove the race.
OVERRUNNING LOW-REVERSE
REAR LOW-REVERSE CLUTCH DRUM
BAND DRUM RACE
REAR
SUPPORT
DRUM
RETAINING
SNAP
RING
J9121-34 J9221-8
Fig. 36 Overrunning Clutch Race Position—36RH/

Fig. 34 Removing Low-Reverse Drum Snap 37RH
Ring—36RH/37RH
, CLUTCH REAR
s\/CAM BAND ADJUSTING
LEVER
Fig. 37 Removing Overrunning Clutch—36RH/37RH

(38) Remove overrunning clutch assembly (Fig.
37). Assembly can be removed without displacing RtAR
rollers and springs if care is exercised. Note position BAND
REACTION
of rollers and springs for assembly reference. PIN
(39) Start rear band reaction pin out of case with
punch or drift (Fig. 38). Fig. 39 Removing Rear Band Levers And Reaction
(40) Remove band adjusting lever, reaction lever Pin-36RH/37RH
and reaction pin (Fig. 39).
(41) Remove strut from rear band. Keep strut with
levers and pin for cleaning, inspection and assembly
reference.
SELECT FRONT SUPPORT ANNULUS GEAR FRONT SUN SUN DRIVING SHELL FRONT DRIVING
FIT ANNULUS SNAP RING SUPPORT PLANETARY GEAR GEAR THRUST PLATE SHELL
PLANETARY SNAP THRUST SPACER
SNAP RING FRONT WASHERS
RING ANNULUS
GEAR
FRONT REAR
ANNULUS PLANETARY
THRUST GEAR
WASHER
DRIVING
SHELL
REAR
THRUST
PLATE SUN GEAR REAR PLANETARY
LOCK RING THRUST WASHERS
OUTPUT
SHAFT
THRUST OUTPUT J9221-17
PLATE SHAFT
Fig. 38 Starting Rear Band Reaction Pin Out Of Case—36RH/37RH

• TRANSMISSION OVERHAUL—38RH/37RH 21 - 201
(42) Remove rear band and link (Fig. 40). groove. Exercise caution w h e n removing snap
ring. Servo bore c a n b e scratched or nicked if
care is not exercised.
(48) Remove tools and remove rear servo retainer,
spring and piston assembly.
Fig. 40 Removing Rear Band And Link—36RH/37RH

(43) Compress front servo rod guide with C-clamp
and Tool C-4470, or Valve Spring Compressor
C-3422-B (Fig. 41). Compress guide only enough to
permit snap ring removal (about 3 mm or 1/8 in.). Fig. 42 Removing Rear Servo Retaining Snap
(44) Remove servo piston snap ring (Fig. 41). Un Ring—36RH/37RH
seat one end of ring. Then carefully work removal (49) Inspect rear support. If support has arrow and
tool around back of ring until free of ring groove. Ex word "pan" on it, note position for assembly refer
ercise caution w h e n removing snap ring. Servo ence. However, if support does not have arrow or
bore c a n be scratched or n i c k e d if care is not word, mark position of support with center punch
exercised. (Fig. 43).
(45) Remove tools and remove servo piston and (50) Remove rear support bolts and remove support
spring. from case (Fig. 44). Use a twisting motion to remove
support if necessary.
Fig. 41 Removing Front Servo Retaining Snap

Fig. 43 Marking Rear Support For Assembly
Ring—36RH/37RH
Reference-36RH/37RH
(46) Compress rear servo piston with C-clamp and
Tool C-4470, or Valve Spring Compressor C-3422-B
(Fig. 42). Compress servo spring retainer only
enough to permit snap ring removal.
(47) Remove servo piston snap ring (Fig. 42). Start
one end of ring out of bore. Then carefully work re
moval tool around back of snap ring until free of ring
TRANSMISSION CASE CLEAN1NI AND

INSPECTION
Clean the case in a solvent tank. Flush the case
bores and fluid passages thoroughly with solvent.
Dry the case and all fluid passages with compressed
air. Be sure all solvent is removed from the case and
t h a t all fluid passages are clear.
Do not u s e s h o p towels or rags to dry the e a s e
(or a n y other transmission component) unless
they are m a d e from lint-free materials. Lint will
readily adhere to case surfaces a n d transmission
components and will circulate throughout the
transmission after assembly. A sufficient quan
tity of lint c a n block fluid p a s s a g e s a n d interfere
with valve b o d y operation.
Inspect the case for cracks, porous spots, worn
Fig. 44 Removing Rear Support—36RH/37RH servo bores, or damaged threads. Damaged threads
OVERHAUL SERVICE INFORMATION can be repaired with Helicoil thread inserts. How
Inspect all the transmission bushings during over ever, the case will have to be replaced if it exhibits
haul. Bushing condition is important as worn, scored damage or wear.
bushings contribute to low pressures, clutch slip and Lubricate the front band adjusting screw with pe
accelerated wear of other components. Replace worn, troleum jelly and thread it part way into the case. Be
or scored bushings, or if doubt exists about bushing sure t h e screw turns freely and does not bind.
condition. Remount the transmission case in Repair Stand
Use recommended tools to replace bushings. The C-3750-B after cleaning and inspection.
tools are sized and designed to remove, install and
seat bushings correctly. The bushing replacement EXTENSION HOUSING AND PARK LOCK
tools are included in Bushing Tool Set C-3887-B. COMPONENTS
Pre-sized service bushings are available for re Clean the housing and park lock components in
placement purposes. Only t h e sun gear bushings are solvent and dry them with compressed air.
not serviced. Low cost of t h e sun gear assembly Examine the park lock components in the housing.
makes it easier to simply replace the gear and bush If replacement is necessary, remove the shaft with
ings as a n assembly. parallel jaw snap ring pliers (Fig. 45) and remove the
Heli-Coil inserts are recommended for repairing sprag and spring. Then remove the spring clip and
damaged, stripped or worn threads in aluminum reaction plug (Fig. 46). Compress the reaction
parts. These inserts are available from most automo plug spring clip only e n o u g h to remove a n d in
tive jobbers. Stainless steel inserts are preferred. stall it. D o not distort the clip during removal or
The use of crocus cloth is permissible where neces installation.
sary, providing it is used carefully. When used on Be sure a replacement sprag is installed so t h e
sprag locking lug will face the park gear (Fig. 47).
Also be sure the spring is correctly positioned as
shown (Fig. 47). The sprag may not retract if the
bore.
spring is improperly installed.
O-rings during overhaul. Replace these parts as a GOVERNOR AND PARK GEAR OVERHAUL
matter of course. Also do not reuse snap rings or
E-clips t h a t are bent or distorted. Replace these parts GOWERNOR/PARK GEAR DISASSEMBLY
as well. (1) Loosen bolts attaching governor to park gear.
Lubricate transmission parts with Mopar ATF (2) Remove governor snap ring from output shaft
Plus, Type 7176 transmission fluid during assembly. (Fig. 48).
This is t h e preferred fluid for use in 36RH/37RH (3) Remove E-clip securing governor valve shaft
transmissions. Use Mopar Dexron II only when ATF and remove shaft and valve from governor body.
Plus is not readily available. (4) Slide governor and park gear off output shaft.
Use Ru-Glyde, Door-Eze, or petroleum jelly to pre- (5) Remove governor retaining bolts and separate
lubricate seals, O-rings, and thrust washers. Petro governor from park gear.
leum jelly can also be used to hold parts in place (6) Remove governor filter from park gear. Keep
during reassembly. filter with governor body.
Fig. 45 Park Sprag, Shaft And Spring

Removal-36RH/37RH
Fig. 48 Governor Snap Rings—36RH/37RH

Examine the governor components carefully (Fig.
49). Discard any snap rings or E-clips if distorted, or
worn. Be sure the valve and weights operate freely
in the bores and do not bind. Also be sure the valve
Fig. 46 Park Sprag Reaction Plug And Spring slides freely on the shaft. Minor scratches or burrs
Location-36RH/37RH can be reduced with crocus cloth soaked in transmis
(7) Remove governor weight snap ring and remove sion fluid. However, do not attempt to salvage com
weight assembly from governor body. Remove inner ponents that are severely worn or scored.
snap ring and separate governor weights. There are three governor component c h a n g e s
o n current 36RH/37RH transmissions that affect
CLEANING AND INSPECTION service procedures. The first change involves
Clean the governor and park gear components in the governor valve w h i c h is n o w made of alumi
solvent and dry with compressed air. num. The s e c o n d c h a n g e c o n c e r n s the 37RH
governor weight assembly w h i c h is m a d e of al-
l o y e d b r a s s . The t h i r d c h a n g e i n v o l v e s t h e PARK REAR FRONT
36RH/37RH o u t p u t shaft w h i c h h a s b e e n spot- GEAR SEAL SEAL
RING RING
faced f o r g o v e r n o r v a l v e e n d c l e a r a n c e . T h e n e w
a l u m i n u m v a l v e m u s t o n l y b e u s e d w i t h a n out
p u t s h a f t t h a t h a s a s p o t f a c e . T h e a l l o y e d gover
n o r w e i g h t m u s t o n l y b e u s e d I n 37RH diesel
transmissions. I n addition, t h e governor body
a n d s p o t f a c e d side of t h e o u t p u t shaft m u s t b e
indexed during assembly.
Check condition of the park gear seal rings, ring
grooves and gear teeth (Fig. 50). Replace the gear as
an assembly if the teeth or ring grooves are worn, or
damaged.
Replace the park gear front and rear seal rings if
cracked, or worn. The production style front ring is a
plain type and the rear ring is a hook style. If re
placement rings are both hook-style, be sure the ring
ends are properly hooked together as shown (Fig. 50).
SPRJNG
OUTER WEIGHT
VALVE T SHAFT
SNAP*
RINGS VALVE
J9121-48
INNER WEIGHT
SNAP
RING
Fig. 50 Park Gear And Seal Rings—36RH/37RH
(4) Insert filter screen in park gear and install
FILTER S C R E E N
governor body on park gear.
(5) Install governor body-to-park gear bolts
finger tight only. Bolts are fully tightened only
after installation on output shaft. This is neces
sary to ensure proper alignment of park gear
a n d governor body.
GOVERNOR
VALVE REAR SUPPORT AND LOW-REVERSE DRUM
SERVICE
SPOTFACE J9221-51 Clean the drum and support in parts cleaning sol
vent and dry them with compressed air.
Fig. 49 Governor Components—36RH/37RH
Inspect the drum and support for evidence of wear,
ASSEMBLING GOVERNOR AND PARK GEAR scoring, or cracks. Assemble the support, drum and
The alloyed brass governor w e i g h t a s s e m b l y is overrunning clutch race and check fit of the compo
d e s i g n e d for exclusive use in 37RH diesel trans nents.
missions. D o not interchange this w e i g h t assem Examine the overrunning clutch race. The race is a
bly. permanent press fit on the hub splines of the low-re
(1) Coat governor body bores governor components verse drum. The drum and race are replaced as an
with transmission fluid. assembly if either part is worn or damaged. Also
(2) Assemble and install governor weights and check fit of the race on the drum. Replace the assem
spring in governor body but do not install shaft and bly if the race is loose on the hub splines.
valve at this time. These parts will not be installed
until after governor and park gear are installed on OVERRUNNING CLUTCH OVERHAUL
output shaft. Inspect condition of the overrunning clutch compo
(3) Install new seal rings on park gear if neces nents.
sary.
Replace the clutch cam if worn or damaged in any

way. Also check fit of t h e cam in the transmission
case. If the cam is loose, the case may worn, or
cracked.
The clutch race is a permanent press fit on the low-
reverse drum hub splines. The drum and race are to
be replaced as an assembly if either part is worn or
damaged. Replace the race and drum if the drum is
damaged or the race is spalled, scored, cracked, or
loose.
Examine the overrunning clutch rollers, springs
and retainer. Replace the assembly if the rollers are
worn, chipped, or cracked. Replace the assembly if
the springs are distorted, or damaged, or if the cage
type retainer is bent or broken.
If the clutch cam must be replaced, install the new
cam as follows: Fig. 52 Removing Overrunning Clutch Cam—36RH/
37RH
REPLACING OVERRUNNING CLUTCH CAM (7) Insert Adapter Tool SP-5124 into rear support
AND SPRING RETAINER (Fig. 53).
(1) Remove clutch cam setscrew (Fig. 51).
Fig. 53 Positioning Adapter Tool In Rear

Fig. 51 Removing/installing Clutch Cam Support-36RH/37RH
Setscrew-36RH/37RH
(8) Assemble Puller Bolt SP-3701 and Press Plate
(2) Tap old cam out of case with pin punch. Insert SP-3583-A (Fig. 54).
punch through bolt holes at rear of case (Fig. 52). Al (9) Install assembled puller plate and bolt (Fig.
ternate position of punch to avoid cocking cam dur 55). Insert bolt through cam, case and adapter tool.
ing removal. Be sure plate is seated squarely on cam.
(3) Clean clutch cam bore and case. Be sure to re (10) Hold puller plate and bolt in place and install
move all chips/shavings generated during cam re puller n u t on puller bolt (Fig. 56).
moval. (11) Tighten puller n u t to draw clutch cam into
(4) Install rear support in case. Align support with case (Fig. 56). Be s u r e c a m Is d r a w n I n t o c a s e
reference marks made at disassembly. evenly a n d d o e s n o t b e c o m e c o c k e d .
(5) Align and start new clutch cam in case. Be (12) Install clutch cam setscrew (Fig. 50).
sure serrations on cam and in case are aligned. Then (13) Remove clutch cam installer tools and rear
tap cam into case just enough to hold it in place. support.
(6) Verify that c a m is correctly positioned be (14) Stake case in 12 places around new clutch
fore proceeding a n y further. Narrow ends of cam to help secure cam in case. Use blunt punch or
c a m ramps should b e to left w h e n cam is v i e w e d chisel to stake case.
from front e n d of case.
PULLER ADAPTER TIGHTEN
BOLT PULLER
SP-3701 NUT TO
DRAW CAM
INTO CASE
J9121-58 J9121-60
Fig. 54 Assembling Clutch Cam Puller Bolt And Fig. 56 Installing Overrunning Clutch Cam—36RH/
Press Piate-36RH/37RH 37RH
BE SURE
PLATE IS
SEATED SQUARELY
O N CAM
J9121-59
Fig. 55 Positioning Puller Plate On Clutch

Cam-36RH/37RH
(15) Clean case and cam thoroughly. Be sure any
chips/shavings generated during cam installation are J922M0
removed from case.
Fig. 57 Overrunning Clutch Roller, Spring And
INSTALLING OVERRUNNING CLUTCH Retainer Assembly—36RH/37RH
(1) Lubricate rear support hub, clutch race, clutch
(3) Install and seat clutch assembly in cam (Fig.
cam, and overrunning clutch rollers with transmis
58). The retainer is a one-way fit in the cam. The
sion fluid or petroleum jelly.
flanged side of the retainer should be facing out
(2) If any overrunning clutch rollers and springs
ward. The retainer and rollers will slip easily
came out of retainer, reinstall them as follows: In
into the cam w h e n properly positioned.
stall and seat spring in retainer first. Then insert
(4) Align and install rear support. Tighten rear
roller between spring and retainer stop as shown #
support bolts to 11 N m (95 in. lbs.) torque.
(Fig. 57). Verify t h a t each roller and spring are fully
TRANSMISSION OVERHAUL—36RH/37RH 21 - 207
(3) Remove and discard servo component O-ring

and seal rings.
(4) Lubricate new O-ring and seal rings with pe
troleum jelly and install them on piston, guide and
rod.
(5) Install rod in piston. Install spring and washer
on rod. Compress spring and install snap ring.
(6) Set servo components aside for installation dur
ing transmission reassembly.
Fig. 58 Overrunning Clutch Seated in Cam—36RH/

37RH
Checking Clutch Operation
(1) Temporarily install low-reverse drum to check
overrunning clutch operation.
(2) Tilt drum slightly and carefully engage clutch RH307
race in clutch rollers.
(3) Raise drum to level position. Then rotate drum Fig. 59 Front Servo Components—36RH/37RH
in clockwise direction until fully seated. REAR SERVO AND BAND OVERHAUL
(4) Check clutch operation by turning low-reverse
drum back and forth. Drum should rotate freely in SERVO AND BAND INSPECTION
clockwise direction but lock in counterclockwise di Clean the servo components with solvent and dry
rection. them with compressed air.
(5) Remove low-reverse drum after checking clutch Inspect the servo components. Replace the spring if
operation. collapsed, distorted or broken. Replace the plug and
piston if cracked, bent, or worn. Discard the servo
FRONT SERVO AND BAND OVERHAUL snap ring if distorted or warped.
Check rear band condition. Replace the band if dis
SERVO AND BAND INSPECTION torted, the lining is burned or flaking off, or the lin
Clean the servo piston components with solvent ing is worn (grooves no longer visible at any point on
and dry them with compressed air. Wipe the band the lining material).
clean with lint free shop towels. If doubt exists about the condition of any servo
Replace the front band if distorted, lining is component, replace it. Do not reuse suspect parts.
burned, flaking off, or worn to the point where the
grooves in the lining material are no longer visible. REAR SERVO PISTON OVERHAUL (FIG. 60)
Inspect the servo components. Replace the springs (1) Remove small snap ring and remove plug and
if collapsed, distorted or broken. Replace the guide, spring from servo piston.
rod and piston if cracked, bent, or worn. Discard the (2) Remove and discard servo piston seal ring.
servo snap ring if distorted or warped. (3) Lubricate piston and guide seals with petro
Check the servo piston bore for wear. If the bore is leum jelly. Lubricate other servo parts with trans
severely scored, or damaged, it will be necessary to mission fluid.
replace the case. (4) Install new seal ring on servo piston.
Replace any servo component if doubt exists about (5) Assemble piston, plug, spring and snap ring.
its condition. Do not reuse suspect parts. (6) Lubricate piston seal lip with petroleum jelly.
(7) Set servo components aside for assembly instal
FRONT SERVO PISTON OVERHAUL (FIG. 59) lation.
(1) Remove seal ring from rod guide.
(2) Remove small snap ring from servo piston rod.
Then remove piston rod, spring and washer from pis
ton.
PISTON PISTON SPRING SNAP
(4) Remove seal rings and thrust washer from re
SNAP
RING SEAL PLUG RETAINER RING action shaft support.
(5) Clean pump and support components with sol
vent and dry them with compressed air.
INSPECTING PUMP AND SUPPORT

Inspect the pump and support components. Replace
the pump or support if the seal ring grooves or ma
CUSHION PISTON chined surfaces are worn, scored, pitted, or damaged.
SPRING J9121-64 Replace the pump gears if pitted, worn chipped, or
PISTON SPRING
damaged. Inspect the fiber thrust washer. Replace
Fig. 60 Rear Servo Components—36RH/37RH the washer if worn or damaged.
Inspect the pump and reaction shaft bushings. Re
OIL PUMP AND REACTION SHAFT SUPPORT place the bushings only if heavily worn, scored or
OVERHAUL damaged. It is not necessary to replace the bushings
DISASSEMBLING PUMP AND SUPPORT (FIG. unless they are actually damaged or worn.
61) Install the gears in the pump body and measure
(1) Mark position of support with scriber. end clearance with a feeler gauge and straightedge
(2) Remove support bolts and separate support and (Fig. 62). Clearance should be 0.025 to 0.064 mm
pump body (Fig. 61). (0.001 to 0.0025 in.).
(3) Remove O-ring seal from pump body.
Fig. 61 Oil Pump And Reaction Shaft Components—36RH/37RH

Measure side clearances with feeler gauge (Fig.

63). Clearance between gear teeth and between outer
gear and pump body should be 0.89 to 1.90 mm
(0.0035 to 0.0075 in.).
STRAIGHTEDGE PUMP
Fig. 62 Checking Pump Gear End Clearance

REPLACING OIL PUMP BUSHING
(1) Position pump housing on clean, smooth sur
face with gear cavity facing down.
(2) Remove bushing with Tool Handle C-4171 and
Bushing Remover SP-3550 (Fig. 64).
(3) Assemble Tool Handle C-4171 and Bushing In
staller SP-5118 (Fig. 64).
(4) Place bushing on installer tool and start bush
ing into shaft (Fig. 64).
(5) Tap bushing into place until Installer Tool SP-
3550 bottoms in pump cavity (Fig. 64). Keep tool and
bushing square with bore. Do not allow bushing to
become cocked during installation.
(6) Stake pump bushing in two places with blunt
punch. Remove burrs from stake points with knife
blade (Fig. 65). J8921-388
REPLACING REACTION SHAFT SUPPORT Fig. 63 Checking Pump Gear Side Clearances
BUSHING (7) Start bushing in shaft. Tap bushing into shaft
(1) Assemble Cup Tool SP-3633, Nut SP-1191 and until installer tool bottoms against support flange
Bushing Remover SP-5301 (Fig. 66). (Fig. 66).
(2) Hold cup tool firmly against reaction shaft. (8) Clean reaction shaft support thoroughly after
Thread remover tool into bushing as far as possible bushing replacement (to remove any chips).
by hand.
(3) Using wrench, thread remover tool an addi ASSEMBLING OIL PUMP AND REACTION
tional 3-4 turns into bushing to firmly engage tool. SHAFT SUPPORT
(4) Tighten tool hex nut against cup tool to pull (1) Lubricate pump gears with transmission fluid
bushing from shaft. Clean all chips from shaft and and install them in pump body.
support after bushing removal. (2) Install new thrust washer and seal rings on re
(5) Place reaction shaft support upright on a clean, action shaft support. Lubricate seal rings with trans
smooth surface. mission fluid or petroleum jelly.
(6) Assemble Bushing Installer Tools C-4171 and (3) Align and install reaction shaft support on
SP-5302 (Fig. 66). Then slide new bushing onto in pump body.
staller tool.
21 - 210 TRANSMISSION OVERHAUL-36RH/37RH •
SPECIAL BUSHING SPECIAL SPECIAL
TOOL m REMOVAL TOOL TOOL
C-4171 SP-119 C-4171
SPECIAL TOOL
SPECIAL
SP-3550 TOOL
PUMP HOUSING
SP-5302
BUSHING
SPECIAL SPECIAL BUSHING

TOOL TOOL BUSHING
C-4171 SP-5118
X REACTION
SHAFT
BUSHING
REMOVAL BUSHING
INSTALLATION
J9221-244 J9221-245
Fig. 64 Oil Pump Bushing Replacement—36RH/ Fig. 66 Reaction Shaft Bushing

37RH Replacement—36RH/37RH
(2) Compress clutch piston retainer and springs
with Compressor Tool C-3863-A (Fig. 68).
(3) Remove piston snap ring and spring retainer
(Fig. 67).
(4) Remove piston springs. Note number and po
sition of piston springs for assembly reference.
(5) Remove compressor tool and remove clutch pis
ton.
(6) Remove and discard clutch piston seals. Also
discard spring retainer snap ring.
FRONT CLUTCH CLEANING AND INSPECTION

Clean and inspect the front clutch components. Re
place the clutch discs if warped, worn, scored, burned
mm or charred, the lugs are damaged, or if the facing is
flaking off. Replace the steel plates if heavily scored,
Fig. 65 Staking And Deburring Oil Pump Bushing warped, or broken. Be sure the driving lugs on the
(4) Install bolts attaching reaction shaft support to discs and plate are also in good condition. The lugs
pump. Tighten bolts to 20 N«m (175 in. lbs.) torque. must not be bent, cracked or damaged in any way.
(5) Install new pump seal with Seal Installer Replace the piston springs and spring retainer if ei
C-3860-A and Tool Handle C-4171. ther are distorted, warped or broken.
(6) Install new O-ring on pump body. Lubricate oil Check the lug grooves in the clutch piston retainer.
seal and O-ring with transmission fluid or petroleum The steel plates should slide freely in the slots. Re
jelly. place the piston retainer if the grooves are worn or
(7) Set pump and support aside for assembly in damaged. Also check action of the check ball in the
stallation. piston retainer. The ball must move freely and not
stick.
FRONT CLUTCH OVERHAUL Replace the retainer bushing if worn, scored, or
there is any doubt about bushing condition.
FRONT CLUTCH DISASSEMBLY Inspect the piston and retainer seal surfaces for
(1) Remove waved snap ring and remove pressure nicks or scratches. Minor scratches can be removed
plate, clutch plates and driving discs (Fig. 67). with crocus cloth. However, replace the piston and/or
4 _ , TRANSMISSION OVERHAUL—3IRH/37RH 21 - 211
PISTON SEAL
REACTION PLATE J9121-65
Fig. 67 Front Clutch Components—36RH/37RH

SPECIAL (5) Install new bushing until installer head bot
TOOL toms against retainer (Fig. 69).
C-3863-A
(6) Remove installer tools and clean retainer thor
oughly.
SPECIAL SPECIAL
TOOL- TOOL
C-4171 SP-3629
FRONT CLUTCH
RETAINER
It REMOVAL
BUSHING
SPECIAL SPECIAL
TOOL TOOL
C-4171 SP-5511
RH290
Fig. 68 Removing Front Clutch Spring Retainer

Snap Ring-36RH/37RH
REPLACING FRONT CLUTCH RETAINER J9221-247
BUSHING
(1) Assemble Tool Handle C-4171 and Bushing Re Fig. 69 Front Clutch Retainer Bushing
mover SP-3629 (Fig. 69). Replacement—36RH/37RH
(2) Insert remover tool in bushing and drive bush ASSEMBLING FRONT CLUTCH
ing straight out of piston retainer. (1) Soak clutch discs in transmission fluid.
(3) Mount Bushing Installer SP-5511 on tool han (2) Lubricate new inner and outer piston seals
dle (Fig. 69). with Ru-Glyde, or Door Ease.
(4) Slide new bushing onto installer head and start (3) Install new seals on clutch piston. Be sure seal
bushing in retainer. lips face interior of retainer.
(4) Install clutch piston in retainer. Use twisting
motion to seat piston in retainer. D o n o t force pis
t o n s t r a i g h t in. T h i s c o u l d fold s e a l s o v e r c a u s
i n g l e a k a g e a n d c l u t c h slip.
(5) Install clutch piston springs. If clutch has nine
springs, position springs as shown (Fig. 70).
9 SPRING
CLUTCH
11 SPRING
CLUTCH
FEELER GAUGE RH288
13 SPRING Fig. 71 Measuring Front Clutch Pack Clearance

CLUTCH
(Typical)
(2) Remove outer pressure plate and steel plates
and discs.
(3) Remove inner pressure plate, wave spring,
spacer ring and piston spring.
(4) Remove clutch piston and piston retainer from
J9221-260 clutch retainer. Bump clutch retainer on a wood
block to dislodge piston and retainer.
Fig. 70 Front Clutch Spring Position—36RH/37RH (5) Remove input shaft thrust washer.
(6) Install retainer on piston springs. (6) Remove input shaft snap ring and press shaft
(7) Compress spring retainer and piston springs out of clutch retainer.
with Compressor Tool C-3863-A. (7) Remove and discard clutch piston seals.
(8) Install new spring retainer snap ring and re (8) Do not remove shaft seal rings unless they are
move compressor tool. obviously damaged (broken, cracked).
(9) Lubricate clutch plates and pressure plate with
transmission fluid. REAR CLUTCH CLEANING AND INSPECTION
(10) Install clutch plates and discs. Install steel Clean the clutch components with solvent and dry
plate followed by a disc until 4 plates and discs are them with compressed air.
installed. Replace the clutch discs if warped, worn, scored,
(11) Install pressure plate and waved snap ring. burned/charred, the lugs are damaged, or if the fac
(12) Check clutch pack clearance (Fig. 71). Clear ing is flaking off.
ance between waved spring and pressure plate Replace the steel plates and the pressure plate if
should be 2.08 to 3.83 m m (0.082 to 0.151 in.). If heavily scored, warped, or broken. Be sure the driv
clearance is incorrect, clutch plates, discs, snap ring ing lugs on the discs and plates are also in good con
dition. The lugs must not be bent, cracked or
and/or pressure plate will have to be changed.
damaged in any way.
REAR CLUTCH OVERHAUL
REAR CLUTCH DISASSEMBLY (FIG. 72) Check the lug grooves in the clutch retainer. The
(1) Remove clutch pack select fit snap ring. steel plates should slide freely in the slots. Replace
the retainer if the grooves are worn or damaged.
# — .—.—, , TRANSMISSION OVERHAUL-3IRH/37RH 21 - 213
Fig. 72 Rear Clutch C -36RH/37RH

Also check action of the retainer check ball. The ball
must move freely and not stick.
retainer if the seal surfaces are seriously damaged.
Check thrust washer condition. Washer thickness
should be 1.55 to 1.60 m m (0.061 to 0.063 in.). Re
place the washer if worn or damaged.
Check condition of the two seal rings on t h e input
shaft and the single seal ring on the piston retainer.
Replace t h e seal rings if worn or damaged.
Check the input shaft for wear, or damage. Replace
the shaft if worn, scored or damaged in any way.
ASSEMBLING REAR CLUTCH (FIG. 72)

(1) Soak clutch discs in transmission fluid. Fig. 73 Input Shaft And Retainer Seal Ring
(2) Install new seal rings on input shaft and piston Locations-36RH/37RH
retainer (Fig. 73). (8) Install piston spring, spacer ring and wave
(3) Press input shaft into retainer. Secure shaft spring in clutch retainer. Be sure wave spring is
with snap ring. Use new snap ring if old one is dis fully seated. Tap spring into place if necessary.
torted, or damaged. (9) Lubricate clutch plates with transmission fluid.
(4) Install new seals on clutch piston. Lubricate (10) Install inner pressure plate.
piston seals with Ru-Glyde, or Door Ease. Be sure (11) Install first clutch disc followed by a steel
seal lips face input shaft. plate until all discs and plates are installed.
(5) Install clutch piston in retainer. Use twisting (12) Install outer pressure plate and snap ring.
motion to seat piston in retainer. D o not p u s h pis (13) Check clutch pack clearance with feeler gauge
ton straight in. This could distort seals causing (Fig. 74). Clearance should be 0.63 to 1.14 m m (0.025
leakage a n d clutch slip. to 0.045 in.). A low limit clearance is preferred.
(6) Install thrust washer on retainer (Fig. 72). Use (14) If clutch pack clearance is incorrect, clutch
petroleum jelly to hold thrust washer in place. pack snap ring, pressure plate, steel plates and discs
(7) Install assembled piston retainer in clutch re will have to be replaced.
tainer (Fig. 72).
21 - 214 TRANSMISSION OVERHAUL—3SRH/37RH
SELECTIVE sembly if the bushings are scored or worn. The sun

SNAP RING gear bushings are not serviceable. Replace the thrust
plate if worn, or severely scored. Replace the driving
shell if distorted, cracked, or damaged in any way.
Inspect the planetary gear sets and annulus gears.
The pinion gears, pinion shafts, pinion washers and
shaft retaining pins are all serviceable and can be re
placed if worn or damaged. However, if a pinion car
rier is damaged, the entire planetary gear set must
be replaced as an assembly.
Replace the annulus gears if the teeth are chipped,
broken, or worn, or the gear is cracked. Replace the
planetary thrust plates and the tabbed thrust wash
ers if cracked, scored or worn.
Inspect the machined surfaces of the output shaft.
Be sure the oil passages are open and clear. Replace
the shaft if scored, pitted, or damaged.
FEELER
GAUGE PLANETARY GEARTRAIN ASSEMBLY AND
ADJUSTMENT
RH295
(1) Lubricate sun gear and planetary gears with
Fig. 74 Measuring Rear Clutch Pack Clearance transmission fluid during assembly. Use petroleum
(Typical) jelly to hold parts in place and to lubricate output
shaft bushing surfaces, thrust washers and thrust
PLANETARY GEAR TRAIN AND OUTPUT SHAFT plates.
OVERHAUL (2) Install front snap ring on sun gear and install
GEARTRAIN AND SHAFT INSPECTION gear in driving shell. Then install thrust plate over
Clean the output shaft and geartrain components sun gear and against rear side of driving shell. In
(Fig. 75). Use parts cleaning solvent and dry with stall rear snap ring to secure sun gear and thrust
compressed air. plate in driving shell.
Remove one of the snap rings that retain the sun (3) Install rear annulus gear on output shaft (Fig.
gear in the driving shell. Then remove the sun gear 76).
and thrust plate. (4) Install thrust plate in annulus gear (Fig. 77).
Check sun gear and driving shell condition. Re Be sure plate is seated on shaft splines and against
place the sun gear as an assembly if the gear teeth gear.
are chipped or worn. Also replace the gear as an as-
SNAP RING
(SELECTIVE) THRUST REAR REAR ANNULUS
FRONT THRUST
WASHER DRIVING SHELL PLANETARY GEAR
ANNULUS GEAR PLATE GEAR
ASSEMBLY
FRONT
PLANETARY GEAR
ASSEMBLY
THRUST
PLATE
LOW-REVERSE
OUTPUT SHAFT
DRUM
J9121-67
Fig. 75 Planetary Geartrain Components—36RH/37RH

(6) Install tabbed t h r u s t washer on front face of

rear planetary gear (Fig. 79). Seat washer tabs in
matching slots in face of gear carrier. Use extra pe
troleum jelly to hold washer in place if desired.
REAR
PLANETARY
GEAR
OUTPUT
J9121-68
SHAFT
Fig. 76 Installing Rear Annulus Gear On Output
Shaft-36RH/37RH
WASHER J9121-71
Fig. 79 Installing Rear Planetary Thrust

Washer-36RH/37RH
(7) Lubricate sun gear bushings with petroleum
jelly or transmission fluid.
(8) Install sun gear and driving shell on output
THRUST shaft (Fig. 80). Seat shell against rear planetary
PLATE gear. Verify t h a t thrust washer on planetary gear
was not displaced during installation.
OUTPUT DRIVING REAR
SHAFT SHELL PLANETARY
GEAR
J9121-69
Fig. 77 Installing Rear Annulus Thrust Plate—36RH/

37RH
(5) Install rear planetary gear in rear annulus
gear (Fig. 78). Be sure planetary carrier is seated
against annulus gear.
REAR
ANNULUS OUTPUT
GEAR SHAFT
SUN
GEAR J9121-72
Fig. 80 Installing Sun Gear And Driving

Shell-36RH/37RH
(9) Install tabbed thrust washer in driving shell
(Fig. 81). be sure washer tabs are seated in tab slots
of driving shell. Use extra petroleum jelly to hold
REAR washer in place if desired.
PLANETARY
GEAR (10) Install tabbed thrust washer on front plane
tary gear (Fig. 82). Seat washer tabs in matching
J9121-70 slots in face of gear carrier. Use extra petroleum jelly
to hold washer in place if desired.
Fig. 78 installing Rear Planetary Gear—36RH/37RH
21-216 TRANSMISSION OVERHAUL—36RH/37RH •
TAB DRIVING
Fig. 81 Installing Driving Shell Thrust Fig. 83 Assembling Front Planetary And Annulus
Washer-36RH/37RH Gears—36RH/37RH
Fig. 84 Installing Front Planetary And Annulus Gear

Fig. 82 Installing Thrust Washer On Front Planetary Assembly-36RH/37RH
Gear—36RH/37RH
(13) Place geartrain in upright position. Rotate
(11) Install front annulus gear over and onto front
gears to be sure all components are seated and prop
planetary gear (Fig. 83). Be sure gears are fully erly assembled. Snap ring groove at forward end of
meshed and seated. output shaft will be completely visible when compo
(12) Install front planetary and annulus gear as nents are correctly assembled.
sembly (Fig. 84). Hold gears together and slide t h e m (14) Install planetary snap ring in groove at end of
onto shaft. Be sure planetary pinions are seated on output shaft (Fig. 85).
sun gear and t h a t planetary carrier is seated on out (15) Turn planetary geartrain over. Position wood
put shaft. block under front end of output shaft and support
and transfer plate resulting in valve bind. Slide

valves and plugs out carefully. D o not u s e force at
any time. The valves and valve body will be dam
aged if force is used. A l s o tag or mark the valve
body springs for reference a s they are removed. D o
not allow them to become intermixed.
(1) Remove screws attaching adjusting screw

bracket to valve body and transfer plate. Hold
bracket firmly against spring force while removing
last screw.
(2) Remove adjusting screw bracket, line pressure
adjusting screw, pressure regulator spring and switch
valve spring (Fig. 87). D o not remove throttle
pressure adjusting screw from bracket and do
not disturb adjusting s c r e w settings during re
moval.
Fig. 85 Installing Planetary Snap Ring—36RH/37RH

geartrain on shaft. Be sure all geartrain parts have
moved forward against planetary snap ring. This is
important for accurate end play check.
feeler gauge (Fig. 86). Insert gauge between rear an
nulus gear and shoulder on output shaft as shown.
End play should be 0.15 to 1.22 mm (0.006 to 0.048
in.).
(17) If end play is incorrect, install thinner/thicker
planetary snap ring as needed.
Removal-36RH/37RH
(3) Secure detent ball and spring in housing with
Detent Retainer Tool 6583 (Fig. 88).
DETENT BALL AND SPRING HOUSING J932M21
Fig. 88 Securing Detent Ball And Spring

Fig. 86 Checking Planetary Geartrain End
(4) Remove manual shaft E-clip, washer and seal
Play-36RH/37RH (Fig. 89).
VALVE BODY SERVICE AND ADJUSTMENT (5) Pull manual shaft and park rod assembly up
ward out of valve body and off throttle lever.
VALWE BODY DISASSEMBLY (6) Remove retainer tool and retain detent ball and
spring (Fig. 89).
C A U T I O N : D o not clamp any part of the valve body (7) Remove throttle lever (Fig. 8 9 ) ,
in a vise. This practice will distort the valve body
THROTTLE PARK REGULATOR
LEVER ROD VALVE END
PLATE
STIFFENER
PLATE
LEVER WASHER
AND
E-CLIP
SHIFT
VALVE
END
PLATE
Q / <o> SHUTTLE
SHUTTLE = VALVE
J9121-80 VALVE SECONDARY DOWNSHIFT
HOUSING J9121-51
END PLATE SPRING
Fig. 89 Removing Manual And Throttle
Levers-36RH/37RH Fig. 91 Stiffener Plate And Shift Valve End
Piates-36RH/37RH
(8) Remove park rod E-clip and separate rod from
manual lever (Fig. 90). valve throttle plug (Fig. 92).
(15) Remove shift valve end plate and 3-2 down
MANUAL shift housing (Fig. 91). Keep housing screws with
LEVER
housing for installation reference.
(16) Remove throttle plug from downshift housing.
Then remove spring retainer and remove limit valve
and spring from downshift housing (Fig. 92).
(17) Remove 1-2 shift control valve and spring, 2-3
shift valve and spring and 1-2 shift valve and spring
(Fig. 92).
(18) Remove regulator valve end plate (Fig. 91).
(19) Remove regulator valve line pressure plug,
pressure plug sleeve, throttle pressure plug and
spring (Fig. 92).
(20) Turn valve body over so transfer plate is fac
PARK ing upward. With valve body in this position, valve
ROD J9121-81
body check balls will remain in place and not fall out
when transfer plate is removed.
Fig. 90 Park Rod Removal-36RH/37RH (21) Remove screws attaching transfer plate to
(9) Remove shuttle valve cover (Fig. 91). valve body and remove transfer plate from valve
(10) Remove governor valve end plate (Fig. 91). body. Note position of valve body check balls for as
(11) Remove stiffener plate (Fig. 91). sembly reference.
(12) Remove switch valve, pressure regulator (22) Position transfer plate on bench so separator
valve, throttle valve, throttle valve detent and man plate and filter are facing up. This will avoid having
ual valve (Fig. 92). rear clutch check ball fall out when plates are sepa
(13) Remove 1-2 and 2-3 valve governor plugs (Fig. rated.
92). (23) Remove screws attaching separator plate to
(14) Remove E-clip t h a t retains shuttle valve and transfer plate and remove separator plate and filter.
spring in valve body. Then remove secondary spring Note position of filter and rear clutch check ball for
and guides, shuttle valve, primary spring and shuttle assembly reference.
SHIFT VALVE THROTTLE SHUTTLE VALVE
E N D PLATE PLUG SECONDARY SPRING,
G U , D E S E C L , P
2-3 SHIFT - "
VALVE A N D
SPRING
1-2 SHIFT
CONTROL VALVE
A N D SPRING
SHUTTLE VALVE
COVER
REGULATOR
VALVE
E N D PLATE
REGULATOR
VALVE
PRESSURE
PLUG
2-3 SHIFT
REGULATOR VALVE G O V E R N O R
VALVE THROTTLE PLUG
PRESSURE
PLUG SHUTTLE VALVE
PLUG (ALUM.)
GOVERNOR
VALVE E N D
PLATE
M A N U A L LEVER
DETENT BALL
LINE A N D SPRING
PRESSURE ADJUSTING
ADJUSTING SCREW
SCREW BRACKET J9121-52
Fig. 92 Valve Body Components—36RH/37RH (ALUM, indicates aluminum part)

VALVE BODY CLEANING AND INSPECTION burrs or scratches on steel valves and plugs can be
The only serviceable valve body components are removed with crocus cloth but do not round off the
the: valve or plug edges. Squareness of these edges is vi
• park lock rod and E-clip tally important; they prevent foreign matter from
• switch valve and spring lodging between the valves and plugs and the bore.
• pressure adjusting screw bracket Inspect all the valve and plug bores in the valve
• throttle valve lever body. Use a penlight to view the bore interiors. Re
• manual shaft place the valve body if any bores are distorted or
• manual shaft seal/washer/E-clip/detent ball scored. Inspect all of the valve body springs. The
• fluid filter. springs must be free of distortion, warpage or broken
The remaining valve body components are serviced coils.
only as part of a complete valve body assembly (Fig. Trial fit each valve and plug in its bore to check
92). freedom of operation. When clean and dry, the valves
Clean the valve body components in a parts clean and plugs should drop freely into the bores.
ing solution only. Do not use gasoline, kerosene, or Valve body bores do not change dimensionally with
any type of caustic solution. use. If the valve body functioned correctly when new,
Dry the parts with compressed air. Make sure all
it will continue to operate properly after cleaning
passages are clean and free from obstructions.
and inspection. It should not be necessary to replace
Do not use rags or s h o p t o w e l s to dry or w i p e
a valve body assembly unless it is damaged in han
off valve b o d y c o m p o n e n t s unless they are m a d e
dling.
from lint free material. Lint will adhere to the
valve b o d y c o m p o n e n t s causing valve bind. Lint
VALVE BODY ASSEMBLY
can also clog filters a n d small fluid p a s s a g e s .
Inspect the throttle and manual valve levers and C A U T I O N : D o not force the valves or plugs into
shafts. D o not attempt to straighten a bent shaft place during reassembly. If the valve body bores
or correct a loose lever. Replace these compo and the valves and plugs are free of distortion or
nents if worn, b e n t , loose o r d a m a g e d in any
burrs, the valves and plugs should slide into place
way.
easily. In addition, d o not overtighten the transfer
Inspect all of the valve body mating surfaces for
plate and valve body screws during reassembly.
scratches, nicks, burrs, or distortion. Use a straight
Overtightening can distort the valve body resulting
edge to check surface flatness. Minor scratches may
be removed with crocus cloth using only very light in valve sticking, c r o s s leakage and unsatisfactory
pressure. operation. Tighten the screws alternately and
Minor distortion of a valve body mating surface evenly to 4 Nnn (35 in. lbs.) torque only.
may be corrected by smoothing the surface with cro
cus cloth. Position the crocus cloth sheet on a surface (1) Lubricate valve body bores, valves and plugs
plate, sheet of plate glass, or equally flat surface. If with ATF Plus, or Dexron II™ transmission fluid.
distortion is severe or any surfaces are heavily (2) Insert rear clutch check ball in transfer plate
scored, the valve body will have to be replaced. and install filter in separator plate (Fig. 93).
SEPARATOR TRANSFER
C A U T I O N : The throttle valve, shuttle valve plug, 1-2 PLATE PLATE
shift valve and 1-2 governor plug are made of
coated aluminum. Aluminum components can be
identified by the dark color of the special coating
applied to the surface (or by testing with a magnet).
D O N O T polish or sand aluminum valves or plugs
with any type of material, or under any circum
stances. This practice will remove the special coat
ing and cause the valves and plugs to stick and
bind.
Inspect the valves and plugs for scratches, burrs,

nicks, or scores. Also inspect the coating on the alu
minum valves and plugs. If the coating is damaged
or worn through, the valve (or valve body) should be FILTER BALL J9121-82
replaced.
Aluminum valves and plugs must not be sanded or Fig. 93 Installing Filter and Rear Clutch Check
polished under any circumstances. However, minor Bali—36RH/37RH
(3) Align and install separator plate on transfer 1/4" DIAMETER

plate (Fig. 94). CHECK BALLS
(4) Verify rear clutch check ball position before se
curing separator plate (Fig. 95). Ball should be visi
ble in fifth orifice at lower right side of separator
plate as shown.
(5) Install stiffener plate on separator plate. Then
secure separator and stiffener plates to transfer plate
with short attaching screws. Tighten screws to 4 Nnn
11/32" DIAMETER
J9121-84
CHECK BALL
Fig. 96 Correct Position Of Valve Body Check

Balis-36RH/37RH
TRANSFER PLATE/
SEPARATOR PLATE ASSEMBLY
TRANSFER SEPARATOR
PLATE PLATE J9121-83
Fig. 94 Installing Separator Plate—36RH/37RH

f^-^. ) REAR CLUTCH-
VALVE
BODY J9121-85
Fig. 97 Installing Transfer Plate On Valve

Body-36RH/37RH
(10) Install 1-2 shift control valve and spring (Fig.
98)
(11) Assemble 3-2 downshift housing (Fig. 92). In
stall throttle plug, limit valve and spring and secure
J9121-53- in housing with retainer.
(12) Position shift valve end plate on 3-2 downshift
Fig. 95 Verifying Rear Clutch Check Ball housing. Then align housing and end plate on valve
Position-36RH/37RH body. Carefully compress shift valve springs and in
(6) Position valve body so internal passages and stall screws t h a t secure housing and end plate to
check ball seats are facing upward. Then install valve body (Fig. 91). Tighten screws to 4 Nnn (35 in.
check balls in valve body (Fig. 96). There are a total lbs.) torque.
of 7 check balls. Single large check ball has a diam (13) Install shuttle valve as follows.
eter of approximately 11/32 inch. Remaining 6 check (a) Insert shuttle valve in bore.
balls have a diameter of approximately 1/4 inch. (b) Insert plastic guides in shuttle valve second
(7) Align and install transfer/separator plate as ary spring.
sembly on valve body (Fig. 97). Install screws attach (c) Install secondary spring on end of valve.
ing transfer plate to valve body. Tighten screws (d) Hold shuttle valve in place.
alternately and in a diagonal pattern to 4 Nnn (35 (e) Compress secondary spring and install E-clip
in. lbs.) torque. in groove at end of shuttle valve. Verify t h a t
(8) Assemble regulator valve line pressure plug, spring and E-clip are properly seated before pro
sleeve, throttle plug and spring (Fig. 98). Insert as ceeding.
sembly in valve body and install end plate. Tighten (14) Install shuttle valve cover (Fig. 99) and cover
screws to 4 Nnn (35 in. lbs.) torque.
end plate screws to 4 Nnn (35 in. lbs.) torque.
(15) Install 1-2 and 2-3 valve governor plugs. Then
(9) Install 1-2 and 2-3 shift valves and springs
install shuttle valve primary spring and throttle plug
(Fig. 98).
(Fig. 99).
21 - 222 TRANSMISSION OVERHAUL-86RH/37RH
REGULATOR
VALVE
SPRING
THROTTLE
PRESSURE
PLUG
SLEEVE
2-3
SHIFT
VALVE
AND LINE
SPRING PRESSURE
PLUG
1-2
1-2 SHIFT
SHIFT CONTROL
VALVE VALVE
AND AND J9121-86
SPRING SPRING
Fig. 98 Shift Valve And Spring installation-36RH/37RH

SHUTTLE
VALVE
END PLATE
SECONDARY
SPRING & GUIDES
SHUTTLE
VALVE
PRIMARY
SWITCH SPRING
VALVE
SHUTTLE
VALVE
LINE THROTTLE
PRESSURE PLUG
REGULATOR
VALVE
GOVERNOR
PLUG-
END PLATE J9121-50
Fig. 99 Control Valve Locations—36RH/37RH

(16) Align and install governor plug end plate

(Fig. 99) on valve body and install end plate screws.
Tighten screws to 4 N»m (35 in. lbs.) torque.
(17) Install manual valve (Fig. 99).
(18) Install throttle valve and spring. Then install
kickdown valve and detent (Fig. 99).
(19) Install pressure regulator valve and switch
valve (Fig. 99).
(20) Install manual lever detent spring in housing.
Place detent ball on end of spring and push ball and
spring into housing. Secure ball and spring with Re
tainer Tool 6583 (Fig. 88).
(21) Insert line pressure adjusting screw in adjust
ing screw bracket (Fig. 92).
(22) Place valve spring on end of line pressure reg
ulator valve.
(23) Install switch valve spring on t a n g at end of Fig. 100 Manual And Throttle Lever
Alignment-36RH/37RH
adjusting screw bracket (Fig. 87).
(24) Install adjusting screw bracket on valve body. suit, both adjustments must be performed properly
Align springs, press bracket toward valve body and and in the correct sequence. Adjust line pressure first
install long bottom bracket attaching screw first. Do and throttle pressure last.
not tighten screw fully at this time.
(25) Carefully align bracket on valve body and Line Pressure Adjustment
transfer plate and install remaining (two) bracket Measure distance from the valve body to the inner
screws. Verify that valve springs and bracket are edge of the adjusting screw with an accurate steel
properly aligned. Then tighten all three bracket scale (Fig. 101).
screws to 4 N*m (35 in. lbs.) torque. Distance should be 33.4 mm (1-5/16 in.).
(26) Install throttle lever in valve body. Then in If adjustment is required, t u r n the adjusting screw
stall manual lever over throttle lever and start man in, or out, to obtain required distance setting.
ual lever into valve body. The 33.4 m m (1-5/16 in.) setting is an approxi
(27) Align manual lever detent with detent ball mate setting. Manufacturing tolerances m a y
and align lever arm with manual valve. Hold throt make it n e c e s s a r y to vary from this dimension to
tle lever upward. Then press down on manual lever obtain desired pressure.
until lever is fully seated. One complete t u r n of the adjusting screw changes
(28) Install manual lever seal, washer and retain line pressure approximately 1-2/3 psi (9 kPa). Turn
ing E-clip. ing the adjusting screw counterclockwise increases
(29) Lubricate shaft of manual lever with light pressure while turning the screw clockwise decreases
coat of petroleum jelly. This will help protect seal lip pressure.
when manual shaft seal is installed.
(30) Verify t h a t throttle lever is aligned with end
of kickdown valve stem and t h a t manual lever a r m
(31) If line pressure and/or throttle pressure ad
justment screw settings were not disturbed, continue
with overhaul or reassembly. However, if adjustment
screw settings w e r e moved or changed, readjust as
described in Valve Body Control Pressure Adjust
ment procedure.
VALVE BODY CONTROL PRESSURE

ADJUSTMENTS
There are two control pressure adjustments on the
valve body which are, line pressure and throttle pres
sure.
Line and throttle pressures are interdependent be Fig. 101 Line Pressure Adjustment—36RH/37RH
cause each affects shift quality and timing. As a re-
Throttle Pressure Adjustment thrust washers, thrust plates and seal rings are cor
Insert Gauge Tool C-3763 between the throttle le rectly positioned. These parts will prevent proper as
ver cam and the kickdown valve stem (Fig. 102). sembly is mispositioned (or "left out" by accident.
Push the gauge tool inward to compress the kick- The planetary geartrain, front/rear clutch assem
down valve against the spring and bottom the throt blies and oil pump are all much easier to install
tle valve. when the transmission case is upright or as close to
Maintain pressure against kickdown valve spring. this position as possible. Either tilt the case upward
Turn throttle lever stop screw until the screw head with wood blocks, or cut a hole in the bench large
touches throttle lever tang and the throttle lever cam enough for the output shaft and rear support. Then
touches gauge tool. lower the shaft and support into the hole and support
T h e k i c k d o w n v a l v e s p r i n g m u s t b e fully com the rear of the case directly on the bench.
p r e s s e d a n d t h e k i c k d o w n v a l v e c o m p l e t e l y bot
tomed to obtain correct adjustment. Assembly Procedure
(1) Lubricate rear servo piston seal with petroleum
HEX jelly, Ru-Glyde, or Door Eze. Lubricate servo bore in
WRENCH
case with transmission fluid.
(2) Install rear servo piston in case. Position piston
at slight angle to bore and insert piston with twist
ing motion (Fig. 103).
REAR
SERVO
PISTON
THROTTLE
LEVER
SPECIAL
TOOL
C-3763
J9121-542
Fig. 102 Throttle Pressure Adjustment—36RH/37RH

TRANSMISSION ASSEMBLY AND ADJUSTMENT
ASSEMBLY TIPS
Do not allow dirt, grease, or foreign material to en J9121-87>
ter the case or transmission components during as
sembly. Fig. 103 Installing Rear Servo Piston—36RH/37RH
Keep the transmission case and components clean.
(3) Install rear servo spring and retainer in case
Also make sure the tools and workbench area used
bore (Fig. 104). Be sure spring is seated on piston.
for reassembly operations are equally clean.
Shop towels used for wiping off tools and your
hands must be made from lint free materials. Lint
will adhere to transmission parts and could interfere
with valve operation or even restrict fluid passages.
Lubricate transmission clutch and gear components
with Mopar ATF Plus, type 7176 transmission fluid
during reassembly. This is the preferred fluid for use
in 36RH/37RH transmissions. Use Mopar Dexron II
only when ATF Plus is not readily available.
Use Ru-Glyde, or Door-Eze, or petroleum jelly on
seals and O-rings to ease installation. Petroleum
jelly can also be used to hold thrust washers and
plates in position during assembly operations. How SPRING
RETAINER
ever, d o n o t use chassis grease, bearing grease,
white grease, or similar lubricants on any part.
These types of lubricants can eventually block or re v-' J9121-88
strict fluid passages and valve operation.
Do not force parts into place. Most of the transmis Fig. 104 Installing Rear Servo Piston Spring And
sion components/sub-assemblies are easily installed
Retainer-36RH/37RH
by hand. If a part seems difficult to install, it is ei
ther misaligned or incorrectly assembled. Verify t h a t
(4) Compress rear servo piston with C-clamp or

Valve Spring Compressor C-3422-B and install servo
piston snap ring (Fig. 105).
Fig. 105 Installing Rear Servo Snap Ring—36RH/

37RH
Fig. 107 Installing Low-Reverse Drum—36RH/37RH
(5) Install overrunning clutch cam, springs, rollers,
race and rear support if not yet installed. Refer to in (8) Install snap ring t h a t secures low-reverse drum
stallation procedure in Subassembly Overhaul sec to rear support hub (Fig. 108).
tion.
(6) Position rear band and link in case (Fig. 106).
Be s u r e n o t c h e d side of l i n k f a c e s a w a y from
band.
Fig. 108 Installing Low-Reverse Drum Snap

Ring—36RH/37RH
(9) Install new O-rings on band reaction pin. Lu
bricate pin and O-rings. Then insert pin into case
Fig. 106 Installing Rear Band And Link—36RH/37RH and part way into band link (Fig. 109).
(7) Install low-reverse drum (Fig. 107). Slide drum (10) Install rear band adjusting lever, strut and re
through rear band, onto rear support hub and into action lever (Fig. 110). Be sure levers and strut are
engagement with overrunning clutch race. aligned and engaged before seating band reaction pin
in case.
REACTION USE SUITABLE TOOL
PIN TO HELP SEAT
PISTON RING
O-RINGS
J9121-91
Fig. 109 Installing Rear Band Reaction Pin—36RH/

37RH
FRONT
ADJUSTING ADJUSTING SERVO
SCREW LEVER PISTON -J9121-98
Fig. 111 Installing Front Servo Piston—36RH/37RH

REACTION
LEVER (c) Slowly compress rod guide while simulta
neously easing seal ring into bore with suitable
tool (tighten clamp screw with one hand and "run"
tool around guide ring with other hand).
(15) Install rod guide snap ring (Fig. 112).
C-CLAMP ROD SMALL
GUIDE SCREWDRIVER
•STRUT
ROD
GUIDE
J9121-92 SNAP
RING
Fig. 110 Rear Band Levers And Strut—36RH/37RH
(11) Lubricate front servo piston components and
servo bore in case with transmission fluid. J9121-99"
(12) Install front servo piston in bore. Carefully
"run" small, suitable tool around piston ring to press Fig. 112 Installing Front Servo Rod Guide And Snap
it back into groove and ease installation (Fig. 111). Ring—36RH/37RH
Rotate piston into bore at same time. Rock piston (16) Position front band lever in case and over
slightly to ease piston ring past snap ring groove and servo rod guide. Then install front band reaction pin
into bore. in case and slide it through lever.
(13) Bottom front servo piston in bore and install (17) Coat threads of front band reaction pin access
servo spring. plug with sealer and install it in case. Tighten plug
(14) Install front servo piston rod guide as follows: to 17 Nnn (13 ft. lbs.) torque.
(a) Place Tool SP-5560 (or similar size tool) on (18) Install assembled output shaft and planetary
guide to serve as press tool for C-clamp. gear components (Fig. 113). S u p p o r t shaft c a r e -
(b) Position C-clamp on press tool and case (Fig.
112).
fully d u r i n g Installation. D o n o t allow shaft

bearing/bushing surfaces to become nicked or
scratched.
ASSEMBLY J Y , i M
^ Fig. 115 Installing Governor And Park Gear
Assembly-36RH/37RH
Fig. 113 installing Output Shaft And Planetary
Geartrain-36RH/37RH (d) Carefully push assembly into place in rear
support (Fig. 115).
(19) Align and install governor/park gear assembly (e) Verify t h a t governor valve shaft holes in out
on output shaft. N o t e t h a t o u t p u t shaft In c u r r e n t put shaft and governor body are still in alignment.
t r a n s m i s s i o n is s p o t f a c e d for g o v e r n o r v a l v e e n d Reposition governor body and park gear if align
c l e a r a n c e (Fig. 114). Shaft m u s t b e i n d e x e d so ment is not correct.
t h a t small e n d of g o v e r n o r v a l v e will s e a t in t h i s (f) Tighten bolts attaching governor body to park
spotface. I n s t a l l g o v e r n o r b o d y a n d p a r k a s fol gear to 11 N-m (95 in. lbs.) torque.
lows to ensure p r o p e r alignment a n d operation. (20) Assemble and install governor valve and shaft
(a) Rotate output shaft until spotface (at gover (Fig. 116). B e s u r e v a l v e shaft o p e r a t e s freely b e
nor valve shaft hole) is facing upward (Fig. 114). fore p r o c e e d i n g .
(b) Position valve bore in governor body over
spotface on output shaft. Then align valve shaft
holes in governor body and output shaft.
(c) Align splines in output shaft and park gear
hub.
J9221-52
Fig. 114 Governor Valve And Output Shaft Spotface Fig. 116 Installing Governor Valve And
Alignment-36RH/37RH Shaft-36RH/37RH
(21) Install E-clips t h a t retain governor valve shaft
(Fig. 117). One clip is required at each end of shaft.
Fig. 119 Input Shaft Seal Ring And Thrust Washer

instaliation-36RH/37RH
Fig. 117 Installing Governor Valve Shaft on rear clutch. Turn front clutch retainer back and
E-CIips-36RH/37RH forth until front clutch discs are fully seated on rear
(22) Lubricate output shaft thrust plate with petro clutch splined hub.
leum jelly and install plate on output shaft hub (Fig.
118).
Fig. 118 Installing Output Shaft Thrust Plate-36RH/

37RH
(23) Check input shaft front seal rings, fiber thrust
washer and rear seal ring (Fig. 119). Be ends of rear Fig. 120 Assembling Front And Rear
seal ring are hooked together and diagonal cut ends Clutches~36RH/37RH
of front seal rings are firmly seated against each
(25) Measure thickness of output shaft thrust
other as shown. Lubricate seal rings with petroleum
washer with micrometer. Record thickness for refer
jelly after checking them.
ence when checking input shaft end play.
(24) Assemble front and rear clutches (Fig. 120). (26) Install output shaft thrust washer in hub rear
Align lugs on front clutch discs. Mount front clutch clutch retainer (Fig. 121). Use petroleum jelly to hold
washer in place. P o s i t i o n w a s h e r so g r o o v e s a r e
facing o u t w a r d . Also n o t e t h a t w a s h e r o n l y fits
o n e w a y in c l u t c h r e t a i n e r h u b .
Fig. 121 Installing Output Shaft Thrust

Washer-36RH/37RH
(27) Slide front band onto driving shell but do not
install band strut or anchor at this time.
(28) Place transmission case in upright position, or
place blocks under front end of transmission repair
stand to tilt case rearward. This makes it easier to
install front/rear clutch assembly.
(29) Align discs in rear clutch. Then install and
engage assembly in front planetary and driving shell
(Fig. 122). Turn clutch retainers back and forth until
both clutches are seated.
(30) Slide front band over front clutch retainer and
install front band strut and anchor (Fig. 123).
(31) Tighten front band adjusting screw until band
is tight on clutch retainer. Verify that front/rear
clutch assembly is still properly seated before tight
ening band.
(32) Install oil pump Pilot Studs C-3288-B in case J9121-18
(Fig. 124).
(33) Install new oil pump gasket on pilot studs and Fig. 123 Front Band Linkage Installation—36RH/
seat it in case. Be sure gasket is properly aligned 37RH
with fluid passages in case (Fig. 124).
21 - 230 TRANSMISSION OWERHAUL-3IRH/37RH •
SEAT
OIL PUMP IN
CASE
BY H A N D
J9121-103
Fig. 124 Installing Oil Pump Gasket And Pilot

Studs-36RH/37RH
REMOVE
(34) Check seal rings on reaction shaft support. Be
PILOT STUDS
sure rings are hooked together correctly. Also be sure W H E N PUMP
J9121-105
fiber thrust washer is in position (Fig. 125). Use pe IS SEATED
troleum jelly to hold washer in place if necessary.
Fig. 126 Oil Pump Installation-36RH/37RH
(38) Verify correct assembly. Rotate input and out
put shafts and check for bind. If bind exists, compo
nents are either misassembled, or not seated.
Disassemble and correct as necessary before proceed
ing.
(39) Check input shaft end play as follows:
(a) Attach dial indicator to converter housing
(Fig. 127). Position indicator plunger against input
shaft and zero indicator.
(b) Move input shaft in and out and record read
ing.
(c) End play should be 0.86 - 2.13 mm (0.034 -
0.084 in.).
(d) If end play is incorrect, change output shaft
t h r u s t washer, thrust plate, or front clutch thrust
J9121-104
Fig. 125 Reaction Shaft Seal Ring And Thrust

Washer Installation-36RH/37RH
(35) Lubricate oil pump seals with petroleum jelly
or transmission fluid.
(36) Mount oil pump on pilot studs and slide pump
into case opening (Fig. 126). Work p u m p into c a s e
b y h a n d . D o not u s e a mallet or similar tools to
seat p u m p .
(37) Remove pilot studs and install oil pump bolts. f
RH278
Tighten pump bolts alternately and evenly to fully
seat pump in case. Then final-tighten pump bolts to Fig. 127 Measuring Input Shaft End Play—36RH/
20 Nnn (15 ft. lbs.) torque. 37RH
# s ; _ TRANSMISSION OWERHAUL—38RH/37RH 21 - 231
washer as needed. Thrust washer is select and (46) Install new filter on valve body (Fig. 130).
comes in three thicknesses. Tighten filter screws to 4 Nnn (35 in. lbs.).
(40) Install accumulator piston and spring (Fig.
128).
Fig. 130 Installing Valve Body Filter-36RH/37RH

(47) Install seal on park/neutral position switch
Fig. 128 Installing Accumulator Piston And (Fig. 131). Then install and tighten switch to 34 Nnn
Spring-36RH/37RH (25 ft. lbs.).
(41) Verify t h a t park/neutral position switch has
not been installed in case. Valve body cannot be in
stalled if switch is in position.
(42) Place valve body manual lever in low to move
park lock rod rearward.
(43) Position valve body on case and install valve
body bolts finger tight.
(44) Install park/neutral position switch in case.
Tighten switch to 34 Nnn (25 ft. lbs.) torque.
(45) Align valve body on case (Fig. 129). Tighten
valve body bolts alternately and evenly to 12 Nnn Fig. 131 Park/Neutral Position Switch Seal
(105 in. lbs.) torque. Start at center and work out Position-36RH/37RH
ward when tightening bolts. Do n o t overtighten (48) Adjust front and rear band as follows:
valve b o d y bolts. This could result in distortion (a) Loosen locknut on each band adjusting screw
and cross leakage after installation.. 4-5 turns.
(b) Tighten both band adjusting screws to 8 Nnn
(72 in. lbs.).
(c) Back off front band adjusting screw 2-1/2
turns.
(d) Back off rear band adjusting screw 2 turns.
(e) Hold each adjusting screw in position and
tighten locknuts to 34 Nnn (25 ft. lbs.). Do not al
low adjusting screws to t u r n when tightening lock-
nuts.
(49) Install magnet in oil pan. Magnet fits over
small protrusion at corner of pan.
(50) Position new oil pan gasket on case and in
stall oil pan. Tighten pan bolts to 17 Nnn (13 ft. lbs.).
(51) Install rear bearing and bearing snap rings on
output shaft. Be sure ring groove in bearing outer
surface is toward front of transmission.
(52) Position new extension housing gasket on rear
Fig. 129 Installing Valve Body-36RH/37RH of transmission case. Use petroleum jelly to hold gas
ket in place if necessary.
(53) Spread rear bearing locating ring and start
extension housing on output shaft and rear bearing.
(54) Align park rod in sprag and work housing
into place. Install and tighten housing bolts to 43
N i n (32 ft. lbs,).
(55) Install rear bearing locating ring access cover
and gasket.
(56) Remove repair stand and t u r n transmission
over.
(57) Install new valve body manual shaft seal in
case (Fig. 132). Lubricate seal lip and manual shaft
with petroleum jelly. Start seal over shaft and into
case. Seat seal with 15/16 inch, deep well socket.
(58) Install throttle and shift levers on manual and
throttle levers. Fig. 132 Installing Manual Lever Shaft Seal
(59) Cap or cover transmission openings (cooler be reverse flushed if overhaul corrected a malfunc
line fittings, filler tube bore, etc.) to prevent dirt en
try.
clutch friction material. The torque converter should
(60) Install torque converter. Use C-clamp or metal
also be replaced if contaminated by the s a m e mal
strap to hold converter in place for installation.
(61) Mount transmission on jack preparatory to in function. Debris and residue not flushed from the
stallation in vehicle. cooler and lines will flow back into the transmission
C A U T I O N ; The transmission cooler and lines must and s h o p comeback.
• TRANSMISSION OVERHAUL-42RH 21 - 233
TRANSMISSION 0¥ERHAUL—42RH
INDEX
page page
Front Clutch Overhaul 245 Rear Clutch Overhaul . . . . . . . . . . . . . . . . . . . . 247
Front Servo and Band Overhaul 254 Rear Servo and Band Overhaul 255
Oil Pump and Reaction Shaft Support Overhaul . 241 Transmission Assembly and Adjustment . 269
Overhaul Service Information 239 Transmission C a s e Cleaning and Inspection . . . 240
Overrunning Clutch—Low-Reverse Drum—Overdrive Transmission Disassembly . 233
Piston Retainer Inspection and Overhaul . . . . 240 Valve Body Cleaning and Inspection 262
Planetary Gear Train and Intermediate Shaft Valve Body Service and Adjustment 256
Overhaul 250
(1) Remove torque converter if not previously re
moved.
with solvent. Wear eye protection during cleaning
operations.
(3) Remove shift a n d throttle levers from valve
body manual lever shaft.
(4) Remove bolts attaching overdrive unit to trans
mission (Fig. 1).
Fig. 1 Overdrive Unit Attaching Bolt Removal

(5) Loosen overdrive unit. Use pry tool to start
overdrive unit off intermediate shaft and transmis
sion case. Position pry tool between flange on over
drive case and transmission rear servo boss (Fig. 2).
(6) Work overdrive unit rearward and off transmis
sion intermediate shaft (Fig. 3). Keep overdrive unit
level during removal. J9121-209
(a) If overdrive unit does not require service, in

Fig. 3 Overdrive Unit Removal—42RH
sert Alignment Tool 6227-2 in overrunning clutch
and planetary gear splines to maintain alignment
(Fig. 4). I f c l u t c h a n d g e a r s p l i n e s rotate o u t o f
a l i g n m e n t , o v e r d r i v e u n i t will h a v e to b e d i s a s
s e m b l e d i n o r d e r to r e a l i g n s p l i n e s .
21 - 234 TRANSMISSION 0VERHAUL-42RH •
J9321-133
Fig. 4 Overdrive Spline Alignment Tool Installation

(7) Remove overdrive piston from retainer (Fig. 5). Installation
(8) Mount transmission unit on Repair Stand
(11) Remove oil pan bolts and remove oil pan and
gasket. Note location of oil pan magnet for assembly
reference (Fig. 8).
Fig. 5 Overdrive Piston Removal—42RH

C-3750-B or similar device. J9121-115
(9) Remove pump oil seal with Special Tool C-3981

Fig. 8 Oil Pan Magnet Position—42RH
(Fig. 6). Be sure to tighten tool threads completely
into seal before using puller bolt to withdraw seal. (12) Remove filter from valve body (Fig. 9). Keep
filter attaching screws with filter for assembly refer
ence. Filter screws are longer t h a n valve body
screws.
Fig. 6 Oil Pump Seal Removal—42RH

I (10) Remove park/neutral position switch (Fig. 7). Fig. 9 Fluid Filter Removal/Installation—42RH
• TRANSMISSION 0VERHAUL-42RH 21 - 235
(13) Remove hex head valve body attaching bolts ACCUMULATOR OUTER
(Fig. 10).
Fig. 12 Accumulator Piston And Springs—42RH
J9321-135
Fig. 10 Valve Body Bolt Locations—42RH
(14) Lift valve body upward. Work solenoid connec Fig. 13 Removing/Installing Front Band Reaction
tor out of case and remove valve body (Fig. 11). Set Pin Access Plug—42RH
valve body aside for disassembly, cleaning and in
spection. (17) Loosen front band adjusting screw locknut 4-5
turns. Then tighten band adjusting screw until band
VALVE BOOST is tight around front clutch retainer. This prevents
BODY VALVE
ASSEMBLY TUBE front/rear clutches from coming out with pump and
possibly damaging clutch or pump components.
(18) Remove oil pump bolts.
(19) Thread bolts of Slide Hammer Tools C-3752
into threaded holes in pump body flange (Fig. 14).
(20) Bump slide hammer weights outward to re
move pump and reaction shaft support assembly from
case (Fig. 14).
PARK CASE
ROD CONNECTOR J9321-136
Fig. 11 Valve Body Removal—42RH
(15) Remove accumulator piston and inner and
outer springs (Fig. 12).
(16) Remove front band reaction pin access plug
(Fig. 13). Plug is accessible through converter hous
ing. Use 1/4 inch drive extension to remove plug as
Fig. 14 Removing Oil Pump And Reaction Shaft
shown.
Support Assembly—42RH
(21) Loosen front band adjusting screw until band (25) Slide front band rearward and onto driving
is completely loose. shell. Band will not be removed until after front/rear
(22) Squeeze front band together and remove band clutch removal.
strut (Fig. 15). (26) Remove front and rear clutch units as assem
bly. Grasp input shaft, hold clutch units together and
remove them from case (Fig. 18).
Fig. 15 Removing/Installing Front Band Strut—42RH

(23) Remove front band reaction pin with pencil
magnet. Pin is accessible from converter housing side
of case (Fig. 16).
J9121-124
Fig. 18 Removing 42RH Front/Rear Clutch

Assemblies
(27) Lift front clutch off rear clutch (Fig. 19). Set
clutch units aside for overhaul.
Fig. 16 Removing Front Band Reaction Pin—42RH

(24) Remove front band lever (Fig. 17)
Fig. 19 Separating Front/Rear Clutch Assemblies

Fig. 17 Removing/Installing Front Band
Lever—42RH
TRANSMISSION OVERHAUL-42RH 21 - 237
(28) Remove intermediate shaft thrust washer ^ DRIVING

from front end of shaft or from rear clutch h u b (Fig. SHELL
20).
(29) Remove output shaft thrust plate from inter
mediate shaft hub (Fig. 21).
INTERMEDIATE
SHAFT THRUST
WASHER
REAR J9121-127
CLUTCH
RETAINER
HUB Fig. 22 Front Band Removal/Installation—42RH
moval. Do not allow machined surfaces on intermedi
ate shaft or overdrive piston retainer to become
nicked or scratched.
INPUT J9121-214
SHAFT
Fig. 20 Removing Intermediate Shaft Thrust

Washer-42RH
J9121-217
INTERMEDIATE
INTERMEDIATE SHAFT Fig. 23 Removing Planetary Geartrain And
SHAFT HUB THRUST PLATE
J9121-215
Intermediate Shaft Assembly—42RH
(32) Loosen rear band adjusting screw 4-5 turns.
Fig. 21 Removing Intermediate Shaft Thrust (33) Remove low-reverse drum snap ring (Fig. 24).
Plate-42RH (34) Remove bolts attaching overdrive piston re
(30) Slide front band off driving shell (Fig. 22) and tainer to rear of case (Fig. 25). Then remove piston
remove band from case. retainer and gasket.
(31) Remove planetary geartrain as assembly (Fig. (35) Remove rear band pivot and reaction pins
23). Support geartrain with both hands during re- (Fig. 26). Use parallel jaw snap ring pliers to remove
pins. Insert and spread plier jaws in pin bore to grip
pin. Then twist and pull pins to remove them.
21 - 238 TRANSMISSION 0VERHAUL-42RH
Fig. 26 Rear Band Pivot And Reaction Pin

Location—42RH
Fig. 24 Removing Low-Reverse Drum Snap

Ring-42RH
Fig. 27 Low-Reverse Drum And Rear Band

Removal—42RH
R
ET
AN
IE
R
BOL
TS
J9121-219
Fig. 25 Overdrive Piston Retainer Bolt

Location—42RH
(36) Remove rear b a n d lever.
(37) Remove low-reverse drum and rear band as
assembly. Turn drum clockwise and pull outward to Fig. 28 Overrunning Clutch Cam Bolt
remove it from overrunning clutch (Fig. 27). Locations—42RH
(38) Remove bolts attaching overrunning clutch (40) Compress front servo rod guide about 1/8 inch
cam to case (Fig. 28). with Valve Spring Compressor C-3422-B (Fig. 30). A
(39) Remove overrunning clutch cam and roller C-clamp and Special Tool C-4470 can also be used to
clutch assembly as a unit (Fig. 29). Turn cam back compress rod guide.
and forth and tilt it inward to remove it from case. (41) Remove front servo rod guide snap ring. Ex-
CL
UT
CH
A
SS
EMB
LY J
912
12
-2
2
Fig. 29 Overrunning Clutch Assembly

Removal—42RH
cercise caution w h e n removing s n a p ring. Servo
b o r e c a n b e s c r a t c h e d o r n i c k e d if c a r e is n o t
excercised.
(42) Remove compressor tools and remove front
servo rod guide, spring and servo piston.
Fig. 31 Compressing Rear Servo Spring—42RH

OVERHAUL SERVICE INFORMATION
Inspect the transmission bushings during overhaul.
Bushing condition is important as worn, scored bush
ings contribute to low pressures, clutch slip and ac
celerated wear of other components. However, do not
replcae bushings as a m a t t e r of course. Replace bush
ings only when they are actually worn, or scored.
Use recommended tools to replace bushings. The
tools are sized and designed to remove, install, and
seat bushings correctly. The bushing replacement
tools are included in Bushing Tool Set C-3887-B.
Pre-sized service bushings are available for re
placement purposes. Only the sun gear bushings are
not serviced. Low cost of the sun gear assembly
makes it easier to simply replace the gear and bush
ings as an assembly.
Heli-Coil inserts can be used to repair damaged,
Fig. 30 Compressing Front Servo Rod Guide—42RH stripped or worn threads in aluminum parts. These
inserts are available from most automotive jobbers.
(43) Compress rear servo spring retainer about
Stainless steel inserts are recommended.
1/16 inch with Valve Spring Compressor C-3422-B The use of crocus cloth is permissible where neces
(Fig. 31). A C-clamp and Tool C-4470 or SP-5560 can sary, providing it is used carefully. When used on
also be used to compress spring retainer. shafts, or valves, use extreme care to avoid rounding
(44) Remove rear servo spring retainer snap ring. off sharp edges. Sharp edges are vital as they pre
Then remove compressor tools and remove rear servo vent foreign matter from getting between the valve
spring and piston. and valve bore.
(45) Inspect transmission and overdrive compo Do not reuse oil seals, gaskets, seal rings, or
nents. If m a j o r c o m p o n e n t s s u c h a s t h e over O-rings during overhaul. Replace these parts as a
d r i v e u n i t , front clutch, o r oil p u m p r e q u i r e matter of course. Also do not reuse snap rings or
service, r e f e r to a p p r o p r i a t e o v e r h a u l p r o c e E-clips that are bent or distorted. Replace these parts
dure. as well.
Lubricate transmission parts with Mopar ATF
Plus, Type 7176, or Dexron II™ transmission fluid
during overhaul and assembly. Use petroleum jelly,
21 - 240 TRANSMISSION OVERHAUL-42RH — _ . *
Ru-Glyde, Door-Eze or similar products to prelubri- CLEANING A N D INSPECTION
cate seals, O-rings, and thrust washers. Petroleum Clean the clutch rollers, springs and retainer,
jelly can also be used to hold parts in place during clutch cam, low-reverse drum and overdrive piston
reassembly. retainer in solvent. Dry them with light bursts of
compressed air, or allow them to air dry after clean
TRANSMISSION CASE CLEANING AND ing.
INSPECTION Inspect condition of each clutch part after cleaning.
Clean the case in a solvent tank. Flush the case Replace the rollers and the retainer and spring as
bores and fluid passages thoroughly with solvent. sembly if the rollers, springs or spring retainer are
Dry the case and all fluid passages with compressed worn or damaged. Replace the clutch cam if worn,
air. Be sure all solvent is removed from the case and cracked or damaged.
t h a t all fluid passages are clear. Inspect the overrunning clutch race and low-re
Do not use s h o p towels or r a g s to d r y the case verse drum. Replace the drum and race as an assem
(or a n y o t h e r t r a n s m i s s i o n c o m p o n e n t ) u n l e s s bly if either part is worn, scored or damaged.
t h e y a r e m a d e from lint-free m a t e r i a l s . L i n t will Examine the overdrive piston retainer carefully for
stick t o c a s e s u r f a c e s a n d t r a n s m i s s i o n c o m p o wear, cracks, scoring or other damage. Be sure the
nents a n d circulate throughout the transmission retainer hub is a snug fit in the case and low-reverse
after a s s e m b l y . A sufficient q u a n t i t y of lint c a n drum. Replace the retainer if worn or damaged.
b l o c k fluid p a s s a g e s a n d i n t e r f e r e w i t h v a l v e
body operation. OVERRUNNING CLUTCH ASSEMBLY
Inspect the case for cracks, porous spots, worn (1) Install clutch rollers in spring retainer (Fig.
bores, or damaged threads. Damaged threads can be 33). Be sure springs are seated squarely against roll
repaired with Helicoil thread inserts. However, the ers.
case will have to be replaced if it exhibits any type of
damage or wear.
Lubricate the front band adjusting screw threads
with petroleum jelly and thread the screw part-way
into the case. Be sure the screw turns freely.
OVERRUNNING CLUTCH-LOW-REVERSE
DRUM-OVERDRIVE PISTON RETAINER
INSPECTION AND OVERHAUL
If the overrunning clutch and cam came out with
the low-reverse drum, remove the cam and clutch
from the drum as follows: Thread two clutch cam
bolts into the cam. Then lift the clutch and cam out J9121-225
of the drum with the bolts (Fig. 32). Rotate the cam
back and forth to ease removal if necessary. Fig. 33 Installing Overrunning Clutch Rollers In
Retainer—42RH
(2) Install roller and spring assembly in clutch
cam (Fig. 34).
(3) Lubricate overrunning clutch rollers, springs
cam and race with transmission fluid. Verify compo
nent installation before proceeding. Bolt holes in
clutch cam are countersunk on one side. Be sure this
side of cam will face rearward as shown (Fig. 34).
(4) Inspect bolt holes in overrunning clutch cam.
Note t h a t one hole is not threaded. Identify location
of non threaded hole with paint mark for assembly
reference (Fig. 35).
(5) Set assembly aside for final installation after
overhaul is complete.
Fig. 32 Removing Overrunning Clutch From Low-

Reverse Drum—42RH
LOW-REVERSE DRUM OVERRUNNING
Fig. 36 Removing Pump Housing Seal
J9121-140
Fig. 34 Checking Overrunning Clutch

Installation-42RH
Fig. 37 Loosening Pump Support Bolts
J9321-213
Fig. 38 Separating Pump Housing From Reaction

Shaft Support-42RH
Fig. 35 Marking Location Of Non-Threaded Hole in

Clutch Cam-42RH
OIL PUMP AND REACTION SHAFT SUPPORT
OVERHAUL
PUMP AND SUPPORT DISASSEMBLY
(1) Remove seal from around pump housing (Fig.
36).
(2) Mark pump housing and support assembly for
alignment reference. J9321-214
(3) Loosen bolts t h a t attach pump body to support
(Fig. 37). Fig. 39 Pump Gear Removal—42RH
(4) Remove pump-to-support bolts and separate sion disassembly, remove seal w i t h p u n c h a n d h a m
support from pump housing (Fig. 38). mer.
(5) Remove inner and outer gears from reaction
shaft support (Fig. 39).
(6) If pump seal was not removed during transmis-
21 - 242 TRANSMISSION OVERHAUL-42RH •
REACTION SHAFT GASKET

SUPPORT
OIL SEAL
BOLT (6)
O-RING
SEAL
PUMP HOUSING THRUST
WASHER
J9321-207
Fig. 40 Oil Pump And Reaction Shaft Support Components—42RH

(7) Remove front clutch thrust washer from sup STRAIGHT EDGE
port hub (Fig. 40).
OIL PUMP AMD REACTION SHAFT SUPPORT FEELER

GAUGE
Clean pump and reaction shaft support components
with solvent and dry them with compressed air.
Inspect the pump housing and support components.
Replace the housing or support if the seal ring
grooves or machined surfaces are worn, scored, pit l
ted, or damaged. ii!|i"j9321-215
Replace the pump gears if pitted, worn chipped, or Fig. 41 Measuring Pump Gear End Clearance—42RH
damaged. Inspect the thrust washer for wear or dam
Measure clearance between the outer gear and the
age. Replace the washer if necessary. Note that the
pump body (Fig. 42). Clearance should be 0.08 - 0.19
inner gear u s e d in 1993 42RH oil p u m p s h a s a
mm (0.0035 - 0.0075 in.).
n e w design drive lug. The n e w design incorpo
Measure gear tooth clearance with a feeler gauge.
rates drive flats instead of the square lug u s e d
Align one tooth of the outer gear in inner gear and
previously. The 1993 torque converter h u b h a s
measure clearance (Fig. 43). Clearance should be
also b e e n redesigned to accept the n e w drive. If
0.08 - 0.19 mm (0.0035 - 0.0075 in.).
p u m p gear replacement is necessary, b e very
sure to order and install the n e w style gears.
Inspect the pump and reaction shaft support bush
ings. Minor bushing wear is acceptable. Replace the
bushings only if scored, or severely worn.
Install the gears in the pump housing and measure
end clearance with a feeler gauge and straightedge
(Fig. 41). Clearance should be 0.010 - 0.06 mm
(0.0004 - 0.0025 in.).
FEELER (3) Stake new pump bushing in two places with

GAUGE blunt punch (Fig. 45). Remove burrs from stake
INNER points with knife blade afterward.
GEAR
J9321-216
Fig. 42 Measuring Pump Housing-To-Inner Gear

Clearances—42RH
INNER
GEAR
RH282
Fig. 45 Staking Oil Pump Bushing—All

OUTER 77 REPLACING REACTION SHAFT SUPPORT
GEAR BUSHING
(1) Assemble Bushing Remover Tools SP-1191,
3633 and 5324 (Fig. 46). Do not c l a m p any part of
J9321-217 reaction shaft or support in vise.
(2) Hold Cup Tool SP-3633 firmly against reaction
Fig. 43 Measuring Pump Gear Tooth shaft and thread remover SP-5324 into bushing as
Clearance—42RH far as possible by hand. Then thread remover tool 3-4
REPLACING OIL PUMP BUSHING additional t u r n s into bushing with a wrench.
(1) Remove pump bushing with Tool Handle
C-4171 and Bushing Remover SP-3551 (Fig. 44). SPECIAL SPECIAL
TOOL TOOL
(2) Install new pump bushing with Tool Handle SP-1191 C-4171
C-4171 and Bushing Installer SP-5117 (Fig. 44).
Bushing should be flush with pump housing bore.
SPECIAL BUSHING
TOOL REMOVAL
C-4171
SPECIAL TOOL
PUMP HOUSING SP-3551
BUSHING
J9221-243
SPECIAL Fig. 46 Replacing Reaction Shaft Support

TOOL Bushing—42RH
C-4171 SPECIAL
TOOL
SP-5117 (3) Turn remover tool hex nut down against re
mover cup to pull bushing from shaft. Clean all chips
from shaft after bushing removal.
(4) Lightly grip old bushing in vise or with pliers
and back remover tool out of bushing.
(5) Assemble Bushing Installer Tools C-4171 and
BUSHING SP-5325 (Fig. 46).
J9221-242 (6) Slide new bushing onto Installer Tool SP-5325.
(7) Position reaction shaft support upright on a
Fig. 44 Removing Oil Pump Bushing—42RH clean smooth surface.
(8) Align bushing in bore. Then tap bushing into bricate seal rings with transmission fluid or petro
place until Bushing Installer SP-5325 bottoms. leum jelly after installation. Squeeze each ring until
(9) Clean reaction shaft support thoroughly after ring ends are securely hooked together.
installing bushing.
C A U T I O N : Th© reaction shaft support seal rings will
ASSEMBLING OIL PUMP AND REACTION break if overspread, or twisted. If new rings are be
SHAFT SUPPORT ing installed, spread them only enough for installa
(1) Lubricate gear bore in pump housing with tion. Also be very sure the ring ends are securely
transmission fluid. hooked together after installation. Otherwise, the
(2) Lubricate pump gears with transmission fluid. rings will either prevent pump installation, or break
(3) Support pump housing on wood blocks (Fig. 47). during installation.
(4) Install outer gear in pump housing (Fig. 47).
Gear can be installed either way (it is not a one-way
fit).
OUTER
GEAR
SUPPORTS-
HUB
Fig. 49 Hub Seal Ring Position—42RH

(8) Install reaction shaft support on pump housing
(Fig. 50).
(9) Align reaction support on pump housing. Use
alignment marks made at disassembly. Or, rotate
J9321-219 support until bolt holes in support and pump housing
are all aligned (holes are offset for one-way fit).
Fig. 47 Supporting Pump And Installing Outer
Gear-42RH
(5) Install pump inner gear (Fig. 48). Gear can be
installed either way (it is not a one-way fit).
INNER
OUTER GEAR
GEAR
Fig. 50 Assembling Reaction Shaft Support And

Pump Housing—42RH
(10) Install all bolts that attach support to pump
housing. Then tighten bolts finger tight.
(11) Tighten support-to-pump bolts to required
torque as follows:
(a) Reverse pump assembly and install it in
J9321-220 transmission case. Position pump so bolts are fac
ing out and are accessible.
Fig. 48 Pump Inner Gear Installation—42RH (b) Secure pump assembly in case with 2 or 3
(6) Install new thrust washer on hub of reaction bolts, or with pilot studs.
shaft support. Lubricate washer with transmission (c) Tighten support-to-pump bolts to 20 N m (15
#
fluid or petroleum jelly. ft. lbs.).

(7) If reaction shaft seal rings are being replaced, (d) Remove pump assembly from transmission
install new seal rings on support hub (Fig. 49). Lu case.
(12) Install new oil seal in pump with Special Tool

FRONT COMPRESSOR
C-4193 and Tool Handle C-4171 (Fig. 51). Be sure TOOL C-3575-A
CLUTCH
seal lip faces inward. SPRING
(13) Install new seal ring around pump housing.
Be sure seal is properly seated in groove.
(14) Lubricate lip of pump oil seal with petroleum
jelly. Lubricate pump seal with Ru-Glyde or petro
leum jelly.
SPECIAL
TOOL
C-4193
PUMP
BODY
PUMP
SEAL SPRING RETAINER
RETAINER \ ^ SNAP RING /J9121-147
J932M83
Fig. 53 Compressing Front Clutch Piston
Fig. 51 Pump Oil Seal Installation—42RH Spring—42RH
FRONT CLUTCH OVERHAUL (4) Remove spring retainer and clutch spring. Note
position of retainer on spring for assembly reference.
FRONT CLUTCH DISASSEMBLY
(5) Remove clutch piston from clutch retainer. Re
(1) Remove waved snap ring and remove pressure
move piston by rotating it up and out of retainer.
plate, clutch plates and clutch discs (Fig. 52).
(6) Remove seals from clutch piston and clutch re
(2) Compress clutch piston spring with Compressor
tainer hub. Discard both seals as they are not reus
Tool C-3575-A (Fig. 53). Be sure legs of tool are
seated squarely on spring retainer before compress able.
ing spring.
(3) Remove retainer snap ring and remove com
pressor tool.
RETAINER HUB
SEAL SNAP RING
CLUTCH
PISTON (WAVED)
PISTON
SPRING SPRING
RETAINER
SNAP RING
PRESSURE
PLATE
FRONT CLUTCH RETAINER
CLUTCH PLATES J9321-222
Fig. 52 Front Clutch Components—42RH

21 - 241 TRANSMISSION OWERHAUL-42RH — •
Clean the front clutch components in solvent and
dry them with compressed air only. Do not use rags
or shop towels to dry any of the clutch parts. Lint
from such materials will adhere to the component
surfaces and could restrict or block fluid passages af
ter assembly.
burned or charred, or if the facing is flaking off. Re
place the steel plates if heavily scored, warped, or
broken. Be sure the driving lugs on the plates are in FRONT
CLUTCH J C < T 7
good condition. The lugs must not be bent, cracked or RETAINER^
damaged in any way. BUSHINGS V ^====*F==^^ /
Replace the clutch spring and spring retainer if ei (NON-SERVICEABLE) ^Mp^^^yr^^
J9321-223
ther is distorted, warped or broken.
Check the lug grooves in the clutch retainer. The Fig. 55 Retainer Bushing Locations—42RH
steel plates should slide freely in the slots. Replace
the retainer if the grooves are worn or damaged. TRIAL FIT
Check action of the check ball in the retainer (Fig. SPRING FOR
54). The ball must move freely and not stick. CORRECT FIT
Inspect the clutch retainer b u s h i n g s carefully
(Fig. 55). The retainer b u s h i n g s are not service
able. It will be n e c e s s a r y to replace the retainer
if either b u s h i n g is scored, or worn.
with crocus cloth. However, replace the piston and/or J9321-225
Fig. 56 Checking Spring Fit In Clutch Piston—42RH
RETAINER
CHECK BALL (3) Install new seals on piston and in hub of re
tainer. Be sure lip of each seal faces interior of clutch
retainer.
(4) Lubricate lips of piston and retainer seals with
liberal quantity of Door Eze, or petroleum jelly. Then
lubricate retainer hub, bore and piston with trans
mission fluid.
(5) Install clutch piston in retainer (Fig. 57). Use
twisting motion to seat piston in bottom of retainer.
D o not attempt to p u s h the piston straight in.
This could fold the seals over causing l e a k a g e
a n d clutch slip.
(6) Position spring in clutch piston.
J9121-368 (7) Position spring retainer on top of piston spring
(Fig. 58). Make sure retainer is properly in
Fig. 54 Front dutch Piston Retainer Check Ball stalled. Small raised tabs should be facing up
Location—42RH ward. Semicircular lugs on underside of retainer
FRONT CLUTCH ASSEMBLY are for positioning retainer in spring.
(1) Soak clutch discs in transmission fluid while (8) Compress piston spring and retainer with Com
assembling other clutch parts. pressor Tool C-3575-A (Fig. 53). Then install new
(2) Check piston spring fit. Trial fit e a c h e n d of snap ring to secure spring retainer and spring.
spring in piston (Fig. 56). One e n d of spring h a s (9) Install clutch plates and discs (Fig. 52). Install
slightly larger inside diameter. This e n d will b e steel plate then disc until all plates and discs are in
slip fit over h u b of piston and ensure full spring stalled.
seating. Mark spring with chalk or paint after (10) Install pressure plate and waved snap ring
determining w h i c h end is b e s t fit in spring seat. (Fig. 52).
FEELER GAUGE
FRONT
CLUTCH
RETAINER
J9121-146
Fig. 57 Front Clutch Piston Installation—42RH
SMALL TABS
O N RETAINER
- FACE
UPWARD
FEELER GAUGE RH288
Fig. 59 Measuring Front Clutch Pack Clearance

materials will adhere to component surfaces and
J9321-224
could restrict or block fluid passages after assembly.
Fig. 58 Correct Spring Retainer Installed
Position—42RH burned/charred, the lugs are damaged, or if the fac
ing is flaking off. Replace the top and bottom pres
(11) Check clutch plate clearance (Fig. 59). Clear sure plates if scored, warped, or cracked. Be sure the
ance should be 1.70 to 3.40 mm (0.067 to 0.134 in.). driving lugs on the pressure and clutch plates are
If clearance is incorrect, clutch discs, plates pressure also in good condition. The lugs must not be bent,
plates and snap ring may have to be changed. cracked or damaged in any way.
REAR CLUTCH OVERHAUL part is distorted, warped or broken.
REAR CLUTCH DISASSEMBLY Check the lug grooves in the clutch retainer. The
(1) Remove fiber thrust washer from forward side clutch and pressure plates should slide freely in the
of clutch retainer. slots. Replace the retainer if the grooves are worn or
(2) Remove selective clutch pack snap ring (Fig. damaged. Also check action of the check ball in the
60). piston. The check ball must move freely and not
(3) Remove top pressure plate, clutch discs, steel stick.
plates, bottom pressure plate and wave spring (Fig. Replace the retainer bushing if worn, scored, or
60). doubt exists about bushing condition.
(4) Remove clutch piston. Grasp piston and rotate Inspect the piston and retainer seal surfaces for
piston up and out of retainer. nicks or scratches. Minor scratches can be removed
(5) Remove and discard piston seals. with crocus cloth. However, replace the piston and/or
(6) Remove input shaft snap ring (Fig. 61). retainer if the seal surfaces are seriously scored.
(7) Press input shaft out of retainer with shop Check condition of the fiber thrust washer and
press and suitable size press tool (Fig. 62). metal output shaft thrust washer. Replace either
(8) Remove input shaft front/rear seal rings. washer if worn or damaged.
Check condition of the seal rings on the input shaft
REAR CLUTCH INSPECTION and clutch retainer hub. Replace the seal rings only
Clean the clutch components with solvent and dry if obviously damaged. The input shaft front seal ring
them with compressed air. Do not use rags or shop is teflon with chamfered ends. The rear ring is metal
towels to dry a n y of the clutch parts. Lint from such with interlocking ends.
-REAR
INPUT REAR INPUT CLUTCH
OUTPUT CLUTCH SHAFT
SHAFT . THRUST
SHAFT RETAINER
SNAP ^ / SHAFT WA|HER
THRUST
RING / FRONT (FIBER)
WASHER
SHAFT SEAL
(METAL)
CLUTCH REAR RING - „ M u
C
PISTON SEAL (TEFLON) ^ H

REAR SEALS RING PACK
CLUTCH (METAL) SNAP
PISTON RING
(SELECTIVE)
PISTON
SPRING
TOP
PRESSURE
PLATE
CLUTCH
BOTTOM DISCS (4)
PRESSURE
PLATE
J9121-539
Fig. 60 Rear Clutch Components—42RH
J912M50
Fig. 62 Removing Input Shaft From Rear Clutch

Retainer—42RH
Fig. 61 Removing/Installing Input Shaft Snap
(a) Be sure clutch h u b retainer seal ring is fully
Ring-42RH
seated in groove (Fig. 63). Ring must not be
Check t h e input shaft for wear, or damage. Replace twisted, or distorted.
the shaft if worn, scored or damaged in any way. (b) Note t h a t input shaft front seal ring is teflon
and rear seal ring is metal (Fig. 64). Be sure cham
REAR CLUTCH ASSEMBLY fered ends of teflon ring are properly joined and
(1) Soak clutch discs in transmission fluid. t h a t ends of rear ring are securely hooked together.
(2) Install new seal rings on clutch retainer h u b (c) Lubricate retainer and shaft seal rings with
and input shaft (Figs. 63 and 64). light coat of petroleum jelly after installation.
• TRANSMISSION OVERHAUL-42RH 21 - 24S
J9121-538
Fig. 63 Installing Rear Clutch Retainer And Input

Shaft Seal Rings—42RH Fig. 65 Pressing Input Shaft Into Rear Clutch
Retainer—42RH
motion to seat piston in bottom of retainer. D o not
attempt to p u s h the piston straight in. This
could fold the seals over causing l e a k a g e and
clutch slip.
(8) Install piston spring in retainer and on top of
piston (Fig. 56). Concave side of spring faces up as
shown.
(9) Install wave spring in retainer (Fig. 66). Be
sure spring is completely seated in retainer groove.
J912M51
Fig. 64 input Shaft Seal Ring Identification—42RH

(3) Lubricate splined end of input shaft and clutch
retainer with transmission fluid. Then press input
shaft into retainer (Fig. 65).
(4) Install input shaft retaining ring (Fig. 61).
(5) Install new seals on clutch piston. Be sure lip
Fig. 66 Piston And Wave Spring Position—42RH
of e a c h seal faces interior of clutch retainer.
(6) Lubricate lip of piston seals with liberal quan (10) Install bottom pressure plate (Fig. 60). Ridged
tity of Door Eze, or petroleum jelly. Then lubricate side of plate faces downward (toward piston) and flat
retainer hub and bore with transmission fluid. side toward clutch pack.
21 - 250 TRANSMISSION 0VERHAUL-42RH — •
(11) Install first clutch disc in retainer on top of
bottom pressure plate. Then install a clutch plate fol
lowed by a clutch disc until entire clutch pack is in
stalled. 4 clutch discs and 3 metal plates are
required.
(12) Install top pressure plate (Fig. 60).
(13) Install selective snap ring (Fig. 60). Be sure
snap ring is fully seated in retainer groove.
(14) Measure clutch pack clearance (Fig. 67).
Clearance should be 0.64 to 1.14 mm (0.025 to 0.045
in.). If clearance is incorrect, steel plates, discs, snap
ring and pressure plates may have to be changed
(Fig. 53).
Fig. 68 Installing Rear Clutch Thrust Washer—42RH

(7) Remove snap ring t h a t retains sun gear in
driving shell and remove sun gear and thrust plates.
Note thrust plate position for assembly reference.
tary gear.
(9) Remove rear planetary gear from rear annulus
gear and remove annulus gear from intermediate
shaft.
(10) Remove snap rings securing annulus gears to
supports. Then separate each gear from support.
PLANETARY GEARTRAIN INSPECTION

Clean the planetary components in solvent and dry
them with compressed air.
Check sun gear and driving shell condition. Re
place the gear if damaged or if the bushings are
scored or worn. The bushings are not serviceable. Re
place the driving shell if worn, cracked or damaged.
Fig. 67 Checking Rear Clutch Pack Clearance
Replace planetary gear sets if gears, pinion pins, or
(15) Coat rear clutch fiber thrust washer with pe carrier are damaged in any way. Replace the annu
troleum jelly and install washer over input shaft and lus gears and supports if either component is worn or
into clutch retainer (Fig. 68). Use enough petroleum damaged.
jelly to hold washer in place. Inspect the geartrain spacers, thrust plates, snap
(16) Set rear clutch aside for installation during fi rings, and thrust washers. Replace any part t h a t is
nal assembly. worn or damaged. Do not attempt to reuse these
parts.
PLANETARY GEAR TRAIN AND INTERMEDIATE Inspect the intermediate shaft carefully. Pay par
SHAFT OVERHAUL ticular attention to the machined bushing/bearing
surfaces on the shaft.
GEARTRAIN DISASSEMBLY (FIG* 69)
Replace the intermediate shaft if any machined
(1) Remove snap ring, tabbed thrust washer and
surfaces are scored, pitted, or damaged in any way.
thrust plate from front of output shaft.
Also replace the shaft if the splines are damaged, or
(2) Remove front annulus gear and support assem
exhibits cracks at any location. Be sure the select
bly.
spacer groove on the shaft is in good condition. Trial
(3) Remove front planetary front thrust washer.
fit the spacer if necessary.
(4) Remove front planetary gear.
(5) Remove front planetary rear t h r u s t washer.
(6) Remove sun gear and driving shell.
# , , . , _ TRANSMISSION 0VERHAUL-42RH 21 - 251
SELECT FRONT SUPPORT FRONT FRONT SUN SUN DRIVING SHELL DRIVING
FIT ANNULUS SNAP ANNULUS PLANETARY GEAR GEAR FRONT THRUST , SHELL
PLANETARY SNAP RING GEAR THRUST SPACER PLATE
SNAP RING WASHERS
RING
FRONT OVERDRIVE
ANNULUS PISTON
THRUST RETAINER
WASHER
DRIVING
SHELL
REAR
THRUST
PLATE
CLUTCH
CAM BOLTS
INTERMEDIATE INTERMEDIATE
SHAFT THRUST SHAFT J9221-18
PLATE
Fig. 69 Transmission Planetary Gear Train—42RH

PLANETARY GEARTRAIN ASSEMBLY
(1) Lubricate intermediate shaft and planetary REAR
components with transmission fluid. Use petroleum ANNULUS
jelly to lubricate and hold thrust washers and plates GEAR
in position.
(2) Assemble rear annulus gear and support if dis TABBED
assembled. Be sure support snap ring is seated and THRUST
WASHER
t h a t shoulder side of support faces rearward.
(3) Install rear thrust washer on rear planetary
washer in place. Also be sure washer tabs are prop
erly engaged in gear slots. REAR
PLANETARY
(4) Install rear annulus over and onto rear plane
(5) Install assembled rear planetary and annulus J
912
11
-5
6
gear on intermediate shaft (Fig. 71). Verify t h a t as
sembly is fully seated on shaft. Fig. 70 Assembling Rear Annulus And Planetary
(6) Install front thrust washer on rear planetary Gear-42RH
washer on gear. (9) Insert sun gear into driving shell (Fig. 75).
(7) Install spacer on sun gear (Fig. 73). (10) Hold sun gear in position and install rear
(8) Install thrust plate over sun gear and on top of thrust plate. Plate goes over sun gear at rear of driv
spacer (Fig. 74). Note t h a t thrust plates are inter ing shell (Fig. 75).
changeable. Use either plate on sun gear and rear of
driving shell.
REAR ANNULUS
A N D PLANETARY GEAR
ASSEMBLY
INTERMEDIATE
SHAFT
THRUST
PLATE
J9121-275
Fig. 71 installing Assembled Rear Annulus And Fig. 74 Installing Spacer And Thrust Plate On Sun
Planetary Gear On Intermediate Shaft—42RH Gear-42RH
FRONT SUN
TABBED DRIVING GEAR
THRUST SHELL
WASHER
REAR
PLANETARY REAR
GEAR J9121-158 THRUST
PLATE J9121-162
Fig. 72 Installing Rear Planetary Front Thrust
Washer-42RH Fig. 75 Installing Sun Gear And Rear Thrust Plate In
Driving Shell-42RH
and install sun gear lock ring. Keep wood block
handy as it will also be used for geartrain end play
check.
SUN
GEAR
SUN
GEAR
SUN GEAR
SPACER
J912M59
WOOD
Fig. 73 Installing Sun Gear Spacer—42RH BLOCK
(11) Position wood block on bench and support sun

gear on block (Fig. 76). This makes it easier to align DRIVING
SHELL J912M63
Fig. 76 Supporting Sun Gear On Wood Block-42RH

(12) Align rear thrust plate on driving shell and

install sun gear lock ring. Be sure ring is fully
seated in sun gear ring groove (Fig. 77).
Fig. 79 Installing Rear Thrust Washer On Front

Planetary Gear—42RH
Fig. 77 Installing Sun Gear Lock Ring—42RH

(13) Install assembled driving shell and sun gear
on intermediate shaft (Fig. 78).
Fig. 80 Installing Thrust Plate On Front Annulus

Support—42RH
Fig. 78 Installing Assembled Sun Gear And Driving

Shell On Intermediate Shaft—42RH
(14) Install rear thrust washer on front planetary
washer on gear and be sure washer tabs are all prop
erly seated.
(15) Assemble front annulus gear and support if
necessary.
(16) Position thrust plate on front annulus gear
support (Fig. 80). Use liberal quantity of petroleum
jelly to hold plate in place.
(17) Install front planetary gear on intermediate
shaft and in driving shell (Fig. 81).
(18) Install front thrust washer on front planetary
Fig. 81 Installing Front Planetary And Annulus
gear (Fig. 81). Use enough petroleum jelly to hold Gears—42RH
washer in place on gear and be sure washer tabs are
seated.
(19) Assemble front annulus gear and support. Be SELECTIVE
sure support snap ring is seated.
(20) Install front annulus t h r u s t washer (Fig. 82).
Align flat on washer with flat on planetary hub. Also
be sure washer tab is facing forward.
Fig. 84 Installing Planetary Selective Snap

Ring-42RH
(25) Geartrain end play should be 0.12 to 1.22 mm
(0.005 to 0.048 in.). If end play is incorrect, snap ring
(or thrust washers) may have to be replaced. Snap
Fig. 82 Installing Front Annulus Thrust ring is available in three different thicknesses for ad
Washer-42RH justment purposes.
(21) Install front annulus snap ring (Fig. 83). Use

snap ring pliers to avoid distorting ring during in
stallation. Also be sure ring is fully seated.
Fig. 83 Installing Front Annulus Snap Ring—42RH

(22) Install planetary selective snap ring with snap
ring pliers (Fig. 84). Be sure ring is fully seated. Fig. 85 Checking Planetary Geartrain End
(23) Turn planetary geartain assembly over so Play-42RH
driving shell is facing workbench. Then support FRONT SERVO AND BAND OVERHAUL
geartrain on wood block positioned under forward
end of output shaft. This is necessary so geartrain FRONT SERVO DISASSEMBLY (FIG. 86)
components will move forward for accurate end play (1) Remove small snap ring from servo piston.
check. (2) Remove piston, rod, springs and guide.
(24) Check planetary geartrain end play with (3) Remove and discard servo piston rings and
feeler gauge (Fig. 85). Gauge goes between shoulder O-ring.
on intermediate shaft and end of rear annulus sup
port.
FRONT BAND AND SERVO INSPECTION (3) Remove snap ring from end of piston plug (Fig.
Clean the servo components with solvent and dry 87).
them with compressed air. (4) Open vise and remove wood block, piston plug,
Inspect the servo components. Replace the springs cushion spring and servo piston.
if collapsed, distorted or broken. Replace the guide, SMALL
rod and piston if cracked, bent, or worn. Discard the WOOD
servo snap ring if distorted or warped. BLOCK
Replace the front band if distorted, the lining is
burned or flaking off, or excessively worn.
Check the servo piston bore for wear. Replace the
piston and rod as an assembly if either part is worn
or damaged.
Replace any servo component if doubt exists about
its condition. Do not reuse suspect parts. SNAP
RING
SERVO PLIERS
PISTON
PISTON PISTON PISTON
R PLUG
ROD OD SNAP
SNAP RING J9121-174
RING
Fig. 87 Removing/lnstailing Servo Piston Piug Snap

Ring—42RH
PISTON
ROD
SEALS REAR SERVO INSPECTION
GUIDE Clean the servo components (Fig. 88) with solvent
and dry them with compressed air.
PISTON Check rear band condition. Replace the band if dis
ROD torted, the lining is burned or flaking off, or the lin
SEAL
ing is excessively worn. Check the band pivot and
reaction pins. Minor pin scoring can be cleaned up
with crocus cloth. However, replace the pins if worn,
PISTON
SPRING severely scored, or cracked. Replace the pin O-rings.
Inspect the servo components. Replace the servo
R O D
SERVO and cushion springs if collapsed, distorted or broken.
SNAP GUIDE
S E A L
RING J912M72
SPRING
Fig. 86 Front Servo Components—42RH RETAINER
ASSEMBLING FRONT SERVO PISTON
SERVO
(1) Lubricate seal rings and O-rings with petro SPRING
leum jelly. Lubricate other servo parts with trans PISTON
mission fluid. PLUG
(2) Install new O-ring on servo piston rod. SERVO
SNAP
(3) Install new seal on piston rod guide and install CUSHION
RING
new seal rings on piston. SPRING
(4) Assemble rod, piston, servo springs and snap
ring (Fig. 86).
PISTON
REAR SER¥0 AND BAND OVERHAUL PLUG
SNAP
REAR SERVO PISTON DISASSEMBLY RING
(1) Remove seal from servo piston. Note which way
seal lip faces for assembly reference.
(2) Compress cushion spring in vise only enough to
allow piston plug snap ring removal (Fig. 87). Use SERVO
wood block between vise jaws and end of piston plug PISTON J9121-173
to keep plug aligned and in position.
Fig. 88 Rear Servo Components—42RH
21 - 256 TRANSMISSION OVERHAUL-42RH
Replace the plug or piston if cracked, bent, or worn.

Discard the servo snap ring and spring retainer if
distorted or warped.
If doubt exists about the condition of any servo
component, replace it. Do not reuse suspect parts.
ASSEMBLING REAR SERWO PISTON

(1) Assemble piston plug, cushion spring and pis
ton (Fig. 88).
(2) Compress cushion spring in vise and install pis
ton plug snap ring (Fig. 87).
(3) Install new seal on piston. Be sure seal lip is
toward servo bore (Fig. 89).
(4) Lubricate piston seal with petroleum jelly. Lu I K ) O °o O O O O
bricate other servo parts with transmission fluid. UPPER
HOUSING J9321-126
BE SURE
SEAL LIP Fig. 90 Boost Valve Cover Location—42RH
IS TOWARD
SERVO BORE BOOST
VALVE
INSTALLED
LOCATION
REAR
SERVO
PISTON
J9121-175
Fig. 89 installing Rear Servo Piston Seal

VALVE BODY SERVICE AND ADJUSTMENT
COVER
WALWE BODY MAIN COMPONENT SCREWS
DISASSEMBLY SPRING BOOST
AND VALVE BOOST
VALVE SPRING VALVE
C A U T I O N : D o not clamp any valve body compo RETAINER
nent in a vise. This practice c a n d a m a g e the c o m
ponent resulting in unsatisfactory operation after
assembly and installation. Remove valves, plugs
and s p r i n g s with a pencil magnet. D o not u s e pliers J9321-127
to remove any of the valves, p l u g s or s p r i n g s a n d
d o not force any of the components out or into
Fig. 91 Boost Valve Components
place. The valves and valve body h o u s i n g s will be
d a m a g e d if force is u s e d . T a g or mark the valve SPECIAL
b o d y s p r i n g s for reference a s they are removed. D o TOOL 6583
not allow them to become intermixed.
(1) Remove boost valve cover (Fig. 90).

(2) Remove boost valve retainer, valve spring and
boost valve (Fig. 91).
(3) Secure detent ball and spring with Retainer
Tool 6583 (Fig. 92).
(4) Remove E-clip t h a t secures throttle lever in
DETENT BALL AND SPRING HOUSING J9321 -121
(5) Lift and rotate manual lever far enough to Fig. 92 Securing Detent Ball And Spring
clear detent housing.
THROTTLE (8) Remove throttle lever from valve body housing

LEVER (Fig. 96).
AAANUAL
LEVER
THROTTLE
LEVER
E-CLIP
J932M41
J9321-138 Fig. 96 Throttle Lever Removal—42RH

Fig. 93 Removing Throttle Lever E-Clip (9) Remove park rod E-clip and separate rod from
(6) Remove retaining tool and remove detent ball
and spring (Fig. 9 4 ) . MANUAL
LEVER
AAANUAL
LEVER
DETENT
HOUSING
DETENT PARK
BALL. ROD J9121-81
AND
SPRING J9321-139
Fig. 97 Park Rod Removal—42RH
Fig. 94 Detent Bali And Spring Removal (10) Remove screws attaching pressure adjusting
(7) Remove washer at top of manual lever shaft. screw bracket to valve body and transfer plate. Hold
Then lift manual lever and park rod assembly up bracket firmly against spring tension while removing
ward and out of valve body (Fig. 95). last screw.
(11) Remove adjusting screw bracket, line pressure
AAANUAL adjusting screw, pressure regulator spring and switch
LEVER valve spring (Fig. 98). D o n o t r e m o v e t h r o t t l e
AND
PARK p r e s s u r e a d j u s t i n g s c r e w from b r a c k e t a n d d o
ROD not disturb adjusting screw settings d u r i n g re
ASSEMBLY
moval.
(12) Remove solenoid connector from 3-4 accumula
tor housing (Fig. 99). Note t h a t c o n n e c t o r is at
tached to housing with shoulder-type screw.
Keep this screw with accumulator housing to
MANUAL
LEVER a v o i d l o s i n g it.
WASHER (13) Note routing of solenoid wires for assembly
(14) Remove screws attaching solenoid assembly to
J932M40 valve body lower housing and remove solenoid and
connector assembly (Fig. 101).
Fig. 95 Manual Lever Removal—42RH
PRESSURE SOLENOID LOWER
REGULATOR ATTACHING HOUSING
VALVE SPRING SCREWS
ADJUSTING
SCREW
BRACKET
SWITCH SOLENOID
VALVE LINE PRESSURE ASSEMBLY J932M44
SPRING ADJUSTING SCREW J9121-512
Fig. 101 Solenoid Assembly Removal—42RH
Removal—42RH (15) Remove 3-4 accumulator housing attaching
screws and remove housing from valve body (Fig.
SOLENOID 3-4
CONNECTOR ACCUMULATOR
102).
HOUSING 3-4
ACCUMULATOR-
HOUSING HOUSING
ATTACHING
SCREWS
=
a J932M43
Fig. 99 Solenoid Connector Position—42RH

SOLENOID
WIRES
(NOTE
WIRE
ROUTING)
Fig. 102 Removing 3-4 Accumulator Housing—42RH

(16) Remove following parts from valve body lower
housing: 3-4 shift valve and spring; pressure regula
tor valve spring; clutch valve; clutch valve spring;
and clutch valve plug (Fig. 103).
(17) Remove boost valve connecting tube (Fig.
104). Disengage tube from upper housing port first.
Then rock opposite end of tube back and forth to
work it out of lower housing.
C A U T I O N : D o not use tools to loosen or pry the

connecting tube out of the valve body housings.
Loosen and remove the tube by hand only.
(18) Turn valve body over so valve lower housing

s r
\^t%U^ ^^^^ is facing upward (Fig. 105). In this position, check
balls in upper housing will remain in place and not
Fig. 100 Solenoid Wire Routing—42RH fall out when lower housing and transfer plate are
removed.
TRANSMISSION 0VERHAUL-42RH 21 - 259
LOWER LOWER VALVE

HOUSING HOUSING BODY
SCREWS (13)
CLUTCH
VALVE A N D
SPRING
c
S ^ TUBE
BRACE J9321-148
Fig. 105 Valve Body Screw And Tube Brace

3-4 Location—42RH
SHIFT PRESSURE
VALVE CLUTCH REGULATOR OVERDRIVE TRANSFER
AND VALVE VALVE SEPARATOR PLATE A N D
SPRING PLUG SPRING J9321-146 PLATE UPPER
HOUSING
Fig. 103 Clutch Valve And 3-4 Shift Vaive
Locations—42 RH
BOOST LOWER
.VALVE HOUSING
TUBE
LOWER
HOUSING J9321-149
Fig. 106 Lower Housing Removal—42RH
UPPER
DISENGAGE HOUSING
UPPER THIS END OF
HOUSING TUBE FIRST J9321-147
Fig. 104 Boost Valve Tube Removal—42RH

(19) Remove screws attaching valve body lower
housing to upper housing and transfer plate (Fig.
105). Note position of boost valve tube brace for
assembly reference.
(20) Remove lower housing and overdrive separa
tor plate from transfer plate (Fig. 106).
TRANSFER
(21) Remove transfer plate from upper housing PLATE
(Fig. 107).
J932M52
(22) Turn transfer plate over so upper housing sep
arator plate is facing upward (Fig. 108).
(23) Remove brace plate from lower housing sepa Fig. 107 Removing Transfer Plate From Upper
Housing—42RH
rator plate and transfer plate (Fig. 108).
(24) Remove upper housing separator plate from (25) Remove rear clutch check ball from transfer
transfer plate (Fig. 109). Note position of filter in plate. Note check ball location for assembly ref
separator plate for assembly reference. e r e n c e before removing it (Fig. 110).
VALVE BODY UPPER HOUSING
DISASSEMBLY
(1) Note location of check balls in valve body upper
housing (Fig. 111). Then remove one large and six
BRACE smaller diameter check balls with magnet (total of 7
check balls are used).
SMALL
DIAMETER
CHECK
BALLS (6)
SEPARATOR TRANSFER
J9321-150 PLATE PLATE
Fig. 108 Brace Plate Removal—42RH

TRANSFER UPPER
PLATE HOUSING
'SEPARATOR
PLATE
FILTER
SCREEN
LARGE DIAMETER
CHECK
BALL (1) J9321-154
Fig. 111 Valve Body Check Ball Locations—42RH

(2) Remove E-clip t h a t secure shuttle valve second
ary spring on valve stem (Fig. 112).
BRACE J932M51
E-CLIP SECONDARY SHUTTLE
Fig. 109 Upper Housing Separator Plate VALVE
Removal—42RH
TRANSFER
PLATE
REAR J9121-179
CLUTCH
CHECK Fig. 112 Shuttle Valve E-Clip And Secondary Spring
BALL
Location—42RH
(3) Remove governor plug and shuttle valve covers
Fig. 110 Rear Clutch Check Ball Location—42RH (Fig. 113).
(4) Remove throttle plug, primary spring, shuttle
valve, secondary spring, and spring guides (Fig. 113).
(5) Remove boost valve retainer, spring and valve
if not previously removed.
• TRANSMISSION OVERHAUL42RH 21 - 261
-156
Fig. 113 Shuttle And Boost Valve Components—42RH

(6) Turn upper housing over and remove switch (8) Remove throttle plug and 1-2 and 2-3 governor
valve, regulator valve and spring, and manual valve plugs (Fig. 114). Also remove shuttle valve primary
(Fig. 114). spring if not removed in prior step.
(7) Remove kickdown detent, kickdown valve, and
throttle valve and spring (Fig. 114).
Fig. 114 Control Valve Locations—42RH Upper Housing

21 - 212 TRANSMISSION OWERHAUL-42RH
UPPER 1-2
HOUSING SHIFT
CONTROL
VALVE
AND SPRING
2-3
SHIFT
VALVE
AND SPRING
THROTTLE COVER
PRESSURE
SPRING
AND
PLUG
PLUG
SLEEVE
LINE
PRESSURE
PLUG
PRESSURE
PLUG
COVER J9321-243
Fig. 115 Shift Waives And Pressure Plugs—42RH Upper Housing

(9) Turn upper housing around and remove limit 3-4 ACCUMULATOR HOUSING DISASSEMBLY
valve and shift valve covers (Fig. 115). (FIG. 117)
(10) Remove limit valve housing. Then remove re (1) Remove end plate from housing.
tainer, spring, limit valve, and 2-3 throttle plug from (2) Remove piston spring.
limit valve housing (Fig. 115). (3) Remove piston. Remove and discard piston
(11) Remove 1-2 shift control valve and spring seals.
(Fig. 115).
(12) Remove 1-2 shift valve and spring (Fig. 115). VALWE 10DY CLEANING AND INSPECTION
(13) Remove 2-3 shift valve and spring from valve The only serviceable valve body components are
body (Fig. 115). (Fig. 118):"
(14) Remove pressure plug cover (Fig. 115). • solenoid and connector assembly
(15) Remove line pressure plug, sleeve, throttle • solenoid gasket and connector screw
pressure plug and spring (Fig. 115). • switch valve and spring
• pressure adjusting screw and bracket
VALWE BODY LOWER HOUSING • throttle valve lever
DISASSEMBLY (FIG. 116) • manual lever and shaft seal
(1) Remove timing valve cover. • throttle lever shaft seal, washer, and E-clip
(2) Remove 3-4 timing valve and spring. • fluid filter and screws
(3) Remove 3-4 shuttle valve E-clip and remove • detent ball
shuttle valve spring and plug. • valve body screws
(4) Remove 3-4 shift valve and spring. The park rod and park rod E-clip are also service
(5) Remove converter clutch valve, spring and able. Refer to the park lock components and over
plug. drive case information in the parts catalogue. The
(6) Remove converter clutch timing valve, retainer remaining valve body components are serviced only
and valve spring. as part of a complete valve body assembly.
Clean the valve body components with a standard
parts cleaning solution only. Do not use gasoline,
kerosene, or any type of caustic solution.
4 TRANSMISSION QVERHAUL-42RH 21 - 263
Fig. 116 Shift Valves And wings—42RH Lower Housing

3-4 ACCUMULATOR valve b o d y components. Lint from these materi
^ HOUSING als will adhere to the valve b o d y components.
Lint will interfere with valve operation and may
clog filters and fluid p a s s a g e s .
Inspect the throttle and manual valve levers and
shafts. Do not attempt to straighten a bent shaft or
correct a loose lever. Replace these components if
worn, bent, loose or damaged in any way.
Inspect all of the valve body mating surfaces for
scratches, nicks, burrs, or distortion. Use a straight
edge to check surface flatness. Minor scratches may
be removed with crocus cloth using only very light
pressure.
Minor distortion of a valve body' mating surface
may be corrected by smoothing the surface with a
sheet of crocus cloth. Position the crocus cloth on a
surface plate, sheet of plate glass or equally flat sur
face. If distortion is severe or any surfaces are
heavily scored, the valve body will have to be re
PLATE J9121-277 placed.
Fig. 117 3-4 Accumulator Housing

Components—42 RH
Dry the parts with compressed air. Make sure all
passages are clean and free from obstructions. D o
not use rags or s h o p towels to dry or wipe off
21 - 264 TRANSMISSION QVERHAUL-42RH
fied by the dark color of the special coating applied

ADJUSTING
- SCREW to the surface (or by testing with a magnet). D O
AND SWITCH NOT polish or sand aluminum valves or plugs un
der any circumstances. This practice could damage
the special coating.
Inspect the valves and plugs for scratches, burrs,

nicks, or scores. Minor surface scratches can be re
moved with crocus cloth but do not round off the
e d g e s of the valve or plug lands. Maintaining
sharpness of these edges is vitally important. The
edges prevent foreign matter from lodging between
the valves and plugs and the bore.
Inspect all the valve and plug bores in the valve
body. Use a penlight to view the bore interiors. Re
place the valve body if any bores are distorted or
scored. Inspect all of the valve body springs. The
springs must be free of distortion, warpage or broken
coils.
Check the two separator plates for distortion or.
damage of any kind. Inspect the upper housing,
lower housing, 3 - 4 accumulator housing, and transfer
plate carefully. Be sure all fluid passages are clean
and clear. Check condition of the upper housing and
transfer plate check balls as well. The check balls
CONNECTOR and ball seats must not be worn or damaged.
SEAL Trial fit each valve and plug in its bore to check
J9321-226
freedom of operation. When clean and dry, the valves
Fig. ! *8 Serviceable Valve Body and plugs should drop freely into the bores.
Components—42RH Valve body bores do not change dimensionally with
use. If the valve body functioned correctly when new,
C A U T I O N ; M a n y of the waives a n d plugs, s u c h a s
it will continue to operate properly after cleaning
the throttle valve, shuttle valve plug, 1-2 shift valve
and inspection. It should not be necessary to replace
and 1-2 governor plug, are made of coated alumi a valve body assembly unless it is damaged in han
n u m (Fig. 119). Aluminum components are identi dling.
END PLATE VALVE AND SECONDARY SPRING,
1-2 SHIFT
CONTROL VALVE
AND SPRING
REGULATOR SHUTTLE VALVE

VALVE COVER
END PLATE
SLEEVE
REGULATOR 2-3 SHIFT

VALVE THROTTLE VALVE GOVERNOR
PRESSURE PLUG PLUG
SHUTTLE VALVE
PLUG (ALUM.)
RETAINER
VALVE
SPRING
GOVERNOR
VALVE END
PLATE
PRESSURE MANUAL LEVER

SWITCH REGULATOR* DETENT BALL
LINE AND SPRING
PRESSURE ADJUSTING VALVE VALVE
ADJUSTING- SCREW AND AND
SCREW BRACKET SPRING SPRING J9221-21
Fig. 119 Upper Housing Components-42RH Valve Body (Alum. Indicates Aluminum Part)
21 - 266 TRANSMISSION OWERHAUL-42RH •
VALVE BODY REASSEMBLY (2) Position transfer plate assembly on upper hous
ing (Fig. 120).
CAUTION: Do not force valves or plugs into place (3) Position lower housing separator plate on
during reassembly. If the valve body bores, valves transfer plate (Fig. 120).
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 op
eration. Tighten valve body screws t o recom
mended torque only.
Lower Housing Assembly (Fig. 116)

(1) Lubricate valves, springs, and the housing
valve and plug bores with transmission fluid.
(2) Install 3-4 timing valve spring and valve in
lower housing. TRANSFER UPPER
(3) Install 3-4 shuttle valve in lower housing. PLATE HOUSING J932M59
Press valve inward and install E-clip on end of valve Fig. 120 Lower Housing Separator Plate Installation
to secure it in housing.
(4) Install 3-4 shuttle valve spring and throttle (4) Install lower housing on assembled transfer
plug in housing. plate and upper housing (Fig. 121).
(5) Install timing valve end plate. Tighten end (5) Install and start valve body screws by hand.
plate screws to 4 N«m (35 in. lbs.) torque. Then tighten screws evenly to 4 N * m (35 in. lbs.)
(6) Install 3-4 shift valve and spring. torque. Start at center and work out to sides when
(7) Install converter clutch valve, spring and plug. tightening screws.
(8) Install converter clutch timing valve and
spring.
3-4 Accumulator Assembly (Fig. 117)

(1) Lubricate accumulator piston, seals and hous
ing piston bore with transmission fluid.
(2) Install new seal rings on accumulator piston.
(3) Install piston and spring in housing.
(4) Install end plate on housing.
Transfer Plate Assembly

(1) Install rear clutch check ball in transfer plate
(Fig. 110).
(2) Install filter screen in upper housing separator
plate (Fig. 109).
(3) Align and position upper housing separator
plate on transfer plate (Fig. 109).
Fig. 121 Assembling Valve Body Upper And Lower
(4) Install brace plate (Fig. 108). Tighten brace at
Housings—42 RH
taching screws to 4 N«m (35 in. lbs.) torque.
(5) Install remaing separator plate attaching Upper Housing Valve And Plug Installation (Figs. 114, 115,
screws. Tighten screws to 4 N r n (35 in. lbs.) torque. 118)
(1) Lubricate valves, plugs, springs with Mopar
Assembling Upper And Lower Housings ATF Plus transmission fluid.
(1) Position upper housing so internal passages (2) Assemble regulator valve line pressure plug,
and check ball seats are facing upward. Then install sleeve, throttle plug and spring. Insert assembly in
check balls in housing (Fig. 111). Seven check balls upper housing and install cover plate. Tighten cover
are used. The single large check ball is approxi plate screws to 4 N * m (35 in. lbs.) torqe.
mately 8.7 m m (11/32 in.) diameter. The remaining 6 (3) Install 1-2 and 2-3 shift valves and springs.
check balls are approximately 6.3 mm (1/4 in.) in di (4) Install 1-2 shift control valve and spring.
ameter. (5) Install shift valve cover plate.
(6) Install shuttle valve as follows: (3) Position plug on end of converter clutch valve
(a) Insert plastic guides in shuttle valve second spring. Then compress and hold springs and plug in
ary spring and install spring on end of valve. place with fingers of one hand.
(b) Hold shuttle valve in place. (4) Swing accumulator housing upward over valve
(c) Compress secondary spring and install E-clip springs and plug.
in groove at end of shuttle valve. (5) Hold accumulator housing firmly in place and
(d) Verify t h a t spring and E-clip are properly install remaining two attaching screws. Be sure
seated before proceeding. springs and clutch valve plug are properly seated
(7) Install shuttle valve cover plate. Tighten cover (Fig. 124).
plate screws to 4 N*m (35 in. lbs.) torque.
RIGHT-SIDE SCREW
(8) Install 1-2 and 2-3 valve governor plugs in
valve body.
(9) Install shuttle valve primary spring and throt
tle plug.
(10) Align and install governor plug cover. Tighten
#
cover screws to 4 N rn (35 in. lbs.) torque.
(11) Install manual valve.
(12) Install throttle valve and spring.
(13) Install kickdown valve and detent.
(14) Install regulator valve.
(15) Install switch valve.
Boost Valve Tube Installation

(1) Position valve body assembly so lower housing
is facing upward (Fig. 122).
(2) Lubricate tube ends and housing ports with
3-4 ACCUMULATOR
transmission fluid or petroleum jelly.
(3) Position tube behind tube brace (Fig. 122).
(4) Start tube in lower housing port first. Then Fig. 123 Installing Converter Clutch And 3-4 Shift
swing tube downward and work opposite end of tube Valve Springs—42RH
into upper housing port (Fig. 122).
Seat both ends of tube once in position.
TUBE BRACE UPPER
CLUTCH ACCUMULATOR
VALVE PLUG BOSS J932M61
LOWER
HOUSING Fig. 124 Seating 3-4 Accumulator On Lower
PORT J932M62 Housing—42RH
Fig. 122 Boost Vaive Tube Installation-42RH (6) Attach solenoid case connector to 3-4 accumula
tor with shoulder-type screw. Connector has small lo
3-4 Accumulator Installation
cating tang t h a t fits in dimple at top of accumulator
(1) Position converter clutch valve and 3-4 shift housing (Fig. 125). Seat tang in dimple before tight
valve springs in housing (Fig. 123). ening connector screw.
(2) Loosely attach accumulator housing with right- (7) Install solenoid assembly and gasket. Tighten
side screw (Fig. 123). Install only one screw at this solenoid attaching screws to 8 N*m (72 in. lbs.)
time as accumulator must be free to pivot upward for torque.
ease of installation.
21 - 268 TRANSMISSION OVERHAUL-42RH _ . . _ +
SOLENOID are properly aligned. Then tighten all three bracket
CASE CONNECTOR screws to 4 N*m (35 in. lbs.) torque.
(6) Install throttle lever in upper housing. Then in
stall manual lever over throttle lever and start man
ual lever into housing.
(7) Position detent ball on end of spring. Then hold
detent ball and spring in detent housing with Re
(8) Align manual lever with detent ball and man
ual valve. Hold throttle lever upward. Then press
down on manual lever until fully seated. Remove de
tent ball retainer tool after lever is seated.
(9) Then Install manual lever seal, washer and
E-clip.
(10) Lubricate solenoid case connector O-rings and
shaft of manual lever with light coat of petroleum
jelly.
(11) Verify t h a t throttle lever is aligned with end
of kickdown valve stem and t h a t manual lever arm
(12) Install boost valve, valve spring, retainer and
Fig. 125 Solenoid Connector Installation—42RH cover plate. Tighten cover plate screws to 4 N*m (35
in. lbs.) torque.
(8) Verify t h a t solenoid wires are properly routed
(13) Obtain new fluid filter for valve body but do
(Fig. 126). S o l e n o i d w i r e s m u s t b e c l e a r of r e a r
not install filter at this time.
b a n d lever, m a n u a l l e v e r a n d p a r k r o d .
ment procedure.
Fig, 126 Solenoid Wire Routing—42RH

Valve Body Final Assembly And Adjustment
(1) Insert manual lever detent spring in upper
housing.
(2) Position line pressure adjusting screw in ad
justing screw bracket. Fig. 127 Manual And Throttle Lever
(3) Install spring on end of line pressure regulator Alignment-42RH
valve. VALVE BODY CONTROL PRESSURE
(4) Install switch valve spring on tang at end of ADJUSTMENTS
adjusting screw bracket. There are two control pressure adjustments on t h e
(5) Position adjusting screw bracket on valve body. valve body which are, line pressure and throttle pres
Align valve springs and press bracket into place. In sure.
stall short, upper bracket screws first and long bot Line and throttle pressure work together as each
tom screw last. Verify t h a t valve springs and bracket affects shift quality and timing. Both adjustments
must be performed properly and in the correct se

quence. Line pressure is adjusted first and throttle
pressure is adjusted last.

Measure distance from the valve body to the inner
edge of the adjusting screw with an accurate steel
scale (Fig. 128).
Distance should be 33.4 mm (1-5/16 inch).
The 33.4 m m (1-5/16 inch) setting is a n approx
imate setting. B e c a u s e of manufacturing toler
ances, it m a y be necessary to vary from this
dimension to obtain desired pressure.
One complete turn of the adjusting screw changes
line pressure approximately 1-2/3 psi (9 kPa). Turn Fig. 129 Throttie Pressure Adjustment
ing the adjusting screw counterclockwise increases clean. Also make sure the tools and workbench area
pressure while turning the screw clockwise decreases used for assembly operations are equally clean.
pressure. Shop towels used for wiping off tools and hands
must be made from lint free material. Lint will stick
to transmission parts and could interfere with valve
operation, or even restrict fluid passages.
Lubricate the transmission components with Mopar
transmission fluid during reassembly. Use petroleum
jelly, Door Eze, or Ru-Glyde on seals and O-rings to
ease installation.
Petroleum jelly can also be used to hold thrust
washers, thrust plates and gaskets in position during
assembly. However, do not use chassis grease, bear
ing grease, white grease, or similar lubricants on any
transmission part. These types of lubricants can
eventually block or restrict fluid passages and inter
fere with valve operation. Use petroleum jelly only.
Do not force parts into place. The transmission
components and sub-assemblies are easily installed
Fig. 128 Line Pressure Adjustment by hand when properly aligned.
If a part seems extremely difficult to install, it is
Throttle Pressure Adjustment
either misaligned or incorrectly assembled. Also ver
Insert Gauge C-3763 between the throttle lever ify that thrust washers, t h r u s t plates and seal rings
cam and the kickdown valve stem (Fig. 129). are correctly positioned before assembly. These parts
Push the gauge tool inward to compress the kick- can interfere with proper assembly if mispositioned
down valve against the spring and bottom the throt (or "left out" by accident).
tle valve. The planetary geartrain, front/rear clutch assem
Maintain pressure against kickdown valve spring. blies and oil pump are all much easier to install
Turn throttle lever stop screw until the screw head when the transmission case is upright or as close to
touches throttle lever tang and the throttle lever cam this position as possible. Either tilt the case upward
touches gauge tool. with wood blocks, or cut a hole in the bench large
The k i c k d o w n valve spring must be fully com enough for the output shaft. Then lower the shaft
p r e s s e d and the k i c k d o w n valve completely bot through the hole and support the transmission case
tomed to obtain correct adjustment. directly on the bench.
TRANSMISSION ASSEMBLY AND ADJUSTMENT TRANSMISSION ASSEMBLY PROCEDURE
(1) Install rear servo piston, spring and retainer
Assembly Tips
(Fig. 130). Install spring on top of servo piston and
Do not allow dirt, grease, or foreign material to en install retainer on top of spring.
ter the case or transmission components during as (2) Install front servo piston assembly, servo
sembly. Keep the transmission case and components spring and rod guide (Fig. 131).
SERVO PISTON SNAP (4) Examine bolt holes in overrunning clutch cam.
PISTON SPR NG RING Note that one hole is n o t t h r e a d e d (Fig. 133). This
hole must align with blank area in clutch cam bolt
circle (Fig. 134). Mark hole location on clutch cam
and blank area in case with grease pencil, paint
stripe, or scribe mark for assembly reference.
NON-THREADED
HOLE
PISTON
SEAL RETAINER J9121-343
Fig. 130 Rear Servo Components—42RH OVERRUNNING
CLUTCH CAM
PISTON SERVO PISTON SNAP RING
SEAL
RINGS
J9121-226
Fig. 133 Location Of Non-Threaded Hole In Clutch

Cam-42RH
S> OVERRUNNING
CLUTCH CAM
SEAT IN CASE
ROD
ROD SPRING GUIDE J9121-344
(3) Compress front/rear servo springs with Valve
Spring Compressor C-3422-B and install each servo
snap ring (Fig. 132). 40N-THREADED
HOLE IN CLUTCH
SPRING CAM ALIGNS
COMPRESSOR HERE (BLANK AREA)
TOOL OF SEAT i
J9121-541
C-3422-B
Fig. 134 Location Of Blank Area In Clutch Cam Bolt
Circle-42RH
(5) Mark location of non-threaded hole in clutch
cam and blank area in bolt circle with grease pencil.
(6) Align and install overrunning clutch and cam
in case (Fig. 135). Be sure cam is correctly in
stalled. Bolt holes in cam are slightly counter
sunk on one side. Be sure this side of cam faces
rearward (toward piston retainer).
(7) Verify t h a t non-threaded hole in clutch cam is
properly aligned. Check alignment by threading a
ROD bolt into each bolt hole. Adjust clutch cam position if
QUIDE necessary.
SNAP
RING J9121-136 (8) Install and tighten overrunning clutch cam
Fig. 132 Compressing Front/Rear Servo Springs bolts to 17 N«m (13 ft. lbs.) torque. Note t h a t clutch
cam bolts are shorter t h a n piston retainer bolts.
Fig. 135 Overrunning Clutch Installation—42RH

(9) Lubricate clutch cam rollers with transmission
fluid.
(10) Install rear band reaction pin (Fig. 136). Be
sure pin is fully seated in case.
Fig. 137 Rear Band Installation—42RH
Fig. 136 Installing Rear Band Reaction Pin—42RH

(11) Install rear band in case (Fig. 137). Be sure Fig. 138 Installing Low-Reverse Drum—42RH
twin lugs on band are seated against reaction pin.
sure to align governor feed holes in gasket with feed
(12) Install low-reverse drum and check overrun
passages in case (Fig. 139). Also install gasket before
ning clutch operation as follows:
overdrive piston retainer. Center hole in gasket is
(a) Lubricate overrunning clutch race (on drum smaller t h a n retainer and cannot be installed over
hub) with transmission fluid.
retainer.
(b) Guide drum through rear band.
(14) Install overdrive piston retainer. Be sure gov
(c) Tilt drum slightly and start race (on drum
ernor tube bores in retainer are aligned with gover
hub) into overrunning clutch rollers.
nor feed passages in gasket and case (Fig. 140).
(d) Press drum rearward and t u r n it in clockwise #
Install and tighten retainer bolts to 17 N m (13 ft.
direction until drum seats in overrunning clutch
lbs.) torque.
(Fig. 138).
(e) Turn drum back and forth. Drum should ro (15) Install snap ring t h a t secures low-reverse
tate freely in clockwise direction a n d lock in drum to hub of piston retainer (Fig. 141).
counterclockwise direction (as v i e w e d from (16) Install rear band lever and pivot pin (Fig.
front of case). 142). Align lever with pin bores in case and push
(13) Install new gasket at rear of transmission pivot pin into place.
case. Use petroleum jelly to hold gasket in place. Be
Fig. 139 Installing/Aligning Case Gasket—42RH Fig. 141 Installing Low-Reverse Drum Retaining
Snap Ring
Fig. 142 Rear Band Lever And Pivot Pin Installation

hooked together. Also verify t h a t shaft seal rings are
installed in sequence shown.
(20) Check rear clutch fiber thrust washer (Fig.
146). Use additional petroleum jelly to hold washer
Fig. 140 installing Overdrive Piston Retainer—42RH in place if necessary.
(17) Install planetary geartrain assembly (Fig. (21) Align clutch discs in front clutch and install
143) front clutch on rear clutch (Fig. 147). Rotate front
clutch retainer back and forth until completely
(18) Install thrust plate on intermediate shaft hub
seated on rear clutch.
(Fig. 144). Use petroleum jelly to hold thrust plate in
(22) Coat intermediate shaft thrust washer with
place.
petroleum jelly. Then install washer in rear clutch
(19) Check seal ring on rear clutch retainer hub
hub (Fig. 148). Use enough petroleum jelly to hold
(Fig. 49) and seal rings on input shaft (Fig. 145). washer in place. B e sure grooved side of w a s h e r
Verify t h a t diagonal-cut ends of teflon seal rings are faces rearward (toward output shaft) as s h o w n .
properly joined and ends of metal ring are correctly Also note t h a t w a s h e r only fits one w a y in
clutch hub.
• TRANSMISSION OVERHAUL-42RH 2"! - 273
INPUT
SHAFT TEFLON
SEAL
/ RING
METAL
SEAL
RING
Fig. 145 Input Shaft Seal Ring Location-42RH
REAR
CLU1CH
J9121-217 ÊTA'Mnk
Fig. 143 installing Planetary Geartrain—42RH
Fig, 146 Installing Rear Clutch Thrust

Washer-42RH
INTERMEDIATE
INTERMEDIATE SHAFT
SHAFT HUB THRUST PLATE
J9121-215
Fig. 144 installing intermediate Shaft Thrust Plate

(23) Align drive teeth on rear clutch discs with
small screwdriver (Fig. 149). This makes installation
on front planetary easier. i i JfiN
(24) Raise front end of transmission upward as far " FRONT
CLIPCr
as possible and support case with wood blocks. Front/ BACK & FO-TH
rear clutch and oil pump assemblies are easier to in { UNTIL
stall if transmission is as close to upright position as i SEATED
REAR
possible. CLUTCH
(25) Install front and rear clutch units as assembly ASSEMBLY J9121-190
(Fig. 150). Align rear clutch with front annulus gear

and install assembly in driving shell. Re sure out Fig. 147 Assembling Front And Rear Clutch
put shaft thrust w a s h e r and thrust plate are not Units-42RH
displaced during installation. (26) Carefully work assembled clutches back and
forth to engage and seat rear clutch discs on front
21 - 274 TRANSMISSION 0WERHAUL-42RH
INTERMEDIATE INPUT FRONT REAR

SHAFT THRUST SHAFT CLUTCH 'CLUTCH
WASHER
REAR
CLUTCH
RETAINER
HUB
INPUT J9121-214
SHAFT J9121-124
Fig. 148 Installing Intermediate Shaft Thrust Fig. 150 Installing Front/Rear Clutch
Washer-42RH Assemblies—42RH
:FRONT
REAR BAND
CLUTCH
DISCS
FRONT
BAND
REACTION
PIN
USE FRONT
SMALL CLUTCH
SCREWDRIVER RETAINER
TO
ALIGN
CLUTCH DISC J912M93
TEETH ^J9121-192
Fig. 149 Aligning Rear Clutch Disc Lugs—42RH Fig. 151 Installing Front Band And Reaction
annulus gear. Also be sure front clutch drive lugs are Pin-42RH
fully engaged in slots of driving shell after installa (32) Check seal rings on reaction shaft support
tion. hub. Verify t h a t seal rings are hooked together and
(27) Slide front band over front clutch retainer t h a t front clutch thrust washer is properly positioned
(Fig. 151). (Fig. 153). Use extra petroleum jelly to hold thrust
(28) Insert front band reaction pin part way into washer in place if necessary.
case (Fig. 151). (33) Thread two Pilot Stud Tools C-3288-B into
(29) Install front band lever, strut and adjusting bolt holes in oil pump flange (Fig. 154).
screw (Fig. 152). (34) Align and install oil pump gasket (Fig. 154).
(30) Push front band reaction pin completely into (35) Lubricate oil pump body seal with Ru-Glyde,
place. Then tighten band adjusting screw until band or petroleum jelly. Lubricate pump shaft seal lip
just grips clutch retainer. Verify t h a t front/rear with petroleum jelly.
clutches are still seated before continuing. (36) Install oil pump (Fig. 155). Align and position
(31) Coat band reaction pin access plug with sealer pump on pilot studs. Slide pump down studs and
and install plug in converter housing.
BAND BAND
Fig. 152 Front Band Linkage Installation—42RH
Fig. 154 Installing Pilot Studs And Oil Pump

Gasket-42RH
SEAL
RINGS J9121-194
Fig. 153 Reaction Shaft Support Seal Rings And

Front Clutch Thrust Washer Position—42RH
work it into front clutch hub and case by hand. Then
install 2 or 3 pump bolts to hold pump in place.
(37) Remove pilot stud tools arid install remaining
oil pump bolts. Tighten bolts alternately in diagonal
pattern to 20 N*m (15 ft. lbs.).
(38) Measure input shaft end play (Fig. 156). At Fig. 155 Installing Oil Pump Assembly In
tach dial indicator to converter housing. Position in Case—42RH
dicator plunger against input shaft and zero (42) Install overdrive piston thrust plate (Fig. 158).
indicator. Move input shaft in and out and record Use liberal quantity of petroleum jelly to hold thrust
reading. End play should be 0.56 - 2.31 mm (0.022 - plate in position on piston.
0.091 in.). (43) Install overdrive piston thrust bearing in di
(39) Install new seals on overdrive piston. Then lu rect clutch hub (Fig. 159). Use liberal quantity of pe
bricate seals with Ru-Glyde, Door-Eze or petroleum troleum jelly to hold thrust bearing in place. Note
jelly. that one side of bearing h a s dark coated sur
(40) Install overdrive piston in retainer. Align lo face. This surface faces overdrive piston. Also
cating l u g s on piston in locating b o r e s in re b e sure raised shoulder o n inside diameter of
tainer (Fig. 157). Use thin plastic strip or feeler bearing faces forward as well.
gauge to help guide piston outer seal into retainer. (44) Apply small amount of petroleum jelly to pilot
(41) Install spacer on intermediate shaft, if not hub of intermediate shaft.
previously installed. (45) Verify alignment of splines in overdrive unit
planetary gear and overrunning clutch. Be sure
OVERDRIVE
OVERDRIVE
PISTON
THRUST
PLATE
J9121-354
Fig. 156 Measuring input Shaft End Play Fig. 158 Installing Overdrive Piston Thrust
Plate-42RH
RETAINER
LUG
BORES
BE SURE
THIS SHOULDER
OVERDRIVE
PISTON
THRUST
IARINC
Fig. 159 Installing Overdrive Piston Thrust

Bearing—42RH
PISTON
LOCATING
LUGS
SPECIAL
TOOL 6227-2
J9121-353
Fig. 157 Overdrive Piston Alignment—42RH

Alignment Tool 6227-2 is still fully seated (Fig. 160).
If planetary gear a n d overrunning clutch splines
b e c o m e misaligned, overdrive unit c a n n o t be
fully installed o n i n t e r m e d i a t e shaft. Overdrive
unit will h a v e to be disassembled in order to re J9221-36
align splines.
Fig. 160 Checking Alignment Of Overdrive Planetary
(46) Carefully withdraw alignment tool from over
Gear And Overrunning Clutch Splines—42RH
drive unit.
(47) Lubricate intermediate shaft splines and bushing (55) Install seal on park/neutral position switch
surfaces with transmission fluid or petroleum jelly. (Fig. 162). Then install and tighten switch to 34 N«m
(48) Install overdrive unit. Be sure governor tubes (25 ft. lbs.).
are aligned with feed holes in piston retainer boss.
Note that intermediate shaft is snug fit in overdrive
planetary gear and overrunning clutch. If overdrive
unit will not seat fully, rotate overdrive output shaft
slightly to align splines and try again.
(49) Apply 1-2 drops of Mopar thread adhesive (or
Loctite 242) to overdrive unit attaching bolts. Then
install and tighten bolts to 34 N« (25 ft. lbs.) torque.
(50) Install accumulator inner spring, piston and
outer spring (Fig. 161).
Fig. 162 Park/Neutral Position Switch Seal Position
ACCUMULATOR OUTER
(56) Install magnet in oil pan. Magnet goes on
stall oil pan. Tighten pan bolts to 17 N*m (13 ft. lbs.).
Fig. 161 Installing Accumulator Piston And

Springs—42RH
(51) Verify t h a t park/neutral position switch has
not been installed in case. Valve body can not be in
stalled if switch is in position.
(52) Install valve body as follows:
(a) Start park rod into park pawl. If rod will not
slide past park pawl, pawl is engaged in park gear.
Rotate overdrive output shaft with socket to free
pawl and allow rod to engage.
(b) Align and seat valve body on case. Be sure
manual lever shaft and overdrive connector are
fully seated in case. (59) Install throttle valve and shift selector levers
(c) Install and start all valve body attaching on valve body manual lever shaft.
bolts by hand. Then tighten bolts evenly, in a di (60) Cap or cover transmission openings (cooler line
agonal pattern to 12 N»m (105 in. lbs.) torque. D o fittings, filler tube bore, etc.) to prevent dirt entry.
n o t overtighten v a l v e b o d y bolts. T h i s could (61) Install torque converter. Use C-clamp or metal
result in distortion and cross leakage after in strap to hold converter in place for installation.
stallation.. (62) Mount transmission on jack for installation in
(53) Install new filter on valve body. Tighten filter vehicle.
screws to 4 N*m (35 in. lbs.). (63) Apply dielectric grease to terminal pins of so
(54) Adjust front and rear bands as follows: lenoid case connector and neutral switch.
(a) Loosen band adjusting screw locknuts.
(b) Tighten each band adjusting screw to 5 Nnn be reverse flushed if overhaul corrected a malfunc
(72 in. lbs.) with torque wrench. tion that generated sludge, metal particles, or
(c) Back off front band adjusting screw 2-1/2 turns. clutch friction material. The torque converter should
(d) Back off rear band screw 4 turns. also be replaced if contaminated by the same mal
(e) Tighten each adjusting screw locknut. Hold function. Debris and residue not flushed from the
adjusting screws with wrench to prevent turning cooler and lines will flow back into the transmission
when tightening locknut. and converter. The result could be a repeat failure
and shop comeback.
21 - 278 TRANSMISSION 0VERHAUL-4IRH •
TRANSMISSION OWERHAUL-46RH
INDEX
page page
Accumulator Overhaul 288 Rear Clutch Overhaul 295
Front Clutch Overhaul 293 Rear Servo and Band Overhaul . 289
Front Servo and Band Overhaul . . . . . . . . . . . . 289 Transmission Assembly . . . . . . . . . . . . . . . . . . . 3 1 5
Oil Pump and Reaction Shaft Support Overhaul . 289 Transmission C a s e Cleaning and Inspection . . . 285
Overdrive Piston and Retainer Service 286 Transmission Disassembly 278
Overhaul Service Information 285 Valve Body Cleaning and Inspection 308
Overrunning Clutch Overhaul 286
Planetary Geartrain Overhaul . . . . . . . . . . . . . . . 297 Valve Body Service and Adjustment . 302
(1) Remove torque converter, if not previously re
moved.
solvent. Wear safety goggles while cleaning trans
mission.
(3) Remove shift and throttle levers from shaft of
valve body manual lever.
(4) Remove bolts attaching overdrive unit to trans
mission case (Fig. 1).
Fig. 2 Loosening Overdrive Unit From Transmission
Fig. 1 Removing Overdrive Unit Attaching Bolts

(5) Loosen overdrive unit. Use pry tool to start
overdrive unit off intermediate shaft and transmis
sion case. Position pry tool between flange on over
drive case and transmission rear servo boss (Fig. 2). J9121-209
(6) Work overdrive unit rearward and off transmis
Fig. 3 Removing Overdrive Unit From
sion intermediate shaft (Fig. 3).
Transmission—46RH
(a) If overdrive unit does not require service, in
sert Alignment Tool 6227-2 in overdrive unit over (7) Remove thrust plate from overdrive piston (Fig.
running clutch and planetary gear to maintain 5).
spline alignment (Fig. 4). If clutch a n d gear (8) Remove overdrive piston from retainer (Fig. 6).
splines rotate out of alignment, overdrive unit (9) Remove overdrive pistop thrust bearing (Fig.
will h a v e to b e disassembled in order to re 7).
align splines. (10) Mount transmission unit on Repair Stand
(b) If overdrive unit does requires service, refer C-3750-B, or support transmission with wood blocks.
to Overdrive unit Overhaul section.
SPECIAL
OVERDRIVE
PISTON
THRUST
BEARING
\ \
J9321-133 J9121-279
Fig. 4 Overdrive Spline Alignment Tool Installation Fig. 7 Removing/Installing Overdrive Piston Thrust
Bearing
>sPISTON THRUST PLATE
(SELECT FIT) (11) Remove pump oil seal with Special Tool C-3861
W (Fig. 8). Be sure to tighten tool threads completely into
seal before using puller bolt to withdraw seal.
OVERDRIVE
PISTON J9121-503 J9321-182\> s
Fig. 5 Removing Overdrive Piston Thrust Plate—46RH Fig. 8 Removing Pump Oil Seal—46RH
PISTON (12) Remove oil pan bolts and remove pan (Fig. 9)
and gasket (Fig. 10). Oil pan magnet can be removed
or left in pan as needed (Fig. 11). Exercise care when
removing pan to avoid distorting or bending pan
flange.
PISTON
RETAINER
J9121-5
Fig. 6 Removing Overdrive Piston—46RH Fig. 9 Removing/Installing Oil Pan—46RH
Fig. 11 Oil Pan Magnet Location—46RH

(13) Remove park/neutral position switch (Fig. 12).
If switch gasket is in good condition, retain gasket
and keep it with switch.
J9321-135
Fig. 14 Valve Body Bolt Locations—46RH
VALVE BOOST
BODY VALVE
ASSEMBLY TUBE
J9321-128 " ' SWITCH

Installation
(14) Remove fluid filter attaching screws and re
move filter (Fig. 13). Keep filter screws separate.
They are longer t h a n valve body screws.
(15) Remove hex head valve body attaching bolts
(Fig. 14). A total of 10 hex head bolts are used to se
cure valve body to case.
(16) Lift valve body upward. Push solenoid connec
tor and manual lever shaft out of case. Then raise
valve body, guide park rod out of case and remove PARK CASE
valve body (Fig. 15). D o not u s e boost valve tube ROD CONNECTOR J9321-136
to lift valve body. Set valve body aside for disas
Fig. 15 Valve Body Removal—46RH
sembly, cleaning and inspection.
(17) Remove accumulator outer spring, piston and

inner spring (Fig. 16). Note position of piston and
springs for assembly reference. Remove and discard
piston seals if worn or cut.
ACCUMULATOR OUTER
Fig. 18 Tightening Front Band To Hold Front Clutch

In Piace-46RH
Fig. 16 Accumulator Component Removal--46RH

(18) Remove front band lever pin access plug (Fig.
17). Use square end of 1/4 in. drive extension to re
move plug as shown.
Fig. 19 Installing Oil Pump Remover Tools—46RH
Fig. 17 Removing/Installing Front Band Lever Pin

Access Plug—46RH
(19) Remove oil pump and reaction shaft support
assembly as follows:
(a) Tighten front band adjusting screw until
band is tight around front clutch retainer (Fig. 18).
This will prevent retainer from coming out with
pump and possibly damaging clutch or pump com
ponents.
(b) Remove oil pump bolts.
(c) Thread Slide Hammer Tools C-3752 into
threaded holes in flange of oil pump housing (Fig.
19).
(d) Remove oil pump and reaction shaft support
by bumping slide hammers outward alternately to
pull pump from case (Fig. 20).
Fig. 20 Oil Pump Removal—46RH
(20) Remove oil pump gasket (Fig. 21). Note gas
ket position in case for assembly reference.
Fig. 21 Removing Oil Pump Gasket—46RH

(21) Loosen front band adjusting screw until band
is completely loose.
(22) Remove front band strut and anchor (Fig. 22).
LEVER STRUT
Fig. 24 Removing/Installing Front And Rear Clutch

Assemblies—46RH
J9121-18
Fig. 22 Front Band Linkage—46RH

(23) Squeeze front band together slightly and slide
band over front clutch retainer and out of case (Fig.
23).
(24) Remove front and rear clutch assemblies as a
unit (Fig. 24). Set assemblies aside for disassembly
and inspection after removal.
(25) Remove front band reaction pin and lever.
Start pin through lever and out of case bore with
drift or punch. Then use pencil magnet to withdraw
pin completely (Fig. 25).
Fig. 25 Removing Front Band Lever And Pin—46RH
• TRANSMISSION 0WERHAUL-46RH 21 - 283
Fig. 26 Removing intermediate Shaft Thrust

ASSEMBLY J9121-508
Washer-46RH
Fig. 28 Removing Intermediate Shaft And Planetary
Geartrain Assembly—46RH
Fig. 27 Removing intermediate Shaft Thrust

Plate-46RH
(26) Remove intermediate shaft thrust washer. Tri Fig. 29 Removing/Installing Low-Reverse Drum
angular shaped washer will either be on shaft pilot Snap Ring—46RH
hub or in rear clutch retainer (Fig. 26).
(27) Remove thrust plate from intermediate shaft
hub (Fig. 27).
(28) Remove intermediate shaft-planetary
geartrain assembly (Fig. 28). Set assembly aside for
disassembly and inspection later in procedure.
(29) Loosen rear band adjusting screw 3-4 turns.
(30) Remove snap ring t h a t retains low-reverse
drum on overdrive piston retainer hub (Fig. 29).
(31) Slide low-reverse drum off piston retainer hub
and out of rear band (Fig. 30).
(32) Note t h a t overrunning clutch race will remain
on splines of low-reverse drum after removal (Fig.
31). The race is a permanent press fit o n the h u b
splines. D o not a t t e m p t to remove the race.
(33) Remove overrunning clutch assembly (Fig.
32). Assembly can be removed without displacing
Fig. 30 Removing/Installing Low-Reverse
Drum—46RH
21 - 284 TRANSMISSION 0¥ERHAUL-46RH
OVERRUNNING LOW-REVERSE REAR

CLUTCH DRUM BAND ADJUSTING
RACE LEVER
REAR
BAND
REACTION _ ^, , ,
J9221-8
P I N ~ y / ( /\~y/ J9121-37
Fig. 31 Overrunning Clutch Race Position—46RH Fig. 33 Removing Rear Band Levers And Reaction
rollers and springs if care is exercised. Note position Pin-46RH
of rollers and springs for assembly reference. BAND
LINK
^CLUTCH
CAM
-J9121-38
Fig. 34 Removing Rear Band And Link—46RH
Fig. 32 Removing/Installing Overrunning ^ ) FRCNT

SERVO
Clutch-46RH ROD
GUIDE
(34) Remove rear band adjusting lever, reaction le
ver and reaction pin (Fig. 33).
(35) Remove strut from rear band. Keep strut with
levers and pin for cleaning, inspection and assembly
reference.
(36) Remove rear band and link (Fig. 34).
(37) Compress front servo rod guide with C-clamp
and Tool C-4470, or Valve Spring Compressor
C-3422-B (Fig. 35). Compress guide only enough to
permit snap ring removal (about 1/8 in.).
(38) Remove servo piston snap ring (Fig. 35). Un TOOL
seat one end of ring. Then carefully work removal /C4470 J9121-39
tool around back of ring until free of ring groove. Ex- Fig. 35 Removing Front Servo Retaining Snap Ring-46RH
ercise c a u t i o n w h e n r e m o v i n g s n a p r i n g . S e r v o
b o r e c a n b e s c r a t c h e d o r n i c k e d if c a r e is n o t
exercised.
(39) Remove tools and remove servo piston and
spring.
(40) Compress rear servo piston with C-clamp and
Tool C-4470, or Valve Spring Compressor C-3422-B
(Fig. 36). Compress servo spring retainer only
enough to permit snap ring removal.
(41) Remove servo piston snap ring (Fig. 36). Start
one end of ring out of bore. Then carefully work re
moval tool around back of snap ring until free of ring
groove. E x e r c i s e c a u t i o n w h e n r e m o v i n g s n a p
r i n g . S e r v o b o r e c a n b e s c r a t c h e d o r n i c k e d if
c a r e is n o t e x e r c i s e d .
(42) Remove tools and remove rear servo retainer,
spring and piston assembly.
Fig. 37 Removing Overdrive Piston Retainer—46RH

Heli-Coil inserts are recommended for repairing
damaged, stripped or worn threads in aluminum
parts. These inserts are available from most automo
tive jobbers. Stainless steel inserts are preferred.
The use of crocus cloth is permissible where neces
sary, providing it is used carefully. When used on
bore.
Fig. 36 Removing Rear Servo Retaining Snap O-rings during overhaul. Replace these parts as a
Ring—46RH matter of course. Also do not reuse snap rings or
(43) Remove overdrive piston retainer bolts and re E-clips t h a t are bent or distorted. Replace these parts
move retainer from case (Fig. 37). as well.
(44) Remove gasket from rear of case after remov Lubricate transmission parts with Mopar ATF
ing piston retainer. Plus, Type 7176 transmission fluid during assembly.
Use Ru-Glyde, petroleum jelly, or Door-Eze to prelu-
OVERHAUL SERVICE INFORMATION bricate seals, O-rings, and thrust washers. Petroleum
Inspect all the transmission bushings during over jelly can also be used to hold parts in place during
haul. Bushing condition is important as worn, scored reassembly.
bushings contribute to low pressures, clutch slip and
accelerated wear of other components. Replace worn, TRANSMISSION CASE CLEANING AND
or scored bushings, or if doubt exists about bushing INSPECTION
condition. Clean the case in a solvent tank. Flush the case
Use recommended tools to replace bushings. The bores and fluid passages thoroughly with solvent.
tools are sized and designed to remove, install and Dry the case and all fluid passages with compressed
seat bushings correctly. The bushing replacement air. Be sure all solvent is removed from the case and
tools are included in Bushing Tool Set C-3887-B. t h a t all fluid passages are clear.
Pre-sized service bushings are available for re Do not use s h o p t o w e l s or rags to dry the c a s e
placement purposes. Only the sun gear bushings are (or any other transmission component) u n l e s s
not serviced. Low cost of the sun gear assembly they are m a d e from lint-free materials. Lint will
makes it easier to simply replace t h e gear and bush readily adhere to c a s e surfaces a n d transmission
ings as an assembly. components a n d will circulate throughout the
t r a n s m i s s i o n after a s s e m b l y . A sufficient q u a n OWERRUNNlNG CLUTCH OVERHAUL
tity of lint c a n b l o c k fluid p a s s a g e s a n d Interfere Inspect condition of the clutch cam, cage-type re
with valve body operation. tainer, rollers, springs and clutch race.
Inspect the case for cracks, porous spots, worn Replace the clutch cam if worn or damaged. Also
servo bores, or damaged threads. Damaged threads check fit of the cam in the transmission case. If the
can be repaired with Helicoil thread inserts. How cam is loose, the case may be worn, or cracked.
ever, the case will have to be replaced if it exhibits The clutch race is permanently pressed onto the
damage or wear. low-reverse drum hub. If either the drum or race are
Lubricate the front band adjusting screw and lock- worn or damaged, replace the drum and race as an
nut with petroleum jelly and thread it part way into assembly. Check fit of the race on the low-reverse
the case. Be sure the screw t u r n s freely and does not drum hub splines. Replace the drum and race as an
bind. Install the locknut on the screw after checking assembly if the race is loose on the hub splines.
screw thread operation. Examine the overrunning clutch assembly care
fully. Replace assembly if the rollers, springs, or
OVERDRIVE PISTON AND RETAINER SERVICE cage-type retainer are worn, or damaged.
Remove and discard the piston seals. If the clutch cam requires replacement, install a
Clean the piston and retainer in parts cleaning sol new cam as described in the following procedure.
vent. Do not use any type of caustic materials for
cleaning. Such materials may etch the surfaces caus OVERRUNNING CLUTCH CAM REPLACEMENT
ing damage. (1) Remove clutch cam setscrew (Fig. 39).
Inspect the piston and retainer carefully. Replace
either part if cracked, porous or damaged in any
way. Check condition of the locating lugs on the pis
ton. Be sure the lugs are in good condition and are
not worn, chipped or broken.
Inspect the check ball in the piston (Fig. 38). Be
sure the ball is secure and is not partially dislodged,
or loose. Replace the piston if doubt exists about pis
ton or check ball condition.
Check the governor feed tube boss in the retainer.
Be sure the boss is in good condition and is not dam
aged in any way.
Fig. 39 Removing/Installing Clutch Cam

Setscrew—46RH
(2) Tap old cam and spring retainer out of case
with pin punch. Insert punch through bolt holes at
rear of case (Fig. 40). Alternate position of punch to
avoid cocking cam during removal.
(3) Clean clutch cam bore and case. Be sure to re
move all chips/shavings generated during cam re
moval.
(4) Install rear support in case. Align support with
reference marks made at disassembly.
(5) Align and start new clutch cam and spring re
tainer in case. Be sure serrations on cam and in case
are aligned (Fig. 41). Then tap cam into case just
enough to hold it in place.
(6) Verify t h a t c a m is c o r r e c t l y p o s i t i o n e d b e
fore p r o c e e d i n g a n y f u r t h e r . N a r r o w e n d s of
Fig. 38 Overdrive Piston—46RH c a m r a m p s s h o u l d b e to left w h e n c a m is v i e w e d
f r o m front e n d of c a s e (Fig. 41).
• TRANSMISSION 0WERHAUL-48RH 21 - 287
Fig. 40 Removing Overrunning Clutch Cam—46RH
Fig. 41 Positioning Replacement Clutch Cam And

Spring Retainer—46RH
(7) Insert Adapter Tool SP-5124 into piston re
tainer (Fig. 42).
(8) Assemble Puller Bolt SP-3701 and Press Plate
SP-3583-A (Fig. 43).
(9) Install assembled puller plate and bolt (Fig. Fig. 43 Assembling Clutch Cam Puller Bolt And
44). Insert bolt through cam, case and adapter tool. Press Plate
Be sure plate is seated squarely on cam.
(15) Clean case and cam thoroughly. Be sure any
(10) Hold puller plate and bolt in place and install
puller nut SP 3701 on puller bolt (Fig. 45). chips/shavings generated during cam installation are
(11) Tighten puller nut to draw clutch cam into removed from case.
case (Fig. 45). B e sure c a m is drawn into case
INSTALLING OVERRUNNING CLUTCH
evenly and does not b e c o m e cocked.
ASSEMBLY
(12) Install clutch cam setscrew (Fig. 39).
(1) Lubricate overdrive piston retainer hub, clutch
(13) Remove clutch cam installer tools and piston
race, clutch cam, and overrunning clutch rollers with
retainer.
transmission fluid.
(14) Stake case in 12 places around clutch cam
(2) If any overrunning clutch rollers or springs
to help secure c a m in case. U s e blunt p u n c h or
came out of retainer, reinstall them as follows: In-
chisel to stake c a s e .
Fig. 44 Positioning Puller Plate On Clutch Cam
Fig. 45 Installing Overrunning Clutch Cam—46RH

Fig. 47 Overrunning Clutch Seated In Cam
stall and seat spring in retainer first. Then insert
roller between spring and retainer stop as shown (5) Check overrunning clutch operation. Low-re
(Fig. 46). Verify t h a t each roller and spring are fully verse drum should rotate freely in clockwise direc
seated before proceeding. tion and lock in counterclockwise direction.
(3) Install and seat clutch assembly in cam (Fig. (6) Align and reinstall overdrive piston retainer.
47). The retainer is a o n e - w a y fit in the cam. The Tighten retainer bolts to 11 N*m (95 in. lbs.) torque.
flanged side of the retainer s h o u l d b e f a c i n g out
ward. The retainer a n d rollers will slip easily ACCUMULATOR OVERHAUL
into the c a m w h e n properly positioned. Inspect the accumulator piston and seal rings (Fig.
(4) Install low-reverse drum. Tilt drum slightly 48). Replace the seal rings if worn or cut. Replace the
and carefully engage clutch race (on drum hub) in piston if chipped or cracked.
overrunning clutch rollers. Raise drum to level posi Check condition of the accumulator inner and outer
tion. Then rotate the drum in clockwise direction un springs (Fig. 48). Replace the springs if the coils are
til fully seated. cracked, distorted or collapsed.
ACCUMULATOR PISTON RINGS (2)

PISTON ROD:
PISTON
SERVO PISTON • SPRING
OUTER < WASHER
INNER SPRING O" RING
SPRING .SNAP RING
PISTON ROD GUIDE
PISTON ROD
(A-727 ONLY)'
SERVO SPRING-
SEAL J9121-230
RINGS SEAL RING.
SNAP RING-
Fig. 48 Accumulator Components—46RH RH307
FRONT SERVO AND BAND OVERHAUL
Clean the servo piston components with solvent
and dry them with compressed air. Wipe the band the lining material). If doubt exists about the condi
clean with lint free shop towels. tion of any servo component, replace it. Do not reuse
Replace the front band if distorted, lining is suspect parts.
burned, flaking off, or worn to the point where the
grooves in the lining material are no longer visible. REAR SERVO PISTON OVERHAUL (FIG. 50)
Inspect the servo components. Replace the springs (1) Remove small snap ring and remove plug and
if collapsed, distorted or broken. Replace the guide, spring from servo piston.
rod and piston if cracked, bent, or worn. Discard the (2) Remove and discard servo piston seal ring.
servo snap ring if distorted or warped. (3) Lubricate piston and guide seals with petro
Check the servo piston bore for wear. If the bore is leum jelly. Lubricate other servo parts with Mopar
severely scored, or damaged, it will be necessary to ATF Plus transmission fluid.
replace the case. (4) Install new seal ring on servo piston.
Replace any servo component if in doubt about its (5) Assemble piston, plug, spring and snap ring.
condition. Do not reuse suspect parts. (6) Lubricate piston seal lip with petroleum jelly.
(7) Set servo components aside for assembly instal
FRONT SERVO PISTON OVERHAUL (FIG. 49) lation.
(1) Remove seal ring from rod guide.
(2) Remove small snap ring from servo piston rod. SNAP PISTON PISTON SPRING SNAP
RING SEAL PLUG RETAINER RING
Then remove piston rod, spring and washer from pis
ton.
(3) Remove and discard servo component O-ring
and seal rings.
(4) Lubricate new O-ring and seal rings with pe
troleum jelly and install them on piston, guide and
rod. CUSHION PISTON
(5) Install rod in piston. Install spring and washer PISTON SPRING SPRING J9121-64
on rod. Compress spring and install snap ring.
(6) Set servo components aside for installation dur Fig. 50 Rear Servo Components—46RH
ing transmission reassembly. OIL PUMP AND REACTION SHAFT SUPPORT
OVERHAUL
REAR SERVO AND BAND OVERHAUL
Clean the servo components with solvent and dry PUMP AND SUPPORT DISASSEMBLY
them with compressed air. Inspect the servo compo (1) Mark position of support in oil pump body for
nents. Replace the spring if collapsed, distorted or assembly alignment reference. Use scriber or paint to
broken. Replace the plug and piston if cracked, bent, make alignment marks.
or worn. Discard the servo snap ring if distorted or (2) Place pump body on two wood blocks.
warped. (3) Remove reaction shaft support bolts and sepa
Check rear band condition. Replace the band if dis rate support from pump body (Fig. 51).
torted, the lining is burned or flaking off, or the lin (4) Remove pump inner and outer gears (Fig. 52).
ing is worn (grooves no longer visible at any point on (5) Remove O-ring seal from pump body (Fig. 53).
Discard seal after removal.
REACTION GEAR PUMP BODY

SHAFT BORE
SUPPORT
INNER
GEAR
J932M76
Fig. 51 Reaction Shaft Support Removal—46RH

(6) Remove oil pump seal with Remover Tool
C-3981. Discard seal after removal.
OUTER
GEAR J932M77
INSPECTING PUMP AND SUPPORT
Clean pump and support components with solvent Fig. 52 Pump Gear Removal—46RH
and dry them with compressed air.
Check condition of the seal rings and t h r u s t Inspect the pump and support components. Replace
washer on the reaction shaft support. The seal rings the pump or support if the seal ring grooves or ma
do not need to be replaced unless cracked, severely chined surfaces are worn, scored, pitted, or damaged.
worn, or no longer hooked together. Replace the pump gears if pitted, worn chipped, or
damaged.
Fig. 53 Oil Pump And Reaction Shaft Components—46RH

+ TRANSMISSION 0VERHAUL-46RH 21 - 291
Check the pump vent (Fig. 54). The vent must be

secure. Replace the pump body if the vent is cracked,
broken, or loose.
Inspect the pump bushing (Fig. 54). Then check the
reaction shaft support bushing. Replace either bush
ing only if heavily worn, scored or damaged. It is not
necessary to replace the bushings unless they are ac
tually damaged.
Install the gears in the pump body and measure
end clearance with a feeler gauge and straightedge
(Fig. 55). Clearance should be 0.89 to 1.90 mm
(0.0035 to 0.0075 in.).
Measure side clearances with feeler gauge (Fig.
56). Clearance between gear teeth and between outer
gear and pump body should be 0.89 to 1.90 mm
(0.0035 to 0.0075 in.).
PUMP
J8921-388
Fig. 56 Checking Pump Gear Side Clearances
(3) Assemble Tool Handle C-4171 and Bushing In

staller SP-5118.
(4) Place bushing on installer tool and start bush
ing into shaft.
(5) Tap bushing into place until Installer Tool SP-
5118 bottoms in pump cavity. Keep tool and bushing
square with bore. Do not allow bushing to become
cocked during installation.
Fig. 55 Checking Pump Gear End Clearance (6) Stake pump bushing in two places with blunt
punch. Remove burrs from stake points with knife
OIL PUMP BUSHING REPLACEMENT (FIG. 57} blade (Fig. 58).
(1) Position pump housing on clean, smooth sur
face with gear cavity facing down.
(2) Remove bushing with Tool Handle C-4171 and
Bushing Remover SP-3550.
SPECIAL BUSHING (7) Start bushing in shaft. Tap bushing into shaft
TOOL REMOVAL until installer tool bottoms against support flange.
C-4171
(8) Clean reaction shaft support thoroughly after
SPECIAL TOOL bushing replacement (to remove any chips).
SP-3550
PUMP HOUSING SPECIAL SPECIAL
TOOL TOOL
SP-1191 C-4171
BUSHING
SPECIAL
TOOL
SP-5302
SPECIAL SPECIAL
TOOL TOOL
C-4171 SP-5118
BUSHING
BUSHING
X REACTION
J9221-244
SHAFT
Fig. 57 Replacing Oil Pump Bushing BUSHING

REMOVAL BUSHING
INSTALLATION
J9221-245
Fig. 59 Reaction Shaft Bushing Replacement—46RH

ASSEMBLING OIL PUMP AND REACTION
SHAFT SUPPORT
(1) Lubricate pump gears with transmission fluid
and install them in pump body.
(2) Install thrust washer on reaction shaft support
hub. Lubricate washer with petroleum jelly or trans
mission fluid before installation.
(3) If reaction shaft seal rings are being replaced,
install new seal rings on support hub. Lubricate seal
rings with transmission fluid or petroleum jelly after
mm
installation. Squeeze each ring until ring ends are
Fig. 58 Staking-Debum'ng Oil Pump Bushing securely hooked together.
REPLACING REACTION SHAFT SUPPORT C A U T I O N : The reaction shaft support seal rings will
BUSHING (FIG. 59) break if overspread, or twisted. If new rings are be
(1) Assemble Cup Tool SP-3633, Nut SP-1191 and ing installed, spread them only enough for installa
Bushing Remover SP-5301. tion. A l s o be very sure the ring ends are securely
(2) Hold cup tool firmly against reaction shaft. hooked together after installation. Otherwise, the
Thread remover tool into bushing as far as possible rings will either prevent pump installation, or break
by hand. during installation.
(3) Using wrench, thread remover tool an addi
tional 3-4 t u r n s into bushing to firmly engage tool. (4) Align and install reaction shaft support on
(4) Tighten tool hex n u t against cup tool to pull pump body.
bushing from shaft. Clean all chips from shaft and (5) Install bolts attaching reaction shaft support to
support after bushing removal. pump. Tighten bolts to 20 N»m (175 in. lbs.) torque.
(6) Install new pump seal with Seal Installer
(5) Place reaction shaft support upright on a clean,
C-3860-A (Fig. 60). Use hammer or mallet to tap seal
smooth surface.
into place.
(6) Assemble Bushing Installer Tools C-4171 and
(7) Install new O-ring on pump body. Lubricate oil
SP-5302. Then slide new bushing onto installer tool.
seal and O-ring with petroleum jelly.
(4) Remove clutch piston springs. N o t e n u m b e r

SPECIAL
TOOL a n d p o s i t i o n of p i s t o n s p r i n g s for a s s e m b l y ref
C-3860-A erence.
(5) Remove clutch piston from retainer with a
twisting motion.
PUMP (6) Remove and discard clutch piston inner and
PUMP BODY outer seals.
SEAL
Clean and inspect the front clutch components. Re
place the clutch discs if warped, worn, scored, burned
or charred, t h e lugs are damaged, or if the facing is
flaking off. Replace the steel plates and reaction
plate if heavily scored, warped, or broken. Be sure
J932M79 the driving lugs on the discs and plate are also in
good condition. The lugs must not be bent, cracked or
Fig. 60 Oil Pump Seal Installation—46RH damaged in any way.
(8) Set pump assembly aside for installation dur Replace the piston springs and spring retainer if ei
ing transmission assembly. ther are distorted, warped or broken.
Check the lug grooves in the clutch piston retainer.
FRONT CLUTCH OVERHAUL The steel plates should slide freely in the slots. Re
place the piston retainer if the grooves are worn or
FRONT CLUTCH DISASSEMBLY damaged. Also check action of the check ball in the
(1) Remove waved snap ring and remove reaction piston retainer. The ball must move freely and not
plate, clutch plates and clutch discs (Fig. 61). Note stick.
n u m b e r of p l a t e s a n d d i s c s i n c l u t c h p a c k for as Replace the retainer bushing if worn, scored, or
sembly reference. Some models use 3 discs, there is any doubt about bushing condition.
while some may have 4 discs. Inspect the piston and retainer seal surfaces for
(2) Compress clutch piston retainer and piston nicks or scratches. Minor scratches can be removed
springs with Compressor Tool C-3863-A (Fig. 62). with crocus cloth. However, replace the piston and/or
(3) Remove retainer snap ring and remove com retainer if the seal surfaces are seriously scored.
pressor tool. Check the clutch piston check ball. The ball should
be securely in place. Replace the piston if the ball is
missing, or seized in place.
INNER CLUTCH CLUTCH PISTON CLUTCH CLUTCH
Fig. 61 46RH Front Clutch Components (3-Disc Clutch Shown)

SPECIAL SPECIAL SPECIAL

TOOL
C-3863-A
TOOL-
C-4171
FRONT CLUTCH
RETAINER
n
v s v
HI
v
BUSHING
REMOVAL
TOOL
SP-3629
SPECIAL SPECIAL
TOOL TOOL
C-4171 SP-5511
RH290 J9221-247
Fig. 62 Removing Front Clutch Spring Retainer Fig. 63 Front Clutch Retainer Bushing
Snap Ring Replacement—46RH
FRONT CLUTCH RETAINER BUSHING
9 SPRING
REPLACEMENT (FIG. 63) CLUTCH
(1) Assemble Tool Handle C-4171 and Bushing Re
mover SP-3629.
(2) Insert remover tool in bushing and drive bush
ing straight out of clutch retainer.
(3) Mount Bushing Installer SP-5511 on tool han
dle.
(4) Slide new bushing onto installer tool and start
bushing into retainer. 11 SPRING
(5) Tap new bushing into place until installer tool CLUTCH
bottoms against clutch retainer.
(6) Remove installer tools and clean retainer thor
oughly.
ASSEMBLING FRONT CLUTCH

(1) Soak clutch discs in transmission fluid. Lubri
cate remaining clutch components with transmission
13 SPRING
fluid. Retainer bushing can be lubricated with petro CLUTCH
leum jelly if desired.
(2) Install new inner and outer seals on clutch pis
ton. Be sure seal lips face interior of retainer.
(3) Lubricate new inner and outer piston seals
with Ru-Glyde, or Door Eze.
motion to seat piston in retainer. D o not force pis J9221-260
ton straight in. This could fold seals over caus
ing l e a k a g e and clutch slip. Fig. 64 Front Clutch Spring Location
(5) Install and position clutch piston springs as (8) Install spring retainer snap ring and remove
shown in Figure 64.
compressor tool.
(6) Install spring retainer on top of piston springs.
(9) Install clutch plates and discs. Install steel
(7) Compress spring retainer and piston springs
plate followed by clutch disc until all plates and discs
with Compressor Tool C-3863-A.
are installed. I n s t a l l s a m e n u m b e r of discs a n d REAR CLUTCH INSPECTION

plates as removed during disassembly. Some Clean the clutch components with solvent and dry
m o d e l s r e q u i r e 3 p l a t e s a n d discs. O t h e r s r e t h e m with compressed air.
quire 4 plates a n d discs. Check condition of the input shaft seal rings. It is
(10) Install reaction plate and waved snap ring. not necessary to remove or replace rings unless they
(11) Check clutch pack clearance with feeler gauge are broken, cracked, or no longer securely hooked to
as follows (Fig. 65): gether.
• On 3 disc clutch, clearance between waved spring Inspect the input shaft splines and machined sur
and pressure plate should 1.78 - 3.28 mm (0.070 - faces. Very minor nicks or scratches can be smoothed
0.129 in.). off with crocus cloth, replace the shaft if the splines
• On 4 disc clutch, clearance between waved spring are damaged, or any of the machined surfaces are se
and pressure plate should be 2.08 to 3.83 mm (0.082 verely scored.
to 0.151 in.). Replace the clutch discs if warped, worn, scored,
• If c l e a r a n c e Is I n c o r r e c t , c l u t c h p l a t e s , c l u t c h burned/charred, the lugs are damaged, or if the fac
discs, s n a p r i n g a n d p r e s s u r e p l a t e will h a v e to ing is flaking off.
b e c h a n g e d . C l u t c h p a c k w a v e d s n a p r i n g is n o t Replace the steel plates and the pressure plate if
select fit. heavily scored, warped, or broken. Be sure the driv
ing lugs on the discs and plates are also in good con
dition. The lugs must not be bent, cracked or
damaged in any way.
Replace t h e piston spring and wave spring if either
Check the lug grooves in the clutch retainer. The
steel plates should slide freely in the slots. Replace
the retainer if the grooves are worn or damaged.
Also check action of the retainer check ball. The ball
must move freely and not stick.
retainer if the seal surfaces are seriously damaged.
Check thrust washer condition. Washer thickness
should be 1.55 to 1.60 mm (0.061 to 0.063 in.). Re
place the washer if worn or damaged.
Check condition of the two seal rings on the input
shaft and the single seal ring on the piston retainer
hub. Replace the seal rings only if severely worn,
cracked, or if they can no longer be hooked together.
FEELER GAUGE RH 288 INPUT SHAFT REPLACEMENT

If the input shaft must be replaced, first remove
Fig. 65 Measuring Front Clutch Pack Clearance the retaining ring t h a t secures the shaft in the pis
ton retainer hub. Then press the old shaft out of the
REAR CLUTCH OVERHAUL retainer with a shop press.
REAR CLUTCH DISASSEMBLY (FIG. 66) Lubricate the splines of the new shaft with petro
(1) Remove clutch pack select fit snap ring. leum jelly or ATF Plus. Then align the shaft in the
(2) Remove reaction plate and remove clutch plates piston retainer and carefully press it into place. Do
and discs. not allow the shaft to become cocked during installa
(3) Remove pressure plate, wave spring, spacer tion. The retainer can be cracked if misalignment oc
ring and piston spring from clutch retainer. curs.
(4) Remove clutch piston from piston retainer with Install the shaft retaining ring after pressing the
a twisting motion. . shaft into place. Be sure the ring is fully seated be
(5) Remove input shaft thrust washer, if washer fore proceeding with clutch assembly.
remained in piston retainer hub during removal.
(6) Remove seals from clutch piston. Discard seals
after removal.
Fig. 66 Rear Clutch Components—46RH

REAR CLUTCH ASSEMBLY (12) Install selective snap ring to secure clutch
(1) Soak clutch discs in transmission fluid. Lubri pack in retainer.
cate remaining clutch components with transmission (13) Install new seal rings on input shaft if neces
fluid. Clutch retainer bushing can be lubricated with sary (Fig. 67). Be very sure ring ends are all securely
petroleum jelly if desired. hooked together before proceeding.
(2) Install new seals on clutch piston. Lubricate
piston seals with Ru-Glyde or petroleum jelly to ease
installation. Be sure seal lips face input shaft.
(3) Install clutch piston in piston retainer. Use
twisting motion to seat piston in retainer. D o not
p u s h piston straight in. This c o u l d d i s t o r t s e a l s
c a u s i n g l e a k a g e a n d clutch slip.
(4) Assemble piston retainer and clutch retainer.
(5) Support clutch retainer with wood blocks, or in
sert input shaft through predrilled, appropriate di
ameter hole in workbench. Clutch pack components
are easier to install if both retainers are properly
supported.
(6) Install piston spring in clutch retainer. Con
cave side of spring faces upward and away from
clutch piston. Convex side faces downward toward
piston. Fig. 67 Input Shaft Seal Ring Locations
(7) Install spacer ring on top of piston spring. (14) Check clutch pack clearance with feeler gauge
(8) Install wave spring on top of spacer ring. Then (Fig. 68). Clearance should be 0.63 to 1.14 mm (0.025
seat wave spring in retainer groove. If w a v e s p r i n g to 0.045 in.).
will not seat properly, spacer ring h a s probably (15) If clutch pack clearance is incorrect, clutch
shifted over a n d into w a v e spring groove i n re pack snap ring, reaction plate, or clutch pack may
tainer. U s e small screwdriver to realign s p a c e r have to be replaced.
ring if necessary. (16) Install t h r u s t washer on piston retainer hub
(9) Install inner pressure plate in clutch retainer. (Fig. 66). Use petroleum jelly to hold thrust washer
(10) Install first clutch disc followed by steel plate in place.
until all discs and plates are installed.
(11) Install reaction plate on top of last clutch disc.
J9321-167
Fig. 68 Measuring Rear Clutch Pack Clearance

PLANETARY GEARTRAIN OVERHAUL
PLANETARY GEARTRAIN DISASSEMBLY
(1) Remove planetary snap ring from intermediate
shaft (Fig. 69). Retain snap ring if in good condition.
It is reusable.
Fig. 69 Removing Planetary Snap Ring—46RH Fig. 71 Disassembling Front Planetary And Annulus
(2) Remove front planetary gear and front annulus Gears—46RH
gear as assembly (Fig. 70). Intermediate Shaft And Geartrain Inspection
(3) Remove front planetary gear and thrust washer Clean the intermediate shaft and planetary compo
from front annulus gear (Fig. 71). Note thrust nents (Fig. 77) in parts cleaning solvent and dry
washer position for assembly reference. them with compressed air.
(4) Remove tabbed thrust washer from driving Inspect the planetary gear sets and annulus gears.
shell (Fig. 72). Note washer position for assembly ref The pinion gears, pinion shafts, pinion washers and
erence. shaft retaining pins are all serviceable and can be re
(5) Remove sun gear and driving shell as assembly placed if worn or damaged. However, if a pinion car
(Fig. 73).
rier is damaged, the entire planetary gear set must
be replaced as an assembly.
tary gear (Fig. 74). Note washer position on gear for
Replace the annulus gears if the teeth are chipped,
assembly reference.
(7) Remove rear planetary gear and rear annulus broken, or worn, or the gear is cracked. Replace the
gear from intermediate shaft (Fig. 75). planetary thrust plates and the tabbed thrust wash
(8) Remove thrust plate from rear annulus gear ers if cracked, scored or worn.
(Fig. 76).
21 - 298 TRANSMISSION 0¥IRHAUL-48RH •
INTERMEDIATE REAR REAR
SHAFT ANNULUS PLANETARY
J932M73
Fig. 72 Driving Shell Thrust Washer Removal—46RH Fig. 75 Rear Planetary And Annulus Gear
Removal—46RH
INTERMEDIATE
SHAFT REAR
J9321-174
Fig. 73 Sun Gear And Driving Shell Assembly
Removal—46RH Fig. 76 Rear Annulus Thrust Plate Removal—46RH
SUN REAR
Inspect the sun gear and driving shell (Fig. 77). If
either component is worn or damaged, remove the
sun gear rear retaining ring and separate the sun
gear and thrust plate from the driving shell. Then
replace the necessary component.
Replace the sun gear as an assembly if the gear
teeth are chipped or worn. Also replace the gear as
an assembly if the bushings are scored or worn. The
sun gear bushings are not serviceable. Replace the
thrust plate if worn, or severely scored. Replace the
driving shell if distorted, cracked, or damaged in any
way.
PLANETARY GEARTRAIN ASSEMBLY AND

SHELL J932M72 ADJUSTMENT
(1) Lubricate sun gear and planetary gears with
Fig. 74 Rear Planetary Thrust Washer
Removal—46RH transmission fluid during assembly. Use petroleum
jelly to lubricate output shaft bushing surfaces,
Inspect the machined surfaces of the intermediate thrust washers and thrust plates.
shaft. Be sure the oil passages are open and clear. (2) Install front snap ring on sun gear and install
Replace the shaft if scored, pitted, or damaged. gear in driving shell. Then install thrust plate over
sun gear and against rear side of driving shell (Fig.
• TRANSMISSION QVERHAUL-46RH 21 - 299
Fig. 77 Planetary Geartrain Components—46 RH

78). Install rear snap ring to secure sun gear and
thrust plate in driving shell.
J932M75 Fig. 79 Installing Rear Annulus Gear On

Intermediate Shaft—46RH
Fig. 78 Sun Gear Installation—46RH
(8) Install sun gear and driving shell on output
(3) Install rear annulus gear on intermediate shaft
shaft (Fig. 83). Seat shell against rear planetary
(Fig. 79).
gear. Verify t h a t thrust washer on planetary gear
(4) Install thrust plate in annulus gear (Fig. 80). was not displaced during installation.
Be sure plate is seated on shaft splines and against
(9) Install tabbed thrust washer in driving shell
gear.
(Fig. 84). be sure washer tabs are seated in tab slots
(5) Install rear planetary gear in rear annulus
of driving shell. Use extra petroleum jelly to hold
gear (Fig. 81). Be sure planetary carrier is seated
washer in place if desired.
against annulus gear.
(10) Install tabbed thrust washer on front plane
(6) Install tabbed thrust washer on front face of
tary gear (Fig. 85). Seat washer tabs in matching
rear planetary gear (Fig. 82). Seat washer tabs in
slots in face of gear carrier. Use extra petroleum jelly
matching slots in face of gear carrier. Use extra pe
to hold washer in place if desired.
troleum jelly to hold washer in place if desired.
(11) Install front annulus gear over and onto front
(7) Lubricate sun gear bushings with petroleum
planetary gear (Fig. 86). Be sure gears are fully
jelly or transmission fluid.
meshed and seated.
21 • 300 TRANSMISSION OVERHAUL-48RH •
OUTPUT DRIVING REAR
SHAFT SHELL PLANETARY
GEAR
THRUST
PLATE
OUTPUT
SHAFT
SUN
J9121-69 GEAR J9121-72
Fig. 80 installing Rear Annulus Thrust Plate—46RH Fig. 83 installing Sun Gear And Driving Shell—46RH
REAR TAB DRIVING
ANNULUS SLOTS (3) SHELL
GEAR
REAR
PLANETARY
GEAR
J9121-70 TABBED
THRUST
Fig. 81 Installing Rear Planetary Gear—46RH WASHER
REAR
PLANETARY
GEAR
J9121-73
Fig. 84 Installing Driving Shell Thrust

Washer-46RH
onto shaft. Be sure planetary pinions are seated on
sun gear and t h a t planetary carrier is seated on out
put shaft.
(13) Place geartrain in upright position. Rotate
gears to be sure all components are seated and prop
erly assembled. Snap ring groove at forward end of
TABBED
THRUST _ output shaft will be completely exposed when compo
1 2 1 7 1
WASHER ^ - nents are assembled correctly.
(14) Install planetary snap ring in groove at end of
Fig. 82 Installing Rear Planetary Thrust output shaft (Fig. 88).
Washer-46RH (15) Turn planetary geartrain over. Position wood
(12) Install front planetary and annulus gear as block under front end of output shaft and support
sembly (Fig. 87). Hold gears together and slide them geartrain on shaft. Be sure all geartrain parts have
moved forward against planetary snap ring. This is
important for accurate end play check.
• TRANSMISSION 0WERHAUL-4SRH 21 - 301
Fig. 85 Installing Thrust Washer On Front Planetary Fig. 87 Installing Front Planetary And Annulus Gear
Gear-46RH Assembly—46RH
Fig. 88 Installing Planetary Snap Ring—46RH

Fig. 86 Assembling Front Planetary And Annulus
Gears—46RH
feeler gauge (Fig. 89). Insert gauge between rear an
nulus gear and shoulder on output shaft as shown.
End play should be 0.15 to 1.22 mm (0.006 to 0.048
in.).
(17) If end play is incorrect, install thinner/thicker
planetary snap ring as needed.
Fig. 89 Checking Planetary Geartrain End Play

VALVE BODY SERVICE AND ADJUSTMENT
VALVE BODY MAIN COMPONENT
DISASSEMBLY
Fig. 91 Boost Valve Components—46RH
C A U T I O N : D o not clamp a n y valve body component
in a vise. T h i s practice c a n d a m a g e the component
resulting in unsatisfactory operation after a s s e m b l y
and installation. R e m o v e valves, p l u g s and s p r i n g s
with a pencil m a g n e t D o not u s e pliers to remove
any of the v a l v e s , p l u g s or springs and d o not force
any of the c o m p o n e n t s out or into place. T h e valves
and valve body h o u s i n g s will be d a m a g e d if force is
u s e d . T a g or mark the valve body s p r i n g s for refer
ence a s they are removed. D o not allow them to be
c o m e intermixed. DETENT BALL AND SPRING HOUSING J9321-121
(1) Remove boost valve cover (Fig. 90). Fig. 92 Securing Detent Ball And Spring
(2) Remove boost valve retainer, valve spring and (4) Remove E-clip t h a t secures throttle lever in
boost valve (Fig. 91). manual lever (Fig. 93).
HOUSING J932M26 J932M38
Fig. 90 Boost Valve Cover Location—46RH Fig. 93 Removing Throttle Lever E-Clip-46RH
(3) Secure detent ball and spring with Retainer (5) Lift and rotate manual lever far enough to
Tool 6583 (Fig. 92). clear detent housing.
(6) Remove retaining tool and remove detent ball (9) Remove park rod E-clip and separate rod from
and spring (Fig. 94). manual lever (Fig. 97).
MANUAL MANUAL
LEVER LEVER
DETENT
HOUSING
DETENT
BALL.
AND PARK
SPRING J9321-139 ROD J9121-81
Fig. 94 Detent Ball And Spring Removal Fig. 97 Park Rod Removal—46RH
(7) Remove washer at top of manual lever shaft. (10) Remove screws attaching pressure adjusting
Then lift manual lever and park rod assembly up screw bracket to valve body and transfer plate. Hold
ward and out of valve body (Fig. 95). bracket firmly against spring tension while removing
last screw.
MANUAL
LEVER (11) Remove adjusting screw bracket, line pressure
AND adjusting screw, pressure regulator spring and switch
PARK valve spring (Fig. 98). Do not remove throttle
ROD
ASSEMBLY pressure adjusting screw from bracket and d o
not disturb adjusting screw settings during re
moval.
PRESSURE
REGULATOR
MANUAL VALVE SPRING
LEVER
WASHER
J9321-140
ADJUSTING
Fig. 95 Manual Lever Removal—46RH SCREW
BRACKET
(8) Remove throttle lever from valve body housing
(Fig. 96).
mm
SWITCH
VALVE LINE PRESSURE
ADJUSTING SCREW J9121-512
SPRING

Removal—46RH
THROTTLE (12) Remove solenoid connector from 3-4 accumula
LEVER tor housing (Fig. 99). Note that connector is at
t a c h e d to housing with shoulder-type screw.
J932M41 Keep this screw with accumulator housing to
avoid losing it.
Fig. 96 Throttle Lever Removal—46RH (13) Note routing of solenoid wires for assembly
SOLENOID 3-4 (15) Remove 3-4 accumulator housing attaching
CONNECTOR ACCUMULATOR screws and remove housing from valve body (Fig.
HOUSING
102).
3-4
ACCUMULATOR
HOUSING HOUSING
ATTACHING
SCREWS
a -J9321-143
Fig. 99 Solenoid Connector Position—46RH

SOLENOID
WIRES
(NOTE
WIRE
ROUTING)
Fig. 102 Removing 3-4 Accumulator Housing

(16) Remove following parts from valve body lower
housing: 3-4 shift valve and spring; pressure regula
tor valve spring; clutch valve; clutch valve spring;
and clutch valve plug (Fig. 103).
LOWER
HOUSING
CLUTCH
VALVE AND
SPRING
J932M42
Fig. 100 Solenoid Wire Routing—46RH

(14) Remove screws attaching solenoid assembly to
valve body lower housing and remove solenoid and
connector assembly (Fig. 101).
SOLENOID LOWER
ATTACHING HOUSING
SCREWS
3-4
SHIFT PRESSURE
VALVE CLUTCH REGULATOR
AND VALVE VALVE
SPRING PLUG SPRING J9321-146
Fig. 103 Clutch Valve And 3-4 Shift Valve

Locations—46RH
(17) Remove boost valve connecting tube (Fig.
104). Disengage tube from upper housing port first.
Then rock opposite end of tube back and forth to
work it out of lower housing.
SOLENOID
ASSEMBLY J9321-144
C A U T I O N : D o not u s e tools to loosen or pry the
Fig. 101 Solenoid Assembly Removal—46RH connecting tube out of the valve body housings.
Loosen and remove the tube by hand only.
BOOST LOWER OVERDRIVE TRANSFER

.VALVE HOUSING SEPARATOR PLATE AND
TUBE PLATE UPPER
HOUSING
DISENGAGE LOWER
UPPER THIS END OF HOUSING J932M49
HOUSING TUBE FIRST J9321-147
Fig. 104 Boost Valve Tube Removal—46RH Fig. 106 Lower Housing Removal—46RH
(18) Turn valve body over so valve lower housing UPPER

is facing upward (Fig. 105). In this position, check HOUSING
balls in upper housing will remain in place and not

fall out when lower housing and transfer plate are
removed.
(19) Remove screws attaching valve body lower
housing to upper housing and transfer plate (Fig.
105). Note position of boost valve tube b r a c e for
a s s e m b l y reference.
LOWER VALVE
HOUSING BODY
SCREWS (13)
TRANSFER
PLATE
J932M52
Fig. 107 Removing Transfer Plate From Upper

Housing—46RH
~\L^ VALVE BRACE

TUBE
BRACE J932M48
Fig. 105 Valve Body Screw And Tube Brace

Location—46RH
(20) Remove lower housing and overdrive separa
tor plate from transfer plate (Fig. 106).
(21) Remove transfer plate from upper housing
(Fig. 107).
SEPARATOR TRANSFER
(22) Turn transfer plate over so upper housing sep J932M50 PLATE PLATE
arator plate is facing upward (Fig. 108).
(23) Remove brace plate from lower housing sepa Fig. 108 Brace Plate Removal—46RH
rator plate and transfer plate (Fig. 108).
(24) Remove upper housing separator plate from erence before removing it (Fig. 110).
transfer plate (Fig. 109). Note position of filter in
separator plate for assembly reference.
(25) Remove rear clutch check ball from transfer
plate. Note c h e c k ball location for a s s e m b l y ref-
TRANSFER UPPER SMALL
DIAMETER
CHECK
BALLS (6)
J9321-151
Fig. 109 Upper Housing Separator Plate

Removal—RH
LARGE DIAMETER
CHECK
BALL (1) J932M54
Fig. 110 Rear Clutch Check Ball Location—46RH

VALWE BODY UPPER HOUSING
DISASSEMBLY
(1) Note location of check balls in valve body upper
housing (Fig. 111). Then remove one large and six
smaller diameter check balls with magnet (total of 7 Fig. 112 Shuttle Valve E-Clip And Secondary Spring
check balls are used). Location
(2) Remove E-clip t h a t secure shuttle valve second (9) Turn upper housing around and remove limit
ary spring on valve stem (Fig. 112). valve and shift valve covers (Fig. 115).
(3) Remove governor plug and shuttle valve covers (10) Remove limit valve housing. Then remove re
(Fig. 113). tainer, spring, limit valve, and 2-3 throttle plug from
(4) Remove throttle plug, primary spring, shuttle limit valve housing (Fig. 115).
valve, secondary spring, and spring guides (Fig. 113). (11) Remove 1-2 shift control valve and spring
(5) Remove boost valve retainer, spring and valve (Fig. 115).
if not previously removed. (12) Remove 1-2 shift valve and spring (Fig. 115).
(6) Turn upper housing over and remove switch (13) Remove 2-3 shift valve and spring from valve
valve, regulator valve and spring, and manual valve body (Fig. 115).
(Fig. 114). (14) Remove pressure plug cover (Fig. 115).
(7) Remove kickdown detent, kickdown valve, and (15) Remove line pressure plug, sleeve, throttle
throttle valve and spring (Fig. 114). pressure plug and spring (Fig. 115).
(8) Remove throttle plug and 1-2 and 2-3 governor
plugs (Fig. 114). Also remove shuttle valve primary
spring if not removed in prior step.
-156
Fig. 113 Shuttle And Boost Valve Components—46RH
Fig. 114 Control Valve Locations—46RH Upper Housing

UPPER
HOUSING
PLUG RETAINER AND VALVE

COVER SPRING COVER J9321-157
Fig. 115 Shift Valves And Pres e Plugs—46RH Upper Housing

VALVE BODY LOWER HOUSING • fluid filter
DISASSEMBLY (FIG. 116) • detent ball and spring
(1) Remove timing valve cover. The remaining valve body components are serviced
(2) Remove 3-4 timing valve and spring. only as part of a complete valve body assembly.
(3) Remove 3-4 shuttle valve E-clip and remove Clean the valve body components with a standard
shuttle valve spring and plug. parts cleaning solution only. Do not use gasoline,
(4) Remove 3-4 shift valve and spring. (5) Remove kerosene, or any type of caustic solution.
converter clutch valve, spring and plug. Dry the parts with compressed air. Make sure all
(6) Remove converter clutch timing valve, retainer passages are clean and free from obstructions. D o
and valve spring. n o t u s e r a g s o r s h o p t o w e l s t o d r y o r w i p e off
v a l v e b o d y c o m p o n e n t s . L i n t from t h e s e m a t e r i
3-4 ACCUMULATOR HOUSING DISASSEMBLY als will stick t o t h e v a l v e b o d y c o m p o n e n t s . L i n t
(FIG. 117) will i n t e r f e r e w i t h v a l v e o p e r a t i o n a n d m a y clog
(1) Remove end plate from housing. filters a n d fluid p a s s a g e s .
(2) Remove piston spring. Inspect the throttle and manual valve levers and
(3) Remove piston. Remove and discard piston shafts. Do not attempt to straighten a bent shaft or
seals. correct a loose lever. Replace these components if
worn, bent, loose or damaged in any way.
VALVE BODY CLEANING AND INSPECTION Inspect all of the valve body mating surfaces for
The only serviceable valve body components are: scratches, nicks, burrs, or distortion. Use a straight
• solenoid and connector assembly edge to check surface flatness. Minor scratches may
• solenoid gasket be removed with crocus cloth using only very light
• park rod and E-clip pressure.
• switch valve and spring
Minor distortion of a valve body mating surface
• pressure adjusting screw bracket
may be corrected by smoothing the surface with a
• throttle valve lever
sheet of crocus cloth. Position the crocus cloth on a
• manual lever
surface plate, sheet of plate glass or equally flat sur-
• manual shaft seal, washer, and E-clip
TRANSMISSION 0VERHAUL-4IRH 21 - 309
LOWER HOUSING 3-4 SHUTTLE 3-4 ACCUMULATOR PISTON 3-4 ACCUMULATOR HOUSING
3-4
SHUTTLE VALVE
THROTTLE PLUG 3-4 SHIFT
VALVE AND
SPRING
SPRING
TIMING RETAINER
VALVE
COVER
CONVERTER CLUTCH
TIMING VALVE
AND SPRING
CONVERTER
CLUTCH
SOLENOID SOLENOID
GASKET
OVERDRIVE
SEPARATOR PLATE J932M58
Fig. 116 Shift Valves And Springs—46RH Lower Housing

3^4 ACCUMULATOR C A U T I O N : Many of the valves and plugs, s u c h a s
HOUSING the throttle valve, shuttle valve plug, 1-2 shift valve
and 1-2 governor plug, are made of coated alumi
num (Fig. 118). Aluminum components are identi
fied by the dark color of the special coating applied
ACCUMULATOR to the surface (or by testing with a magnet). D o not
PISTON polish or sand aluminum valves or plugs with any
type of material. This practice could damage the
special coating and cause the valves and plugs to
stick and bind.
PISTON
SEAL Inspect t h e valves and plugs for scratches, burrs,
RING nicks, or scores. Minor surface scratches on steel
PISTON valves or plugs can be removed with crocus cloth but
SPRING do not round off the e d g e s of the valve or plug
lands. Maintaining sharpness of these edges is vi
tally important. The edges prevent foreign matter
from lodging between the valves and plugs and t h e
bore.
END Inspect all the valve and plug bores in the valve
PLATE J9121-277 body. Use a penlight to view the bore interiors. Re
place the valve body if any bores are distorted or
Fig. 117 3-4 Accumulator Housing scored. Inspect all of the valve body springs. The
Components—46RH springs must be free of distortion, warpage or broken
face. If distortion is severe or any surfaces are coils.
heavily scored, the valve body will have to be re Check the two separator plates for distortion or
placed. damage of any kind. Inspect the upper housing,
lower housing, 3-4 accumulator housing, and transfer
plate carefully. Be sure all fluid passages are clean (3) Install 3-4 shuttle valve in lower housing.
and clear. Check condition of the upper housing and Press valve inward and install E-clip on end of valve
transfer plate check balls as well. The check balls to secure it in housing.
and ball seats must not be worn or damaged. (4) Install 3-4 shuttle valve spring and throttle
Trial fit each valve and plug in its bore to check plug in housing.
freedom of operation. When clean and dry, the valves (5) Install timing valve end plate. Tighten end
and plugs should drop freely into the bores. plate screws to 4 N»m (35 in. lbs.) torque.
Valve body bores do not change dimensionally with (6) Install 3-4 shift valve and spring.
use. If the valve body functioned correctly when new, (7) Install converter clutch valve, spring and plug.
it will continue to operate properly after cleaning (8) Install converter clutch timing valve and
and inspection. It should not be necessary to replace spring.
a valve body assembly unless it is damaged in han
dling. 3-4 Accumulator Assembly (Fig. 117)
VALWE BODY BEASSEMBLY (1) Lubricate accumulator piston, seals and hous
ing piston bore with ATF Plus, or Dexron II®.
CAUTION; D o not force valves or plugs into place (2) Install new seal rings on accumulator piston.
during reassembly. If the valve body bores, valves (3) Install piston and spring in housing.
and plugs are free of distortion or burrs, the valve (4) Install end plate on housing.
body components should all slide into place easily.
In addition, d o not overtighten the transfer plate Transfer Plate Assembly
and valve body screws during reassembly. Over (1) Install rear clutch check ball in transfer plate
tightening can distort the h o u s i n g s resulting in (Fig. 110).
valve sticking, c r o s s leakage and unsatisfactory o p (2) Install filter screen in upper housing separator
eration. Tighten valve body screws to recom plate (Fig. 109).
mended torque only. (3) Align and position upper housing separator
plate on transfer plate (Fig. 109).
(4) Install brace plate (Fig. 108). Tighten brace at
Lower Housing Assembly (Fig. 116)
taching screws to 4 Nnn (35 in. lbs.) torque.
(1) Lubricate valves, springs, and the housing
(5) Install remaining separator plate attaching
valve and plug bores with Mopar ATF Plus, or
screws. Tighten screws to 4 N*m (35 in. lbs.) torque.
Dexron II® transmission fluid.
(2) Install 3-4 timing valve spring and valve in
lower housing.
END PLATE VALVE AND SECONDARY SPRING,
1-2 SHIFT
CONTROL VALVE
AND SPRING
REGULATOR SHUTTLE VALVE

VALVE COVER
END PLATE
SLEEVE
REGULATOR 2-3 SHIFT

VALVE THROTTLE VALVE GOVERNOR
PRESSURE PLUG PLUG
SHUTTLE VALVE
PLUG (ALUM.)
RETAINER E
w
00
VALVE
SPRING
GOVERNOR o
VALVE END
PLATE z
AAANUAL LEVER m
DETENT BALL 30
LINE AND SPRING
PRESSURE ADJUSTING
ADJUSTING* SCREW
J9221-21
SCREW BRACKET
Fig. 118 Upper Housing Components—46RH Valve Body (Alum. Indicates Aluminum Part)
Assembling Upper And Lower Housings Upper Housing Valve And Plug Installation (Figs. 114,111,
(1) Position upper housing so internal passages 118)
and check ball seats are facing upward. Then install (1) Lubricate valves, plugs, springs with Mopar
check balls in housing (Fig. 111). Seven check balls ATF Plus transmission fluid.
are used. The single large check ball is approxi (2) Assemble regulator valve line pressure plug,
mately 8.7 m m (11/32 in.) diameter. The remaining 6 sleeve, throttle plug and spring. Insert assembly in
check balls are approximately 6.3 m m (1/4 in.) in di upper housing and install cover plate. Tighten cover
plate screws to 4 N»m (35 in. lbs.) torque.
ameter.
(3) Install 1-2 and 2-3 shift valves and springs.
(2) Position transfer plate assembly on upper hous
(4) Install 1-2 shift control valve and spring.
ing (Fig. 119).
(5) Install shift valve cover plate.
(3) Position lower housing separator plate on
(6) Install shuttle valve as follows:
transfer plate (Fig. 119). (a) Insert plastic guides in shuttle valve second
ary spring and install spring on end of valve.
(b) Hold shuttle valve in place.
(c) Compress secondary spring and install E-clip
in groove at end of shuttle valve.
(d) Verify t h a t spring and E-clip are properly
(7) Install shuttle valve cover plate. Tighten cover
plate screws to 4 N®m (35 in. lbs.) torque.
(8) Install 1-2 and 2-3 valve governor plugs in
valve body.
(9) Install shuttle valve primary spring and throt
tle plug.
(10) Align and install governor plug cover. Tighten
#
TRANSFER UPPER
cover screws to 4 N m (35 in. lbs.) torque.
PLATE HOUSING J932M59
(11) Install manual valve.
(12) Install throttle valve and spring.
Fig. 119 Lower Housing Separator Plate (13) Install kickdown valve, and detent.
Installation—46RH (14) Install regulator valve.
(4) Install lower housing on assembled transfer (15) Install switch valve.
plate and upper housing (Fig. 120).
Boost Valve Tube Installation
(5) Install and start valve body screws by hand.
(1) Position valve body assembly so lower housing
Then tighten screws evenly to 4 N*m (35 in. lbs.)
is facing upward (Fig. 121).
torque. Start at center and work out to sides when
(2) Lubricate tube ends and housing ports with
tightening screws.
transmission fluid or petroleum jelly.
(3) Position tube behind tube brace (Fig. 121).
(4) Start tube in lower housing port first. Then
swing tube downward and work opposite end of tube
into upper housing port (Fig. 121).
(5) Seat each end of tube in housings.
3-4 Accumulator Installation

(1) Position converter clutch valve and 3-4 shift
valve springs in housing (Fig. 122).
(2) Loosely attach accumulator housing with right-
side screw (Fig. 122). Install only one screw at this
time as accumulator must be free to pivot upward for
ease of installation.
(3) Position plug on end of converter clutch valve
spring. Then compress and hold springs and plug in
place with fingers of one hand.
Fig. 120 Assembling Valve Body Upper And Lower (4) Swing accumulator housing upward over valve
Housings—46RH springs and plug.
(5) Hold accumulator housing firmly in place and
install remaining two attaching screws. Be sure
TUBE BRACE UPPER (6) Attach solenoid case connector to 3-4 accumula
tor with shoulder-type screw. Connector h a s small lo
cating tang t h a t fits in dimple at top of accumulator
housing (Fig. 124). Seat t a n g in dimple before tight
ening connector screw.
(7) Install solenoid assembly and gasket. Tighten
solenoid attaching screws to 8 N*m (72 in. lbs.)
torque.
SOLENOID
CASE CONNECTOR
LOWER
HOUSING
PORT J932M62
Fig. 121 Boost Valve Tube Installation—46RH

springs and clutch valve plug are properly seated
(Fig. 123).
RIGHT-SIDE SCREW
Fig. 124 Solenoid Connector Installation—46RH

(8) Verify t h a t solenoid wires are properly routed
(Fig. 125). Solenoid w i r e s must b e clear of rear
b a n d lever, manual lever a n d park rod.
3-4 ACCUMULATOR
Fig. 122 Installing Converter Clutch And 3-4 Shift

Valve Springs—46RH
Fig. 125 Solenoid Wire Routing—46RH

CLUTCH ACCUMULATOR Valve Body Final Assembly And Adjustment
VALVE PLUG BOSS J9321-161
(1) Insert manual lever detent spring in upper
Fig. 123 Seating 3-4 Accumulator On Lower housing.
Housing—46RH
21 - 314 TRANSMISSION OVERHAUL-46RH — •
(2) Position line pressure adjusting screw in ad
justing screw bracket.
(3) Install spring on end of line pressure regulator
valve.
(4) Install switch valve spring on tang at end of
adjusting screw bracket.
(5) Position adjusting screw bracket on valve body.
Align valve springs and press bracket into place. In
stall short, upper bracket screws first and long bot
tom screw last. Verify t h a t valve springs and bracket
are properly aligned. Then tighten all three bracket
screws to 4 N*m (35 in. lbs.) torque.
(6) Install throttle lever in upper housing. Then in
stall manual lever over throttle lever and start man
ual lever into housing.
(7) Position detent ball on end of spring. Then hold
detent ball and spring in detent housing with Re Fig. 126 Manual And Throttle Lever Alignment
(8) Align manual lever with detent ball and man
ual valve. Hold throttle lever upward. Then press
down on manual lever until fully seated. Remove de The 33.4 m m (1-5/16 in.) setting is an approxi
tent ball retainer fool after lever is seated. mate setting. Manufacturing tolerances m a y
(9) Then Install manual lever seal, washer and m a k e it n e c e s s a r y to vary from this dimension to
E-clip. obtain desired pressure.
(10) Lubricate solenoid case connector O-rings and One complete t u r n of the adjusting screw changes
shaft of manual lever with light coat of petroleum line pressure approximately 1-2/3 psi (9 kPa).
jelly. Turning the adjusting screw counterclockwise in
(11) Verify t h a t throttle lever is aligned with end creases pressure while turning the screw clockwise
of kickdown valve stem and t h a t manual lever arm decreases pressure.
(12) Install boost valve, valve spring, retainer and
cover plate. Tighten cover plate screws to 4 N»m (35
in. lbs.) torque.
(13) Obtain new fluid filter for valve body but do
not install filter at this time.
ment procedure.
VALVE BODY CONTROL PRESSURE

ADJUSTMENTS
There are two control pressure adjustments on the
valve body which are, line pressure and throttle pres
Fig. 127 Line Pressure Adjustment
sure.
Line and throttle pressures are interdependent be Throttle Pressure Adjustment
cause each affects shift quality and timing. As a re Insert Gauge Tool C-3763 between the throttle le
sult, both adjustments must be performed properly ver cam and the kickdown valve stem (Fig. 128).
and in the correct sequence. Adjust line pressure first Push the gauge tool inward to compress the kick-
and throttle pressure last. down valve against the spring and bottom the throt
tle valve.
Maintain pressure against kickdown valve spring.
Measure distance from the valve body to the inner Turn throttle lever stop screw until the screw head
edge of the adjusting screw with an accurate steel touches throttle lever tang and the throttle lever cam
scale (Fig. 127).
touches gauge tool.
Distance should be 33.4 mm (1-5/16 in.).
T h e k i c k d o w n v a l v e s p r i n g m u s t b e fully com with wood blocks, or cut a hole in the bench large
p r e s s e d a n d t h e k i c k d o w n v a l v e c o m p l e t e l y bot enough for the output shaft and rear support. Then
tomed to obtain correct adjustment. lower the shaft and support into the hole and support
the rear of the case directly on the bench.
TRANSMISSION ASSEMBLY PROCEDURE

(1) Lubricate rear servo piston seal with petroleum
jelly, or Door Eze. Lubricate servo bore in case with
transmission fluid.
(2) Install rear servo piston in case. Position piston
at slight angle to bore and insert piston with twist
ing motion (Fig. 129).
Fig. 128 Throttle Pressure Adjustment

TRANSMISSION ASSEMBLY
Assembly Tips
Do not allow dirt, grease, or foreign material to en
ter the case or transmission components during as
sembly. Keep the transmission case and components
clean. Also make sure the tools and workbench area
used for reassembly operations are equally clean.
Shop towels used for wiping off tools and your Fig. 129 Installing Rear Servo Piston—46RH
hands must be made from lint free materials. Lint (3) Install rear servo spring and retainer in case
will stick to transmission parts and could interfere bore (Fig. 130). Be sure spring is seated on piston.
with valve operation or even restrict fluid passages.
Lubricate transmission clutch and gear components
with Mopar ATF Plus or Dexron II™ during reassem
bly. Soak clutch discs in transmission fluid before in
stallation.
Use Ru-Glyde, Door-Eze, or petroleum jelly on
seals and O-rings to ease installation. Petroleum
jelly can also be used to hold thrust washers and
plates in position during assembly operations. How
ever, d o not use chassis grease, bearing grease,
white grease, or similar lubricants on any part.
These types of lubricants can eventually block or re
strict fluid passages and valve operation. Use petro
leum jelly only.
Do not force parts into place. The transmission
components and sub-assemblies are easily installed
by hand when properly aligned. If a part seems diffi
cult to install, it is either misaligned or incorrectly Fig. 130 Installing Rear Servo Piston Spring And
assembled. Verify that thrust washers, thrust plates Retainer—46RH
and seal rings are correctly positioned. These parts (4) Compress rear servo piston with C-clamp or
will prevent proper assembly is mispositioned (or Valve Spring Compressor C-3422-B and install servo
"left out" by accident). piston snap ring (Fig. 131).
The planetary geartrain, front/rear clutch assem (5) Install new gasket at rear of transmission case.
blies and oil pump are all much easier to install Use petroleum jelly to hold gasket in place. Be sure
when the transmission case is upright or as close to to align governor feed holes in gasket with feed
this position as possible. Either tilt the case upward p a s s a g e s in c a s e (Fig. 132). Install gasket before
21 - 31S TRANSMISSION 0VERHAUL-46RH •
Fig. 131 Installing Rear Servo Snap Ring—46RH

overdrive piston retainer. Center hole in gasket
is s m a l l e r t h a n r e t a i n e r a n d c a n n o t b e i n s t a l l e d
over retainer.
Fig. 133 Installing Overdrive Piston Retainer—46RH
Fig. 132 Installing Case Gasket—46RH

(6) Install overdrive piston retainer. Be sure gover
Fig. 134 Installing Rear Band And Link—46RH
nor tube bores in retainer are aligned with governor
feed passages in gasket and case (Fig. 133). Install (9) Install low-reverse drum (Fig. 135). Slide drum
and tighten retainer bolts to 17 N»m (13 ft. lbs.) through rear band, onto rear support hub and into
torque. engagement with overrunning clutch race.
(7) Install overrunning clutch components if not (10) Install snap ring t h a t secures low-reverse
yet installed. Refer to Overrunning Clutch Overhaul drum to rear support hub (Fig. 136).
in this section if necessary. (11) Insert band reaction pin part way case and
(8) Position rear band and link in case (Fig. 134). band link (Fig. 137).
Be s u r e n o t c h e d s i d e of l i n k f a c e s a w a y f r o m
band.
• TRANSMISSION 0VERHAUL-4SRH 21 - 317
Fig, 137 Installing Rear Band Reaction Pin—46RH
A
DJU
ST
NIG A
DJU
ST
NIG
J
912
1-
92
Fig. 138 Rear Band Levers And Strut—46RH

Fig. 136 Installing Low-Reverse Drum Snap
Ring-46RH (a) Place Tool SP-5560 (or similar size tool) on
guide and position C-clamp on tool and case (Fig.
(12) Install rear band adjusting lever, strut and re
140).
action lever (Fig. 138). Be sure levers and strut are
(b) Slowly compress rod guide while simulta
aligned and engaged before seating band reaction pin
neously easing seal ring into bore with suitable
in case.
tool.
(13) Lubricate front servo piston components and
(17) Install rod guide snap ring (Fig. 140).
servo bore in case with transmission fluid.
(18) Position front band lever in case and over
(14) Install front servo piston in bore. Carefully
servo rod guide. Then install front band lever pin in
"run" small, suitable tool around piston ring to press
case and slide it through lever.
it back into groove and ease installation (Fig. 139).
(19) Coat threads of front band lever pin access
Rotate piston into bore at same time. Rock piston
plug with sealer and install it in case. Tighten plug
slightly to ease piston ring past snap ring groove and
into bore.
(15) Bottom front servo piston in bore and install
servo spring.
(16) Install front servo piston rod guide as follows:
21 - 318 TRANSMISSION 0WERHAUL-46RH •
ASSEMBLY J9121-508
Fig. 141 Installing Intermediate Shaft And Planetary

Geartrain—46RH
Fig. 142 Installing Intermediate Shaft Thrust

Plate-46RH
Fig. 140 Installing Front Servo Rod Guide And Snap on rear clutch. Turn front clutch retainer back and
Ring-46RH forth until front clutch discs are fully seated on rear
(20) Install assembled output shaft and planetary clutch splined hub.
gear components (Fig. 141). S u p p o r t shaft c a r e (24) Install intermediate shaft thrust washer in
fully d u r i n g i n s t a l l a t i o n . D o n o t a l l o w shaft hub of rear clutch retainer (Fig. 145). Use petroleum
bearing/bushing surfaces to become nicked or jelly to hold washer in place. Position washer so
scratched. grooves are facing outward. W a s h e r o n l y fits o n e
(21) Lubricate intermediate shaft thrust plate with w a y in clutch retainer h u b .
petroleum jelly and install plate on shaft pilot hub (25) Place transmission case in upright position, or
(Fig. 142). place blocks under front end of transmission repair
(22) Check input shaft front seal rings, fiber t h r u s t stand to tilt case rearward. This makes it easier to
washer and rear seal ring (Fig. 143). Be ends of rear install front/rear clutch assembly.
seal ring are hooked together and diagonal cut ends (26) Align discs in rear clutch. Then install and
of front seal rings are firmly seated against each engage assembly in front planetary and driving shell
other as shown. Lubricate seal rings with petroleum (Fig. 146). Turn clutch retainers back and forth until
jelly after checking them. both clutches are seated.
(23) Assemble front and rear clutches (Fig. 144). (27) Slide front band over front clutch retainer and
Align lugs on front clutch discs. Mount front clutch install front band strut and anchor (Fig. 147).
Fig. 143 input Shaft Seat Ring And Thrust Washer Fig. 145 Installing intermediate Shaft Thrust
Installation—46RH Washer-46RH
Fig. 144 Assembling Front And Rear Fig. 146 Installing Front/Rear Clutch
Clutches-46RH Assemblies—46RH
(28) Tighten front band adjusting screw until band (30) Install new oil pump gasket on pilot studs and
is tight on clutch retainer. Verify t h a t front/rear seat it in case. Be sure gasket is properly aligned
clutch assembly is still properly seated b e f o r e tight with fluid passages in case (Fig. 148).
ening band. (31) Check seal rings on reaction shaft support. Be
(29) Install oil pump Pilot Studs C-3288-B in case sure rings are hooked together correctly. Also be sure
(Fig. 148). fiber thrust washer is in position (Fig. 149). Use pe
troleum jelly to hold washer in place if necessary.
21 - 320 TRANSMISSION 0¥ERHAUL-46RH •
LEVER STRUT
J9121-18
Fig. 147 Front Band And Linkage Installation—46RH

Fig. 149 Reaction Shaft Seal Ring And Thrust
Washer installation—46RH
Fig. 148 Installing Oil Pump Gasket And Pilot

Studs-46RH
(32) Lubricate oil pump seals with petroleum jelly
or transmission fluid.
(33) Mount oil pump on pilot studs and slide pump
into case opening (Fig. 150). Work p u m p into c a s e
b y hand. D o not u s e a mallet or similar tools to
seat p u m p . Fig. 150 Oil Pump installation—46RH
(34) Remove pilot studs and install oil pump bolts. (a) Attach dial indicator to converter housing
Tighten pump bolts alternately and evenly to fully (Fig. 151). Position indicator plunger against input
seat pump in case. Then final-tighten pump bolts to shaft and zero indicator.
20 N-m (15 ft. lbs.) torque. (b) Move input shaft in and out and record read
(35) Verify correct assembly. Rotate input and out ing.
put shafts and check for bind. If bind exists, compo (c) End play should be 0.86 - 2.13 mm (0.034 -
nents are either misassembled, or not seated. 0.084 in.).
Disassemble and correct as necessary before proceed
ing.
(36) Check input shaft end play as follows:
• TRANSMISSION 0VERHAUL-4IRH 21 - 321
(d) If end play is incorrect, change output shaft (39) Install spacer on intermediate shaft, if not
thrust washer, thrust plate, or front clutch thrust previously installed.
washer. (40) Install overdrive piston t h r u s t plate (Fig. 153).
Use liberal quantity of petroleum jelly to hold thrust
plate in position on piston.
(41) Install overdrive piston thrust bearing in di
rect clutch hub (Fig. 154). Use liberal quantity of pe
troleum jelly to hold thrust bearing in place. Note
that one side of bearing h a s dark coated sur
face. This surface faces overdrive piston. Also
be sure raised shoulder o n inside diameter of
bearing faces forward as well.
Fig. 151 Checking input Shaft End Play

(37) Install new seals on overdrive piston. Then lu
bricate seals with transmission fluid, Ru-Glyde,
Door-Eze or petroleum jelly.
(38) Install overdrive piston in retainer. Align lo
cating lugs o n piston in locating b o r e s in re
tainer (Fig. 152). Use thin plastic strip or feeler
gauge to help guide piston outer seal into retainer.
Fig. 153 Installing Overdrive Piston Thrust Plate
Fig. 154 Installing Overdrive Piston Thrust Bearing

(42) Apply small amount of petroleum jelly to pilot
hub of intermediate shaft.
(43) Verify alignment of splines in overdrive unit
planetary gear and overrunning clutch. Be sure
Alignment Tool 6227-2 is fully seated (Fig. 155). If
planetary gear and overrunning clutch splines
b e c o m e misaligned, overdrive unit cannot be
fully installed o n intermediate shaft. Overdrive
unit will h a v e to be disassembled in order to re
Fig. 152 Overdrive Piston Alignment align splines.
(b) Align and seat valve body on case. Be sure
manual lever shaft and overdrive connector are
fully seated in case.
(c) Install and start all valve body attaching
bolts by hand. Then tighten bolts evenly, in a di
agonal pattern to 12 Nnn (105 in. lbs.) torque. D o
not overtighten valve body bolts. This could
r e s u l t i n d i s t o r t i o n a n d c r o s s l e a k a g e after in
stallation..
(51) Install new filter on valve body. Tighten filter
screws to 4 Nnn (35 in. lbs.).
(52) Install seal on park/neutral position switch
(Fig. 157). Then install and tighten switch to 34 Nnn
(25 ft. lbs.).
J932M33
Fig. 155 Checking Alignment Of Overdrive Planetary

Gear And Overrunning Clutch Splines—46RH
(44) Carefully withdraw alignment tool from over
drive unit.
(45) Lubricate intermediate shaft splines and
bushing surfaces with transmission fluid or petro
leum jelly.
(46) Install overdrive unit. Be sure governor tubes
are aligned with feed holes in piston retainer boss.
Intermediate shaft is snug fit in overdrive planetary Fig. 157 Park/Neutral Position Switch Seal Position
gear and overrunning clutch. If overdrive unit will (53) Adjust front and rear bands as follows:
not seat fully, rotate overdrive output shaft slightly (a) Loosen locknut on each band adjusting screw
to align splines and try again. 4-5 turns.
(47) Apply 1-2 drops of Mopar thread adhesive (or (b) Tighten both adjusting screws to 8 Nnn (72
Loctite 242) to overdrive unit attaching bolts. Then in. lbs.).
install and tighten bolts to 34 N» (25 ft. lbs.) torque. (c) Back off front band adjusting screw 2-1/2
(48) Install accumulator inner spring, piston and turns.
outer spring (Fig. 156). (d) Back off rear band adjusting screw 2 turns.
ACCUMULATOR OUTER (e) Hold each adjusting screw in position and
tighten locknuts to 34 Nnn (25 ft. lbs.) torque.
(54) Install magnet in oil pan. Magnet goes on
stall oil pan. Tighten pan bolts to 17 Nnn (13 ft. lbs.).
(57) Install throttle valve and shift selector levers
on valve body manual lever shaft.
Fig. 156 Installing Accumulator Piston And Springs (58) Cap or cover transmission openings (cooler
(49) Verify t h a t park/neutral position switch has line fittings, filler tube bore, etc.) to prevent dirt en
n o t been installed in case. Valve body can not be in try.
stalled if switch is in position. (59) Install torque converter. Use C-clamp or metal
(50) Install valve body as follows: strap to hold converter in place for installation.
(a) Start park rod into park pawl. If rod will not (60) Mount transmission on jack for installation in
slide past park pawl, pawl is engaged in park gear. vehicle.
Rotate overdrive output shaft with socket to free (61) Apply dielectric grease to terminal pins of so
pawl and allow rod to engage. lenoid case connector and neutral switch.

be reverse flushed if overhaul corrected a malfunc
clutch friction material. The torque converter should
also be replaced if contaminated by the same mal
function. Debris and residue not flushed from the
cooler and lines will flow back into the transmission
and s h o p comeback.
Fig. 158 Installing Manual Lever Shaft Seal

21 - 324 OVERDRIVE UNIT OVERHAUL—42RH/46RH •
OVERDRIVE UNIT OVERHAUL—42RH/46RH
INDEX
page page
Overdrive Geartrain Assembly 333 Overdrive Unit Cleaning and Inspection . . . . . . . 330
Overdrive Geartrain Disassembly 326 Overdrive Unit Disassembly 324
Overdrive Unit Assembly and Adjustment 338
OVERDRIVE UNIT DISASSEMBLY

(1) Remove overdrive piston thrust plate (Fig. 1).
Retain thrust plate. It is a select fit part and can be
reused.
Fig. 3 Removing Overdrive Piston
Fig. 4 Removing Overdrive Piston Thrust Bearing

(6) Remove overdrive clutch pack (Fig. 6). Note that
thickest plate is positioned at rear of clutch pack.
(7) Remove overdrive clutch wave spring (Fig. 7).
(8) Remove overdrive clutch reaction snap ring
(Fig. 8). Note t h a t snap ring is located in same
groove as wave spring.
(9) Remove access cover and gasket from case (Fig.
Fig. 2 Intermediate Shaft Spacer Location
9). Cover provides access to output shaft front bear
(3) Remove overdrive piston from retainer (Fig. 3). ing locating ring.
(4) Remove overdrive piston thrust bearing from (10) Expand output shaft bearing snap ring with
direct clutch hub (Fig. 4). snap ring pliers and push output shaft forward to re
(5) Remove overdrive clutch pack retaining ring lease shaft front bearing from locating ring (Fig. 10).
(Fig. 5).
• OVERDRIVE UNIT OVERHAUL—42RH/46RH 21 - 325
Fig. 5 Removing/Installing Overdrive Clutch Pack Fig. 8 Removing Overdrive Clutch Reaction Snap
Retaining Ring Ring
Fig. 6 Overdrive Clutch Pack Removal Fig. 9 Removing/Installing Locating Ring Access
Cover
Fig. 7 Removing/installing Overdrive Clutch Wave

Spring Fig. 10 Releasing Shaft Front Bearing From
Locating Ring
(11) Remove geartrain assembly from housing
(Fig. 11). Set geartrain aside.
Fig. 11 Removing Overdrive Unit Geartrain

(12) Remove output shaft front bearing locating
ring and governor support snap ring (Fig. 12).
Fig. 13 Removing Governor Support And Tube
Assembly
Fig. 12 Front Bearing Locating Ring And Governor

Support Snap Ring Location
(13) Remove governor support and tube assembly Fig. 14 Park Lock Component Removal
from case (Fig. 13).
(14) Remove park pawl retaining bolt and reaction OVERDRIVE GEARTRAIN DISASSEMBLY
plug snap ring (Fig. 14). Compress snap ring only (1) Remove E-clip from one end of governor valve
enough to remove it. Snap ring can be distorted if shaft and remove shaft and valve (Fig. 16).
overcompressed. (2) Remove governor snap ring (fig. 17).
(15) Remove park pawl shaft, park pawl, pawl (3) Remove governor body and drive as assembly
spring and reaction plug (Fig. 14). (Fig. 18).
(16) Remove output shaft rear bearing snap ring (4) Remove governor drive key (Fig. 19).
(Fig. 15). Remove snap ring with long jaw internal (5) Remove output shaft front bearing snap ring
type snap ring pliers. Or, rotate snap ring until one (Fig. 20).
end is adjacent to notch in case. Then unseat ring (6) Remove front bearing from output shaft (Fig.
with long flat blade screwdriver. 21).
(17) Remove rear bearing by tapping overdrive
case on wood block to dislodge bearing.
OVERDRIVE UNIT OVERHAUL—42RH/48RH 21 - 327
GOVERNOR
OUTPUT S H A F T / BODY A N D
REAR BEARING DRIVE ASSEMBLY
•SNAP-
RING 8921-239 J9221-39
Fig. 15 Output Shaft Rear Bearing And Snap Ring Fig. 18 Removing/Installing Governor Body And
Location Drive Assembly
GOVERNOR OUTPUT
BODY SHAFT
E-CLIP GOVERNOR
VALVE GOVERNOR
SHAFT DRIVE KEY
GOVERNOR
J9121-302 VALVE E-CLIP- J9221-43
Fig. 16 Governor Valve And Shaft

Removal/Installation Fig. 19 Removing Governor Drive Key
GOVERNOR
ASSEMBLY FRONT
BEARING
SNAP RING
GOVERNOR
SNAP RING
j9121 303
j m r r / -
Fig. 20 Removing/Installing Front Bearing Snap
Fig. 17 Removing/Installing Governor Snap Ring
Ring
Fig. 21 Removing/Installing Output Shaft Front

Bearing
WARNING: THE NEXT STEP IN GEARTRAIN
DISASSEMBLY INVOLVES COMPRESSING THE DI
RECT CLUTCH SPRING. IT IS EXTREMELY IMPOR
TANT THAT PROPER EQUIPMENT BE USED TO
COMPRESS THE SPRING AS SPRING FORCE IS
APPROXIMATELY 800 POUNDS. USE SPRING COM
PRESSOR TOOL C-6227-1 AND A HYDRAULIC-
TYPE SHOP PRESS WITH A MINIMUM RAM
TRAVEL O F 5-6 INCHES. THE PRESS MUST ALSO
HAVE A BED THAT CAN BE ADJUSTED UP OR Fig. 22 Removing Direct Clutch Pack Snap Ring
DOWN AS REQUIRED. RELEASE CLUTCH SPRING
TENSION SLOWLY AND COMPLETELY TO AVOID
PERSONAL INJURY.
(7) Mount geartrain assembly in shop press

(8) Position Compressor Tool 6227-1 on clutch hub
(Fig. 22). Support output shaft flange with steel press
plates as shown and center assembly under press
ram.
(9) Use Bushing Tool MB990891 (or similar size
tool) at top of Tool 6227-1 to help distribute load and
provide needed extra press length.
(10) Apply press pressure slowly. Compress hub
and spring far enough to expose clutch hub retaining
ring and relieve spring pressure on clutch pack snap
ring (Fig. 22).
(11) Remove direct clutch pack snap ring first (Fig. Fig. 23 Removing Direct Clutch Hub Retaining Ring
22).
into clutch hub. Expand pliers to grip hub splines
(12) Remove direct clutch hub retaining ring (Fig.
and remove clutch with counterclockwise, twisting
23).
motion.
(13) Release press load on clutch spring slowly
(18) Remove thrust bearing from overrunning
and completely. Remove press tools and geartrain.
clutch hub (Fig. 28).
(14) Remove direct clutch pack from hub (Fig. 24).
(19) Remove overrunning clutch from hub (Fig.
(15) Remove direct clutch hub and spring (Fig. 25).
28).
(16) Remove sun gear and spring plate, planetary
thrust bearing and planetary gear (Fig. 26).
(17) Remove overrunning clutch assembly with ex
panding type snap ring pliers (Fig. 27). Insert pliers
Fig. 24 Direct Clutch Pack Removal Fig. 27 Removing Overrunning Clutch Assembly
J9121-312
Fig. 26 Removing Sun Gear/Thrust

Bearing/Planetary Gear
DIRECT
CLUTCH
DRUM
OUTER
8921-249 RETAINING RING J9121-293
PUNCH
Fig. 29 Marking Direct Clutch Drum And Annulus Fig. 31 Removing Clutch Drum Outer Retaining
Gear For Assembly Alignment Ring
DIRECT OUTPUT SHAFT-
INNER CLUTCH
RETAINING DRUM
RING
ANNULUS
GEAR
J9121-292 PUNCH J9221-46
Fig. 30 Removing Clutch Drum Inner Retaining Ring Fig. 32 Marking Annulus Gear And Output Shaft For
Assembly Alignment
(20) Mark position of annulus gear and direct
clutch drum for assembly alignment reference (Fig. OUTPUT
29). Use small center punch or scriber to make align SHAFT
ment marks.
(21) Remove direct clutch drum rear retaining ring
(Fig. 30).
(22) Remove direct clutch drum outer retaining
ring (Fig. 31).
(23) Mark annulus gear and output shaft for as
sembly alignment reference (Fig. 32).
(24) Remove annulus gear from output shaft (Fig.
33). Use rawhide or plastic mallet to tap gear off shaft.
(25) Remove output shaft front bearing if not pre
viously removed.
ANNULUS
GEAR J9021-288
OVERDRIVE UNIT CLEANING AND INSPECTION
Clean the geartrain (Fig. 34) and case components Fig. 33 Removing Annulus Gear
(Fig. 35) with solvent. Dry all parts except the bear ficient quantity of lint (from shop towels, cloths,
ings with compressed air. Allow bearings to air dry. rags, etc.) could plug the transmission filter and fluid
Do not use shop towels for wiping parts dry unless passages.
the towels are made from a lint-free material. A suf-
THRUST SUN PLANETARY GEAR OVERRUNNING CLUTCH

BEARING GEAR
SPRING
OVERDRIVE PLATE OUTER
CLUTCH RETAINING RING
PISTON f
RETAINER DIRECT CLUTCH
DRUM
INNER
RETAINING RING
OVERDRIVE
CLUTCH PISTON
PISTON CLUTCH HUB

THRUST SNAP RING
PLATE
(SELECTIVE)
PISTON
THRUST
BEARING
CLUTCH PACK
RETAINING
RING
OVERDRIVE
REACTION REACTION
CLUTCH PACK
PLATE SNAP RING J9J21-289
Fig. 34 Overdrive Geartrain Components (42RH Shown)
SEAL ACCESS PLATE CASE GASKET
AND GASKET
PLATE
SPACER
INSULATOR SHAFT
RETAINING BOLT
DAMPER
WEIGHT
PARK PAWL REACTION

SPRING PLUG A N D SNAP RING PARK LOCK ROD J9121-290
Fig. 35 Overdrive Case And Park Lock Components

GOVERNOR GOVERNOR REAR BEARING OUTPUT SHAFT
Fig. 36 Output Shaft And Governor Components

Discard the old case gasket and seals. Do not at Check condition of the annulus gear, direct clutch
tempt to salvage these parts. They are not reusable. hub, clutch drum and clutch spring (Fig. 34). Replace
Replace any of the overdrive unit snap rings if dis the gear, hub and drum if worn or damaged. Replace
torted or damaged. the spring if collapsed, distorted, or cracked.
Minor nicks or scratches on components can be Be sure the splines and lugs on the gear, drum and
smoothed with crocus cloth. However, do not attempt hub are in good condition. The clutch plates and
to reduce severe scoring on any components with discs should slide freely in these components.
abrasive materials. Replace severely scored compo Inspect the thrust bearings and spring plate (Fig.
nents; do not try to salvage them. 34). Replace the plate if worn or scored. Replace the
Check condition of the park lock components and bearings if rough, noisy, brinneled, or worn.
the overdrive case (Fig. 36). Inspect the planetery gear assembly and the sun
Replace the case if cracked, scored, or damaged. gear and bushings (Fig. 34). If either the sun gear or
Replace the park lock pawl, plug, or spring if worn or the bushings are damaged, replace the gear and
damaged. Re sure the bullet at the end of the park bushings as an assembly. The gear and bushings are
lock rod is in good condition. Replace the rod if the not serviced separately.
bullet is worn or the rod itself is bent or distorted. The planetary carrier and pinions must be in good
Do not attempt to straighten the rod. condition. Also be sure the pinion pins are secure
Check the bushings in the overdrive case. Replace and in good condition. Replace the carrier if worn or
the bushings if severely scored or worn. Also replace damaged.
Inspect the overrunning clutch and race. The race
the case seal if loose, distorted, or damaged.
surface should be smooth and free of scores. Replace
Examine the overdrive and direct clutch discs and
the overrunning clutch assembly or the race if either
plates (Fig. 34). Replace the discs if the facing is
assembly is worn or damaged in any way.
worn, severely scored, or burned and flaking off. Re
Inspect the output shaft and governor components
place the clutch plates if worn, heavily scored, or
(Fig. 36). Replace the shaft pilot bushing and inner
cracked. Check the lugs on the clutch plates for bushing if damaged. Replace either shaft bearing if
wear. The plates should slide freely in the drum. Re rough or noisy. Replace the bearing snap rings if dis
place the plates or drum if binding occurs. torted or cracked.
Check the machined surfaces on the output shaft.

These surfaces should clean and smooth. Very minor
nicks or scratches can be smoothed with crocus cloth.
Replace the shaft if worn, scored or damaged in any
way.
Check condition of the governor components. Re
place the governor drive seal rings if damaged. Be
sure the drive ring grooves are in good condition.
Check operation of the governor valve, weights and
shaft. The valves and weights should slide freely in
the governor body (Fig. 36).
There are t w o governor component changes in
current overdrive unit units. The first involves
the governor valve w h i c h is n o w m a d e of alumi
num. The s e c o n d involves the output shaft
which h a s a spotface for governor valve end
clearance. The n e w aluminum valve is not inter
Fig. 37 Output Shaft Bushing Location
changeable. It must only be u s e d w i t h an output
shaft that h a s the spotface for valve end clear (5) Align and install annulus gear on output shaft
ance. (Fig. 38).
Inspect the governor support and the two oil pres (6) Install annulus snap ring (Fig. 38).
sure tubes (Fig. 36). The tubes are an integral
part of the support. D o not attempt to remove
them.
The oil tubes must not be pinched, kinked, col
lapsed, or distorted. Blow them out with compressed
air to be sure they are clear. The tubes are designed
to be a slip fit in the piston retainer boss. Do not
modify the tube ends in an effort to make them fit
tighter.
Replace the governor support and the oil tubes as
an assembly if either component is damaged.
Check condition of the governor valve and weight
snap rings. Replace any snap ring t h a t appears bent
or distorted. Replace any snap ring if its condition is
doubtful.
Inspect the output shaft bushings (Fig. 37). The
small bushing is the intermediate shaft pilot bush
ing. The large bushing is the overrunning clutch hub Fig. 38 Installing Annulus Gear And Snap Ring
bushing. Replace either bushing if scored, pitted, (7) Align and install clutch drum on annulus gear
cracked, or worn. (Fig. 39). Be sure drum is engaged in annulus gear
The bushings can be removed with "blind hole lugs.
puller tools" such as Snap-On set CG40CB for small (8) Install clutch drum outer retaining ring (Fig.
bushings and set CG46 for large bushings. New 31).
bushings can be installed with tools from an all pur (9) Slide clutch drum forward and install inner re
pose installer kit such as the Snap-On A257 bushing taining ring (Fig. 39).
driver set.
(10) Install overrunning clutch on hub (Fig. 40).
Note that clutch only fits one w a y . Shoulder on
OVERDRIVE GEARTRAIN ASSEMBLY
clutch should seat in small recess at e d g e of
(1) Lubricate geartrain components with Mopar
ATF Plus or Dexron II™ transmission fluid. hub.
(2) Soak direct and overdrive clutch discs in trans (11) Install thrust bearing on overrunning clutch
mission fluid before installation. hub (Fig. 41). Use generous amount of petroleum
(3) Install new pilot bushing and clutch hub bush jelly to hold bearing in place for installation. Bear
ing in output shaft if necessary (Fig. 37). Lubricate ing fits one w a y only. Be sure bearing is seated
new (or old) bushings with petroleum jelly. squarely against hub. Reinstall bearing if it d o e s
(4) Install front bearing and bearing snap ring on not seat squarely.
output shaft (Fig. 38)
(12) Install overrunning clutch (Fig. 42). Insert
snap r i n g pliers in hub splines. Expand pliers to grip
hub. Then install assembly with counterclockwise,
twisting motion.
CLUTCH OVERRUNNING
DRUM CLUTCH
ASSEMBLY
EXPAN DING-TYPE
ANNULUS SNAP RING
GEAR PLIERS
INNER
RETAINING
RING J9121-294
Fig. 39 installing Clutch Drum Inner Retaining Ring

CLUTCH OVERRUNNING
HUB CLUTCH ASSEMBLY
SEATED IN
OUTPUT SHAFT
CLUTCH
DRUM
ANNULUS
GEAR
J9121-314
OVERRUNNING
J9121-322
CLUTCH Fig. 42 Installing Overrunning Clutch
Fig. 40 Assembling Overrunning Clutch And Hub (13) Install planetary gear in annulus gear (Fig.
43). Be sure planetary pinions are fully seated in
BE SURE annulus gear before proceeding.
THRUST BEARING
IS SEATED SQUARELY
AGAINST CLUTCH HUB PLANETARY
GEAR
CLUTCH
HUB
ANNULUS
GEAR
J9121-323
Fig. 41 Installing Overrunning Clutch Thrust J9121-324

Bearing
Fig. 43 Installing Planetary Gear
(14) Install direct clutch spring plate on sun gear.

Shoulder side of plate should face outward and to
ward front. Then secure plate to sun gear with snap
ring (Fig. 44).
SUN
Fig. 46 Sun Gear Installation

(19) Install direct clutch spring. Be sure spring is
properly seated on spring plate (Fig. 47).
Fig. 44 Sun Gear And Spring Plate Assembly

(15) Coat planetary thrust bearing and bearing
contact surface of spring plate with generous amount
of petroleum jelly. This will help hold bearing in
place during installation.
(16) Install planetary thrust bearing on sun gear
(Fig. 45). Slide bearing onto gear and seat it against
spring plate as shown. Bearing fits one w a y only.
If it does not seat squarely against spring plate,
remove and reposition bearing.
Fig. 47 Installing Direct Clutch Spring

(20) Assemble direct clutch pack for installation on
hub (Fig. 48).
(21) Install direct clutch reaction plate on clutch
J9121-326 hub. Note that one side of reaction plate is coun-
terbored. Be sure this side faces rearward.
Fig. 45 Installing Planetary Thrust Bearing Splines at rear of h u b are raised slightly. Coun-
terbore in plate fits over raised splines. Plate
(17) Install assembled sun gear, spring plate and
should be flush w i t h this end of h u b (Fig. 49).
thrust bearing (Fig. 46). Be sure sun gear and thrust
(22) Install remainder of direct clutch components
bearing are fully seated before proceeding.
as follows:
(18) Align splines in hubs of planetary gear and
(a) Install first clutch disc on reaction plate fol
overrunning clutch with Alignment tool 6227-2 (Fig.
lowed by a steel plate.
47). Insert tool through sun gear and into splines of (b) Install remaining discs and plates alternately
both hubs. Be sure alignment tool is fully seated be until required number of discs and plates are in
fore proceeding. stalled.
21 - 336 OVERDRIVE UNIT OVERHAUL—42RH/46RH
CLUTCH DISCS (6) 42RH

A
REACTION
PLATE
PRESSURE
PLATE CLUTCH PLATES (5) CLUTCH
DISCS ( 8 ) 46RH
PRESSURE
PLATE
REACTION CLUTCH
PLATE PLATES (7) J922M41
Fig. 48 Direct Clutch Pack Components
(c) Check direct clutch pack. 42RH requires 6 REACTION
discs and 5 steel plates. 46RH requires 8 discs and PLATE
7 steel plates (Fig. 48). COUNTERBORE
(d) Last clutch pack item installed is clutch pres
sure plate. Be sure plate is installed with shoulder
side of plate facing upward (Fig. 50).
(23) Install clutch hub and clutch pack on direct
clutch spring (Fig. 51).
(24) Mount geartrain assembly in shop press (Fig.
52)
WARNING: THE NEXT STEP IN GEARTRAIN AS

SEMBLY INVOLVES COMPRESSING THE DIRECT
CLUTCH HUB AND SPRING. IT IS EXTREMELY IM
PORTANT THAT PROPER EQUIPMENT BE USED DIRECT
TO COMPRESS THE SPRING AS SPRING FORCE IS CLUTCH
REACTION
APPROXIMATELY 800 POUNDS. USE SPRING COM PLATE
PRESSOR TOOL C-6227-1 AND A HYDRAULIC- (FLUSH WITH
TYPE SHOP PRESS WITH A MINIMUM RAM END OF HUB)
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. CLUTCH
HUB
(25) Position Compressor Tool 6227-2 on clutch
hub (Fig. 52). J9121-329
(26) Position Tool MB990891 or similar size tool on
Fig. 49 Correct Position Of Direct Clutch Reaction Plate
top of compressor tool (Fig. 52). Similar size tool
OVERDRIVE UNIT OVERHAUL—42RH/4IRH 21 - 337
DR
IE
CT
CL
UTC
H
P
RES
SU
RE
P
LA
TE S
PEC
AIL T
OOL
M B
9 9
08
91
S
PEC
AIL S
PEC
AIL
TOOL TOOL
622
7 -
2 622
7 -
1
D
RIE
CT
C
LUT
CH
PACK
C
LU
TCH C
LUT C
H
PA
CK HUB
BE SURE S HOUL
DER
SD
IE OF C
LU
TC
H
PLATE F
ACES DR
UM
UPWARD J
912
1-
330
Fig. 50 Correct Position Of Direct Clutch Pressure

Plate
D
RIE
CT
C
LUT
CH
PACK
J
922
1-
2
Fig. 52 Mounting Geartrain Assembly In Shop Press

C
LUT C
H
HUB (28) Slowly compress clutch hub and spring (Fig.
53). Compress spring and hub only enough to expose
ring grooves for clutch pack snap ring and clutch hub
retaining ring.
(29) Realign clutch pack on hub and seat clutch
discs and plates in clutch drum (Fig. 53).
DR
IE
C T
S
PECA
IL CL
UTCH
TOOL P
LAT
ESD
/
SIC
S
6
227-
2
J
912
1-
331
Fig. 51 Installing Assembled Direct Clutch Pack And C

LU
TC
H
Hub D
RUM
should have minimum outside diameter of 3-1/2 inch,
minimum wall thickness of 1/4 inch and be approxi
J
922
1-
3
mately 4 inches long.
(27) Slide direct clutch pack upwards on hub (Fig. Fig. 53 Seating Clutch Pack In Drum
52). Slide pack upward and set it partially on edge of
hub and compressor tool as shown in Figure 52.
(30) Install direct clutch pack snap ring (Fig. 54).
Be v e r y s u r e s n a p r i n g Is fully s e a t e d In c l u t c h
d r u m ring groove.
(31) Install clutch h u b retaining ring (Fig. 55). B e
v e r y s u r e r e t a i n i n g r i n g Is fully s e a t e d i n s u n
gear ring groove.
(32) Slowly release press ram, remove compressor
tools and remove geartrain assembly.
Fig. 56 Front Bearing And Drive Key Installation

GOVERNOR
BODY
Fig. 54 Installing Direct Clutch Pack Snap Ring
GOVERNOR
DRIVE
Fig. 57 Governor Drive Seal Rings
J9221-5
Fig. 55 Installing Clutch Hub Retaining Ring

OVERDRIVE UNIT ASSEMBLY AND ADJUSTMENT
(1) Install front bearing and snap ring on output
shaft (Fig. 56). B e s u r e l o c a t i n g r i n g g r o o v e i n
b e a r i n g is t o w a r d r e a r of shaft. Fig. 58 Installing Governor Weight Assembly
(2) Install governor drive key in output shaft (Fig. body (Fig. 58). Be sure all retaining snap rings are
56). securely seated.
(3) Install new seal rings on governor drive. Be
sure ring ends are securely interlocked before pro
ceeding (Fig. 57).
(4) Assemble governor drive and body. Be sure fil
ter is properly seated and positioned in governor
body before tightening attaching bolts.
(5) Assemble governor inner and outer weights
and spring. Then install weight assembly in governor
(6) Install governor assembly on output shaft (Fig. (13) Install reaction plug snap ring (Fig. 61). Com
59). Be sure drive key is fully engaged drive slot and press snap ring only e n o u g h for installation; d o
is not displaced during installation. not distort it.
PLIERS 8921-240
Fig. 59 Installing Governor Assembly Fig. 61 Reaction Plug And Snap Ring Installation
(7) Align shaft holes in governor body and output (14) Install alignment clip on governor tubes (Fig.
shaft and install governor valve and shaft (Fig. 16). 62). Slide clip up against shoulder on each tube.
Be very sure that E-clip retainer at e a c h end of
governor valve shaft is securely e n g a g e d . GOVERNOR
(8) Install governor snap ring (Fig. 17).
(9) Install output shaft rear bearing in case and in
stall bearing snap ring. Be sure snap ring is fully
seated.
(10) Position park pawl and spring in case and in
stall park pawl shaft (Fig. 14). Verify that spring end
is hooked to pawl and straight end of spring
(11) Install pawl shaft retaining bolt. Tighten bolt
to 27 Nnn (20 ft. lbs.) torque.
(12) Install park lock reaction plug. Note that
p l u g h a s locating pin at rear (Fig. 6 0 ) . Be sure Fig. 62 Positioning Governor Tube Alignment Clip
pin is s e a t e d in h o l e in c a s e before installing
s n a p ring. (15) Install governor support and pressure tubes in
case (Fig. 63).
REACTION
Fig. 60 Reaction Plug Locating Pin And Snap Ring
Fig. 63 Installing Governor Support And Pressure

Tubes
21 - 340 OVERDRIVE UNIT OVERHAUL—42RH/46RH
(16) Install governor support snap ring (Fig. 64).
SNAP / © ^ S ^ ^ S ^ /^SCREWDRIVER
7
RING
CASE
GEARTRAIN
SPECIAL
SPECIAL TOOL
TOOL 6227-1
8921-264
6227-2
Fig. 64 Installing Governor Support Snap Ring

(17) Install output shaft front bearing locating ring
in case (Fig. 65). J9221-6
OUTPUT SHAFT
FRONT BEARING Fig. 66 Installing Overdrive Case On Geartrain
LOCATING RING (e) Install remaining clutch discs and plates in
same order.
(f) Verify clutch pack before proceeding:
• gas engine version of 42RH/46RH, requires 4
clutch discs, 3 steel plates, 1 reaction plate and 1
pressure plate.
• diesel engine version of 46RH, requires 5 clutch
discs, 4 steel plates, 1 reaction plate and 1 pressure
plate.
(g) Install clutch pack pressure plate (Fig. 68).
(h) Install clutch pack wire-type retaining ring
(Fig. 67).
J9121-339
WAVE
Fig. 65 Front Bearing Locating Ring Installation SPRING
(18) Support geartrain on Tool 6227-1 (Fig. 66). Be

sure tool is securely seated in clutch hub.
(19) Install overdrive unit case over geartrain (Fig.
66).
(20) Expand front bearing locating ring with snap
ring pliers. Then slide case downward until locating
ring locks in bearing groove and release snap ring.
(21) Install locating ring access plate and gasket in
overdrive unit case (Fig. 9).
(22) Install overdrive clutch components as follows:
(a) Install reaction ring first. Reaction ring is
flat with notched ends (Fig. 67). REACTION RETAINING RING
RING (WIRE-TYPE) J9121-470
(b) Install wave spring on top of reaction ring.
Reaction ring a n d w a v e ring both fit in s a m e
Fig. 67 Overdrive Clutch Ring Identification
ring groove. Use screwdriver to seat each ring se
curely in groove. (23) Place overdrive unit in vertical position.
(c) Install reaction plate (Fig. 68). Mount unit in vise or in workbench with appropriate
(d) Install first clutch disc followed by first size mounting hole cut into it. Be sure unit is facing
clutch plate. upward for access to direct clutch hub.
• NP205 TRANSFER CASE 21 - 341
REACTION End P l a y
PLATE Measurement S p a c e r Thickness
(Inches) (Inches)
.7336 - .7505 .158 - .159

.7506 - .7675 .175 - .176
.7676 - .7855 .193 - .194
.7856- .8011 .211 - .212
J9121-341
Fig. 70 Intermediate Shaft End Play Spacer Selection
CLUTCH DISCS (4) (c) Select and install required thrust plate from in
formation provided in thrust plate chart (Fig. 72).
J9321-227
(26) Leave Alignment Tool 6227-2 in place. Tool
Fig. 68 Overdrive Clutch Pack (Gas Engine Version
will keep planetary and clutch hub splines in align
Shown)
ment until overdrive unit is ready for installation on
(24) Determine correct thickness intermediate transmission.
shaft spacer as follows: (27) Set overdrive unit aside for final assembly of
(a) Insert Special Tool 6312 through sun gear, plan transmission.
etary gear and into pilot bushing in output shaft. Be
sure tool bottoms against planetary shoulder.
(b) Position Gauge Tool 6311 across face of over
drive case (Fig. 69). Then position Dial Caliper
C-4962 over gauge tool.
(c) Extend sliding scale of dial caliper downward
through gauge tool slot until scale contacts end of
Alignment Tool 6312. Lock scale in place. Remove
dial caliper tool and note distance measured (Fig. 69).
(d) Select proper thickness end play spacer from
spacer chart based on distance measured (Fig. 70).
(e) Remove Alignment Tool 6312.
SPECIAL
TOOL 6311 Fig. 71 Overdrive Piston Thrust Plate Measurement
End P l o y
SPECIAL Measurement Spacer Thickness
TOOL 6312 (Inches) (Inches)
1.7500 - 1.7649 .108 - .110
1.7650- 1.7799 .123 - .125
1.7800 - 1.7949 .138 - .140
1.7950 - 1.8099 .153 - .155
1.8100 - 1.8249 .168 - .170
J9221-47 1.8250 - 1.8399 .183 - .185
1.8400 - 1.8549 .198 - .200
Fig. 69 Shaft End Play Measurement 1.8550 - 1.8699 .213 - .215
(25) Determine correct thickness overdrive piston 1.8700 - 1.8849 .228 - .230
thrust plate as follows: 1.8850 - 1.8999 .243 - .245
(a) Position Gauge Tool 6311 across face of over J9121-342
drive case. Then position Dial Caliper C-4962 over
gauge tool (Fig. 71). Fig. 72 Overdrive Piston Thrust Plate Selection
(b) Measure distance to clutch hub thrust bear
ing seat at four points 90° apart. Then average
measurements by adding them and dividing by 4.
21 - 342 NP205 TRANSFER CASE •
NP205 T R A N S F E R CASE
INDEX
page page
General Information 342 Transfer Case Assembly 348
Recommended Lubricants 342 Transfer Case Disassembly . . . . . . . . . . 345
Service Diagnosis 342 Transfer Case Identification 342
Shift Linkage Adjustment 344 Transfer Case Installation 345
Speedometer Service 345 Transfer Case Removal 345
GENERAL INFORMATION SAE multi-purpose gear lubricants with an API

The NP205 transfer case is a heavy duty, part-time grade rating of GL 5 are recommended for severe
unit with constant mesh, helical gears. The gears are duty operation. SAE grades 80, 75W-90, 90, 80W-90,
mounted in a one-piece, cast iron gear case. 140 and 80W-140 are all acceptable.
The NP205 provides four operating ranges which Use SAE 80 or 75W-90 when ambient tempera
are: 4-wheel drive high, neutral, 2-wheel drive high tures are below -23° C (-10° F). Use SAE 90, or
and 4-wheel drive low (Fig. 1). 80W-90 when ambient temperature is above t h e
The transfer case gears rotate on shafts supported stated range.
by ball and roller bearings. Sliding clutch sleeves SAE 140, or 80W-140 can be used when severe ser
and shift forks are used to engage or disengage the vice is anticipated, or when ambient temperatures
drive gears. are expected to exceed +32° C (90° F).
The NP205 geartrain provides high and low ranges
in 4-wheel drive mode. The high range has a 1:1 ra Transfer Case Shift Linkage Lubrication
tio for normal operation and a low range with a re The transfer case shift linkage pivot and contact
duction ratio of 1.96:1 for extra pulling power in off surfaces should be lubricated with engine oil a t rec
road situations. ommended intervals. Lubrication frequency for the
In two-wheel drive range, the transfer case front linkage is described in Lubrication And Maintenance
output shaft drive gear is disengaged. Torque is not Group O.
transmitted to the front propeller shaft.
TRANSFER CASE IDENTIFICATION
The NP205 identification t a g is attached to t h e
PTO cover on the driver side of the transfer case.
The tag contains transfer case manufacturing and as
sembly part numbers. Refer to this information when
ordering service replacement parts.
SERVICE DIAGNOSIS
The most frequent causes of transfer case malfunc
tions are:
• improper operation
• insufficient lubricant
• non-recommended lubricant
• misadjusted shift linkage
• improper assembly after repair.
The general problems and causes of transfer case
malfunctions are outlined below.
Fig. 1 NP205 Transfer case LOW LUBRICANT LEVEL
RECOMMENDED LUBRICANTS A low lubricant level is usually the result of loose
Recommended lubricants for the NP205 transfer components, leakage, or improper checking and/or
case include multi-purpose gear lubricants and single filling techniques.
weight engine oils. Lubricant leaks can occur a t t h e shaft seals, case
Engine oil should be API classification SF/CC or vent, or gasket joints. Most leaks will be evident by
SF/CD. Use SAE 30 at ambient temperatures below the presence of lubricant around t h e leakage point.
0° C ( + 32° F) and SAE 50 a t ambient temperatures However, be sure the leakage is actually from a
above this point. transfer case component.
Leakage from other sources (engine, transmission, Low lubricant levels are a frequent cause of noisy
etc.) can be blown back onto the transfer case by air operation. Insufficient lubricant will lead to over
flow under the vehicle. A blocked transfer case vent heating, subsequent damage to bearing and gear sur
can also cause leakage at the shaft seals due to in faces and hard shifting.
ternal pressure build up. Transfer case bearing noise is higher in pitch t h a n
Overfilling the transfer case can force fluid out the gear noise. If the unit is noisy in 4WD range only,
vent and be mistaken for a leak. Correct fluid level the front shaft bearings are probably at fault. If the
checking methods should prevent overfill problems. unit is noisy in all ranges, an overhaul will be nec
essary to locate the faulty bearing.
Checking Fluid Level Gear noise is lower in pitch and usually most no
The correct method of checking transfer case fluid ticeable when engaged and under load. Gear noise in
level requires that the vehicle be level. 4WD drive range only is an indicator t h a t the front
If fluid level is checked with the vehicle parked on shaft gears are damaged. Noise in all ranges could be
the shop floor, be sure the floor area used is level. If the idler or drive gears. An overhaul will be neces
a hoist is used, a drive-on, or swivel a r m type is pre sary to determine which is at fault.
ferred. Frequently, suspected transfer case noise may actu
Allow the transfer case fluid to settle for a minute ally originate from another driveline component. The
or so before checking. Correct fluid level is to the proximity of other driveline components can some
bottom edge of the fill plug hole. times make it difficult to pinpoint the noise source.
HARD SHIFTING TRANSFER CASE OPERATIONAL CHECK

Hard shifting is generally caused by: The transfer case should not be removed until di
• misadjusted or binding linkage agnosis indicates the unit has actually malfunc
• loose linkage or driveline components tioned. If a transfer case problem is suspected, check
• torque loads caused by 4WD operation on hard and verify operation before attempting repair. A
paved surfaces transfer case operational check may reveal t h a t a
• improper shifting techniques problem is actually related to another driveline com
• lack of lubricant which caused internal wear and ponent.
damage. (1) Raise vehicle on a hoist t h a t will allow all four
Loose linkage or driveline components are a result wheels to rotate.
of improperly tightened, stripped, or missing fasten (2) Check lubricant level. If lubricant level is low,
ers. Remember t h a t loose crossmember and mounting check for leaks at the bearing and seal retainers,
parts can also generate a hard shift condition. yokes, drain/fill plugs, PTO cover and vent.
Torque loads in the transfer case can cause hard (3) If vehicle is equipped with locking hubs, en
shifting or even prevent shifting. Such loads are gen gage hubs.
erally a product of extensive operation on hard, (4) Start engine, shift transmission into gear and
paved surfaces in 4WD range, unequal size tires, or operate transfer case in all ranges. Observe propeller
by mismatched front/rear axle gear ratios. shaft action, shift efforts and operational sound lev
Linkage adjustment should be performed as de els as follows:
scribed in the service section. Improper shift and op (a) Only the rear propeller shaft should rotate in
erating techniques can be corrected by instructing two-wheel drive. Both propeller shafts should both
the driver. Internal component damage will require rotate in four-wheel drive high and low ranges.
overhaul to correct. (b) If the front propeller shaft did not rotate in
Failure to lubricate the shift linkage at recom either four-wheel drive range, the transfer case
mended intervals will cause the linkage to bind. If shift components may be worn or damaged. Or, if
bind is severe enough to cause hard shifting, the the front shaft did rotate but the front wheels did
linkage will have to be removed in order to correct not, check the front axle shift mechanism and the
the condition. The linkage can be soaked in auto locking hubs (if equipped).
matic transmission fluid if necessary. The fluid will (c) If both propeller shafts rotate in four-wheel
break up accumulated rust and corrosion. drive but the wheels on one axle did not rotate, the
problem is in the axle.
NOISE (d) If neither propeller shaft rotates in any
Some transfer case operating noise is normal. The range, the problem is in the transmission or trans
rotating gear train can produce sounds t h a t may be fer case. To determine which component is at fault,
come audible at higher speeds and loads. However, proceed to next step.
unusual noise is an indicator t h a t internal compo (5) Determine if fault is with transfer case or
nents may be worn or damaged. transmission as follows:
(a) Raise vehicle and disconnect both propeller
shafts at the transfer case.
(b) Position supports under the transmission.
(c) Remove the bolts/nuts attaching the transfer
case adapter to the crossmember and transmission.
(d) Support the transfer case with a transmission
jack and slide the transfer case and adapter clear
of the transmission output shaft.
(e) Have helper start engine and shift transmis
sion into gear. If transmission output shaft rotates,
problem is with transfer case. If transmission shaft
does not rotate, problem is with transmission or re
lated component.
SHIFT LINKAGE ADJUSTMENT

(1) Shift transfer case into neutral.
(2) Remove screws attaching shift lever boot and
seal to floor pan (Fig. 2).
(3) Slide shift lever boot and seal upward for vi
sual access to shift gate. Verify that lever is in Neu
tral position.
(4) Loosen bolts" attaching shift lever bracket to
adapter (Fig. 3). Fig. 2 Shift Lever Boot And Seal
Fig. 3 NP205 Shift Linkage

• NP20I TRANSFER CASE 21 - 3 4 i
(5) Verify that transfer case range lever is in Neu

tral.
(6) Move shift lever bracket forward and retighten
bracket bolts (Fig. 3). Shift rod should not bind in
shift lever and range lever. Rod should be slip-fit
both levers.
(7) Shift transfer case into 4H range. Shift rod
should now be tension-fit in each lever. Shift lever DISTANCE
should be in 4H detent in gate and range lever SENSOR
should be fully into 4H position.
(8) Shift transfer case into 2H and 4L ranges to
verify correct adjustment.
ADAPTER
DRIVEN
SPEEDOMETER SERVICE GEAR J9021-151
The speedometer driven gear, adapter and vehicle
Fig. 4 Speedometer Components.
speed sensor can be serviced with the transfer case in
the vehicle. (10) Lower jack and move transfer case from under
vehicle.
SPEEDOMETER COMPONENT REMOVAL/ (11) Remove old gasket material from transmission
INSTALLATION (FIG. 4) adapter.
(1) Shift transfer case into Neutral.
(2) Raise vehicle. TRANSFER CASE INSTALLATION
(3) Disconnect wires at vehicle speed sensor. (1) Apply Mopar perfect seal, silicone sealer, or
(4) Loosen and disconnect coupling n u t t h a t at Permatex No. 2 sealer to both sides of transfer case-
taches speed sensor to adapter. Then loosen and dis to-transmission gasket. Then position gasket on
connect coupling n u t attaching adapter to driven transmission.
gear. (2) Align and seat transfer case on transmission.
(5) Remove vehicle speed sensor and speedometer Be sure transfer case input gear splines are aligned
adapter. with transmission output shaft. Align splines by ro
(6) Loosen and remove speedometer driven gear. tating transfer case rear output shaft yoke if neces
(7) Lubricate driven gear with engine or gear oil sary. D o not install a n y transfer c a s e a t t a c h i n g
and install gear in transfer case. Tighten gear to 11 nuts until the transfer case is completely s e a t e d
N*m (100 in. lbs.) torque. against the transmission.
(8) Install adapter and speed sensor. Tighten cou (3) Install and tighten transfer case attaching n u t s
pling nuts to 17 N»m (150 in. lbs.) torque. to 47 N*m (35 ft. lbs.).
(9) Connect wires to speed sensor. (4) Install rear crossmember.
(10) Lower vehicle. (5) Remove jack stand from under transmission.
(6) Align and connect propeller shafts.
TRANSFER CASE REMOVAL (7) Connect vehicle speed sensor wires.
(1) Raise vehicle. (8) Connect transfer case shift lever to range lever.
(2) Remove drain plug and drain transfer case lu Tighten lever locknut to 10 N»m (90 in. lbs.).
bricant. (9) Fill transfer case with recommended lubricant.
(3) Disconnect vehicle speed sensor wires. (10) Install transfer case fill plug.
(4) Mark front/rear propeller shafts and yokes for (11) Install skid plate and skid plate crossmember.
installation reference. (12) Lower vehicle.
(5) Disconnect and remove propeller shafts. Or dis
connect shafts at transfer case yokes. Then move TRANSFER CASE DISASSEMBLY (FIG. S)
shafts aside for working clearance and secure them REAR RETAINER AND OUTPUT SHAFT
to frame rails with wire. REMOVAL/DISASSEMBL Y
(6) Disconnect transfer case shift lever from range
(1) Loosen rear yoke nut until only 2-3 threads are
lever on transfer case.
holding nut on shaft.
(7) Support transfer case with transmission jack.
(2) Remove bolts attaching rear bearing retainer to
Secure transfer case to jack with safety chains.
case.
(8) Remove nuts attaching transfer case to trans
(3) Pull yoke rearward to start rear output shaft
mission adapter.
out of clutch.
(9) Slide transfer case rearward until it is clear of
(4) Remove rear yoke nut, washer, seal washer and
transmission output shaft.
yoke.
NP205 TRANSFER CASE 21 - 347
LEGEND FOR NP205 TRANSFER CASE
YOKE NUT ® GASKET CASE M A G N E T A N D CLIP

WASHER © IDLER SHAFT © FILL PLUG
SEAL W A S H E R © IDLER G E A R B E A R I N G S © PTO COVER A N D GASKET
REAR YOKE © B E A R I N G RACES © G E A R CASE
OIL SEAL © B E A R I N G SPACER © SHIFT RAIL DETENT BALLS
REAR SEAL RETAINER © IDLER G E A R A N D SPRINGS
GASKET © IDLER G E A R B E A R I N G S H I M S © 4 W D INDICATOR LIGHT
SNAP RING © WASHER SWITCH A N D GASKET
REAR OUTPUT SHAFT B E A R I N G © IDLER SHAFT LOCK NUT © SHIFT FORK A N D RAIL - REAR
SPEEDOMETER G E A R ® THRUST W A S H E R PIN WHEEL
B E A R I N G RETAINER - REAR © FRONT OUTPUT SHAFT ® INTERLOCK P I N S (2)
VENT TUBE C O N N E C T O R © S L I D I N G CLUTCH FORK-TO-RAIL LOCK PIN
GASKET © HIGH G E A R © SHIFT RAIL OIL S E A L S
REAR OUTPUT SHAFT SUPPORT © THRUST W A S H E R © SHIFT RAIL LINK
BEARING © FRONT OUTPUT SHAFT FRONT ® RETAINING CLIP (21
LOW G E A R RETAINING R I N G BEARING ® LINK-TO-RAIL RETAINING P I N
THRUST W A S H E R (3/16" THICK)
THRUST W A S H E R (1/16" THICK)
LOW G E A R ROLLER B E A R I N G S
©
©
BEARING S N A P RING
FRONT OUTPUT SHAFT REAR
BEARING
© 3HIFT FORK A N D RAIL -
FRONT WHEEL
[64) © B E A R I N G RETAINER - FRONT © INTERLOCK HOLE PLUGS (4)
B E A R I N G SPACER © GASKET © FRONT OUTPUT SHAFT
LOW G E A R - REAR SHAFT © RETAINING R I N G BEARING
THRUST W A S H E R (1/16" THICK) ® THRUST W A S H E R (3/16" THICK) © BEARING S N A P RING
REAR OUTPUT SHAFT © LOW G E A R - FRONT SHAFT © INPUT SHAFT S N A P R I N G
THRUST W A S H E R PIN © LOW G E A R ROLLER B E A R I N G S ADAPTER OIL SEAL (2)
S L I D I N G CLUTCH ©^ GASKET
PILOT B E A R I N G ROLLERS (15)
PILOT B E A R I N G THRUST
©
©
(S3. iRING SPACER
FLANGE
©
©
TRANSFER C A S E ADAPTER
ADAPTER SLEEVE
WASHER © OIL SEAL ® SLEEVE RETAINING R I N G
LOCK R I N G © FRONT SEAL RETAINER © GASKET
INPUT G E A R © GASKET © T R A N S M I S S I O N ADAPTER
IDLER SHAFT COVER © D R A I N PLUG
J9021-149
(5) Remove rear retainer, rear output shaft and (9) Remove thrust washer, gear, bearings and
gears as assembly. spacer.
(6) Remove rear seal retainer from bearing re
tainer.
(7) Remove snap ring.
(8) Remove rear bearing retainer.
(9) Remove rear bearing, speedometer gear, shaft
HAMMER
support bearings, t h r u s t washer pin and low gear
from rear output shaft (Fig. 5).
(10) Remove lock ring, t h r u s t washer and pilot
bearing rollers from rear output shaft (Fig. 5).
FRONT OUTPUT SHAFT RETAINER REMOVAL

(1) Remove front yoke nut, washer and flange (Fig.
FRONT
5). OUTPUT
(2) Remove front seal retainer and gasket. SHAFT
REAR
(3) Remove PTO cover and gasket.
BEARING
(4) Remove detent plug and 4WD indicator light RETAINER
RH320
switch from case (Fig. 5).
(5) Remove shift rail detent springs and balls (Fig. Fig. 6 Removing/Installing Front Output Shaft
5). Use pencil m a g n e t to remove these components.
(6) Remove bolts attaching front bearing retainer SHIFT RAIL, IDLER GEAR, INPUT GEAR AND
to case. FRONT SHAFT REMOVAL
(7) Tap front output shaft with plastic mallet to (1) Remove adapter and gasket.
loosen it. Then remove shaft, retainer and gears (Fig. (2) Remove idler shaft n u t and washer.
6). (3) Remove idler shaft cover plate and gasket.
(8) Remove shaft snap ring (Fig. 7).
21 - 348 NP20S TRANSFER CASE 4
Fig. 9 Idler Shaft Removal

Fig. 7 Removing/installing Front Shaft Snap Ring (16) Remove interlock pins from inside case. Re
move pins through PTO cover opening.
(4) Remove cup plugs at top of case for access to shift
(17) If front output shaft rear bearing must be re
fork lock pins. Use small punch to remove plugs.
placed, replace the bearing and retainer as an assem
(5) Place shift rails in Neutral position.
bly only.
(6) Remove lock, pins from shift forks with long
handle easy-out tool (Fig. 8).
TRANSFER CASE ASSEMBLY
Lubricate the transfer case gears and shafts with
gear oil during assembly. Use petroleum jelly to pre-
lubricate and hold bearings in place during installa
tion.
Use new gaskets and seals throughout. Do not re
use these components. Replace snap rings if distorted
or damaged and use new yoke locknuts to secure the
yoke and flange.
(1) Install bearing cups in idler gear with shop
press (Fig. 10).
(2) Assemble idler gear, gear bearing cones, bear
ing spacer and shims on Shaft Tool DD1272 (Fig. 10).
(3) Check gear end play (Fig. 10). End play should
be 0.000 to 0.05 mm (0.000 to 0.002 in.). Add or re
move shims as needed to adjust end play.
(4) Press shift rail seals into case. Seals are wiper-
type and should be installed with seal lip facing out
Fig. 8 Removing/Installing Shift Fork Lock Pins ward.
(7) Remove pins attaching shift rail link and re (5) Install assembled idler gear assembly and shaft
move link. tool in case. Insert assembly through front shaft
(8) Remove shift forks and sliding clutches. bore, large end first. Tilt case at 45° angle to ease
(9) Remove snap ring, thrust washer and bearing bearing installation at boss (Fig. 11).
from front shaft. (6) Install idler shaft. Insert shaft from large bore
(10) Remove front shaft and high gear. side and tap shaft into gear and bearings with dead-
(11) Remove input gear, bearing, seals and washer. blow hammer. Remove shaft alignment tool as idler
(12) Loosen and remove idler shaft with plastic shaft pushes it out of gear and case.
mallet (Fig. 9). (7) Install idler shaft washer and n e w locknut.
(13) Tilt case, roll idler gear toward front shaft open Check end play and free rotation. Tighten locknut to
ing in case and remove gear through this opening. 203 N-m (150 ft. lbs.).
(8) Install front bearing and snap ring on input
(14) Remove and retain idler shaft shims. Tie
gear.
shims together to avoid losing them.
(9) Assemble front output shaft. Install gears, slid
(15) Remove bearing cups and bearings from idler
ing clutch, bearings, thrust washer pin, thrust wash
gear.
ers, snap ring and retainer on front output shaft.
1 NP241 TRANSFER CASE 21 - 349
•
a l i g n e d with drain hole i n c a s e b e f o r e tightening
bolts. Use new gaskets and apply sealer to bolt
threads before installation. Use extra gasket on re
tainers if necessary.
(17) Install flange on front shaft. Install seal washer
on shaft and install flange locknut finger tight.
(18) Install washer, seals gasket and adapter on
input shaft (Fig. 5).
(19) Install shift link and link retaining pins, clips.
(20) Assemble rear output shaft. Install gears,
bearings and spacers (Fig. 5).
(21) Install new snap ring. Tap ring to seat it and
check end play. End play should be 0.05 to 0.68 mm
(0.002 to 0.027 in.).
(22) Install pilot bearing rollers in rear output
shaft. Use as much petroleum jelly as needed to hold
bearing rollers in place.
(23) Install pilot bearing thrust washer and new
snap ring.
(24) Install retainer on rear output shaft install
speedometer gear and spacer, install bearing (Fig. 12).
Fig. 11 Installing Idler Gear Fig. 12 Assembling Rear Retainer And Output Shaft
(10) Install interlock pins through large case bore (25) Install retainer and shaft assembly. Be sure
or PTO opening, oil d r a i n slot in r e t a i n e r is aligned with d r a i n
(11) Install input gear in case. Then install sliding hole in case. Use one or two retainer gaskets de
clutch on input gear and position shift fork in clutch. pending on clearance. Tighten retainer bolts to 54
(12) Install rear wheel shift rail into case (from N»m (40 ft. lbs.).
back), with slotted end first and detent notches fac (26) Install seals in front and rear seal retainers.
ing up (Fig. 8). Then push rail through shift fork and Position gaskets on case and install retainers over
into opposite end of case. shafts and against case. Tighten bolts to 54 Nnn (40
ft. lbs.).
(13) Install front output shaft in case.
(27) Install yoke and flange. Tighten yoke and
(14) Install front wheel shift fork in sliding clutch
flange nuts to 176 N» (130 ft. lbs.).
on front shaft. Then install front wheel shift rail into (28) Install detent balls, springs, plugs, cup plugs
case and through shift fork. and 4WD indicator light switch.
(15) Secure shift forks to shift rails with new lock (29) Install drain plug.
pins. Install pins through small bores at top of case. (30) Fill transfer case to bottom edge of fill plug
(16) Install front output shaft bearing retainers. hole with recommended lubricant.
Be sure oil drain slot in bearing retainer is (31) Install fill plug.
NP241 TRANSFER CASE
INDEl
page page
Checking Fluid Level 351 Speedometer Gear, Shaft Seal, Bearing and Retainer
Component Cleaning and Inspection 359 Service 352
Fluid Drain/Refill 351 Transfer C a s e Assembly . . . . . . . . . . . . . . . . . . 361
General Information 350 Transfer C a s e Bearing Replacement . . . . . . . . . 360
Recommended Lubricant . . . . . . . . . . . . . . . . . . 350 Transfer C a s e Disassembly . . . . . . . . . . . . . . . . 356
Service Diagnosis . . . . . . . . . . . . . . . . . . . . . . . 350 Transfer C a s e Identification . . . . . . . . . . . . . . . . 350
Shift Linkage Adjustment 354 Transfer C a s e Installation . . . . . . . . . . . . . . . . . 356
Speedometer Adapter/Distance Sensor Service . 352 Transfer C a s e Removal 356
GENERAL INFORMATION
The NP241 is a part-time transfer case with a low-
range gear system. It has three operating ranges
plus a Neutral position. The low range system pro
vides a gear reduction ratio for increased low speed
torque capability. NP241 operating ranges are:
2-high, 4-high and 4-low.
The NP241 has an aluminum, two-piece gear case.
Drive sprockets and an interconnecting drive chain
are used to transmit engine torque to the propeller
shafts.
Four-wheel high and low ranges are undifferenti
ated. The transfer case is not designed for continuous
operation in 4WD range on hard or paved surfaces.
Four wheel drive ranges are recommended for off
road operation, or on snow covered or similar low Fig. 1 NP 241 Transfer Case
traction surfaces.
A front axle disconnect system is used to achieve A synchronizer assembly in the transfer case al
two-wheel drive mode. The axle disconnect vacuum lows the unit to be shifted between 2H and 4H
motor is actuated by a vacuum switch on the transfer ranges while the vehicle is in motion. The vehicle
case. The switch is operated by the transfer case should be stopped before shifting into 4L range.
range rod.
Two-wheel drive range is used for on road, high
RECOMMENDED LUBRICANT
Recommended lubricant for the NP241 is Mopar
way operation. The four-wheel drive ranges are for
ATF Plus, type 7176, or Dexron II™ automatic trans
off road operation or when the vehicle is driven on
mission fluid. Use either fluid for topping off the
paved road surfaces covered by snow, ice or similar
level, or refilling after service, or normal fluid
low traction elements.
changes.
Do not use anti-friction additives or similar prod
TRANSFER CASE IDENTIFICATION
ucts in the NP241 transfer case. Use the recom
An identification tag (Fig, 1) is attached to the rear
mended lubricant only.
case of each NP241 transfer case. The tag provides
NP241 transfer case lubricant should be changed
the transfer case model number, assembly number,
at the intervals specified in the Maintenance Sched
serial number, and low range ratio.
ule or after service repairs.
The transfer case serial number also represents the
date of build. For example, a serial number of SERVICE DIAGNOSIS
9-10-92 would represent September 10, 1992. Before attempting to repair a suspected transfer
Transfer case operating ranges are selected with a case malfunction, check all other driveline compo
floor-mounted shift lever. The shift lever is connected nents beforehand.
to the transfer case range lever by an adjustable The actual cause of a problem may be related to
linkage rod (Fig. 2). A straight line shift pattern is such items as: front hubs, axles, propeller shafts,
used. Range positions are marked on the gearshift le wheels and tires, transmission, or clutch instead. If
ver knob. all other driveline components are in good condition
SERVICE DIAGNOSIS

TRANSFER CASE (a) Vehicle speed too great to permit (a) Stop vehicle and shift into desired
DIFFICULT T O S H I R shifting. range. Or reduce speed to 3-4 km/h
O R WILL N O T SHIFT (2-3 mph) before attempting to shift.
INTO DESIRED (b) Stop vehicle, shift transmission to
RANGE (b) If vehicle was operated for extended neutral, shift transfer case to 2H mode
period in 4H mode on dry paved and operate vehicle on 2H on dry
surface, driveline torque load may paved surface.
cause difficulty. (c) Lubricate, repair or replace linkage, or
(c) Transfer case external shift linkage tighten loosen components as necessary.
binding. (d) Drain and refill to edge of fill hole with
M O P A R ATF PLUS (Type 7176) or
(d) Insufficient or incorrect lubricant. DEXRON II Automatic Transmission
Fluid.
(e) Disassemble unit and replace worn or
(e) Internal components binding, worn or damaged components as necessary.
damaged.
TRANSFER CASE (a) Insufficient or incorrect lubricant. (a) Drain and refill to edge of fill hole with
NOISY I N ALL M O P A R ATF PLUS (Type 7176) or
DRIVE M O D E S DEXRON II Automatic Transmission
Fluid. Check for leaks and repair if
necessary. If unit is still noisy after
drain and refill, disassembly and
inspection may be required to locate
source of noise.
(a) Stop vehicle, shift transfer case to
NOISY I N - O R (a) Transfer case not completely engaged Neutral, then shift back into 4L position.
JUMPS OUT OF in 4L position. (b) Tighten, lubricate, or repair linkage as
FOUR-WHEEL-DRIVE necessary.
LOW RANGE (b) Shift linkage loose or binding. (c) Disassemble unit and repair as
necessary
(c) Range fork cracked, inserts worn, or
fork is binding on shift rail. (d) Disassemble unit and repair as
necessary
(d) Annulus gear or lockplate work or
damaged. (a) Drain to correct level.
LUBRICANT (a) Transfer case overfilled. (b) Clear or replace vent if necessary.
LEAKING FROM (b) Vent closed or restricted. (c) Replace seals. Be sure seal lip faces
OUTPUT SHAFT
(c) Output shaft seals damaged or interior of case when installed. Also be
SEALS O R FROM
installed correctly. sure yoke seal surfaces are not scored
VENT
or nicked. Remove scores and nicks with
fine sandpaper or replace yoke(s) if
necessary.
(a) Operate in 2H on hard surface (paved)
ABNORMAL (a) Extended operation on dry hard roads.
TIRE W E A R surface (paved) roads in 4H range.
J9021-152
and operating properly, refer to t h e Service Diagno fluid level is checked with t h e vehicle raised, use ei
sis chart for further information. ther a swivel a r m or drive-on type hoist to be sure
the vehicle is level.
CHECKING FLUID LEVEL
Correct fluid level for the NP241 transfer case is to FLUID DRAIN/REFILL
the bottom edge of t h e fill plug hole. (1) Raise vehicle.
A correct m e t h o d of c h e c k i n g fluid level is im (2) Position drain p a n under transfer case.
portant. A n accurate c h e c k requires that t h e ( 3 ) Remove drain and fill plugs and drain lubri
transfer c a s e b e level. cant completely.
If fluid level is checked with t h e vehicle parked on (4) Install drain plug. Tighten plug to 54 N»m (40
the shop floor, be sure the floor area used is level. If ft. lbs.).
(5) Remove drain pan.
21 - 352 NP241 TRANSFER CASE — •
(6) Fill transfer case to bottom edge of fill plug
opening with Mopar ATF Plus, or Dexron II auto
matic transmission fluid.
(7) Install fill plug. Tighten plug to 54 N«m (40 ft.
lbs.).
(8) Lower vehicle.
SPEEDOMETER GEAR, SHAFT SEAL, BEARING

AND RETAINER SERVICE
The front and rear yokes, output shaft seals, re
tainers and bearings, and speedometer drive gear can
all be serviced with the transfer case in the vehicle.
The following combined procedure outlines removal
and installation of these components:
RETAINER AND SPEEDOMETER COMPONENT

REMOVAL Fig. 2 Loosening Rear Retainer
(1) Raise vehicle.
(2) Remove fill and drain plugs and drain oil from
transfer case.
(3) Mark propeller shaft and transfer case yoke for
alignment reference.
(4) Disconnect propeller shaft. Secure shaft to un
derside of vehicle.
(5) Remove transfer case yoke retaining n u t and
seal washer. Use Special Tool C-3281 to hold yoke
while removing nut.
(6) Remove transfer case yoke.
(7) Remove retainer seal (if seal or bushing is to be
replaced) using suitable tool.
(8) Install a new seal, if old seal was removed.
(9) Remove speedometer gear from rear retainer.
(10) Mark rear retainer for assembly alignment
reference.
Fig. 3 Removing/Installing Rear Retainer
(11) Remove retainer attaching bolts and remove
retainer. Pry retainer with screwdrivers to remove it (7) Install speedometer driven gear.
(Fig. 2). (8) Install drain plug. Tighten plug to 54 N-m (40
(12) Remove rear retainer (Fig. 3). Remove speed ft. lbs.).
ometer drive gear, if necessary. (9) Fill transfer case to edge of fill plug opening
(13) Completely clean off old sealant. with recommended transmission fluid.
(14) If the retainer or bearing are to be replaced, (10) Install fill plug. Tighten plug to 54 N-m (40 ft.
remove bearing retainer snap ring from rear retainer lbs.).
and remove bearing. (11) Connect propeller shaft. Tighten attaching
bolts to 19 N-m (170 in. lbs.).
RETAINER AND SPEEDOMETER COMPONENT (12) Lower vehicle.
INSTALLATION
(1) Install rear output bearing in rear retainer and SPEEDOMETER ADAPTER/DISTANCE SENSOR
install snap ring.
SERVICE
(2) Apply a 5 mm (3/16 in.) wide bead of Mopar
Gasket Maker, Loctite 518, or Loctite 573 sealant to ADAPTER/SENSOR REMOVAL
mating surface of rear retainer. (1) Raise vehicle.
(3) Align retainer case reference m a r k s and install (2) Remove skid plate and crossmember for access,
rear retainer on case. if necessary.
(4) Install and tighten rear retainer attaching (3) Remove vehicle speed sensor from pinion gear
bolts to 24 N«m (18 ft. lbs.). adapter (Fig. 4). On models with automatic transmis
(5) Install output shaft seal (if required).
sion, remove sensor adapter as well.
(6) Install yoke, a new yoke seal washer and yoke
nut. Tighten n u t to 149 N-m (110 ft. lbs.) torque.
LOCK OIL (3) Count number of teeth on pinion gear before

RING SEAL installing gear in adapter.
(4) Note range numbers on adapter face (Fig. 6).
These numbers correspond to number of teeth on pin
ion.
SPEEDOMETER (5) Install adapter in housing.
ADAPTER PINION GEAR
(OVERDRIVE ONLY) (6) Rotate adapter until required range numbers
are a t six o-clock position (Fig. 6). Be sure adapter
ADAPTER O-RING range numbers correspond to number of teeth on pin
ion.
SPEEDOMETER ADAPTER (7) Seat adapter in housing.
(8) Install adapter retainer. Tighten retainer bolt
RETAINER to 11 N-m (100 in. lbs.) torque.
(9) Install vehicle speed sensor. Tighten sensor
J9021-99 coupling n u t to 17 N-m (150 in. lbs.) torque and in
DISTANCE SENSOR
stall sensor wires.
Fig. 4 Speedometer Components (10) Check and correct transfer case lubricant level
if necessary.
(4) Check vehicle speed sensor mounting area in (11) Install skid plate and crossmember if re
pinion adapter. If transmission fluid is found in this moved.
area, adapter oil seal is leaking and will have to be (12) Lower vehicle.
replaced.
(5) Remove bolt and retainer securing pinion gear
adapter to extension housing.
(6) Carefully work adapter and gear out of hous
ing.
(7) Remove and discard adapter O-ring (Fig. 4).
SPEEDOMETER ADAPTER OIL SEAL

REPLACEMENT
Remove adapter oil seal if necessary. Start new
seal in adapter by hand. Then press seal into adapter
with Installer Tool C-4004 until tool bottoms (Fig. 5). ADAPTER
O'CLOCK POSITION RH75
ADAPTER LOCK RING
Fig. 6 Indexing Speedometer Adapter
TOOL
OIL SEAL
RH263
Fig. 5 Replacing Speedometer Adapter Seal

ADAPTER/SENSOR INSTALLATION
C A U T I O N : Before installing the pinion arid adapter

assembly make sure the adapter flange and its
mounting area in transfer c a s e are perfectly clean.
Dirt or sand will cause misalignment resulting in
speedometer pinion gear d a m a g e .
(1) Thoroughly clean adapter flange and adapter

mounting surface in extension housing. These sur
faces must be clean for proper adapter alignment and
speedometer operation.
(2) Lubricate adapter oil seal and O-ring with
transmission fluid.
SHIFT LINKAGE ADJUSTMENT
(1) Remove screws attaching shift lever boot and
seal to floorpan (Fig. 7). Then move boot and seal
aside for visual access to shift gate.
(2) Move shift lever into 4H position. Be sure lever
is against 4H position in gate.
(3) Raise vehicle.
(4) Loosen lock bolt in shift rod adjusting swivel
(Fig. 8).
(5) Check shift rod fit in swivel. Be sure rod does
not bind in swivel.
(6) Verify t h a t transfer case range lever is in 4H
position (vertical). Move lever if necessary.
(7) Tighten shift rod lock bolt to (90 in. lbs.)
torque.
(8) Lower vehicle.
(9) Check shift linkage operation.
Fig. 7 Shift Lever Boot And Seal

TRANSFER CASE REMOVAL (2) Remove rear retainer (Figs. 2-3). Remove and
(1) Raise vehicle. discard retainer seal.
(2) Position drain oil container under transfer case. (3) Remove upper snap ring t h a t retains speedom
(3) Remove transfer case drain plug and drain lu eter gear on shaft. Then remove speedometer gear
bricant into container. (Fig. 1).
(4) Disconnect wires at vehicle speed sensor.
(5) Disconnect vacuum hoses at vacuum switch.
(6) Disconnect transfer case shift lever from range
lever.
(7) Remove skid plate and skid plate crossmember.
(8) Support transmission with jack stand.
(9) Remove rear crossmember.
(10) Mark front and rear propeller shaft yokes for
assembly reference.
(11) Remove front and rear propeller shafts.
(12) Support transfer case with suitable jack. Se
cure transfer case to jack with safety chains.
(13) Remove nuts attaching transfer case to trans
mission.
(14) Move transfer case assembly rearward until
free of transmission output shaft.
Fig. 1 Snap Ring And Speedometer Gear Removal/
(15) Lower jack and move transfer case from under
Installation
vehicle.
(16) Remove all gasket material from rear of (4) Remove shaft lower snap ring (Fig. 2)
transmission adapter housing. (5) Remove oil pump. Remove and discard oil
pump seal.
TRANSFER CASE INSTALLATION (6) Loosen rear case by prying corners loose to
(1) Apply Mopar Perfect Seal, silicone sealer, or break sealant bead (Fig. 3).
Permatex No. 2 to both sides of transfer case-to-
transmission gasket. Then position gasket on trans
mission.
(2) Align and seat transfer case on transmission.
Be sure transfer case input gear splines are aligned
with transmission output shaft. Align splines by ro
tating transfer case rear output shaft yoke if neces
sary. D o not install any transfer c a s e attaching
nuts until the transfer case is completely s e a t e d
against t h e t r a n s m i s s i o n .
(3) Install and tighten transfer case attaching nuts
to 47 N*m (35 ft. lbs.).
(4) Install rear crossmember.
(5) Remove jack stand from under transmission.
(6) Align and connect propeller shafts.
(7) Connect speed sensor wires and vacuum switch
hoses. Fig. 2 Removing/Installing Shaft Lower Snap Ring
(8) Connect transfer case shift lever to range lever.
(7) Remove rear case from front case (Fig. 4)
Tighten lever locknut to 10 N*m (90 in. lbs.).
(9) Fill transfer case with recommended transmis (8) Remove oil pickup screen, tube and magnet
sion fluid. from rear case.
(10) Install transfer case fill plug.
DRIVE CHAIN, SPROCKET, SHIFT FORK AND
(11) Install skid plate and skid plate crossmember.
MAINSHAFT SHAFT REMOVAL
(12) Lower vehicle.
(1) Remove mode spring from shift rail (Fig. 5).
TRANSFER CASE DISASSEMBLY (2) Remove driven sprocket snap ring (Fig. 6).
(3) Remove sprocket and drive chain (Fig. 7). Tilt
RETAINER AND REAR CASE REMOVAL mainshaft for clearance if necessary.
(1) Remove indicator switch from front case.
• NP241 TRANSFER CASE 21 - 3i7
Fig. 3 Loosening Rear Case
Fig. 5 Removing/Installing Mode Spring

(4) Remove mainshaft, mode fork and shift rail as
assembly.
(5) Remove front output shaft (Fig. 8).
Fig. 8 Removing/Installing Front Output Shaft

RANGE FORK RANGE FORK ANNULUS LOW RANGE GEAR
SHIR HUB
-RR21F42
Fig. 9 Removing/Installing Range Fork And Hub
Fig. 12 Removing/Installing Low Range Gear And
INPUT SHAFT Input Shaft
^BEARING RETAINER
FRONT
SNAP
RING
LOW
, RR21F49 RANGE
Fig. 10 Removing/Installing input Gear Bearing Retainer GEAR RR21F44
Fig. 13 Removing/Installing Low Range Gear Snap

SNAP RING / INPUT GEAR
PLIERS L
Ring
(3) Remove low range gear and input gear as as
sembly (Fig. 12).
(4) Remove low range gear snap ring (Fig. 13).
(5) Remove input gear and thrust washer from low
range gear.
(6) Remove shift detent plug and O-ring seal. Then
remove the detent spring and plunger (Fig. 14). Re
place O-ring seal on plug if seal is worn or cut.
(7) Remove shift sector and sector seals (Fig. 15).
MAINSHAFT DISASSEMBLY
(1) Remove Synchronizer snap ring (Fig. 16).
SNAP RING RR21F53 (2) Remove synchronizer sleeve and hub as assem
Fig. 11 Removing/instaliing Input Gear Snap Ring bly (Fig. 17). It is not necessary to disassemble the
synchronizer components unless wear or damage is
(6) Remove range fork and hub (Fig. 9).
evident.
INPUT GEAR LOW, RANGE GEAR, RETAINER (3) Remove stop ring (Fig. 17).
AND SECTOR REMOVAL (4) Remove drive sprocket from mainshaft (Fig. 18)
(1) Remove input gear bearing retainer (Fig. 10).
(2) Remove input gear snap ring (Fig. 11).
J U L L MAINSHAFT SYNCHRONIZER
ASSEMBLY ASSEMBLY
VACUUM
SWITCH
SNAP
RING
PLIERS
SNAP
RING RR21F45
Fig. 16 Removing/Installing Synchronizer Snap Ring

DETENT SYNCHRONIZER
SPRING SLEEVE AND
HUB
O-RING
SEAL J9121-536
Fig. 14 Detent Plug-Spring-Plunger Location
SHIFT
SECTOR MAINSHAFT
STOP
RING
DRIVE SPROCKET
RR21F46
Fig. 17 Removing/Installing Synchronizer Sleeve,

Hub And Stop Ring
DRIVE
SPROCKET
J9021-8
Fig. 15 Removing/Installing Shift Sector

COMPONENT CLEANING AND INSPECTION
Wash all parts thoroughly in clean solvent. Be sure
all old
lubricant, sealant, metal particles, dirt and foreign
material are removed from the surfaces of every part.
Apply compressed air to each oil feed port and
channel in both case halves to remove any foreign
material or cleaning solvent residue.
Inspect the spline teeth on synchronizer sleeve, RR21F47
MAINSHAFT
hub, and stop ring. If there is evidence of chipping or
excessive wear, install new parts at reassembly. Be Fig. 18 Removing/Installing Mainshaft Drive
sure the clutch sleeve slides easily on the clutch hub. Sprocket
Synchronizer springs should be in place with the
Inspect the stop ring for cracks and wear. Replace
tang inside the cavity of one strut. The rings should
the ring if cracked or excessively worn on the
not exhibit any evidence of interference with the pol
threaded bore. Check new rings for proper fit on the
ished gear cone or inside diameters of the clutch hub.
cone with a minimum of wobble. Also check the syn (4) Install new sprocket bearings one at a time
chronizer struts for wear or damage. starting with front bearing.
Inspect all gear teeth for excessive wear or damage (a) Press front bearing flush with end of bore as
and check all gear splines for burrs, nicks, wear, or shown (Fig. 20).
damage. Remove minor nicks or scratches with an oil (b) Press rear bearing into sprocket until bearing
stone. Replace any part exhibiting excessive wear or is 4.6 mm (11/64 in.) below edge of bore.
damage.
Inspect all snap rings and thrust washers for exces
sive wear, distortion or damage. Replace worn or
damaged parts.
Inspect the two case halves for cracks, porosity,
damaged mating surfaces, stripped bolt threads, or
distortion. Replace either case half if necessary.
Inspect condition of all needle, roller, ball, and
thrust bearings in the front and rear case halves and
the input gear. Also check condition of the bearing
bores in both cases and in the input gear, rear output
shaft, side gear, and rear retainer. Replace any com
ponent exhibiting excessive wear or damage.
If the case or input gear bearings require replace
ment, refer to the Transfer Case Bearing Replace
ment procedures.
TRANSFER CASE BEARING REPLACEMENT

C A U T I O N : M o s t of the transfer c a s e bearing bores
contain oil feed holes. B e sure replacement bear
ings d o not block these feed holes.
DRIVE SPROCKET BEARING REPLACEMENT

(1) Remove both drive sprocket bearings simulta
neously using a shop press, Tool Handle C-4171 and
Remover/Installer Tool C-4697-1 (Fig. 19).
(2) Clean sprocket bearing bore after removing old
bearings.
(3) Before proceeding, note t h a t sprocket bearings RR21F32
are positioned differently (Fig. 20). Front bearing is
installed flush with end of bore. However, rear bear Fig. 20 Drive Sprocket Bearing Installation
ing is recessed slightly. Be sure to install bearings as MAINSHAFT PILOT BEARING REPLACEMENT
shown in Figure 20. The mainshaft pilot bearing is located in the input
shaft. The bearing is removed from the shaft bore
with Remover Tool MD-998346 and two appropriate
size backup wrenches (Fig. 21).
The new bearing is installed with Tool Handle
C-4171 and Installer 5065 (Fig. 22).
A shop press is recommended to press the bearing
into place. The bearing is seated when the installer
tool contacts the input shaft.
REPLACING MAINSHAFT REAR (OUTPUT)

BEARING
The mainshaft rear (output) bearing is located in
the rear retainer. The seal must be removed before
the bearing can be replaced.
(1) Remove seal with Remover Tool C-4613 (Fig.
23).
Fig. 19 Removing Drive Sprocket Bearings
Fig. 21 Removing Mainshaft Pilot Bearing

Fig. 23 Removing Rear Retainer Seal
Fig. 22 Installing Mainshaft Pilot Bearing

(2) Remove bearing with Tool Handle C-4171 and
Remover C-4610 (Fig. 24).
(3) Clean bearing bore thoroughly. Fig. 24 Removing Mainshaft Rear (Output) Bearing
(4) Install new bearing with Handle C-4171 and
(3) Install new bearing with Handle C-4171 and
Installer C-4609 (Fig. 25).
Installer C-4608 (Fig. 29).
(5) Install new seal in rear retainer.
FRONT OUTPUT SHAFT FRONT BEARING TRANSFER CASE ASSEMBLY

REPLACEMENT (1) Lubricate transfer case components with auto
(1) Remove bearing from front case bore with Tool matic transmission fluid during assembly.
Handle C-4171, Remover C-4610 and a shop press (2) If transfer case bearings were replaced, verify
(Fig. 26). t h a t new bearings do not block any oil feed holes.
(2) Clean bearing bore thoroughly. (3) Assemble input gear, thrust washer and low
(3) Install new bearing with Tool C-4210, Handle range gear. Be sure low range snap ring is fully
C-4171 and a shop press (Fig. 27). seated.
(4) Install input and low range gear assembly in
FRONT OUTPUT SHAFT REAR BEARING front case. Secure input gear with snap ring (Fig.
REPLACEMENT 11).
(1) Remove bearing from rear case bore with Re (5) Install shift sector and new sector shaft seals.
mover Tools L-4518-1 and L-4454-1 (Fig. 28). Install range lever on sector shaft and tighten lever
(2) Clean bearing bore thoroughly. locknut to 30 N*m (22 ft. lbs.) torque.
(6) Install range fork and hub (Fig. 9).
21 - 3S2 NP241 TRANSFER CASE •
Fig. 28 Removing Front Output Shaft Rear Bearing
Fig. 29 Installing Front Output Shaft Rear Bearing

Fig. 26 Removing Front Output Shaft Front Bearing (8) Assemble mainshaft, stop ring, synchronizer
and mainshaft drive sprocket.
(9) Insert mode fork in synchronizer sleeve. Then
install mainshaft and fork as assembly. Be sure shift
rail is aligned in range fork and is seated in case
bore.
(10) Install drive chain and front shaft sprocket
(Fig. 7).
(11) Install snap ring t h a t secures driven sprocket
to front output shaft (Fig. 6).
(12) Install detent plunger, spring and plug (Fig.
14). Replace O-ring on plug if necessary. Do not re
use old O-ring if damaged. Tighten plug to 21 N»m
(13) Install mode spring on shift rail (Fig. 5).
(14) Install oil pump, pickup tube and screen in
rear case.
Fig. 27 installing Front Output Shaft Front Bearing (15) Apply 3 mm (1/8 in.) wide bead of Mopar gas
ket maker, silicone adhesive/sealer, or Loctite 515 to
(7) Install front output shaft in case (Fig. 8).
front case sealing surface.
NP241 TRANSFER CASE 21 - 363
(16) Align and install rear case on front case. In install retainer and tighten retainer bolts to 31 Nnn
stall and tighten rear case-to-front case bolts to 27-34 (23 ft. lbs.).
Nnn (20-25 ft. lbs.). (21) Install yokes, seal washers and retaining nuts.
(17) Install lower snap ring on mainshaft (Fig. 2). Tighten yoke nuts to 176-271 Nnn (130-200 ft. lbs.)
(18) Install speedometer gear and upper snap ring torque.
(Fig. 1).
(22) Install vacuum switch. Tighten switch to 27
(19) Install new seals in retainers if necessary.
Nnn (20 ft. lbs.).
(20) Apply 3 mm (1/8 in.) wide bead of Mopar gas
ket maker, silicone adhesive/sealer, Loctite 518, or (23) Fill transfer case with Mopar ATF Plus, type
Loctite 573 to sealing surface of rear retainer. Then 7176 transmission fluid.
21 - 364 TRANSMISSION/TRANSFER CASE SPECIFICATIONS •
TRANSMISSION/TRANSFER CASE SPECIFICATIONS
AUTOMATIC TRANSMISSION GENERAL SPECIFICATIONS

TRANSMISSION MODEL 32RHI42RH '36RH/37RHI46RH
Oil Pump Clearances (all) 0.089-0.190 mm 0.089-0.190 mm
(0.0035-0.0075 in) (0.0035-0.0075 in)
Planetary End Play 0.127-1.22 mm 0.15-1.22 mm
(0.005-0.048 in) (0.006-0.048 in)
Input Shaft End Play 0.56-2.31 mm 0.86-2.13 mm
(0.022-0.091 in) (0.034-0.084 in)
Clutch Pack Clearance:
Front Clutch - 3 Disc 1.88-3.17 mm 1.78-3.28 mm
(0.074-0.125 in) (0.070-0.129 in)
Front Clutch - 4 Disc 1.70-3.40 mm 2.08-3.83 mm
(0.067-0.134 in) (0.082-0.151 in)
Front Clutch - 5 Disc 1.90-3.86 mm
(0.075-0.152 in)
Rear Clutch - 3 Disc 0.81-1.40 mm
(0.032-0.055 in)
Rear Clutch - 4 Disc 0.81-1.40 mm 0.64-1.14 mm
(0.032-0.055 in) (0.025-0.045 in)
Clutch Disc Usage: 32RH 42RH 36RH/37 RH 46RH
Front Clutch 4 4 3/4 3/4
Rear Clutch 4 4 4 4
Overdrive Clutch (Gas) 4 4
Overdrive Clutch (Diesel) 5
Direct Clutch 6 8
Front Clutch Spring Usage 1 1 9 9/11
Band Adjustments:
(backed off from 72 in. lbs.)
Front Band 2Vi 2Yi 214 Th
Rear Band 4 4 2 2
Recommended Fluid (all) MOPAR ATF Plus, Type 7176 Automatic Transmission Fluid
J9321-210
32RH/36RH/37RH SPACER/THRUST PLATE/SNAP RING SPECIFICATIONS

TRANSMISSION MODEL
COMPONENT 32RH 36RH/37RH
Front Clutch Thrust Washer .061 in. .061 in
(on reaction shaft support hub) .084 in
.102 in
Rear Clutch Thrust Washer .061 in .061 in
(on clutch retainer)
Output Shaft Thrust Plate .060-.063 in .060-.063 in

(on Output shaft pilot hub)
Output Shaft Thrust Washer .052-.054 in .068-.070 in
(in rear clutch hub) .068-.070 in
.083-085 in
Rear Clutch Pack Snap Ring .068 in .060 - .062 in
.060 in .074 - .076 in
.076 in .088 - .090 in
.098 in .106 - .108 in
.040 - .044 in .048 - .052 in
Planetary Geartrain Snap Ring
.062 - .066 in .055 - .059 in
(At front end of output shaft)
.082 - .086 in .062 - .066 in
J922M42
• TRANSMISSION/TRANSFER CASE SPECIFICATIONS 21 - 365
42RH/46RH SPACER/THRUST PLATE/SNAP RING SPECIFICATIONS
411H m m
Front Clutch Thrust Washer .016 in. .061 in.

(on reaction shaft support hub) .084 in.
.102 in.
Rear Clutch Thrust Washer .061 in. .061 in.

(on clutch retainer)
Intermediate Shaft Thrust Plate .060-.063 in. .060-.063 in.

(on shaft pilot hub)
Output Shaft Thrust Washer .068-.070 in. .052-.054 in.

(in rear clutch hub) .068-.070 in.
.083-.085 in.
Rear Clutch Pack Snap Ring .060 in. .060 in.

.076 in. .074 in.
.098 in.
Planetary Geartrain Snap Ring .062 in. .055-059 in.

(at front end of intermediate shaft) .074 in. .062-.066 in.
Overdrive Piston Thrust Plate

Thrust plate and spacer are select fit
Intermediate Shaft Spacer components. Refer to size charts and
selection procedures in "Overdrive Unit
Assembly and Adjustment."
J9221-143
AUTOMATIC TRANSMISSION PRESSURE TEST SPECIFICATIONS (32RH/36RH/37RH)
Overdrive Clutch Fourth Gear Only Pressure should be within 21 kPa

(3 psi) of line pressure
Line Pressure Closed Throttle 372-414 kPa (54-60 psi)

(at accumulator) 1000 rpm and above 648 kPa (94 psi)
Front Servo Third Gear Only No more than 21 kPa (3 psi) lower than line pressure.
1 Range No more than 21 kPa (3 psi) lower than line pressure. 1103 kPa (160 psi) at idle,
Rear Servo
R Range builds to 1862 kPa (270 psi) at 1600 rpm.
D Range Pressure should respond smoothly to changes in mph and return to 0-7 kPa (0-114
Governor psi) when stopped with transmission in D, 1, 2. Pmmmf® mb&wm 7 kPm (1 Va psi)
Closed Throttle
at standstill will p r m n f transmission from drnwrnhlfflmg*
J9121-524
21 • 366 TRANSMISSION/TRANSFER CASE SPECIFICATIONS •
AUTOMATIC TRANSMISSION PRESSURE TEST SPECIFICATIONS (42RH/46RH)
Pressure should be 469-496 kPa (68-72 psi) with closed throttle and increase to
Overdrive Clutch Fourth Gear Only 620-896 kPa (90-130 psi) at 1/2 to 3/4 throttle.
Line Pressure Closed Throttle 372-414 kPa (54-60 psi)

(at accumulator) 1000 rpm and above 648 kPa (94 psi)
Front Servo Third Gear Only No more than 21 kPa (3 psi) lower than line pressure.
1 Range No more then 21 kPa (3 psi) lower than line pressure. 1103 kPa (160 psi) at idle,
Rear Servo builds to 1862 kPa (270 psi) at 1600 rpm.
R Range
Pressure should respond smoothly to changes in mph and return to 0-7 kPa (0-1 Vi
D Range psi) when stopped with transmission in D, 1, 2. Pressure a b o v e 7 k P a (IV2
Governor
Closed Throttle psi) a t s t a n d s t i l l w i l l p r e v e n t t r a n s m i s s i o n f r o m d o w n s h i f t i n g .
J9321-192
AUTOMATIC TRANSMISSION TORQUE SPECIFICATIONS
Cooler Line Fittings 18 N-m (13 ft. lbs.) Overrunning Clutch Cam Bolts 17 N-m (150 in. lbs.
Converter Bolts: Overdrive Compounder-to-
9.5 in., 3-lug converter 54 N-m (40 ft. lbs. Transmission Case Bolts 34 N-m (25 ft. lbs.
9.5 in., 4-lug converter 74 N-m (55 ft. lbs. Overdrive Piston Retainer
10.0 in., 4-lug converter 74 N-m (55 ft. lbs. Bolts (42RH/46RH) 17 N-m (150 in. lbs.
10.75 in., 4-lug converter 31 N-m (270 in. lbs. Pressure Test Port Plugs 14 N-m (10 ft. lbs.
Crossmember Bolts/Nuts 68 N-m (50 ft. lbs. Propeller Shaft Clamp Bolts 19 N-m (170 in. lbs.
Driveplate Bolts 75 N-m (55 ft. lbs. Reaction Shaft Support Bolts 20 N-m (15 ft. lbs.
Extension Housing Bolts 43 N-m (32 ft. lbs. Rear Band Adjusting Screw Locknut 41 N-m (30 ft. lbs.
Front Band Reaction Pin Access Plug 17 N-m (13 ft. lbs. Rear Mount Bolts/Nuts 68 N-m (50 ft. lbs.
Front Band Adjusting Screw Locknut 34 N-m (25 ft. lbs. Rear Support Bolts (32RH/36RH) 17 N-m (150 in. lbs.
Governor Body-to-Park Gear Bolts 11 N-m (8 ft. lbs. Solenoid Wiring Connector Screw 17 N-m (13 ft. lbs.
Lockup Module Screws 4 N-m (35 in. lbs. Solenoid-to-Transfer Plate Screw 4 N-m (35 in. lbs.
Neutral Switch 34 N-m (25 ft. lbs. Speedometer Adapter Bolt 11 N-m (8 ft. lbs.
Oil Filter Screws 4 N-m (35 in. lbs. Valve Body Housing Screws 4 N-m (35 in. lbs.
Oil Pan Bolt 17 N-m (13 ft. lbs. Valve Body-to-Case Bolts 12 N-m (100 in. lbs.
Oil Pump Bolt 20 N-m (15 ft. lbs.
Overrunning Clutch Cam Set
Screw (36RH/46RH) 5 N-m (40 in. lbs. J9221-157
• TRANSMISSION/TRANSFER CASE SPECIFICATIONS 21 - 367
NV4500 TORQUE SPECIFICATIONS NP205 TORQUE SPECIFICATIONS
Backup Light Switch 22-34 N-m (193-300 in. lbs.) Bearing Preload 7-41 N»m (5-30 in. lbs.)
Countershaft Bearing Case Bolts 31 mm (23 ft. lbs.)
Plate Bolts 19-26 N-m (170-230 in. lbs.) Distance Sensor
Coupling Nut 17 N»m (150 in. lbs.)
Fifth Gear Nut 339-475 N-m (250-350 ft. lbs.) Detent Bolt 31 N»m (23 ft. lbs.)
Drain and Fill Plugs 34-47 N-m (25-35 ft. lbs.) Drain/Fill Plugs 54 N«m (40 ft. lbs.)
Front Bearing Retainer Bolts 27-34 N-m (235-305 in. lbs.) Front/Rear Yoke Nuts 176 N®m (130 ft. lbs.)
Indicator Switch 24 N«m (18 ft. lbs.)
Mainshaft Bearing Plate Bolts 19-26 N-m (170-230 in. lbs.)
Range Lever Locknut.. 10 N * m (90 in. lbs.)
PTO Cover Bolts 27-54 N-rn (20-40ft.lbs.) Rear Retainer Bolts . . . 54 N«m (40 ft. lbs.)
Extension/Adapter Housing Bolts 41-68 N-m (30-50ft.lbs.) Speedometer Driven
Gear Nut 11 N»m (100 in. lbs.)
Reverse Inhibitor Screws 8-14 N-m (75-115 in. lbs.)
Transfer Case
Shift Cover Bolts 27-31 N-m (216-276 in. lbs.) Mounting Nuts. . . . . 54 N«m (40 ft. lbs.)
J9221-12 J9221-250
G360 SET-TO TORQUE SPECIFICATIONS NP241 TORQUE SPECIFICATIONS
Clutch Housing Bolts 47 N-m (35 ft. lbs.) DESCRIPTION TORQUE

Drain/Fill Plugs 47 Nm (35 ft. lbs.)
Front/Rear Bearing
Retainer Bolts . 22-30 N-m (16-22 ft. lbs.) Oil Pump Screws 1.4-1.8 N«m (12-15 in. lbs.)
Rear Crossmember Yoke Nut (front/rear) 176-271 N»m (130-200 ft. lbs.)
Bolts/Nuts . 68 N-m (50 ft. lbs.) Vacuum Switch 20-34 N«m (15-25 ft. lbs.)
Shift Cover Bolts 22-30 N-m (16-22 ft. lbs.)
Range Lever Nut 27-34 N»m (20-25 ft. lbs.)
Skid Plate And Crossmember
Bolts/Nuts 41 N-m (30 ft. lbs.) Front Case-To-Rear Case Bolts . . 27-34 N»m (20-25 ft. lbs.)
Transfer Case Attaching Rear Retainer Bolts 47-61 N»m (35-45 ft. lbs.)
Nuts 47 N m (35 ft. lbs.) Extension Housing Bolts 35-46 N»m (26-34 ft. lbs.)
Transmission-To-Clutch
Drain/Fill Plugs 41-54 N*m (30-40 ft. lbs.)
Housing Bolts 68 N-m (35 ft. lbs.)
U-Joint Clamp Bolts 19 N m (14 ft. lbs.) Detent Plug 16-24 N@m (12-18 ft. lbs.)
Yoke Nut 380 N-m (280 ft. lbs.) Front Bearing Retainer Bolts 16-24 N»m (12-18 ft. lbs.)
J9321-333 Vacuum Switch 20-34 N*m (15-25 ft. lbs.)
Rear Case Stud Nut 27-34 N*m (20-25 ft. lbs.)
Strut Mounting Bracket Stud Nut 27-34 N»m (20-25 ft. lbs.)
J9221-248
• WHEELS AND TIRES 22 - 1
WHEELS A N D TIRES
CONTENTS
page page
TIRES 1 VEHICLE VIBRATION 11

TORQUE SPECIFICATIONS 13 WHEELS 6
TIRES
INDEX
page page
Cleaning of Tires 2 Rotation . 3
General Information 1 Tire Inflation Pressures 2
Pressure Gauges . 2 Tire Noise or Vibration 4
Repairing Leaks 3 Tire Wear Patterns 4
Replacement Tires 2 Tread Wear Indicators 3
GENERAL INFORMATION not always printed on the tire side wall. The letter S
Tires are designed for each specific vehicle. They indicates t h a t the tire is speed rated up to 112 mph.
provide the best overall performance for normal op • Q up to 100 mph
eration. The ride and handling characteristics match • T up to 118 mph
the vehicle's requirements. With proper care they • U up to 124 mph
will give excellent reliability, traction, skid resis • H up to 130 mph
tance, and tread life. These tires have specific load • V up to 149 mph
carrying capacities. When correctly inflated, they • Z more t h a n 149 mph (consult the tire manufac
will operate properly. t u r e r for the specific speed rating)
Tires used in cool climates, and with light loads An All Season type tire will have either M + S, M
will have a longer life t h a n tires used in hot climates & S or M—S (indicating mud and snow traction) im
with heavy loads. Abrasive road surfaces will accel printed on the side wall.
erate tire wear.
Driving habits have more effect on tire life than RADIAL-PLY TIRES
any other factor. Careful drivers will obtain much Radial-ply tires improve handling, tread life, ride
greater mileage t h a n careless drivers. quality and decrease rolling resistance.
Driving habits t h a t shorten the life of any tire; Radial-ply tires must always be used in sets of
• Rapid acceleration and deceleration four. Under no circumstances should they be used on
• Severe application of brakes the front only. They may be mixed with temporary
• High-speed driving spare tires when necessary, but reduced speeds are
• Taking t u r n s at excessive speeds recommended.
• Striking curbs and other obstacles Radial-ply tires have the same load-carrying capac
It is very important to follow the tire rotation in ity as other types of tires of the same size. They use
terval t h e same recommended inflation pressures.
IDENTIFICATION SPARE TIRE (TEMPORARY)

Tire type, size, aspect ratio and speed rating are The compact spare tire is designed for emergency
encoded in the letters and numbers imprinted on the use only. The original tire should be repaired and re
side wall of the tire. Refer to the chart to decipher installed at the first opportunity. Refer to Owner's
the tire identification code (Fig. 1). Manual for complete details.
Performance tires will have a speed rating letter
after the aspect ratio number. The speed rating is
22 - 2 WHEELS AND TIRES •
METRIC TIRE SIZES
P 205 / 75 I 15
Fig. 2 Under infiation Wear
J9322-6
Fig. 1 Tire Size identification

TIRE CHAINS
Tire snow chains may be used on certain models.
Refer to Owner's Manual for more information.
CLEANING OF TIRES
Fig. 3 Over Infiation Wear
Steam cleaning may be used for cleaning.
DO NOT use gasoline or wire brush for cleaning. checked cold once per month. Tire pressure de
DO NOT use mineral oil or an oil-based solvent. creases when the outside temperature drops.
Inflation pressures specified on the placards are al
PRESSURE GAUGES ways cold i n f l a t i o n pressure. Cold inflation pres
High-quality, dial-type, air-pressure gauges are sure is obtained after the vehicle has not been
recommended. After checking with the gauge, re operated for at least 3 hours. Tire inflation pressures
place valve caps and tighten finger tight. may increase from 2 to 6 pounds per square inch
(psi) during operation. Do not reduce this normal
TIRE INFLATION PRESSURES pressure build-up.
Under inflation (Fig. 2) causes rapid shoulder wear Vehicles loaded to the maximum capacity should
and tire flexing. not be driven at continuous speeds above 75 mph
Over inflation (Fig. 3) causes rapid center wear (120 km/h).
and loss of the tire's ability to cushion shocks.
Improper inflation can cause; WARNING: OVER O R UNDER INFLATED TIRES C A N
• Uneven wear patterns A F F E C T VEHICLE HANDLING A N D C A N FAIL S U D
• Reduced tread life D E N L Y , R E S U L T I N G IN L O S S O F V E H I C L E C O N
• Reduced fuel economy TROL
• Unsatisfactory ride
• Cause the vehicle to drift
Refer to the Owner's Manual for information re REPLACEMENT TIRES
garding proper tire inflation pressure. OEM tires provide a proper balance of many fea
This pressure has been carefully selected to provide tures such as;
for safe vehicle operation. Tire pressure should be • Ride
• Noise
• Handling
• Durability
• Tread life
• Traction
• Rolling resistance
• Speed capability
We recommend that tires equivalent to the original
equipment tires be used when replacement is needed. LEFT 'I RIGHT
Refer to the placard on the vehicle or the FRONT II FRONT
Owner's Manual for the correct replacement
tire. LEFT II RIGHT
Failure to use original equipment replacement REAR p REAR
tires may adversely affect the handling of the vehi 1 || |
cle. L
The use of oversize tires is not recommended.
They may cause interference with vehicle suspension
and steering travel. This can cause tire damage or
failure.
W A R N I N G : F A I L U R E TO EQUIP T H E V E H I C L E W I T H
HN838
TIRES HAVING ADEQUATE LOAD CAPABILITY C A N
R E S U L T IN S U D D E N T I R E F A I L U R E . Fig. 5 Dual Wheel Tire Rotation Pattern
TREAD WEAR INDICATORS
ROTATION Tread wear indicators are molded into the bottom
Tires on the front and rear axles operate at differ of the tread grooves. When tread is 1.6 mm (1/16 in.),
ent loads and perform different steering, driving, and the tread wear indicators will appear as a 13 mm
braking functions. For these reasons; (1/2 in.) band.
• They wear at unequal rates Tire replacement is necessary when indicators ap
• Tend to develop irregular wear patterns pear in two or more grooves, or if localized balding
These effects can be reduced by timely rotation of occurs (Fig. 6).
tires. The benefits of rotation are especially worth
TREAD TREAD
while. Rotation will: ACCEPTABLE UNACCEPTABLE
• Increase tread life
• Help to maintain mud, snow, and wet traction lev
els
• Contribute to a smooth, quiet ride
The suggested method of tire rotation is the same
side front to rear pattern (Fig. 4). Other rotation
methods can be used, but they will not provide all
the tire longevity benefits.
Dual wheel vehicles require a different tire rota
tion than that of the conventional four wheel type.
Refer to Figure 5 for the proper tire rotation with
v
dual wheels.
WEAR
INDICATOR
FRONT
J8922-5
m kz —~i
Fig. 6 Tread Wear Indicators
REPAIRING LEAKS
J9222-8
For proper repairing, a radial tire must be removed
from the wheel. Repairs should only be made if the
Fig. 4 Tire Rotation Pattern
puncture is in the tread area (Fig. 7). If outside the solution when dismounting or mounting tire. Use
tread area the tire should be replaced. tools free of burrs or sharp edges.
Before mounting tire on wheel, make sure all rust
scale is removed from the rim. Repaint or seal if nec
essary.
TIRE NOISE OR VIBRATION

The radial-ply tire on your vehicle is more sensi
tive to improper mounting, or imbalance.
To determine if tires are the cause of vibration,
drive the vehicle over a smooth road at different
speeds. Note the effect of acceleration and decelera
tion on noise level. Differential and exhaust noise
will change in intensity as speed varies. Tire noise
will usually remain constant.
TIRE WEAR PATTERNS

Under inflation results in faster wear on shoulders
of tire. Over inflation causes faster wear at center of
tread.
Excessive camber causes the tire to run at an angle
J8922-6 to the road. One side of tread is worn more t h a n the
other.
Fig. 7 Tire Repair Area
Excessive toe-in or toe-out causes wear on the
Deflate tire completely before dismounting tire tread edges of the tire, from dragging of tire. There
from the wheel. Use lubrication such as a mild soap is a feathered effect across the tread (Fig. 8).
WEAR ON
CRACKED TREADS FEATHERED EDGE BALD SPOTS SCALLOPED WEAR
ONE SIDE
IP
fa
EXCESSIVE CAMBER INCORRECT TOE UNBALANCED
WHEEL LACK OF
ROTATION
OF TIRES
OR
EXCESSIVE SPEED* WORN OR OUT-
OF-ALIGNMENT
SUSPENSION.
OR TIRE DEFECT*
ADJUST PRESSURE TO
SPECIFICATIONS WHEN ADJUST CAMBER ADJUST TOE-IN DYNAMIC OR ROTATE TIRES AND
TIRES ARE COOL TO TO STATIC INSPECT SUSPENSION
ROTATE TIRES SPECIFICATIONS SPECIFICATIONS BALANCE WHEELS SEE GROUP 2
•HAVE TIRE INSPECTED FOR FURTHER USE. RN797
Fig. 8 Abnormal Tire Tread Wear Patterns

WHEELS AND TIRES 22 - 5
LEAD CORRECTION CHART
A D J U S T TIRE P R E S S U R E R O A D TEST OK
TO R E D U C E D L O A D O N
PRESSURE PLACARD
CAR LEADS
CROSS SWITCH FRONT
TIRE & WHEEL ASSEMBLIES
I
R O A D TEST OK
I
I
CAR LEADS
1
C A R LEADS
S A M E DIRECTION OPPOSITE DIRECTION
P R O B A B L E C A U S E - TIRES
S W I T C H TIRES F R O N T T O REAR
P R O B A B L E C A U S E - VEHICLE
CHECK FRONT A L I G N M E N T LEFT F R O N T T O LEFT R E A R
TOE-CASTER-CAMBER LEFT R E A R TO LEFT F R O N T
RIGHT F R O N T T O R I G H T REAR
RIGHT R E A R TO R I G H T F R O N T
I
ALIGNMENT NOT OK R O A D TEST OK
ADJUST ALIGNMENT TO
PREFERRED SETTINGS. £
CAR STILL LEADS
CROSS SWITCH FRONT TIRES
R O A D TEST
A
CAR STILL LEADS
SWITCH RIGHT FRONT
1 OK
R O A D TEST
CAR STILL LEADS

LEAD CAUSED BY
LEFT FRONT
TIRE - REPLACE
9
122
-77
22 - e WHEELS AND TIRES •
WHEELS
GENERAL INFORMATION WHEEL INSTALLATION
Original equipment wheels are designed for all The wheel studs and nuts are designed for specific
loads up to the specified Maximum Vehicle Capacity. applications. They must be replaced with equivalent
All models use steel or cast aluminum drop center parts. Do not use replacement parts of lesser quality
wheels. The safety rim wheel (Fig. 1) has raised sec or a substitute design. All aluminum and some steel
tions between the rim flanges and the rim well. wheels have wheel stud nuts which feature an en
larged nose. This enlarged nose is necessary to en
sure proper retention of the aluminum wheels.
Before installing the wheel, be sure to remove any
build up of corrosion on the wheel mounting surfaces.
Ensure wheels are installed with good metal-to-metal
contact. Improper installation could cause loosening
of wheel nuts. This could affect the safety and han
dling of your vehicle.
To install the wheel, first position it properly on
the mounting surface. All wheel nuts should then be
tightened just snug. Gradually tighten them in se
quence to 129 N-m (95 ft. lbs.) torque (Fig. 3, 4).
Never u s e oil or grease on studs or nuts.
S J9022-3
Fig. 1 Wheel Safety Rim

Initial inflation of the tire forces the bead over
these raised sections. In case of tire failure, the
raised sections hold the tire in position on the wheel
until the vehicle can be brought to a safe stop.
Cast aluminum wheels require special balance
weights and alignment equipment.
DUAL REAR WHEELS

Ram Truck Models D-350 and W-350 equipped
with dual rear wheels have eight-stud hole rear A. 5 STUD WHEEL
wheels. Four equally-spaced stud holes flanged out B. 8 STUD WHEEL
ward and four flanged inward. The wheels must be J9122-7
installed so the flanged stud holes mate correctly
(Fig. 2). Fig. 3 Lug Nut Tightening Pattern
LOCATING PIN HOLE IN BOTH INNER & OUTER WHEEL MUST EN 118 LBS. FORCE THESE NUMBERS SHOW THE
GAGE LOCATING PIN IN HUB WHEN WHEELS ARE INSTALLED. SEQUENCE IN WHICH STUD NUTS
ARE TO BE TIGHTENED.
FT. LBS.
TORQUE
PR1100
PU884
Fig. 2 Dual Rear Wheels Fig. 4 Dual Rear Wheel Tightening Pattern
A locating pin in the hub provides assistance for
DUAL REAR WHEELS
correctly aligning the inner and outer wheels.
Dual rear wheels: a special heavy duty lug n u t
wrench is required (Fig. 4). It is recommended to re-
move and install dual r e a r wheels only when the • Load carrying capacity
proper wrench is available. • Diameter
® Width
INSTALLATION • Offset
The tires on both wheels must be completely raised • Mounting configuration
off t h e ground when tightening the lug nuts (Fig. 5). Failure to use equivalent replacement wheels may
This will ensure correct wheel centering and maxi affect the safety and handling of your vehicle. Re
mum wheel clamping. placement with u s e d wheels is not recommended.
HUB ^ INWARD
Their service history may have included severe treat
ment.
R e f e r t o t h e Specifications C h a r t for i n f o r m a
tion r e g a r d i n g above requirements.
WHEEL ORNAMENTATION
WARNING; HANDLE ALL WHEEL ORNAMENTATION
WITH E X T R E M E C A R E DURING R E M O V A L A N D IN
S T A L L A T I O N . S H A R P E D G E S ON T H E C O V E R S O R
C A P S C A N C A U S E P E R S O N A L INJURY.
TIRE AND WHEEL BALANCE

It is recommended t h a t a two plane dynamic bal
ancer be used when a wheel and tire assembly re
Fig. 5 Flange Centering And Alignment quire balancing. Static should be used only when a
two plane balancer is not available.
A 1 1/8-inch diameter flanged-type wheel lug n u t For static imbalance, find location of heavy spot
with right-hand threads is used for retaining dual causing imbalance. Counter balance wheel directly
rear wheels on the hubs. A special, heavy duty wheel opposite the heavy spot. Determine weight required
lug n u t wrench is necessary to correctly tighten the
to counterbalance the area of imbalance. Place half
nuts with the required torque (Fig. 4).
of this weight on the i n n e r rim flange and the other
The dual rear wheel lug nuts should be tightened
half on the o u t e r rim flange (Fig. 6, Fig. 7). Off-ve
according to the following procedure:
hicle balancing is necessary.
• Tighten the wheel lug nuts in the numbered se
Wheel balancing can be accomplished with either
quential pattern until they are snug tight (Fig. 4).
• Tighten the wheel lug nuts in the numbered se on or off vehicle equipment. When using on-vehicle
quential pattern to 440 N m (325 ft-lb) torque.
# balancing equipment, follow these precautions:
• Tighten the lug nuts in the numbered sequential • Limited-slip rear axle differential, remove the op
pattern a second time to the specified torque. This posite wheel/tire
will ensure t h a t the wheels are thoroughly mated. • Before balancing the wheels/tires on a vehicle
• Retighten the lug nuts to the specified torque after equipped with a transfer case, disconnect the drive
100 miles (160 kilometers). Also retighten after 500 shafts
miles (800 kilometers) of vehicle operation.
The w h e e l lug nuts should be tightened with MATCH MOUNTING
the specified torque at every c h a s s i s lubrication Wheels and tires are match mounted at the factory.
interval thereafter. This means t h a t the high spot of the tire is matched
to the low spot on the wheel rim. This technique is
WHEEL REPLACEMENT used to reduce run-out in the wheel/tire assembly.
Wheels must be replaced if they have: The high spot on the tire is marked with a paint
• Excessive runout m a r k or a bright colored adhesive label on the out
• Bent or dented board sidewall. The low spot on the rim is at t h e
• Leak air through welds valve stem location on the wheel rim.
• Have damaged bolt holes Before dismounting a tire from its wheel, a refer
Wheel repairs employing hammering, heating, or ence mark should be placed on the tire at the valve
welding are not allowed. stem location. This reference will ensure that it is re
Original equipment wheels are available through mounted in the original position on the wheel.
your dealer. Replacement wheels from any other (1) Measure the total indicator runout on the cen
source should be equivalent in: ter of the tire tread rib. Record the indicator reading.
ADP BALANCE
WEIGHTS HERE
TIRE OR WHEEL TRAMP, CORRECTIVE

OR WHEEL HOP WEIGHT
LOCATION
J8922-8
Fig. 6 Static Unbalance & Balance

ADD BALANCE
WEIGHTS HERE
CORRECTIVE WEIGHT
HEAVY SPOT LOCATION
WHEEL SHIMMY
A N D VIBRATION
J8922-9
Fig. 7 Dynamic Unbalance & Balance

Mark the tire to indicate the high spot. Place a m a r k • If the high spot is NOT within 101.6 m m (4.0 in.)
on the tire at the valve stem location (Fig. 8). of either high spot, draw an arrow on the tread from
(2) Break down the tire and remount it 180 de second high spot to first. Break down the tire and re
grees on the rim (Fig. 9). mount it 90 degrees on the rim in t h a t direction (Fig.
(3) Measure the total indicator runout again. Mark 10). This procedure will normally reduce the runout
the tire to indicate the high spot. to an acceptable amount.
(4) If runout is still excessive, the following proce
dures must be done. TIRE AND WHEEL RUNOUT
• If the high spot is within 101.6 mm (4.0 in.) of the Radial runout is the difference between the high
first spot and is still excessive, replace the tire. and low points on the tire or wheel (Fig. 11).
• If the high spot is within 101.6 mm (4.0 in.) of the Lateral runout is the w o b b l e of the tire or wheel.
first spot on the wheel, the wheel may be out of spec Radial runout of more t h a n 1.5 mm (.060 inch)
ifications. Refer to Wheel and Tire Runout. measured at the center line of the tread may cause
the vehicle to shake.
2 N D H I G H SPOT
O N TIRE
SPOT O N
TIRE
J9322-5
Fig. 10 Remount Tire 90 Degrees In Direction of

Fig. 8 First Measurement On Tire
Arrow
VALVE STEM
J9022-4
REFERENCE Fig. 11 Checking Tire Runout

AAARK J9322-4 METHOD 1 (RELOCATE WHEEL ON HUB)
Check accuracy of the wheel mounting surface; ad
Fig. 9 Remount Tire 180 Degrees
just wheel bearings.
Lateral runout of more t h a n 2.0 mm (.080 inch) Drive vehicle a short distance to eliminate tire flat
measured near the shoulder of the tire may cause the spotting from a parked position.
vehicle to shake. Make sure all wheel nuts are properly torqued.
Sometimes radial runout can be reduced. Relocate Relocate wheel on the mounting, two studs over
the wheel and tire assembly on the mounting studs from the original position.
(See Method 1). If this does not reduce runout to an Re-tighten wheel nuts until all are properly
acceptable level, the tire can be rotated on the wheel. torqued, to eliminate brake distortion.
(See Method 2). Check radial runout. If still excessive, m a r k tire
sidewall, wheel, and stud at point of maximum
runout and proceed to Method 2.
METHOD 2 (RELOCATE TIRE ON WHEEL)
Rotating tire on wheel is particularly effective
when there is runout in both tire and wheel.
Remove tire from wheel and re-mount wheel on
hub in former position.
Check wheel radial runout (Fig. 12).
• STEEL WHEELS: Radial runout 0.040 in., Lateral
runout 0.045 in.
• ALUMINUM WHEELS: Radial runout 0.030 in.,
Lateral runout 0.035 in.
If point of greatest runout is near original chalk
mark, remount tire 180 degrees. Recheck runout.
J8922-11
Fig. 12 Checking Wheel Runout

• WHEELS AND TIRES 22-11
VEHICLE VIBRATION
Vehicle vibration can be caused by: • Identify t h e vehicle speed range when t h e vibra
• Tire/wheel unbalance or excessive runout tion occurs
• Defective tires with extreme tread wear • Identify the type of vibration
• Nylon overlay flat spots (performance tires only) • Identify the vibration sensitivity
• Incorrect wheel bearing adjustment (if applicable) • Determine if the vibration is affected by changes
• Loose or worn suspension/steering components in vehicle speed, engine speed and engine torque.
• Certain tire tread patterns When the vibration h a s been identified, refer to the
• Incorrect drive shaft angles or excessive drive Vibration Diagnosis chart for causes. Consider cor
shaft/yoke runout recting only those causes coded in t h e chart t h a t are
• Defective or worn U-joints related to the vibration condition.
• Excessive brake rotor or drum runout Refer to the following cause codes and descriptions
• Loose engine or transmission supports/mounts for explanations when referring to the chart.
• And by engine operated accessories TRR—Tire a n d Wheel Radial Runout: Vehicle
Refer t o t h e appropriate Groups i n this man speed sensitive, mechanical vibration. The runout
ual for additional information. will not cause vibration below 20 mph (32 km/h).
WH—Wheel Hop: Vehicle speed sensitive, me
VIBRATION TYPES chanical vibration. T h e wheel hop generates rapid
There are two types of vehicle vibration: up-down movement in the steering wheel. The vibra
• Mechanical tion is most noticeable in t h e 20 - 40 mph (32 - 64
• Audible. km/h) range. The wheel hop will not cause vibration
Mechanical vehicle vibration can be felt through below 20 mph (32 km/h). Wheel hop is caused by a
the seats, floor pan and/or steering wheel. tire/wheel t h a t h a s a radial runout of more t h a n
Audible vehicle vibration is heard above normal 0.045 of-an-inch (1.14 mm). If wheel runout is accept
background noise. The sound can be a droning or able and combined runout cannot be reduced by re
drumming noise. positioning the tire on wheel, replace tire.
Vibrations a r e sensitive to change i n engine TB—Tire/Wheel Balance: Vehicle speed sensitive,
torque, vehicle speed or engine speed. mechanical vibration. Static tire/wheel unbalance
will not cause vibration below 30 mph (46 km/h). Dy
ENGINE TORQUE SENSITIVE VIBRATION namic tire/wheel unbalance will not cause vibration
This vibration can be increased or decreased by: below 40 mph (64 km/h).
• Accelerating TLR—Tire/Wheel Lateral runout: Vehicle speed
• Decelerating sensitive, mechanical vibration. The runout will not
• Coasting cause vibration below 50 - 55 m p h (80 - 88 km/h).
• Maintaining a constant vehicle speed Excessive lateral runout will also cause front-end
shimmy.
VEHICLE SPEED SENSITIVE VIBRATION TW—Tire Wear: Vehicle speed sensitive, audible
This vibration condition always occurs a t the same vibration. Abnormal tire wear causes small vibration
vehicle speed regardless of the engine torque or en in t h e 30 - 55 mph (88 km/h) range. This will pro
gine speed. duce a whine noise a t high speed. The whine will
change to a growl noise when the speed is reduced.
ENGINE SPEED {RPM} SENSITIVE VIBRATION
W—Tire Waddle: Vehicle speed sensitive, mechan
This vibration occurs a t varying engine speeds. It
ical vibration. Irregular tire uniformity can cause
can be isolated by increasing or decreasing the en side-to-side motion during speeds u p to 15 mph (24
gine speed with the transmission in NEUTRAL posi km/h). If the motion is excessive, identify t h e defec
tion. tive tire and replace it.
U A J—Universal J o i n t (Drive Shaft) Angles:
VIBRATION DIAGNOSIS Torque/vehicle speed sensitive, mechanical/audible
A vibration diagnosis should always begin with a vibration. Incorrect drive shaft angles cause mechan
10 mile (16 km) trip (to warm the vehicle and tires). ical vibration below 20 mph (32 km/h) and in the 70
Then a road test to identify the vibration. Corrective mph (112 km/h) range. The incorrect angles can also
action should not be attempted until t h e vibration produce a n audible vibration in the 20 - 50 mph (32 -
type h a s been identified via a road test. 80 km/h) range. Caster adjustment could be required
During the road test, drive the vehicle on a smooth to correct the angles.
surface. If vibration exists, note and record t h e fol UJ—Universal Joints: Engine torque/vehicle
lowing information: speed sensitive, mechanical/audible vibration. If the
22-12 WHEELS AND TIRES
VIBRATION DIAGNOSIS
Correction Codes For Mechanical Vibrations Within Specific M P H (km/h) Ranges

Vibration
Sensitivity 10 20 30 40 50 60 70 80 90
(16km) (32 km) (48 km) (64 km) (80 km) (96 km) (112 km) (128 km) (144 km)
-TRR and S S C -
Vehicle •W -TB-
Speed
-WH- •TLR-
-DSY
Sensitive -UJ and A N -
-WB-
Torque • UJ and A N •
I
Sensitive -UJA- •UJA-
•ES
Engine
Speed •EA-
Sensitive •DEM-
Correction Codes For Audible Vibrations Within Specific MPH (km/h) Ranges
Vibration
Sensitivity 10 20 30 40 50 60 70 80 90
(16 km) (32 km) (48 km) (64 km) (80 km) (96 km) (112 km) (128 km) (144 km)
•UJA- •DSY"
Vehicle
JU and W H
Speed
Sensitive -TW-
•WB-
Torque -AN *
Sensitive -UJ and TED,
Engine • EA and E S -
Speed -ADB-
Sensitive -DEM- J8922-12
U-joint is worn it will cause vibration with almost cal vibration at speeds above 20 mph (32 km/h).
any vehicle speed/engine torque condition. Identify and repair or replace the defective compo
DSY—Drive Shaft a n d Yokes: Vehicle speed sen nent (s).
sitive, mechanical/audible vibration. The condition EA—Engine Driven Accessories: Engine speed
will not cause vibration below 35 mph (56 km/h). Ex sensitive, mechanical/audible vibration. Vibration
cessive runout, unbalance or dents and bends in the can be caused by loose or broken A/C compressor, PS
pump, water pump, generator or brackets, etc. Usu
shaft will cause the vibration. Identify the actual
ally more noticeable when the transmission is shifted
cause and repair/replace as necessary.
into the NEUTRAL position and the engine speed
WB—Wheel Bearings: Vehicle speed sensitive, (rpm) increased. Inspect the engine driven accesso
mechanical/audible vibration. Loose wheel bearings ries in the engine compartment. Repair/replace as
cause shimmy-like vibration at 35 mph (56 km/h) necessary.
and above. Worn bearings will also produce a growl ADB—Accessory Drive Belts: Engine speed sen
noise at low vehicle speed and a whine noise at high sitive, audible vibration. Worn drive belts can cause
vehicle speed. The wheel bearings must be adjusted a vibration t h a t produces either a droning, fluttering
or replaced, as applicable. or rumbling noise. Inspect the drive belt(s) and tight
AN—Axle Noise: Engine torque/vehicle speed sen en/replace as necessary.
sitive, mechanical/audible vibration. The axle will DEM—Damaged Engine or Transmission Sup
not cause mechanical vibration unless the axle shaft port Mounts: Engine speed sensitive, mechanical/
audible vibration. If a support mount is worn, noise
is bent. Worn or damaged axle pinion shaft or differ
or vibration will occur. Inspect the support mounts
ential gears and bearings will cause noise. Replace
and repair/replace as necessary.
the defective component(s) as necessary.
ES—Exhaust System: Engine speed sensitive, me
SSC—Suspension a n d Steering Components: chanical/audible vibration. If loose exhaust compo
Vehicle speed sensitive, mechanical vibration. Worn nents contact the vehicle body they will cause noise
suspension/steering components can cause mechani and vibration. Inspect the exhaust system for loose,
broken and mis-aligned components and repair/re
place as necessary.
LUG NUT TORQUE
DESCRIPTION TORQUE
1/2x20 with 60° Cone 109 to 150 N-m
15 Inch Wheel (80 to 110 ft. lbs.)
1/2x20 with 90° Cone 115 to 155 N-m
16 Inch Single Wheel (85 to 115 ft. lbs.)
5 / 8 x 1 8 with 90° Cone 240 to 305 N-m
16 Inch Single Wheel (175 to 225 ft. lbs.)
5 / 8 x 1 8 with Flanged Nut.. 410 to 475 N-m
16 Inch Dual Wheel (300 to 350 ft. lbs.)
J9322-9
• BODY COMPONENTS 23 - 1
BODY COMPONENTS
CONTENTS
page page
CAB/BODY INTERIOR COMPONENTS 35 FIXED GLASS . 29
DOORS 21 PAINT CODE CHART 54
EXTERIOR COMPONENTS 1 REFINISHING PROCEDURES 54
EXTERIOR COMPONENTS
INDEX
page page
Battery Tray 7 Grille Opening Panel ( G O P ) and Radiator
Blower Motor Housing Insulation Panel—Diesel Support Panel 3
Engine Only 7 Hatchgate and Components 16
Body Mouldings, Nameplates and Decals ....... 9 Hood 5
Cab . 14 Hood Inside Release Cable 5
Cab/Body and Cargo Box Stripes 11
Hood Latch 4
Cargo Box 19
Cowl Grille 7 Labels/Decals/Plates 1
Front Fenders 8 Outside Mirrors 13
Fuel Filler Door and Nozzle/Tubes 12 Roof Vent—Ramcharger . 20
Grille and Grille Extension Panel 1 Splash Shields—Front Fender 9
Grille Extension Panel Support Bracket (With Sport Bar 18
Diesel Engine Only) 3 Tailgate 14
LABELS/DECALS/PLATES EMISSION CONTROL DRIVE BELT

INFORMATION AND VACUUM ROUTING LABEL
GENERAL INFORMATION HOSE ROUTING LABEL (DIESEL
The labels, decals a n d plates t h a t a r e attached to
Ram Van and Wagon vehicles contain safety or oth
erwise essential information (Figs. 1, 2, 3 a n d 4).
INSTALLATION
Follow the instructions included with each replace
ment label, decal or plate to affix it to a panel or
component.
GRILLE AND GRILLE EXTENSION PANEL
GRILLE REMOVAL
(1) Remove screws t h a t attach the headlamp bezels
(Fig. 5) to t h e grille.
(2) Separate t h e bezels from t h e headlamps (Fig.
5).
(3) Raise and support t h e hood.
(4) Remove the grille screws from the radiator sup
port panel and t h e extension panel (Fig. 6).
(5) Remove t h e grille from the front of the vehicle.
Fig. 1 Underhood Labels, Decals & Plates
23 - 2 BODY COMPONENTS •
EXPORT VEHICLE ORIGIN NATIONAL EXTERNAL
LABEL LABEL SAFETY NOISE
MARK GLASS
CERTIFICATION
(CANADA) EXHAUST LABEL
(OVER 10,000 LBS.)
GAS
WARNING
DECAL
UNLEADED/DIESEL
B-PILLAR FUEL LABEL
(U.S.)
VEHICLE
HANDLING
LABEL
(RAMCHARGER)
J9123-599
UNLEADED/DIESEL Fig. 4 Sunvisor Front Labels

FUEL LABEL
EXHAUST (CANADA)
EXHAUST EMISSION EMISSION SCREW HEADIAMP
STANDARDS-CALIF. STADARDS-CALIF. ANCHOR BEZEL •
GRILLE
(MODELS 30 A N D 60) (RAMCHARGER) J9123-408
Fig. 2 Exterior Labels & Decals

ARM NOISE SNOW
BRACKET CERTIFICATION PLOW
LABEL TRANSMISSION
5
UOVER 10,000 LBS) CAUTION HEADLINER
LABEL
J9123-600
Fig. 5 Headlamp Bezel & Grille

TRANSFER CASE
SHIFT LABEL RADIATOR
(4WD) GRILLE SUPPORT
REAR BRACKET PANEL
SUN VIEW
J9123-410 NUT
VISOR MIRROR SCREW *
Fig. 3 Sunvisor Rear Labels

GRILLE INSTALLATION
(1) Position t h e grille at the radiator support panel
and extension panel. Install the screws (Fig. 6).
(2) Tighten the extension panel screws to 2 N»m
(17 in. lbs.) torque. Tighten t h e radiator support
panel screws to 3 Nnn (21 in. lbs.) torque. SUPPORT
BRACKET
(3) Install t h e headlamp bezels and t h e screws PUSH-IN
(Fig. 5). Tighten t h e screws to 2 Nnn (17 in. lbs.) NUT
J9123-328
torque. SCREW NUT SCREW
(4) Remove t h e support and lower t h e hood.
Fig. 6 Grille, Radiator Support Panel & Extension
GRILLE EMTENSION PANEL REMOVAL Panel
(1) Raise and support t h e hood. (4) Remove the extension panel.
(2) Remove t h e grille. If necessary, refer to t h e re
moval procedure.
(3) Remove t h e screws from t h e fender panels and
the support bracket (Fig. 7).
GRILLE EXTENSION PANEL INSTALLATION SCREW U-NUT RADIATOR

(1) Position the grille extension panel at the fender
panels and the support bracket.
(2) Install the panel screws. Tighten the screws to
23 N*m (200 in. lbs.) torque.
(3) Install the grille. If necessary, refer to the in
stallation procedure.
(4) Remove the support and close the hood.
U-NUT RADIATOR GRILLE
Fig. 8 Grille Extension Panel Support

Bracket—Diesel Engine only
GRILLE OPENING PANEL (GOP) AND RADIATOR
SUPPORT PANEL
REMOVAL
(1) Raise and support the hood. Remove the bat
tery.
(2) Remove the grille.
(3) Remove the extension panel.
(4) If equipped, remove the extension panel sup
port bracket.
(5) Remove the headlamps from the headlamp re
ceptacles in the GOP.
Fig. 7 Grille Extension Panel (6) Drain the engine coolant from the radiator in a
clean container for reuse. Remove the radiator from
GRILLE EXTENSION PANEL SUPPORT BRACKET the GOP. If necessary, refer to Group 7—Cooling
(WITH DIESEL ENGINE ONLY) System for the procedure.
REMOWAL (7) Remove the battery and tray from the GOP.
(1) Remove the grille. (8) Remove the horns from the GOP.
(2) Remove the extension panel. (9) Remove the screws, hood latch and the rein
(3) Remove support bracket-to-grille opening panel forcement plate from the radiator support panel.
screw. (10) Detach the latch release cable from the clip on
(4) Remove the support bracket-to-radiator support the radiator support panel.
panel screw (Fig. 8). (11) Remove the screws t h a t attach the splash
(5) Remove the support bracket from the vehicle. shields to the GOP (Fig. 9).
(12) Remove the cab/body front holddowns from
INSTALLATION the front crossmember (Fig. 10).
(1) Position the support bracket at the grille open (13) Remove the screws t h a t attach the fenders to
ing panel (GOP) and radiator support panel. the GOP.
(2) Install the support bracket-to-radiator support (14) Remove the screws t h a t attach the fenders to
panel screw. Tighten the screw to 11 N*m (95 in. lbs.) the radiator support panel.
torque. (15) Remove the screws t h a t attach the splash
(3) Install the support bracket-to-grille opening shield to the right fender inner support panel.
panel (GOP) screw. Tighten the screw to 23 N-m (200 (16) Repeat step (15) for the left fender panel.
in. lbs.) torque. (17) Move both fender panels outward at the front.
(4) Install the grille extension panel. Remove the GOP and the radiator support panel
(5) Install the grille. from the vehicle.
INSTALLATION BUMPER INNER FENDER SPLASH
(1) If necessary, install U-nuts at the GOP lower SUPPORT PANEL SHIELD
flange. SCREW PANEL
(2) Move both fender panels outward at the front.
Position the GOP on the frame rails (Fig. 10). SCREW
(3) Move both fender panels inward at the front. U-NUT
Install the screws to attach the fender splash shields
to the fender inner support panels. Tighten the
#
screws to 11 N m (95 in. lbs.) torque.
(4) Install the cab/body front holddown bolts at the
GOP to the front crossmember. Tighten the nuts to
(5) Install the screws at the fenders to the GOP
and radiator support panel. Tighten the screws to 11
N»m (95 in. lbs.) torque. Tighten the radiator support
panel screws to 23 Nnn (200 in. lbs.) torque.
(6) Align the holes and install the splash shield U-NUT
screws. Tighten the screws to 11 N»m (95 in. lbs.)
torque. REINFORCEMENT
PANEL GRILLE
(7) Install the horns on the GOP. (4WD ONLY) PANEL J9123-567
(8) Attach the battery tray to the GOP. If neces
sary, refer to the installation procedure. Tighten the Fig. 9 Grille Opening Panel (GOP) & Radiator
screws to 11 Nnn (95 in. lbs.) torque. Support Panel
(9) Install the radiator on the GOP. Refill the en BOLT
gine with coolant. If necessary, refer to Group (RAMCHARGER)
7—Cooling System for the procedures.
(10) Attach the hood release cable to the clip on WASHER
the radiator support panel. GRILLE OPENING AND INSULATOR
RADIATOR SUPPORT
(11) Adjust the hood latch cable. PANEL
(12) Position the shield and the hood latch on the
radiator support panel. Install the screws. Tighten
the screws to 23 Nnn (200 in. lbs.) torque.
(13) Test the hood latch and the release cable for BOLT
proper operation. WITH INSULATOR SPACER
(MODELS 30 AND 60) WASHER (4 FOR ADI)
(14) Install the headlamps in the headlamp recep
tacles. INSULATOR ^
(15) Install the extension panel support bracket (if FRAME
RAIL BOLT RETAINER
equipped). Install the grille extension panel and the
. FRAME
grille. — " " CROSSMEMBER
(16) Install the battery and the holddown bracket.
Tighten the holddown rod nuts to 2 Nnn (20 in. lbs.)
torque.
WASHER
(18) If necessary, adjust the headlamp beams. J9113-19
NUT
HOOD LATCH Fig. 10 Cab/Body Front Holddowns

(1) Position the hood latch on the radiator support
REMOVAL panel. Install the screws. Tighten the screws to 23
(1) Open and support the hood. Nnn (200 in. lbs.) torque.
(2) Remove the hood latch and screws from the ra (2) Connect latch release cable to the hood latch.
diator support panel (Fig. 11). (3) Adjust the hood latch cable.
(3) Disconnect release cable from the hood latch. (4) Test the hood latch and release cable for proper
operation.
INSTALLATION
If a replacement h o o d latch is being installed,
lubricate it thoroughly.
(5) If necessary, align t h e hood, the latch, a n d the

striker. Refer to Fore/Aft And Latch/Striker Adjust
ment.
BOLT
CABLE
SHIELD
RELEASE
CABLE
HANDLE
BRACKET
RADIATOR
RADIATOR HOOD BAFFLE
GRILL SUPPORT LATCH PANEL J9123-376
RB1346
Fig. 11 Hood Latch & Release Cable Fig. 12 Release Cable Removal/Installation
HOOD INSIDE RELEASE CABLE LOCATOR INSTRUMENT

CLIP PANEL
LOWER
REMOWAL REINFORCEMENT
(1) Open and support the hood. BRACKET
(2) Disconnect release cable from the hood latch.
(3) Detach the release cable from t h e clip in the
engine compartment (Fig. 12).
(4) Separate the release cable grommet from the
dash panel hole.
(5) From inside t h e vehicle, remove the screws. Re
move the release cable handle bracket from t h e bot
HOOD
tom of the instrument panel. LATCH
(6) Route t h e hood release cable through t h e dash RELEASE
panel hole. Remove it via the inside of the vehicle. CABLE RWAL BRAKE
BRACKET TEST CONNECTOR J9123-360
INSTALLATION
Fig. 13 Release Cable Handle Bracket & RWAL
(1) Route the hood release cable through t h e hole
Brake Test Connector
in the dash panel.
(2) Position the release cable handle a t the bottom HOOD
of the instrument panel. Install t h e screws. Tighten
e POSITION ADJUSTMENT
the screws to 11 N m (95 in. lbs.) torque.
The hood hinge bolt holes are oversize and elon
(3) Install the cable grommet in the dash panel
gated for ease of adjustment (Fig. 15). Loosen the
hole (Fig. 12).
hinge bolts at the fender for up/down adjustment.
(4) Attach the cable to t h e rear clip in the engine
Loosen the hinge bolts at the hood for front/back ad
compartment.
justment.
(5) Route t h e cable under t h e radiator support
panel flange. Attach it to t h e clip and then connect it REMOVAL
to the hood latch. (1) Raise and support the hood at t h e full-open po
(6) Adjust t h e latch cable. sition.
(7) Test t h e hood latch release cable for proper op (2) If equipped, disconnect t h e underhood lamp
eration. wire connector (Fig. 16).
(3) With the aid of an assistant, remove the hinge
arm-to-hood bolts. Remove the hood from vehicle.
INSTRUMENT PANEL
COWL
PANEL
REGULATOR
BRACKET J9123-437 LATCH SAFETY SUPPORT HOOD
STRIKER LATCH PANEL HINGE J9123-375
Fig. 14 Release Cable Handle Bracket & Diesel
Engine Speed Control Regulator Bracket
(4) If a replacement hood is being installed, trans
fer the underhood lamp and the insulator panel (Fig.
17).
(5) Test the hood hinges for correct operation.
(6) Lubricate the hood hinges with engine oil.
INSTALLATION
(1) With the aid of an assistant, position the hood
on the vehicle. Align the hood bolt holes with the
hinge arm holes. Install and finger-tighten the bolts.
(2) Align the hood, the latch, and the striker.
HINGE REPLACEMENT
REMOVAL
If both h i n g e s are being replaced, remove the Fig. 16 Underhood Lamp
h o o d a n d both hinges as a unit. If only one
hinge is being replaced, u s e the following proce INSTALLATION
dure. (1) Position the striker on the hood.
(1) Raise and support the hood at the full-open po (2) Install and tighten the screws.
sition.
(2) Mark the position of the hinge bolts. Loosen HOOD SUPPORT ROD
the bolts (Fig. 15).
(3) Support the hood at the side being removed. REMOVAL
Remove the bolts and hinge from the hood and (1) Raise and support the hood.
fender panel. (2) Drill out the support rod rivet from the radia
tor support panel.
INSTALLATION (3) Remove the support rod from the radiator sup
(1) Position the replacement hinge against the port panel.
fender panel. Install and finger-tighten the bolts.
(2) Align the hood bolt holes with the marks. INSTALLATION
(3) Tighten the hinge bolts to 23 N-m (200 in. lbs.) (1) Position the support rod on the radiator support
torque. panel.
(2) Install the rivet to attach the rod to the panel.
LATCH STRIKER
REMOVAL
(1) Raise and support the hood.
(2) Remove the screws and the latch striker from
the hood.
DASH TAB
ENGINE) SCREW J9123-385
Fig. 17 Hood Insulator Panel Fig. 18 Blower Motor Housing Insulation Panel
BLOWER MOTOR HOUSING INSULATION INSTALLATION
PANEL-DIESEL ENGINE ONLY (1) Position the grille on the cowl upper panel and
under the windshield weatherstrip seal. Align the
REMOVAL screw holes.
(1) Remove the insulation panel screws from the (2) Attach windshield washer hoses to the nozzles
dash panel (Fig. 18). and the clips.
(2) Remove the insulation panel from the blower (3) Install the grille screws. Tighten the front
motor housing and the dash panel. screws to 1 N»m (12 in. lbs.) torque.
INSTALLATION
(5) Install the windshield wiper arms.
(1) Position the insulation panel over the blower
motor housing. SCREW WEATHERSTRIP
(2) Install the insulation panel screws. Tighten the
#
COWL GRILLE
REMOVAL
(1) Remove the windshield wiper arms. If neces
sary, refer to the procedure in Group 8—Electrical.
(2) Raise and support the hood.
(3) Remove the cowl grille screws (Fig. 19).
Ramcharger vehicles h a v e extra s c r e w s lo
cated at the rear of the c o w l grille under the
seal.
(4) Disengage the rear of the grille from the wind
shield weatherstrip seal.
(5) Detach windshield washer hoses from the noz Fig. 19 Cowl Grille Removal/Installation
zles and the clips. BATTERY TRAY
(6) Separate the grille from the cowl. Remove it
from the cowl upper panel. REMOVAL
(1) Remove the nuts, holddown strap and support
bracket from the holddown rods.
(2) Disconnect the cables. Remove the battery from (3) Remove the grille extension panel.
the tray. (4) Remove the battery and tray for left fender re
(3) Remove the bolts t h a t attach the battery tray moval only.
to the fender inner panel and the radiator baffle (5) Remove the screws t h a t attach the fender and
panel. inner panel (Fig. 21) to the radiator support panel.
(4) Remove the screws t h a t attach the rear brace BU
MPE
RNINER FE
NDE
R S
PL
ASH
to the tray and to the inner fender panel. S
UPP
ORT P
ANE
L S
HE
IL
D
(5) Remove the battery tray from the vehicle. S
CR
EW PANE
L
(6) If necessary, remove the holddown rods from
the battery tray.
S
CR
EW
U
N
-UT
INSTALLATION
(1) If removed, install the holddown rods on the
battery tray.
(2) Position the battery tray against the radiator
baffle panel and the fender inner panel.
(3) Attach the battery tray to the radiator baffle
panel and the fender inner panel. Tighten the bolts
to 11 N«m (95 in. lbs.) torque.
(4) Position the rear brace at the tray and at the
fender inner panel. Install the brace screws in the
tray and the fender inner panel. Tighten the screws
to 11 N*m (95 in. lbs.) torque. U
N
-UT
(5) Install the battery in the tray.
(6) Position the holddown strap and the support R
E
N IF
ORCEMENT
bracket over the holddown rods. P
A N
EL GR
LI
LE
(4WD ONL
Y) P
ANE L J9123-567
(7) Install the nuts on the holddown rods. Tighten
the nuts to 2 N»m (20 in. lbs.) torque. Fig. 21 Front Fender-To-Grille/Radiator Support
(8) Connect the cables to the battery. Panels Hardware
H
OL
DDOWN NUT S
UPP
ORT
B
'R
ACKET (6) Remove the screw and nut t h a t attach the top
ST
RAP
of the fender (Fig. 22) to the cowl.
RE
AR
B
RAC
E S
-
C R
EW NUT SPA
CERCAB
B
AT
TE
RY S
TUD \H
OL
DDOWN
BRA
CKE
T
S
CR
EW
U
N
-UT U
N
-UT
C
OWL
L
EFT SD
IE
F
RO N
T P
ANEL
F
ENDE
R
NUT
S
UPP
ORT
B
RACK
ET
B
OLT
NUT
-
R
AD
AIT
OR F
END
ER
WA
SHE
R^
— BAFF
LE PA
NEL S
PA
CER
J9123-355 BO L
T -
^ FWD PANEL
V
S
PA
CERS
CR
EW
Fig. 20 Battery Tray Removal/Installation GR
LI
LE S
CR
EW
P
ANE L J9123-566
FRONT FENDERS
Fig. 22 Front Fender-To-Cowl/Dash Panel Hardware
REMOWAL
(1) Raise and support the hood. (7) Remove the screws t h a t attach the bottom of
(2) Remove the grille. the fender and inner panel to the dash panel.
(8) Remove the fender and the inner panel from INSTALLATION
the cab/body. (1) Position the splash shield on the frame rail and
(9) Remove the screws t h a t attach the fender inner the fender inner panel.
panel to the fender panel. Remove the inner panel (2) Install the retainers to attach the shield to the
from the fender outer panel (Fig. 23). fender inner panel and to the frame rail.
(3) Install the frame rail-to-shield screws and
INSTALLATION pushnuts.
(1) Position the fender inner panel liner on the
RIGHT CLIP RETAINER CLIP RETAINER
outer panel. Install the screws. Tighten them to 23 FRONT LEFT
N-m (200 in. lbs.) torque. FENDER FRAME FRONT
(2) Position the fender with inner panel on the cab/ FENDER
body.
(3) Install the screws t h a t attach the fender to the
radiator support panel. Tighten the screws to 23 N-m
(4) Install the screws t h a t attaches the fender and
inner panel to the dash panel. Tighten the screws to
23 N-m (200 in. lbs.) torque. SPLASH LEFT
(5) Install the screw and n u t t h a t attaches the top SHIELD FRONT
FENDER
of the fender to the cowl. Tighten the screw and nut FRAME SPLASH
to 23 N-m (200 in. lbs.) torque. RAIL SHIELD
(6) If removed, install the battery and tray. RIGHT SIDE
SCREW J9123-327
Tighten the battery tray bolts to 11 N-m (95 in. lbs.)
torque. Tighten the support bracket-to-fender inner Fig. 24 Splash Shields—Front Fender
panel bolt to 23 N-m (200 in. lbs.) torque.
(7) Install the grille extension panel and the grille.
BODY MOULDINGS, NAMEPLATES AND DECALS
(8) Remove the support and close the hood. BODY SIDE (VINYL) MOULDING
REPLACEMENT
FENDER
PANEL Vinyl mouldings are attached to outer panels by
tape.
Wheel lip mouldings are attached by screws and
tape.
Ensure t h a t the method of moulding attachment is
known before attempting removal (Fig. 25).
REMOVAL—MOULDINGS ATTACHED WITH ADHESIVE TAPE

GRILLE (1) Soften the body side moulding tape adhesive
EXTENSION (Fig. 25 with a heat gun.
PANEL (2) Lift one edge of the moulding with a putty
knife and peel the moulding and tape from the panel.
Apply heat to any location where the moulding tape
remains adhered to a panel.
J9123-565
(3) Remove the residual tape adhesive from the
Fig. 23 Front Fender Outer Panel panel with 3M All Purpose Cleaner or an equivalent.
SPLASH SHIELDS—FRONT FENDER INSTALLATION — MOULDINGS ATTACHED WITH ADHESIVE

TAPE
REMOVAL (1) Clean the panel surface with a commercial wax
(1) Remove the plastic clip t h a t attach the splash and silicone removal solution. Wipe the surface with
shield to the frame rail. a clean cloth and allow it to dry.
(2) Remove the pushnuts and the screws t h a t at (2) To ensure proper vertical alignment, use mask
tach the splash shield to the frame rail. ing tape as an alignment reference.
(3) Remove the push retainers t h a t attach the (3) Remove the backing from the double-sided
splash shield to t h e fender inner panel. tape. Align the moulding with the alignment refer
(4) Remove the splash shield from the frame rail ence tape. Position it on the panel.
and the fender inner panel. (4) Verify t h a t the moulding is properly aligned.
Remove the alignment reference tape.
23-10 BODY COMPONENTS
(5) Press the moulding onto the panel with a roller INSTALLATION
(or use hand pressure) to ensure complete adhesion. (1) Clean the painted panel surface with a com
FRONT mercial wax and silicone removal solution. Wipe the
QUARTER PANEL
MOLDING FENDER FRONT surface with a clean cloth and allow it to dry.
REAR FENDER (2) Use masking tape to indicate the upper posi
MOLDING FRONT
MOLDING tion for the nameplate on the panel (Figs. 26 and 27).
(3) Remove the backing from the nameplate. Align
the nameplate with the alignment reference tape. Po
sition the nameplate on the panel.
(4) Verify t h a t the nameplate is properly aligned.
Remove the alignment reference tape.
CARGO DOOR FRONT
REAR W $E (5) Press the nameplate onto the panel with a
^WHEEWOUSE
SIDE OPENING SIDE
~SST MSSNG ^|S
OPENING roller (or use hand pressure).
MOLDING
PANEL MOLDING PANEL
REAR MOLDING
MOLDING ADHESIVE-BACKED
MOLDING
QUARTER QUARTER
PANEL PANEL
MOLDING MOLDING
NUT
10.5 MMlyx
CHARACTER \ DOOR
UNE OPENING
EXTENDED CAB STANDARD CAB J9123-603
Fig. 25 Ram Truck Body Side Mouldings

REMOVAL—WHEEL LIP MOULDINGS
(1) Remove the screws from the moulding (Fig. 25). B-PILLAR
NAMEPLATE J9123-356
(2) Soften the wheel lip moulding tape adhesive
with a heat gun. Fig. 26 Ram Truck Nameplates
(3) Peel the moulding and tape from the wheel-
house. Apply additional heat to any location where
the moulding adhesive remains.
INSTALLATION—WHEEL LIP MOULDINGS

(1) Remove the backing from the double sided SIDE
WINDOW
tape.
(2) Align the moulding with the screws holes in
the fender panel. Install the screws into the fender
panel. Tighten the screws to 3 N*m (24 in. lbs.) FRONT
torque. FENDER
NAMEPLATE
(3) Press the moulding onto the wheelhouse with a
roller (or use hand pressure).
B-PILLAR
NAMEPLATES NAMEPLATE DOOR OPENING J9123-357
REMOVAL Fig. 27 Ramcharger Nameplates

(1) Soften the nameplate/badge tape adhesive TAILGATE AND CARGO BOM DECALS
(Figs. 26 and 27) with a heat gun. The raised letters on the tailgate are covered with
(2) Lift one edge of the nameplate with a putty a durable, weather-resistant decal. The cargo box
knife (or a similar thin-blade tool). Peel the mould side panel decal also is a durable, weather-resistant
ing and tape from the panel. Apply additional heat to decal.
any location where the tape remains.
(3) Remove the residual tape adhesive from the REMOVAL
panel with 3M All Purpose Cleaner or an equivalent. (1) Soften the decal adhesive with a heat gun.
(2) Lift one edge of the decal with a putty knife.
Slowly peel the decal from the panel.
(3) Apply additional heat to any location where the

decal remains adhered to the panel.
(4) Remove the extra adhesive from the panel with
a cloth saturated with an adhesive remover.
INSTALLATION
(1) Clean the panel surface with a commercial wax
and silicone removal solution. Wipe the surface with
a clean cloth.
(2) Remove the backing from the decal. Position it
on the panel.
(3) Verify t h a t the decal is properly aligned.
(4) Press the decal onto the panel with a roller to
ensure complete adhesion.
RETAINER APPLIQUE J9123-538
Fig. 29 Tailgate Applique
Fig. 28 Tailgate & Cargo Box Decals

TMILGA TE/HA TCHGA TE APPLIQUE
REMOVAL
(1) Open the tailgate/hatchgate.
(2) If applicable, remove the hatchgate trim panel.
(3) Remove the applique screws (Figs. 29 and 30).
(4) Pry the applique from the tailgate/hatchgate to
separate the corner studs from the retainers.
(5) Remove the applique from the tailgate/hatch Fig. 30 Hatchgate Applique
gate. INSTALLATION
(1) Position the roof moulding with retainers at
INSTALLATION
the roof drip rail.
(1) Position the applique on the tailgate/hatchgate (2) Force the moulding onto the drip rail until it is
with the corner studs mated with the retainers.
seated against the roof edge.
(2) Install the applique screws in the tailgate/
(3) Install the moulding end caps.
hatchgate (Figs. 29 and 30). Tighten the screws to 2
CAB/BODY AND CARGO BOX STRIPES
(3) If applicable, install the hatchgate trim panel.
(4) Close the tailgate/hatchgate. GENERAL INFORMATION
The cab/body and cargo box stripes are durable,
ROOF MOULDING
weather-resistant tape stripes with pressure-sensitive
REMOVAL backing (Figs. 32 and 33). The tape stripe is pro
tected by a carrier until installed on a body panel.
(1) Remove the moulding end caps.
(2) Pry the moulding from the drip rail. Remove The carrier also is an installation alignment aid.
the moulding from the roof edge.
(9) Push air pockets from under tape stripe to the
perimeter of the panel from the center of the tape
stripe out.
(10) Remove air bubbles from under tape stripe us
ing a body putty squeegee (Fig 34).
C A U T I O N : Do nut cut Into painted surface of body

when trimming tape stripe to size.
(11) Trim tape stripe to size using a razor knife.

Leave at least 13 mm (0.5 in.) for edges of doors and
openings.
CAUTION; D o not overheat tape stripe when per

forming step 12.
Fig. 31 Roof Moulding (12) Apply heat to tape stripe to evaporate residual
REMOVAL moisture from edges of tape stripe. This will also al
(1) Remove exterior trim as necessary to clear cap low tape stripe to be stretched into concave surfaces.
tured edges of the tape stripe being removed (13) Edge t u r n tape stripe around doors or fenders
(2) Remove tape stripe using a suitable heat gun (Fig 35).
or lamp. (14) Install exterior trim if necessary. Small air or
This will soften the adhesive backing. water bubbles under tape stripe can be pierced with
(3) Clean adhesive residue from body finish using a pin and smoothed out.
a suitable adhesive remover.
TAILGATE CARGO BOX CAB AND FENDER
TAPE SIDE TAPE DOOR TAPE TAPE
INSTALLATION STRIPE STRIPE STRIPE STRIPE
INSTALLATION EQUIPMENT
• Bucket filled with a mild dish soap solution.
• Lint free applicator cloth or sponge.
• Body putty applicator squeegee.
• Heat gun or sun lamp.
• Razor knife.
The painted surface of the body panel to be covered
by a tape stripe must be smooth and completely
cured before the stripe can be applied. If the painted
surface is not smooth, wet sand with 600 grit wet/dry
sand paper until surface is smooth.
Ripples and feather edges will read through the J9123-532
stripe if surface is not properly prepared.
(1) With backing still in place, position stripe Fig. 32 Cab & Cargo Box Upper Stripes
across panel to receive the stripe. Apply masking at FUEL FILLER DOOR AND NOZZLE/TUBES
top of stripe to hold it in position.
(2) Mark outside edge of panel on stripe with DOOR
grease pencil.
(3) Trim stripe to within 17 mm (0.750 in.) of out REMOVAL
line marks. (1) Open the fuel filler door.
(4) Spread stripe across a smooth flat work surface, (2) Remove the screws from the cargo box side
stripe side down. outer panel.
(5) Peel paper backing away from stripe exposing (3) Remove the door from the panel.
adhesive backing of stripe.
(6) Apply soap solution liberally to adhesive back INSTALLATION
ing of stripe. (1) Position the fuel filler door on the cargo box
(7) Apply soap solution to body panel surface. side outer panel.
(8) Place stripe into position on body panel. (2) Install the door screws in the cargo box side
Smooth out wrinkles by pulling lightly on edges of outer panel. Tighten the screws to 4 Nnn (35 in. lbs.)
tape stripe until it lays flat on panel surface. torque.
TAPE CARGO BOX BUMPER SIDE OUTER

STRIPE LOWER PANEL
AM. REAR, SIDE P A N E L
— • SECONDARY
COLOR
SCREW
WHEELHOUSE
LIP
DOOR
PANEL FUEL
FRONT / FILLER
FENDER J9123-555 J9123-342
DOOR
Fig. 33 Cab & Cargo Box Stripes With Two-Tom Fig. 36 Fuel Filler Door
Paint NOZZLE/TUBES
TAPE STRIPE
REMOVAL
(1) Remove the fuel filler door (Fig. 36).
(2) Remove the cap from the nozzle (Fig. 37).
(3) Loosen the clamps and separate the hose from
the tube.
(4) Remove the screws t h a t attach the housing and
nozzle to the cargo box panel.
The fuel cap tether is a l s o a t t a c h e d to the
c a r g o box panel w i t h o n e of t h e s c r e w s ,
(5) Remove the housing and nozzle/tube from the
cargo box panel.
INSTALLATION
(1) Position the fuel filler housing and nozzle/tube,
and the fuel cap tether at t h e opening in the cargo
box panel.
(2) Install the housing, nozzle and tether screws in
the panel. Tighten the screws to 2 N»m (20 in. lbs.)
torque.
(3) Attach the hose to the tube with the clamp.
Tighten the fuel hose clamp screw to 2 N*m (20 in.
lbs.) torque. Tighten the vent hose clamp screw to 1
N m (12 in. lbs.) torque.
#
(4) Install the cap on the nozzle (Fig. 37),

(5) Install the fuel filler door.
OUTSIDE MIRRORS
STANDARD (NON-REMOTE) MANUAL MIRROR
REMOVAL
FLANGE J9123-593
(1) Remove the screws from the mirror base.
Fig. 35 Tape Stripe installation On Door Flange (2) Remove the mirror and base from the door out
side panel.
(3) Close the fuel filler door.
(3) If necessary, separate the mirror from the base.
23 - 14 BODY COMPONENTS
HOUSING U-NUT CARGO BOX (2) Position the mirror base on the door outside panel
with the studs inserted in the mirror base holes.
(3) Install the mirror base nuts. Tighten the nuts
(4) Position the cover over the mirror base.
(5) Install the cover screw. Tighten the screw to 2
LOW PROFILE OUTSIDE MIRROR
REMOVAL
(1) Remove the bolts t h a t attach the support
braces to the door outer panel.
(2) Remove the mirror and braces from the door
FWD HOSE CLAMP J9123-551 outer panel.
Fig. 37 Fuel Filler Housing & Nozzle/Tubes INSTALLATION
INSTALLATION (1) Position the mirror and braces on the door

outer panel with the brace holes aligned with the n u t
(1) If necessary, clean the door panel-mirror base
inserts.
contact surface.
(2) Install the mirror brace bolts in the nut inserts.
(2) If separated, attach the mirror to the base.
Tighten the bolts to 11 N-m (95 in. lbs.) torque.
Tighten the stud-nut to 11 N-m (95 in. lbs.) torque.
(3) Position the mirror base on the door outside panel
with its screw holes aligned with the panel holes.
(4) Install the mirror base screws. Tighten the
screws to 4 N-m (35 in. lbs.) torque.
LOCKWASHER OUTSIDE REINFORCEMENT
WASHER
PLATE Fig. 39 Low Profile Mirror

61/2 x 9 IN. MIRROR
MANUAL MIRROR MANUAL OR POWER CAB
J9123-332
SERVICE INFORMATION
Fig. 38 Standard&6X9 Wide-View Mirrors The cab is attached to the vehicle frame structure
6X9 WIDE-VIEW MIRROR with bolts (Figs. 40 and 41). If necessary, the cab can
be removed for repair or service access. Refer to the
REMOVAL procedure within Group 13—Frame.
(1) Remove the mirror cover screw. Separate the
mirror cover from the base. TAILGATE
(2) Remove the mirror base nuts from the rein
REMOVAL
forcement plate studs.
(1) Open the tailgate.
(3) Remove the mirror and the base from the door
(2) Separate the tailgate check arms from the pins.
outside panel.
Separate the check arms from the tailgate (Fig. 42).
INSTALLATION • Single wheel vehicles: On the right side, remove
(1) If necessary, clean the door panel-mirror base the tailgate hinge-half from the slot in cargo box
contact surface.
BOLT
CAB FRONT D O W N HOLD CAB REAR D O W N HOLD
J9113-18
Fig. 41 Cab Holddowns—Typical
Fig. 40 Cab/Body Front-End Holddowns • Single rear wheel: On the left side, insert the tail
gate hinge-half into the cargo box hinge-half. Move
hinge-half. On the left side, remove the tailgate the tailgate to the left. On the right side, insert the
hinge-half from the cargo box hinge-half by moving tailgate hinge-half into the slot in cargo box hinge-
the tailgate to the right. half.
• Dual wheel vehicles: On the right side, remove the • Dual rear wheel: On the left side, connect the tail
rivet. Remove the tailgate hinge-half from the slot in gate clearance/ID lamp wire harness connectors. In
cargo box hinge-half. On the left side, pull the tail sert the wire harness in the cargo box. Insert the
gate clearance/ID lamp wire harness outward from tailgate hinge-half into the cargo box hinge-half.
the cargo box and disconnect the connectors (Fig. 43). Move the tailgate to the left. On the right side, in
(3) Remove the tailgate from the cargo box. stall the rivet in the tailgate hinge-halves.
(2) Install the check arms onto the pins.
INSTALLATION
Note that the t a i l g a t e e n d of the check arms
(1) Position the tailgate at the cargo box.
are identified as to w h i c h side faces the tailgate.
Fig. 42 Tailgate Removal/Installation

(3) Test the handle and latches for correct opera (4) Remove the bolts, the latch and the rod from
tion. If necessary, adjust the strikers to eliminate each end of the tailgate.
tailgate looseness and noise. (5) Separate the clip and rod from each latch.
(4) Close the tailgate.
TAILGATE ASSEMBLY
CONNECTOR TO LT TAIL. STOP, (1) Lubricate the latches, the handle and lock, and
TURN & B / U P
LAMPS
the rod ends before assembly.
(2) Install the rod and clip on each latch.
(3) At each end of the tailgate, insert the rod into
the opening. Position the latch on the end of the tail
gate. Install the bolts. Tighten them to 23 N-m (200
in. lbs) torque.
(4) Connect the lock latch rods to the lock arms.
Retain them with the clips.
HOUSING
(5) Insert the handle and lock in the tailgate open
ing.
CLEARANCE
(6) Install the lock and handle screws in the tail
AND ID
LAMPS gate inner panel. Tighten the screws to 11 N-m (95
J9123-570 in. lbs.) torque.
(7) Test the handle and latches for correct opera
Fig. 43 Tailgate Clearance/ID Lamps & Wire Harness tion. Adjust the strikers to eliminate tailgate loose
STRIKER ADJUSTMENT ness and noise.
(1) Remove the striker from the cargo box inner
panel. HATCHGATE AND COMPONENTS
(2) As necessary, add or remove spacers. SUPPORT ROD
(3) Install the striker in the cargo box inner panel.
Tighten the striker to 23 N-m (200 in. lbs.) torque. REMOVAL
TAILGATE DISASSEMBLY W A R N I N G : D O NOT D I S C O N N E C T A S U P P O R T

(1) Remove the screws that attach the lock and R O D WITH T H E H A T C H G A T E C L O S E D . T H E S U P
latch release handle to the tailgate inside panel. P O R T R O D P I S T O N S A R E O P E R A T E D B Y HIGH
(2) Lower the lock and handle. Remove from the P R E S S U R E G A S . THIS C O U L D C A U S E D A M A G E
tailgate opening. A N D / O R P E R S O N A L INJURY IF THEY A R E R E
(3) Disconnect the clips t h a t attach the lock latch M O V E D WHILE T H E P I S T O N S A R E C O M P R E S S E D .
rods to the lock arms.
Fig. 44 Tailgate Disassembly/Assembly

(1) Open and support the hatchgate. AUXILIARY RETAINER

(2) Remove the support rod upper bolt from the
rear pillar (Fig. 45).
(3) Remove the support rod lower screw from the
hatchgate (Fig. 46).
(4) Remove the support rod from the hatchgate.
INSTALLATION
(1) Position the upper end of the support rod at the
roof panel. Install the n u t and bolt. Tighten them to
23 N ' m (200 in. lbs.) torque.
(2) Position the lower end of the support rod at the
hatchgate. Install the n u t and screw. Tighten them
(3) Test the support rod and hatchgate for correct
operation.
ROOF PANEL REAR
SCREW NUT HATCHGATE J9123-387
Fig. 46 Hatchgate Support Rod & Hinge Removal/

Installation
HATCHGATE
REMOVAL
(1) Open and support the hatchgate.
(2) Remove the hinge roof panel screws.
WARNING: D O NOT DISCONNECT THE SUPPORT

R O D S WITH T H E H A T C H G A T E C L O S E D . T H E S U P
P O R T R O D P I S T O N S A R E O P E R A T E D B Y HIGH
P R E S S U R E G A S . THIS C O U L D C A U S E D A M A G E
A N D / O R P E R S O N A L I N J U R Y IF T H E Y A R E R E
MOVED WHILE THE PISTONS A R E C O M P R E S S E D .
(3) Remove support rod upper bolts from the rear

Fig. 45 Hatchgate pillar.
(4) Remove hatchgate and support rods from the
HATCHGATE HINGE
vehicle.
REMOVAL
INSTALLATION
(1) Open and support the hatchgate.
(2) Remove the hinge roof panel screws. (1) Position and support the hatchgate in the vehi
(3) Remove the hinge hatchgate screws. cle opening.
(4) Remove the hinge from the hatchgate and roof (2) Align the support rod bolt holes. Install the
panel. nuts and bolts. Tighten the bolts to 23 N*m (200 in.
lbs.) torque.
INSTALLATION (3) Install the hinge roof panel screws. Tighten
(1) Position the hinge on the hatchgate. screws to 23 N«m (200 in. lbs.) torque.
(2) Install the hinge hatchgate screws. Tighten the (4) Test the hatchgate and hinge operation. If nec
screws to 23 N*m (200 in. lbs.) torque. essary, add spacer(s) for hinge adjustment.
(3) Position the hinge on the roof panel.
(4) Install the hinge roof panel screws. Tighten the LATCH STRIKER REMOVAL/INSTALLATION
screws to 23 N»m (200 in. lbs.) torque. (1) Raise the hatchgate.
(5) Test the hatchgate and hinge operation. If nec
essary, add spacer(s) for hinge adjustment.
(2) Remove the latch striker from the inner quar (8) Remove the retainer and the lock cylinder from
ter panel (Fig. 45) the hatchgate.
(3) Install the latch striker in the inner quarter
INSTALLATION
panel. Tighten striker to 23 N»m (200 in. lbs.) torque.
(4) Close the hatchgate. (1) Position the lock cylinder in the hatchgate
opening. Install the retainer.
HATCHGATE OPENING WEATHERSTRIP SEAL (2) Position the latch in the inner panel opening.
Mate it with the lock cylinder. Install the screws in
REMOVAL #
the inner panel. Tighten the screws to 4 N m (35 in.
(1) Separate the weatherstrip seal at the lower cen-
lbs.) torque.
terline of the rear cross sill. Remove the connector.
(3) Connect the hatchgate ajar switch and ground
(2) Pull the seal away from the flange around the
wire to the latch (Fig. 49).
perimeter
(4) Insert both lock tubes in the hatchgate. Engage
of the hatchgate opening.
them with the latch.
(3) Clean the flange as necessary.
(5) Install the lock tube screws at each side of the
INSTALLATION hatchgate. Tighten the screws to 4 N*m (35 in. lbs.)
(1) Position the left end of the seal at the lower torque.
centerline rear cross sill. Install it in a clockwise di (6) Position the latch cover on the hatchgate inner
rection. panel. Install the screws. Tighten the screws to 1
(2) Seat the installed part of the seal with a roller. N*m (12 in. lbs.) torque.
Move the roller from the left-bottom end of the seal (7) Position the trim panel on the hatchgate inner
to the top-left half of the seal. panel. Align the retainers with the inner panel holes.
(3) Move around the edge of the flange and seat Force the trim panel inward to engage the retainers
the seal. with the holes.
(4) Center and butt the seal ends together at th (8) Remove the support and close the hatchgate.
centerline. (9) Test the latch, lock tubes and lock for correct
(5) Seat the remaining part of the seal with a operation.
roller. Move the roller from the top-left half of the
seal to the right-bottom end of the seal.
(6) Install the connector in the butted seal ends.
TRIM PANEL
REMOVAL
(1) Use a trim panel removal tool to detach the
panel from the hatchgate (Fig. 47).
(2) Remove the trim panel from the hatchgate.
INSTALLATION
(1) Position the trim panel on the hatchgate.
(2) Align the trim panel retainers with the holes
in the hatchgate inner panel. Force the trim panel
inward to seat the retainers in the holes.
LATCH, LOCK TUBES AND LOCK CYLINDER
REMOVAL TRIM PANEL RB514

(1) Open and support the hatchgate. Fig. 47 Hatchgate Trim Panel Removal/Installation
(2) Use a trim panel removal tool to detach the re
tainers from the inner panel. Remove the trim panel SPORT BAR
from the hatchgate. REMOWAL
(3) Remove the screws and the latch cover (Fig. 48). (1) Remove the bolts t h a t attach the sport bar base
(4) Remove the screws at each side of the hatch- flanges to the cargo box floor panel and wheelhouses.
gate. Disengage both lock tubes from the latch. (2) Lift the sport bar upward. Remove it from the
(5) Remove both lock tubes from the hatchgate. vehicle.
(6) Disconnect the hatchgate ajar switch and (3) Remove and retain the four base flange gaskets.
ground wire from the latch (Fig. 49). (4) If necessary, disassemble the sport bar tubes
(7) Remove the screws and the latch from the and struts.
hatchgate inner panel.
SCREW REINFORCEMENT
Fig. 50 Sport Bar

CARGO CARGO BOX
Fig. 49 Hatchgate Ajar Switch & Ground Wire

INSTALLATION SIDE PANEL BRACES-DUAL REAR WHEELS
(1) If disassembled, assemble the sport bar tubes
and struts. REMOVAL
(2) Position the base plate gaskets on the cargo (1) Remove the brace side panel screw and U-nut.
box floor panel and at each wheelhouse. (2) Remove the floor cross sill screw.
(3) Position the sport bar base flanges on the gaskets. (3) Remove the brace from the cargo box.
(4) Apply sealant to the underside of each base
INSTALLATION
flange bolt head. Install and tighten the bolts to 41
(1) Position the brace at the cargo box floor cross sill.
(2) Install the floor cross sill screw finger-tight.
CAR00 BOX (3) Position the brace and U-nut at the cargo box
side panel.
SERVICE INFORMATION
(4) Install the brace side panel screw. Tighten the
The cargo box is attached to the vehicle rear frame #
screw to 11 N m (95 in. lbs.) torque.
structure with bolts (Fig. 51). If necessary, the box can
(5) Tighten the floor cross sill screw to 11 N»m (95
be removed for repair, service access, or replacement.
in. lbs.) torque.
Refer to the procedure within Group 13—Frame.
Fig. 52 Cargo Box Side Panel Braces

ROOF VENT—RAMCHARGER
WENT COWER
REMOVAL
(1) Open the vent cover.
(2) Remove the upper rivet head from the cover/
handle with a drill and bit.
(3) Remove the screws and the vent cover hinge. Fig. 53 Roof Vent
(4) Remove the vent cover from the seal and frame.
(2) Separate the seal between the frame and the
INSTALLATION roof panel.
(1) Position the vent cover on the seal and the frame. (3) Remove the vent cover and frame from the roof
(2) Install the hinge on the cover with the screws. panel as a unit.
Tighten the screws to 11 N-m (95 in. lbs.) torque.
(3) Install the handle on the cover with a rivet INSTALLATION
from the replacement handle package. (1) Clean frame and roof panel seal contact surfaces.
(2) Position the seal on the frame.
WENT COWER SEAL
(3) Position frame and seal on the roof panel.
REMOVAL (4) Position the inner trim ring on the headliner. In
(1) Open the vent cover. stall and tighten the screws to 11 N-m (95 in. lbs.)
(2) Remove the screws and the vent cover hinge. torque.
(3) Remove the vent cover from the seal and frame. (5) Water test the roof vent frame and seal area.
(4) Remove the seal from the frame.
HANDLE
INSTALLATION REMOVAL
(1) Clean the seal contact area on the frame. (1) Open the vent cover
(2) Apply a weatherstrip cement to the seal. Install (2) Remove the handle rivet head with a drill and bit.
it on the frame. (3) Remove the handle frame rivet head with a
(3) Position the vent cover on the seal and the frame. drill and a bit.
(4) Install the hinge on the cover with the screws. (4) Remove the handle from the frame.
Tighten the screws to 11 N-m (95 in. lbs.) torque.
(5) Water test the roof vent. INSTALLATION
FRAME (1) Position the handle on the cover.

(2) Install the handle cover rivet (the rivet is sup
REMOVAL plied with the replacement handle).
(1) Remove the screws and the inner trim ring (3) Install the handle frame rivet (the rivet is sup
from the headliner and roof panel. plied with the replacement handle).
DOORS
INDEX
page page
Complete Door . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Hinge Replacement , 21
Door Adjustment . 21 Key Lock Cylinder . . . . . . . . . . . . . . . . . . . . . . . . 2 5
Door Inside Handle . 26 Power Door Lock Motor 26
Door Latch 27 Service Information 21
Door Latch Striker 25 Vent Window and Channel 23
Door Outside Handle 26 Window Glass and Door Weatherstrip Seals . . . . 27
Door Trim Panel/Waterdam 21 Window Glass/Channels/Regulators . . . . . . . . . . . 2 3
SERVICE INFORMATION (7) Remove t h e floor jack from t h e door.

(8) If necessary, adjust t h e door. Refer to t h e ad
The front door service procedures include:
• Complete door removal/installation justment procedure(s).
f Component removal/installation
• Component replacement DOOR ADJUSTMENT
• Adjustments The door position is adjusted at t h e hinge locations
Care should b e taken to prevent undercoating at either the cowl or t h e door, as applicable. Slightly
material from contacting the door internal com enlarged bolt holes are located in t h e cowl for fore/aft
ponents. A major c a u s e of door c o m p o n e n t fail and up/down adjustments. Slightly enlarged bolt
ure is contamination b y rust prevention holes are located in t h e door for in/out adjustments.
material. It is important to adjust a door properly. If n o t
the door weatherstrip seal could b e damaged. A
BLIND RIVET REMOVAL
simple test of weatherstrip seal contact can be done
The rivets used to attach t h e various door compo
with a strip of newspaper. Place t h e paper adjacent
nents should be removed according to t h e following
to the door pillar. Close the door. Pull the paper out
information:
ward. A slight drag should be detected. If the paper
• Remove the center of the rivet with a drift punch
is difficult to remove, t h e door should be re-adjusted.
• Drill out t h e rivet with a 6 mm (1/4-in) diameter
drill bit. Prior to door adjustment, t h e door latch must be re
When installed, t h e components should be attached moved. This will allow t h e door to close freely and be
to the door with 1/4-20 x 1/2 bolts and nuts. Tighten properly aligned without interference.
the nuts to 10 N«m (90 in. lbs.) torque. (1) Support t h e door with a padded floor jack.
(2) Loosen t h e hinge bolts. Move the door to the
HINGE REPLACEMENT correct position.
(3) Tighten t h e hinge bolts to 41 N«m (30 ft. lbs.)
REMOVAL torque.
(1) Use a wax pencil to mark the outline of t h e (4) Remove t h e floor jack from t h e door.
hinge-halves on the door and the cowl for installation
alignment reference. DOOR TRIM PANEL/WATERDAM
(2) Support t h e door with a padded floor jack.
(3) Remove the hinge screws. Remove t h e hinge REMOVAL
from t h e door and the cowl. (1) If equipped, remove the:
• Power switch housing
INSTALLATION • Window regulator handle (Figs. 1 and 2)
(1) Clean t h e hinge. • Inside latch release handle
(2) Color coat the hinge to match t h e body color. • Inside release handle bezel
(3) Lubricate t h e hinge with engine oil. • Trim panel lower screws
(4) Position the hinge on the door. Install t h e (2) Use a trim removal tool and carefully pry t h e
hinge screws finger-tight. trim panel away from t h e door inner panel. Remove
(5) Align t h e hinge with the installation reference the trim panel from t h e door.
outlines. (3 Separate t h e waterdam from t h e door inner
(6) Tighten t h e hinge screws to 41 N»m (30 ft. lbs.) panel (Fig. 3). Remove t h e waterdam from t h e door
torque. inner panel.
INSTALLATION U-NUT
(1) Apply an appropriate adhesive/sealant to the
waterdam.
(2) Position the waterdam on the door inner panel.
Press it inward to attach it to the inner panel.
(3) Position the trim panel on the door inner panel.
Press inward around the edge of the panel to attach
the retainers to the inner panel holes.
(4) Install the trim panel lower screws. Tighten
the screws to 4 N»m (35 in. lbs.) torque. Install the
cover plugs. SPACER
(5) Install the:
• Inside release handle bezel
• Inside latch release handle
• Window glass regulator handle
• Power switch housing INNER
When the w i n d o w is closed the w i n d o w regu LATCH
RELEASE
lator handle should b e installed in the horizontal HANDLE
position with k n o b forward. WINDOW
TRIM REGULATOR
PANEL RETAINER SCREW PLUG HANDLE J9123-382
GLASS
Fig. 2 Door Trim Panel Removal/Installation

AIR
EXHAUST
DOOR LOUVER DOOR
(UPPER) OUTER
PANEL
WINDOW
REGULATOR'
HANDLE
WATER
DAM
TRIM
PANEL J9123-404
BEZEL
Fig. 1 Window Glass Regulator Handle
COMPLETE DOOR
f
REMOVAL
(1) For doors equipped with a power window, AIR
EXHAUST
power door lock, and radio speaker, remove the door LOUVER _ DOOR
trim panel and waterdam. If necessary, refer to the RIVET (LOWER) ^ INNER
PANEL J9123-399
removal procedure.
(2) Disconnect the component wire harness from
the main wire harness. Remove the main wire har Fig. 3 Door Waterdam
ness retainer from the door panel. Remove the main (2) Before installing a replacement door, as appli
wire harness from the door. cable, transfer:
(3) Support the door with a padded floor jack. • Window glass and regulator
(4) Remove the door hinge bolts from the cowl. Re • Electric motors
move the floor jack and the door from the vehicle. • Key lock cylinder
(5) If equipped, retain the door hinge shims for • Latch release handles
proper installation. • Trim panel
• Remaining components to the replacement door.
INSTALLATION
If necessary, refer to the applicable removal/instal
(1) If a replacement front door is being installed,
lation procedures.
coat the door interior with anti-corrosion wax. Also,
(3) Lubricate the hinges with engine oil.
seal the door hem flange with sealant.
(4) Position the door in the door opening.

(5) Support the door with a padded floor jack.
(6) Align the door hinge holes with the bolt holes
in the cowl. Install (but do not tighten) the hinge
screws.
(7) Adjust the door as necessary. If necessary, refer
to the adjustment procedure. Tighten the hinge
screws to 35 N»m (26 ft. lbs.) torque.
(8) Adjust the latch striker and the latch as neces
sary.
(9) Remove the floor jack from the door.
(10) If applicable, insert the main wire harness in
the door. Install the retainer in the door panel. Con
nect the necessary component connectors to the main
wire harness connectors.
(11) If removed, install the waterdam and the trim Fig. 4 Vent Window & Glass Channels
panel.
VENT WINDOW GLASS
VENT WINDOW AND CHANNEL
REMOVAL
REMOVAL (1) Remove the vent window (Fig. 4). If necessary,
(1) Remove the door trim panel and the waterdam. refer to the removal procedure.
(2) Lower the window glass to the full open posi (2) Remove the screw from the glass lower pivot.
tion. Remove the inner beltline weatherstrip seal. (3) Remove the glass upper pivot rivet. Remove the
(3) Raise window glass 20 - 25 cm (8 - 10 in). glass from the vent window frame.
(4) Remove window glass front channel lower
bracket screw and J-nut (Fig. 4). INSTALLATION
(5) Remove vent window frame front screw located (1) Lubricate the glass lower pivot with a white lu
under door weatherstrip. bricant spray, or an equivalent.
(6) Tilt vent window rearward. Lift it out of the (2) Install the glass lower pivot in the glass frame.
door opening. (3) Install the glass upper pivot rivet.
(4) Install the vent window.
INSTALLATION
(1) Use a replacement plastic n u t spacer and J-nut WINDOW GLASS/CHANNELS/REGULATORS
when installing the vent window.
(2) Tilt the vent window rearward. Position it in GLASS RUN CHANNEL
the door opening. The window glass r u n channel is press-fitted into
(3) Install the window frame plastic n u t spacer and the door top channel guide and the door rear/side
upper screw finger-tight. channel guide.
(4) Install the window glass front channel lower
REMOVAL
bracket screw and J-nut finger-tight.
(1) Remove the door trim panel and the waterdam.
(5) Mate the glass rear channel with the vent win
(2) Lower the window glass. Pry the run channel
dow glass channel.
from the door top and side channel guide.
(6) Install the beltline weatherstrip seal.
(3) Raise the window glass.
(7) Raise or lower the vent window to provide a 1.6
(4) Use the door inner panel opening for access.
mm (0.06 in) fore-aft glass freeplay. Then, raise the
Pry the r u n channel from lower part of the door side
window to the closed position. Tighten the upper
channel guide.
screw to 2 N»m (18 in. lbs.) torque.
(5) Remove run channel from window opening.
(8) Lower the window glass completely. Position
the front channel tightly against the glass. Tighten INSTALLATION
#
the front channel lower bracket screw to 11 N m (95 (1) Lower window glass. Position run channel in
in. lbs.) torque. the window opening.
(9) Test the vent window operation. Adjust as nec (2) Force the r u n channel into door top channel
essary. guide and the upper part of the door side channel
(10) Install the door waterdam and the trim panel. guide.
(3) Raise window glass.
(4) Use the door inner panel opening for access. a drift punch (Fig. 6). Drill them out with a 6 mm
Position run channel into the lower part of door side (1/4-in) diameter drill bit.
channel guide while lowering the window glass. (6) Remove the regulator from the door.
(5) Test the window glass operation and correct as
necessary. INSTALLATION
(1) Position the regulator in the door (Fig. 6). Re
(6) Install the door waterdam and the trim panel.
tain it on the inner door panel with 1/4-20 x 1/2 bolts
WINDOW GLASS and nuts. Tighten the nuts to 10 N*m (90 in. lbs.)
torque.
REMOVAL (2) Raise the glass. Slide it rearward and engage
Remove door trim panel and the waterdam. the channel with the regulator arm roller.
(2) Remove the beltline weatherstrip seals (Fig. 5 ) . (3) Install the vent window.
(3) Lower the glass to the full open position. Re (4) Test the window glass and regulator operation.
move the vent window. Correct as necessary.
(4) Slide the glass forward until the channel sepa (5) Install the door waterdam and the trim panel.
rates from the window regulator arm roller.
D O O R OUTER GUIDE DOOR REAR FRONT
(5) Remove the glass and channel from the door. PANEL INNER RIVET RIVET
INSTALLATION PANEL HOLES HOLES
(1) Lubricate the glass channel.

(2) Position the glass and channel in the door.
RIVET
(3) Slide the glafes rearward and engage the chan
nel with the regulator arm roller.
(4) Install the vent window. If necessary, refer to
the installation procedure. Raise the glass to the full
closed position.
(5) Install the beltline weatherstrip seals.
DOOR
INNER MANUAL
WEATHERSTRIP
PANEL REGULATOR J9123-395
Fig. 6 Manual Window Glass Regulator

GLASS
POWER WINDOW GLASS REGULATOR
DOOR
OUTER REMOVAL
PANEL
(1) Remove the trim panel and the waterdam.
(2) Open the window glass.
REGULATOR
(MANUAL)
(3) Remove the vent window.
(4) Slide the glass forward until the channel sepa
rates from the window regulator arm roller.
(5) Lower the glass and channel to the bottom of
J9123-398 the door.
(6) Remove the center of the regulator rivets (Fig.
Fig. 5 Window Glass, Regulator, Weatherstrip Seals 7) with a drift punch. Drill them out with a 6 mm
& Channel (1/4-in) diameter drill bit.
MANUAL WINDOW GLASS REGULATOR (7) Disconnect the regulator motor wire harness
connector.
REMOVAL (8) Remove the power regulator from the door.
(2) Lower the glass to the full open position. Re INSTALLATION
move the vent window. (1) Position the power regulator in the door. Re
(3) Slide the glass forward until the channel sepa tain it on the inner door panel with 1/4-20 x 1/2 bolts
rates from the window regulator arm roller. and nuts. Tighten the nuts to 10 Nnn (90 in. lbs.)
(4) Lower the glass and channel to the bottom of torque.
the door. (2) Connect the regulator motor wire harness con
(5) Remove the center of the regulator rivets with nector.
• BODY COMPONENTS 23 - 2 i
(3) Raise the glass. Slide it rearward and engage DOOR KEY
the channel with the regulator a r m roller.
(4) Install the vent window.
(5) Test the window glass and regulator operation.
Correct as necessary.
Fig. 8 Key Lock Cylinder Removal/Installation

(4) Use t h e code plate to determine the code num
ber for each set and record the results.
(5) Continue, as instructed above, to determine the
complete key/lock code with the remaining sets of
spring, driver and tumbler.
(6) Assemble the original tumbler, driver and
spring sets (if not damaged) in the lock cylinder
housing.
(7) Install a replacement tumbler cover on the lock
cylinder housing.
(8) Install the key lock cylinder in the door. If nec
Fig. 7 Power Window Glass Regulator essary, refer to the installation procedure.
KEY LOCK CYLINDER
REMOVAL
(1) Raise the window glass to the closed position.
(3) Disconnect the lock cylinder latch rod at the
door latch.
(4) Remove the key lock cylinder retainer clip. Re
move the lock cylinder from the door (Fig. 8).
INSTALLATION
(1) Install the lock cylinder in the door hole. Re
tain the lock cylinder with the retainer clip.
(2) Connect the lock cylinder latch rod to the door
latch.
(3) Test (and adjust, if necessary) the door lock cyl
inder latch rod operation.
(4) Install the door trim panel and the waterdam.
DETERMINING KEY/LOCK CODE

When the door key or the key code is not available, Fig. 9 Key Lock Cylinder Components
the following procedure can be used to determine the DOOR LATCH STRIKER
key code.
(1) Remove the lock cylinder from the door. REPLACEMENT
(2) Remove the tumbler cover from the lock cylin (1) Remove the striker and spacer from the B-pil-
der housing and discard it (Fig. 9). lar (Fig. 10).
(3) Individually remove each spring, driver and
tumbler set from the lock cylinder housing.
(2) Install the spacer and replacement striker on DOOR INSIDE HANDLE
the B-pillar.
(3) Adjust the door latch striker to engage com REMOVAL
pletely when the door is closed. When closed, the (1) Raise the window glass to the closed position.
door should be flush with t h e adjacent body panels. (2) Remove the door trim panel and the waterdam.
(3) Remove the handle latch rod from the inside
IOCK handle actuator (Fig. 10).
KNOB
(4) Remove the screws from the reinforcement
OUTSIDE GROMMET
HANDLE plate. Remove inside handle (and seal) from the door
inner panel.
B-PILLAR
INSTALLATION
DOOR (1) Position the seal and inside handle on the door
inner panel.
(2) Connect the handle latch rod to the handle ac
tuator.
(3) Position the reinforcement plate at the inside of
the door inner panel. Attach the inside handle to the
LATCH #
door panel. Tighten the screws to 15 N m (130 in.
OUTSIDE INSIDE lbs.) torque.
HANDLE-TO- HANDLE
LATCH ROD (4) If necessary, adjust to eliminate excess handle
LOCK MOTOR-TO- ACTUATOR
LATCH ROD travel.
SCREW
If necessary, refer to the installation procedure.
LOCK
MOTOR DOOR INSIDE DOOR
J9123-601 LATCH OUTER
INNER
PANEL RELEASE SCREW PANEL
Fig. 10 Striker, Lock Motor, Door Handle, Latch & HANDLE
REINFORCEMENT
Rods PLATE
POWER DOOR LOCK MOTOR

REMOVAL
(1) Raise the window glass to the completely closed
position.
(3) Disconnect wire harness connector from the
lock motor.
(4) Disconnect the lock motor latch rod from the
motor (Fig. 10).
(5) Remove the screws and the motor from the
DOOR
door. INNER
PANEL
INSTALLATION
INSIDE
(1) Position the motor in door inner panel. LATCH
(2) Connect the lock motor latch rod to the motor. RELEASE J9123-394
(3) Install the lock motor screws. Tighten the HANDLE
#
Fig. 11 Door Inside Handle Removal/Installation
(4) Connect the lock motor connector to the door
harness connector. DOOR OUTSIDE HANDLE
(5) Test and verify t h a t the lock motor and latch
lock operate correctly. REMOVAL
(6) Install the door waterdam and the trim panel. (1) Raise the window glass to the closed position.
If necessary, refer to the installation procedure. (2) Remove the door trim panel and the waterdam.
(3) Remove the door handle nuts from the inside of
the door.
(4) Disconnect handle latch rod from latch.
(5) Remove handle from door outer panel.
INSTALLATION (3) Install the latch screws in the door panel face
(1) Apply silicone spray lubricant to the handle in (Fig. 12). Tighten the screws to 9 Nnn (7 ft-lbs)
ternal moving parts. torque.
(2) Install t h e handle on the door outer panel. (4) Test and verify t h a t the latch operates cor
(3) Tighten the handle nuts to 7 N*m (65 in. lbs.) rectly.
torque. (5) Install the door waterdam and the trim panel.
(4) Connect the handle latch rod to t h e latch. If necessary, refer to the installation procedure.
(5) Test and verify the handle operates correctly.
(6) Install t h e door waterdam and the trim panel. WINDOW GLASS AND DOOR WEATHERSTRIP
SEALS
OUTSIDE HANDLE LATCH ROD RELEASE
ADJUSTMENT WINDOW GLASS BELTLINE WEATHERSTRIP
SEALS
(1) Locate the 4-mm (5/32-in) diameter Allen-head
adjustment screw inside the door panel face slot near REMOVAL
the latch (Fig. 12).
The window glass beltline weatherstrip seals can
(2) Loosen t h e door latch adjustment screw. be removed according to the following procedure.
(3) Push upward on the latch lever to remove all (1) Open the window glass.
the slack from the handle latch rod. (2) Pry the inner and outer beltline weatherstrip
(4) Tighten adjustment screw. seals from the door panels with a small putty knife.
(5) Test and verify proper operation. (3) Remove the beltline seals from the door (Fig.
INNER DOOR LOCK SCREW DOOR 13).
RELEASE LATCH /CYLINDER-TO OUTER
HANDLE-TO LATCH ROD PANEL INSTALLATION
LATCH
ROD
Position the beltline weatherstrip seals on the door
DOOR panels. Force them downward until the retainers are
LOCK LATCH seated in the panel slots.
KNOB
TO-LATCH DOOR DOOR
ROD INNER INNER
OUTER P A N E L
PANEL
RELEASE ADJUSTMENT WEATHERSTRIP
POWER LOCK SCREW SLOT
HANDLE-TO
MOTOR-TO-
LATCH ROD
LATCH ROD GLASS
OUTER RELEASE HANDLE-TO-
LEFT DOOR LATCH LATCH ROD ADJUSTMENT DOOR
SCREW ACCESS SLOT OUTER
PANEL
J9123-384
Fig. 12 Door Latch & Rods REGULATOR

(MANUAL)
DOOR LATCH
REMOVAL
(1) Raise the window glass to the closed position. J9123-398
(3) Disconnect the: Fig. 13 Beltline Weatherstrip Seals
• Outside handle latch rod
DOOR WEATHERSTRIP SEAL
• Key lock cylinder latch rod
• Inside handle latch rod REMOVAL
• Lock knob latch rod (1) Start at the lower ends and pull outward on the
• Lock motor latch rod seal. Separate it from the door opening panel flanges
(4) Remove the door latch screws from the door in (Fig. 14).
ner panel face. (2) Continue around the edge of the seal and pull
(5) Remove the door latch from the door. outward on the seal to separate it from the flanges.
(3) Remove the seal from the door opening.
INSTALLATION
(1) Install the latch striker, if removed. INSTALLATION
(2) Insert the door latch. Position it at the door in (1) Position the weatherstrip seal in the door open
ner panel face and connect the rods to it. ing.
(2) Start at the upper, rear corner of the door open
BUTYL DOOR
ing. Move forward and downward around the edge of
the door opening. Force the seal inward against the
panel. Seat the flange in the seal slot.
Seal p o s i t i o n i n g a t t h e c o r n e r s is critical. T h e
seal m u s t b e s e a t e d a t e a c h c o r n e r . A v o i d p u c k
e r i n g a n d s t r e t c h i n g t h e seal a t t h e c o r n e r s .
(3) When correctly installed, the seal ends will
meet at the door lower centerline.
(4) Inspect the fit of the door in the door opening.
If not correct, adjust the door fit so the seal is not
damaged when the door is closed. Refer to the door
adjustment procedure.
Fig. 14 Cab/Body-To-Door Weatherstrip Seat

• IODY COMPONENTS 23 - 29
FIXED GLASS
1NDE1
page page
C a b Rear Window 30 Quarter Window Glass . 32
Hatchgate Window Glass—Ramcharger . . . . . . . . 32 Rearview Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Mirror Support Bracket 29 Service Information 29
Quarter Vent W i n d o w - C l u b C a b 30 Windshield Glass 29
SERVICE INFORMATION WINDSHIELD GLASS

Do not use a putty knife, a razor blade, or steel
wool to remove foreign material from glass. Glass REMOVAL
surfaces are best cleaned with the use of a commer (1) Remove the wiper arms. Place a cover over the
cial glass cleaner. upper cowl area. If necessary, refer to Group 8—Elec
trical for the wiper arm removal procedure.
REARVIEW MIRROR (2) Remove the interior rearview mirror.
(3) Remove the locking strip retainer from the
REMOVAL windshield glass weatherstrip seal (Fig. 2).
(1) Loosen the mirror base setscrew. (4) Position an assistant outside the vehicle to re
(2) Slide the mirror base upward and off the sup ceive the windshield glass.
port bracket. (5) Starting at either inside, upper corner, gently
push the glass outward. Separate it from the weath
INSTALLATION erstrip seal. Continue until the glass is completely
(1) Position the mirror base at the support bracket. separated from the seal (Fig. 3).
Slide it downward onto the support bracket. (6) The assistant now can remove the glass from
outside the vehicle.
CAUTION: D o not over-tighten the mirror b a s e set-
(7) Remove the weatherstrip seal from the wind
screw. Windshield g l a s s chipping and/or breakage
shield opening.
could result.
(8) Remove the residual sealant from the wind
(2) Tighten the setscrew securely. shield opening flange.
(9) Clean the windshield opening flange and
MIRROR SUPPORT BRACKET groove with an appropriate cleaning solution.
REPLACEMENT INSTALLATION
(1) To replace the mirror support bracket follow (1) Apply a 3-mm (1/8-in) diameter bead of syn
the directions provided in the repair kit. thetic rubber-based sealant to the windshield open
ing flange and groove.
(2) Install the weatherstrip seal on the flange. Ver
ify t h a t it is completely seated around the edge of the
windshield opening.
(3) With the aid of an assistant, insert one corner
of the windshield glass into the weatherstrip seal
groove.
(4) Use a trim stick to force the seal lip over the
glass around the edge of the seal.
If necessary, use mineral spirits as a lubricant
to aid locking strip installation.
(5) Start at the lower, center area of the weather
strip seal. Install the locking strip in the weather
strip seal with Tool L-4567, or an equivalent (Fig. 4).
(6) Install the locking strip end cap over the ends
of the locking strip.
Fig. 1 Rearview Mirror Bracket. (7) Test the windshield for water leaks.
(8) Install the wiper arms. If necessary, refer to
Group 8—Electrical for the installation procedure.
(9) If necessary, install the rearview mirror sup
port bracket on the windshield glass.
(10) Install the rearview mirror. If necessary, refer
to the installation procedure.
Fig. 4 Weatherstrip Seal Locking Strip Retainer

Installation
(2) Position the vent window in the cab. Install the
#
screws. Tighten the nuts to 3 N m (24 in. lbs.)
torque.
(3) Attach the latch to the quarter panel. Tighten
the screws to 3 N«m (24 in. lbs.) torque.
Fig. 2 Windshield Glass (4) Test the vent window for water leaks.
WEATHERSTRIP SEAL
REMOVAL
(1) Remove the vent window. If necessary, refer to
the removal procedure.
(2) Pull the seal away from the flange.
(3) Clean the flange as necessary.
INSTALLATION
(1) Position the seal at the window opening.
(2) Mate the seal with the front flange.
(3) Move upward and mate the seal with the top
Fig. 3 Windshield Glass Removal flange.
(4) Mate the seal with the rear flange.
QUARTER WENT WINDOW-CLUB CAB (5) Mate the seal with the bottom flange.
REMOVAL
CAB REAR WINDOW
(1) Remove the vent window latch screws from the
cab quarter panel. SERVICE INFORMATION
(2) Remove the hinge screws from the cab side, in The rear window glass is attached to the window
ner panel. frame with urethane adhesive (Figs. 6 and 7). The
(3) Remove the vent window from the cab. urethane adhesive seals the window frame and the
(4) If necessary, remove the latch and hinge from glass. The window weatherstrip seal attaches the
the glass. window frame to the window opening flange.
INSTALLATION REMOVAL-STANDARD GLASS

(1) If removed, install the latch and hinge on the (1) As applicable, remove the window reveal moul
glass. ding/retainer.
WEATHERSTRIP CAB WEATHERSTRIP

SEAL BACK SEAL
VENT PANEL
GLASS
AND FRAME
SCREW
FIXED
SLIDING GLASS
RETAINER GLASS
A N D FRAME J9123-339
RIVET-NUT J9123-340
Fig. 6 Cab Rear Windows

Fig. 5 Vent Window Removal/installation
CAB CAB
(2) Separate the seal lip from the glass at one cor BACK
ner with a trim stick. Carefully push the glass out of RETAINER
PANEL WEATHERSTRIP SEAL PANEL
WITH
the seal (Fig. 8). MOULDING
(3) Force the glass out of the weatherstrip seal. Re FIXED
WEATHERSTRIP
move it from the seal and the window opening. WINDOW
SEAL
(4) Remove the weatherstrip seal from the window GLASS FIXED
WEATHERSTRIP SEAL WINDOW
opening. GLASS
' WITH MOULDING
CAB
INSTALLATION RETAINER BACK
(1) Clean the seal channels and the window PANEL
RETAINER RETAINER
flanges in the cab.
CAP WEATHERSTRIP
(2) Install the seal on the window glass or frame. SLIDING
<tOF W I N D O W SEAL GLASS
(3) Apply a 6-mm (1/4-in) diameter bead of sealant LOWER UPPER A N D FRAME
to the window flange. J9123-338
(4) Install the glass according to the following in
structions: Fig. 7 Rear Window
• Moisten a length of 6-mm (1/4-in) diameter cord Glass/Frame—Removal/Installation
with a soap and water solution
• Verify t h a t the cord is long enough to go around
the edge of the seal.
• Insert the cord into the window flange in the seal
(Fig. 9)
• Position the window and seal in the opening with
the free ends of the cord inside t h e vehicle
• Pull on the cord ends. Pull t h e seal channel lip
over the window flange.
(5) Test the window for water leaks.
(6) As applicable, install the window reveal moul
ding or retainer.
(7) Clean the vehicle, as necessary.
SLIDING WENT GLASS PU866
REMOVAL
Fig. 8 Rear Window Removal— Typical
(1) Remove the complete rear window from the cab (4) Carefully spread the frame apart.
opening. If necessary, refer to the removal procedure. (5) Remove the sliding vent glass from the frame
(2) Place the frame and glass on a clean, padded track.
area.
(3) Loosen the screws located on the bottom of the
frame.
• Position the glass in the window opening with the
free ends of the cord inside the vehicle
• Pull on the cords to pull the seal channel lip over
the window flange
(5) After installation, release any curls from the
seal outer lip.
(6) Test the hatchgate window for water leaks.
(7) Clean the glass.
HATCHGATE RETAINER WEATHERSTRIP
Fig. 9 Window installation Cord—Typical

INSTALLATION
(1) Position the sliding vent glass in the frame
track.
(2) Tighten all the screws at the bottom of the
frame, Fig. 10 Hatchgate Window Glass & Seal
(3) Test for correct travel. Check the latch opera QUARTER WINDOW GLASS
tion for the sliding vent glass.
(4) Install rear window in the cab opening. If nec REMOVAL
essary, refer to the installation procedure. (1) Remove the quarter window glass interior trim
(5) Verify t h a t the drain holes are not restricted. panel (Fig. 11).
HATCHGATE WINDOW GLASS-RAMCHARGER

REMOVAL
(1) Use a trim stick to separate the glass seal lip
from the hatchgate flanges. Push the window glass
and seal outward from the top.
(2) Remove the seal and glass from the hatchgate.
(3) Remove the retainer strip from the weather
strip seal.
(4) Remove the seal from the window glass.
(5) Clean the seal channels and window opening
flanges.
INSTALLATION
(1) Install the seal on the window glass.
(2) Apply mineral spirits to the retainer strip Fig. 11 Quarter Window Interior Trim Panel
channel in the weatherstrip seal.
(3) Install the retainer strip in the seal channel. (2) Remove the quarter window exterior mouldings
(4) Install the hatchgate window glass according to (Fig. 12).
the following instructions: (3) Use an electric knife (Tool 4386 or an equiva
• Moisten a length of 6-mm (1/4-in) diameter cord lent) to cut the butyl tape.
with a soap and water solution; (4) Remove the glass from the opening by applying
• Verify t h a t the cord is long enough to go all the even pressure to the inside of the glass.
way around the edge of the weatherstrip seal
• Insert the cord into the window flange in the seal
(2) Apply primer to the glass and allow 10 minutes

for it to dry. Avoid contact with the primed surface.
(3) Inspect the quarter window spacers for correct
installation (Fig. 13).
(4) Apply butyl tape to the entire edge of the win
dow flange (Fig. 14).
SECTION A-A SECTION B-B
Fig. 14 Butyl Tape Installation

(5) Remove excess tape and butt the tape-ends
Fig. 12 Quarter Window Exterior Mouldings firmly together.
(6) Install the quarter window glass on the butyl
INSTALLATION tape (Fig. 15)
(1) Remove the residual butyl tape from the win (7) Force the glass against the butyl tape to obtain
dow opening. If the original glass will be installed, a good seal (Fig. 15).
remove all the residual butyl tape from the glass. (8) Test the quarter window glass for water leaks.
(9) If leakage occurs, additional sealing will be re
quired. Use an appropriate windshield sealer (Fig.
16).
(10) Install the exterior mouldings.
(11) Install the interior trim panel.
(12) Clean the glass.
CAB/BODY INTERIOR COMPONENTS
INDEX
page page
Carpets and Floor Mats 51 Interior Trim Panels . 42
Floor Console and Rear Storage Tray . . . . . . . . . 50 Rear Seats 41
Front Seats 38 Shoulder Belts/Lap Belt/Buckles 45
Headliners 48 Spare Tire Carrier 45
Instrument Panel 35
INSTRUMENT PANEL INSTALLATION

(1) Position the IP cluster or component at t h e in
INSTRUMENT CLUSTER BEZEL strument panel. Connect t h e wire harness connec
tors).
REMOVAL (2) Install t h e cluster or component in the instru
(1) Remove the bezel screws. ment panel (Fig. 2).
(2) Remove the bezel from the instrument panel. (3) If applicable, connect t h e shift position indica
tor to the steering column (Fig. 3).
INSTALLATION (4) Install the IP cluster or component screws.
(1) Position the bezel on the instrument panel. #
Tighten the screws to 2 N m (17 in. lbs.) torque.
(2) Install t h e bezel screws. Tighten the screws to (5) Position the bezel on t h e instrument panel.
2 Nnn (17 in. lbs.) torque. (6) Install t h e bezel screws. Tighten t h e screws to
2 Nnn (17 in. lbs.) torque.
INSTRUMENT 4WD
PANEL INDICATOR INSTRUMENT
COVER PANEL
EDGE 4WD)
TRIM
LAMP
ACC
SWITCH
INSTRUMENT BEZEL
CLUSTER
BEZEL SCREW
HEADLAMP
Fig. 11nstrument Cluster Bezel Removal/Installation SWITCH
INSTRUMENT CLUSTER AND/OR IP HEADLAMP

SCREW
COMPONENT SWITCH
A N D POWER
MIRROR
REMOVAL CONTROL INSTRUMENT J 9 1 2 3 3 5 1
(1) Remove the instrument cluster bezel screws BEZEL CLUSTER J9123-351
(Fig. 1). Remove the bezel from the instrument
panel. Fig. 2 Instrument Cluster Removal/Installation
(2) As applicable, remove the instrument cluster or A/T SHIFT POSITION (PRNDL) INDICATOR
other IP component screws (Fig. 2).
(3) Disconnect the wire harness connector(s) from REMOVAL
the IP cluster or component. Refer to Group 8—Elec (1) Disconnect the shift position (PRNDL) indicator
trical for additional information. cable from t h e steering column.
(4) If applicable, disconnect the shift position indi (2) Remove the indicator screws from t h e rear of
cator from t h e steering column (Fig. 3). the instrument cluster.
(5) Remove the IP cluster or component from the (3) Remove the indicator from the instrument clus
instrument panel. ter.
SCREW
INSTRUMENT
PANEL
SCREW
INSTRUMENT
CLUSTER LAMP
(REAR) HOOD
LIGHTER
ELEMENT
PANEL
SHIFT ASH LIGHTER
INDICATOR TRAY CLAMP
' HOUSING - SCREW
STEERING
COLUMN J9123-539
Fig. 3 A/T Shift Position Indicator

ASH
INSTALLATION ASH LIGHTER RECEIVER
TRAY SHELL TRAY
(1) Position the shift position (PRNDL) indicator HOUSING
on the instrument cluster. J9123-346
(2) Install the indicator screws in the rear of the
Fig. 4 Ash Receiver Tray & Housing
instrument cluster. Tighten the screws to 2 N»m (17
in. lbs.) torque. INSTALLATION
(3) Connect the indicator wire to the steering col (1) Position the glove box at the instrument panel.
umn. (2) Install the door hinge screws. Tighten the
screws to 3 N»m (24 in. lbs.) torque.
ASH RECEIVER TRAY AND HOUSING
INSTRUMENT STRIKER SCREW BUMPER
PANEL
REMOVAL
GLOVE
cigarette lighter. Remove the ash receiver tray from BOX
the housing.
(2) Remove the housing screws from t h e instru DOOR
ment panel.
lamp. Remove the housing from the instrument
panel.
INSTALLATION LAMP NAME

(1) Position the ash receiver tray housing at the SWITCH PLATE
instrument panel. Connect the wire harness connec LAMP J9123-345
LENSE SCREW HINGE
tor to the lamp.
(2) Install the housing screws in the instrument Fig. 5 Glove Box
panel. Tighten the screws to 2 N«m (17 in. lbs.)
torque. LOCK CYLINDER AND LATCH REMOVAL
(3) Position the ash receiver tray in the housing. (1) Remove the glove box latch screws from the
Connect the wire harness connector to the cigarette door panel.
lighter. (2) Separate the latch from the lock cylinder.
(3) Remove the lock cylinder and the latch from
GLOVE BOX the door panel.
REMOVAL LOCK CYLINDER AND LATCH INSTALLATION

(1) Remove the glove box door hinge screws from (1) Insert the lock cylinder in the door panel hole.
the instrument panel (Fig. 5). Engage it with the latch.
(2) Remove the glove box from the instrument (2) Install the latch screws in the door panel.
panel. Tighten the screws to 2 N»m (17 in. lbs.) torque.
BODY COMPONENTS 23 - 37
DOOR LATCH S T R I K E R A D J U S T M E N T dle brackets on the I/P (Fig. 8). Tighten the screws to
(1) Insert a small pry bar in the latch striker slot. 3 N*m (30 in. lbs.) torque.
(2) Pry on the striker as necessary to obtain cor (7) If equipped, install the h a n d throttle bracket on
rect adjustment. the I/P (Fig. 9). Tighten t h e locknut to 2 N*m (17 in.
lbs.) torque. Tighten the screw to 3 N*m (24 in. lbs.)
INSTRUMENT PANEL (UP) torque.
REMOVAL SCREW PLENUM SCREW BRACE PLENUM
(1) Remove the I/P screws from the dash panel
(Fig. 6).
(2) Remove the steering column cover inserts from
the I/P (Fig. 7).
(3) Remove the I/P reinforcement bracket screws
from the brace.
(4) Remove the hood and parking brake release
handle brackets from the I/P (Fig. 8).
(5) If equipped, remove the hand throttle bracket
from t h e I/P (Fig. 9).
(6) Remove the I/P screws from the each cowl
panel.
(7) Pull the I/P outward from the dash panel for
clearance and disconnect the:
• Wire harness connectors
• Window defogger tubes
• Speedometer cable
• Heat/vent tube
• PRNDL cable
• Temperature control cable
Refer to the applicable service information groups
for additional information. Fig. 6 Instrument Panel
(8) Remove the I/P from the dash panel.
(9) If necessary, remove the reinforcement brackets
from the inside of the panel (Fig. 10).
INSTALLATION
(1) If applicable, install the reinforcement brackets
at the inside of the I/P (Fig. 10). Tighten the bracket
#
screws to 23 N m (200 in. lbs.) torque. Tighten the
reinforcement bracket I/P screws to 3 N*m (24 in.
lbs.) torque.
(2) Position the I/P at the dash panel.
(3) Connect the:
• Wire harness connectors
• Window defog tubes
INSTRUMENT LOWER UPPER
• Speedometer cable irt
PANEL COVER COVER J9123-350

• Heat/vent tube
• PRNDL cable Fig. 7 Steering Column Cover Inserts Removal/
• Temperature control cable Installation
to the I/P. Refer to the applicable service informa
tion groups for additional information. DASH PANEL INSULATION MAT
(4) Install the I/P screws. Tighten t h e IP cowl
REMOVAL
screws to 23 N-m (200 in. lbs.) torque. Tighten the IP
dash panel screws and reinforcement bracket screws (1) Remove the instrument panel from the dash
to 4 N»m (35 in. lbs.) torque. panel. If necessary, refer to the removal procedure.
(5) Install the steering column cover inserts on the (2) Remove the defroster duct from the dash panel.
17P (Fig. 7). Tighten the screws to 2 N*m (17 in. lbs.) (3) Remove the heater/A/C unit from the dash
torque. panel. If necessary, refer to the removal procedure in
(6) Install the hood and parking brake release han Group 24.
23 - 38 BODY COMPONENTS — — ^ — _ _ _ _ _ — — •
P
AWU S
UPP
ORT NUT GL
OVE N
IS
TRUME
NT
B
RAC
KET N
IS
TRUME
NT PA
NEL
PA
NEL B
OX
O
PEN
NIG NIS
TRUME
NT
NUT - CL
UST
ER
R
EL
EAS
E S
CR
EW OPEN
N
IG
H
ANDL
E
WASHER S
CR
EW
SEALS
DASH
PANEL
l/P-T
P
LEN U M P AN
EL
R
EN
IF
O R CE
MEN
T; 7
S
EAL B
R A C
KE
T LO
W ERSCR
EW
PARK
N
IG R
GIHT
BR
AKE RE
N IF
OR C
EMEN
T RE
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IF
ORCE
MEN
T
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N
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' S
CR
EWL
EV
ER J
912
35
-6
8 BR
A C
KE
T B
RAC
KE
TJ 9
123
3
-48
Fig. 10 Inside Of Instrument Panel
Fig. 8 Parking Brake Release Handle
HA
ND P
ROT
ECT
V
I
E DASH R
G
IHT
S
CR
EW CA
P PA
N E
L COWL
T
HROT
TL
E
BR
ACKE
T N
OS
IE N
IS
ULA
TORNO
S
IE N
IS
ULAT
OR
L
O C K LE
FTC OWL
NUT NOS
IE N
ISU
LA
TOR
N
IS
TRU
MENT
P
ANEL
LE
H
AN
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D
T
TL
E
^TfJl
R
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N
IE
R
L
EF
T DIP CE
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NOS
IE NOS
IE
A
CCE
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RAT
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IS
ULA
TORN IS
ULA
TOR
P
EDAL DA S
H
P
A NEL
C L
PI DA
SH J
912
3-
411
W
(T
IH HYD. C
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ANEL J
912
35
-5
6
Fig. 11 Insulation Mat—Gasoline Engine
Fig. 9 Hand Throttle FRONT SEATS
(4) As applicable, remove the retainers, screws and
BENCH SEAT
insulation mat from the dash panel (Figs. 11 and 12).
REMOVAL
INSTALLATION
(1) Detach the shoulder belt and lap belt/buckle
(1) Position the insulation mat on the dash panel.
from the seat.
As applicable, install the screws. Tighten the screws
(2) For convenience, raise and support the vehicle.
to 1 N«m (12 in. lbs.) torque.
Remove the seat platform nuts from the studs. Re
(2) Install the heater/A/C units on the dash panel.
move the support. Lower the vehicle.
If necessary, refer to the installation procedure in
(3) Remove the seat from the cab.
Group 24.
(4) Remove the platforms and seat tracks from the
(3) Position the defroster duct on the dash panel.
seat, if necessary.
Install the screws. Tighten the screws to 2 N*m (20
in. lbs.) torque. INSTALLATION
(4) Install the instrument panel on the dash panel. (1) Install the seat tracks and platforms on the
If necessary, refer to the installation procedure. seat, if removed.
platform stud spacers, retainers, and n u t s . Tighten

the nuts to 26 Nnn (230 in. lbs.) torque.
(2) Position the seat in the vehicle.
(3) Install the platform bolts. Tighten the nuts to
26 Nnn (230 in. lbs.) torque.
Fig. 12 Insulation Mat—Diesel Engine

(2) Position the seat in the cab.
Install the seat platform nuts on the studs. Tighten
the nuts to 26 Nnn (230 in. lbs.) torque. Remove the
support. Lower the vehicle.
(4) Position the shoulder belt buckles and lap belt/
buckle between the seatback and seat cushion.
8923-56
Fig. 14 Left-Side Bucket Seat

REMOVAL—RIGHT SEAT
The right side bucket seat is equipped with a tilt-
able platform. This is to provide entry to the rear
seating area (Fig. 15). When tilted, a gas operated
rod supports the seat. The tilt-latch release levers
are located on the side and on the rear of the seat.
(1) Remove the bolts t h a t attach the seat platform
Fig. 13 Bench Seat tilt hinge to the reinforcement panel and the floor
panel.
BUCKET SEATS-RAMCHARGER AND CLUB
(2) Disconnect the gas operated support rod from
CAB
the seat platform (Fig. 15).
REMOVAL—LEFT SEAT (3) Release the latch. Remove the seat from the ve
hicle.
(1) Remove the bolts t h a t attach the seat platform
to the reinforcement panel and the floor panel. (4) The bucket seat can be removed without the
platform. Remove the seat platform stud nuts, spac
(2) Remove the left bucket seat from the vehicle.
ers and retainers.
(3) The bucket seat can be removed without the
platform. Remove the seat platform stud nuts, spac
INSTALLATION-RIGHT SEAT
ers and retainers.
(1) If removed without the platform, position the
INSTALLATION—LEFT SEAT bucket seat on the seat platform. Install the seat
platform stud spacers, retainers, and nuts. Tighten
(1) If removed without the platform, position the
the nuts to 26 Nnn (230 in. lbs.) torque.
bucket seat on the seat platform. Install the seat
(2) Position the seat in the vehicle.
(3) Install the tilt-hinge bolts. Tighten the bolts to TILT-LATCH R E L E A S E L E V E R S — R I G H T S E A T
26 N*m (230 in. lbs.) torque. The tilt-latch release levers have a handle, escutch
(4) Connect the gas operated support rod to the eon, spring pin and snap ring. For removal and in
seat platform. stallation, refer to Figures 15 and 16.
(5) The seat latch should be aligned with the latch
striker.
If necessary, the latch striker c a n be adjusted.
REINFORCEMENT SEAT
BUCKET PANEL L A T C H
SEAT
PLUG
(W/O BENCH SEAT)
ARMREST
STUD
TILT
I RELEASE SPACER
SEAT ' LEVER RETAINER
PLATFORM
GAS
SUPPORT
ROD
TILT
HINGE SUPPORT
ROD FLOOR
SCREW REINFORCEMENT PANEL
PANEL
TILT
STOP SEAT
BRACKET GAS PROP RR23A52
FLOOR LATCH
PANEL STRIKER J9123-337
Fig. 16 Tilt-Latch Release Levers
Fig. 15 Right-Side Bucket Seat SEAT T R A C K S R E M O V A L - L E F T SEAT
TILT LATCH R E M O V A L - R I G H T SEAT (1) Remove the seat platform stud nuts, spacers
(1) Remove the screws t h a t attach the latch to the and retainers. Remove the seat from the platform.
seat platform. (2) Remove the seat track platform screws from
(2) Remove the clip from the inside end of the link. the seat cushion frame.
(3) Remove the latch from the seat platform. (3) Remove the tracks from the seat cushion frame
(Fig. 17).
TILT LATCH I N S T A L L A T I O N - R I G H T SEAT
SEAT TRACKS I N S T A L L A T I O N - L E F T SEAT
(1) Position the latch on the seat platform. Install
the screws. Tighten them to 23 N*m (200 in. lbs.) (1) Position the tracks on the seat cushion frame.
torque. (2) Install the seat track screws in the seat cushion
(2) Attach the clip to the inside end of the link. frame.
(3) Adjust the latch to eliminate all vertical (3) Adjust the seat track adjustment release wire
freeplay at rear of the seat platform. as necessary.
(4) Position the seat on the platform. Install the
TILT-LATCH S T R I K E R R E M O V A L - R I G H T SEAT seat platform stud spacers, retainers, and nuts.
(1) Remove the striker bolts from the reinforce Tighten the nuts to 26 N*m (230 in. lbs.) torque.
ment panel and the floor panel.
ARMREST REMOVAL
(2) Remove t h e striker from the panels.
(1) Position the armrest at an angle t h a t will allow
TILT-LATCH S T R I K E R I N S T A L L A T I O N - R I G H T SEAT access to the armrest pivot support bracket screw
The latch striker can be adjusted via the slotted (Fig. 18).
holes in the striker base. (2) Remove the armrest pivot support bracket
(1) Position the striker on the reinforcement panel. screw.
(2) Install the striker bolts in the reinforcement (3) Remove the armrest from the bracket.
panel and the floor panel. (4) Remove the armrest pivot support bracket from
the seatback.
(2) Remove the nuts from the studs. Pull outward.

RELEASE
Remove the backrest from the cab side panel support
brackets.
(3) Raise and support the vehicle. Remove the
jump seat hinge stud nuts from the under side of the
cab.
(4) Remove the support. Lower the vehicle. Re
move the jump seat cushion from the cab.
INSTALLATION
(1) Position the backrest at the cab side panel. In
stall the nuts. Tighten them to 4 N*m (35 in. lbs.)
J 9 1 2 3 3 3 5
torque.
SCREW TRACK " (2) Install the cab side trim panel.
(3) Position the seat cushion in the cab.
Fig. 17 Left Seat Tracks
(4) Raise and support t h e vehicle. Install the nuts
ARMREST INSTALLATION #
on the hinge studs. Tighten the nuts to 23 N m (200
(1) Position the armrest pivot support bracket on in. lbs.) torque.
the seatback. (5) Remove the support. Lower the vehicle.
(2) Install the screws in the seatback. Tighten the
SIDE BACK REST
screws to 23 N*m (200 in. lbs.) torque.
(3) Position the armrest on the pivot support
bracket.
(4) Install the armrest screw in the pivot support
bracket. Tighten the screw to 11 N*m (100 in. lbs.)
torque.
SEAT BACK SEAT
Fig. 19 Jump Seat Removal/installation

FOLDING HEAR SEAT-RAMCHARGER
The instructions for operating the folding rear seat
mechanism is included in the owners manual. This
manual is included with the vehicle.
REMOVAL
Fig. 18 Armrest Removal/Installation
REAR SEATS (2) Remove the nuts and washers from the seat
front hinge studs (Fig. 20).
JUMP SEAT-CLUB CAB (3) Remove the support. Lower the vehicle.
(4) Release the seat cushion rear latches from the
REMOVAL
strikers (Fig. 20).
(1) Remove the cab side trim panel.
(5) Remove the folding seat from the vehicle.
(6) If necessary, remove the seat cushion hinges.
Remove the torsion bar and armrests. Remove the
armrest supports and seatback hinges from the seat
(Figs. 22 and 23).
INSTALLATION
(1) If applicable, install the seat cushion hinges.
Install the torsion bar and armrests. Install the arm
rest supports and seatback hinges on the seat.
(2) Position the folding seat in the vehicle. Engage
the seat cushion rear latches with the strikers.
(4) Install the washers and nuts on the seat front
hinge studs. Tighten the nuts to 11 N»m (95 in. lbs.)
RD156
torque.
(5) Remove the support. Lower the vehicle. Fig. 21 Folded Seatback
V l t w I I N
DIRECTION OF ARROW D
DIRECTION OF ARROW C
SEAT CUSHION
Fig. 22 Folding Seat Cushion Hinges & Torsion Bar

• Rear window lower trim panel
• Rear header (hatchgate) trim panel
§ Lower side trim panels
• Seat belt retractor covers
Fig. 20 Folding Rear Seat All the interior trim panels are attached with
screws and/or clip retainers.
INTERIOR TRIM PANELS
C A U T I O N : Remove overlapping panels before re
SERVICE INFORMATION
moving inboard trim panels. Also verify that all
Ram Truck, Chassis Cab and Ramcharger interior
screws and retainer clips are removed before re
trim panels are comprised of the:
moving a trim panel. Trim panels are somewhat
• Windshield header trim panel
• Door header trim panels flexible but can be damaged if handled improperly.
• A-pillar trim panels
Install the screws finger-tight, align the panels at
• Cowl side trim panels
each end and then tighten the screws. U s e care to
• Rear corner trim panels
• Quarter window trim panels avoid overtightening the s c r e w s or, otherwise,
• Rear window upper trim panel the trim panels will be damaged.
HINGE ROOF WEATHERSTRIP ROOF DOOR

A N D LATCH I N N E R PANEL SEAL INNER HEADER
SEAT BACK PANEL TRIM
A R M REST A-PILLAR PANEL
REAR
TRIM WINDSHIELD
PANEL A-PILLAR GLASS
TRIM <
PANEL
WINDSHIELD
DOOR HEADER
DOOR
TRIM WINDSHIELD
HEADER HEADER
TRIM PANEL GLASS
TRIM
PANEL PANEL D O O R HEADER
A N D WINDSHIELD
D O O R HEADER D O O R HEADER
HEADER TRIM
A N D REAR A N D A-PILLAR
PANEL J U N C T I O N
TRIM PANEL TRIM PANEL
JUNCTION JUNCTION J9123-380
NUT SUPPORT RY670 Fig. 25 Overlapping Trim Panels

Fig. 23 Folding Seatback Armrests, Supports & Hinges (1) Remove the trim panel screws from the body
COWL SIDE TRIM PANEL inner panels (Fig. 26).
(2) Remove the trim panels from the body inner
REMOVAL panels (Fig. 26).
(1) Remove the screws from the cowl side trim
INSTALLATION
panel (or air vent) and the cowl panel (Fig. 24).
(2) Remove the trim panel (or air vent) from the (1) Position the trim panels at the body inner pan
cowl panel. els.
(2) Install the trim panel screws in the body inner
INSTALLATION panels. Tighten the screws to 1 N»m (12 in. lbs.)
(1) Position the cowl side trim panel at the cowl torque.
panel. ROOF A-PILLAR WINDSHIELD
UPPER REAR
(2) Install the screws in the cowl panel. Tighten TRIM PANEL INNER HEADER
the screws to 4 N»m (35 in. lbs.) torque. A v o i d over PANEL TRIM
PANEL
tightening the screws.
AIR FWD
AIR VENT
( W / O TRIM PANEL) VENT
AND
COWL SCREW
SIDE
TRIM PANEL
COWL
SIDE
TRIM
PANEL
SCREW WINDSHIELD
GLASS
DOOR
COWL HEADER
SIDE TRIM PANEL
COWL RIGHT SIDE PANEL SCREW
SIDE
PANEL SCREW SCREW J9123-354
A-PILLAR
Fig. 24 Cowl Side Trim Panels & Air Vent TRIM PANEL J9123-379
WINDSHIELD HEADER, A-PILLAR AND FRONT Fig. 26 Door Header, A-PUIar & Windshield Header
DOOR HEADER TRIM PANELS Trim Panels
REMOVAL
R e m o v e the nearest screw in a n adjacent over
lapping trim panel to avoid possible d a m a g e to
b o t h trim panels (Fig. 25).
CAB REAR CORNER/QUARTER WINDOW AND
REAR WINDOW UPPER/LOWER TRIM PANELS
REMOVAL
(1) Remove the trim panel screws from the body
inner panels (Figs. 27 and 28).
(2) Remove the screw and coat hanger hook from
the rear window upper trim panel (Fig. 29). REAR
(3) Remove the trim panels from the body interior UPPER
panels. . TRIM
PANEL
INSTALLATION
(1) Position the trim panels at the body inner pan COAT
els. HANGER
(2) Install the trim panel screws in the body inner SCREW HOOK J9123-381
panels. Tighten the screws to 1 N»m (12 in. lbs.)
torque. Fig. 29 Coat Hanger Hook
(3) Position the coat hanger hook a t the rear win QUARTER WINDOW UPPER AND HATCHGATE
dow upper trim panel (Fig. 29). Install and tighten HEADER TRIM PANELS
e
the screw to 1 N m (12 in. lbs.) torque.
REMOVAL
REAR SCREW
WINDOW (1) For convenience, fold forward the rear passen
UPPER TRIM ger seat. If necessary, refer to the removal procedure.
PANEL
(2) Remove the spare tire.
(3) Remove the trim panel screws from the quarter
inner panel and the hatchgate header panel (Figs. 30
and 31).
(4) Remove the trim panels from the quarter inner
panel and the header panel.
INSTALLATION
(1) Position the trim panels at the quarter inner
REAR panel and the hatchgate header panel.
CORNER REAR WINDOW (2) Install the trim panel screws in the quarter in
TRIM LOWER TRIM
PANEL PANEL SCREW J9123-390 ner panel and header panel. Tighten the screws to 1
Fig. 27 Standard Cab Rear Corner & Rear Window (3) Install the spare tire.
Upper/Lower Trim Panels
COAT QUARTER SCREW REAR
ROOF RAIL REAR W I N D O W HANGER WINDOW HEADER
k
TRIM PANEL' UPPER* HOOK SCREW TRIM

PANEL
kTRIM PANEL
SCREW ([BODY
FOAM
LOWER SPACER
SIDE TRIM REAR
PANEL PILLAR
QUARTER CLIP LOWER
WINDOW RETAINER TRIM PANEL
TRIM
RETAINER
PANEL
SCREW FLOOR
REAR W I N D O W RETRACTOR RAIL PANEL
REAR W I N D O W COAT LOWER TRIM COVER WHEELHOUSE RETAINER J9123-391
LOWER TRIM PANEL HOOK PANEL
J9023-58
Fig. 30 Quarter Panel Upper/Lower & Hatchgate
Fig. 28 Club Cab Quarter Window & Rear Window Header Trim Panels—Ramcharger
Upper/Lower Trim Panels
QUARTER ROOF (2) Remove the quarter window trim panel and the
WINDOW INNER quarter panel lower trim panels. If necessary, refer
LOWER TRIM PANEL
SIDE TRIM PANEL \ C
SCREW to the removal procedures.
PANEL
QUARTER (3) Remove the rod retainer from the quarter panel
PANEL
SCREW support bracket.
(4) Remove the tire stand-off cap, nut, bolt and
QUARTER W I N D O W QUARTER W I N D O W spacer from the quarter window lower panel.
TRIM PANEL TRIM PANEL
LOWER S E C T I O N UPPER SECTION INSTALLATION
ROOF (1) Install the tire stand-off bolt, spacer, nut and
LOWER
SIDE TRIM
INNER cap. Tighten the nut to 41 N»m (30 ft. lbs.) torque.
PANEL
PANEL (2) Install the rod retainer in the quarter panel
SCREW support bracket hole.
ASH (3) Install the quarter window trim panel and the
CLIP
RECEIVER
RETAINER quarter panel lower trim panels. If necessary, refer
BEZEL
RETAINER
S C R E W
REAR to the installation procedures.
HEADER
RAIL
TRIM
(4) Install the spare tire.
PANEL
A S H RECEIVER LOWER SIDE QUARTER SIDE SIDE
ABOVE HATCHGATE WINDOW INNER INNER
LOWER SIDE TRIM PANEL
TRIM PANEL ' PANEL PANEL
TRIM PANEL AT FLOOR PANEL J9123-392 STAND-OFF
SPACER
Fig. 31 Quarter Panel & Hatchgate Header Trim BOLT
Panels—Removal/Installation
QUARTER PANEL LOWER TRIM PANELS CAP
TIRE STAND-OFF
REMOVAL
(1) For convenience, fold forward the rear passen
ger seat.
(2) Remove the spare tire.
(3) Remove the rear pillar panel screws from the
hatchgate pillar inner panel (Fig. 30).
NUT A N D INSERT J9123-409
(4) Pry the trim panel end retainers from the quar
ter inner panel slots.
Fig. 32 Spare Tire/Wheel
(5) Disengage the lower trim panel clip retainers
from the wheelhouse. SHOULDER BELTS/LAP BELT/BUCKLES
(6) Remove the lower trim panel from the vehicle.
WARNING: W H E N INSTALLING SHOULDER BELT,
INSTALLATION L A P BELT A N D B U C K L E A N C H O R BOLTS, VERIFY
(1) Position the lower trim panel in the vehicle at THAT T H E Y A R E T I G H T E N E D T O 40 N-M (350 I N .
the quarter. LBS.) T O R Q U E .
(2) Engage the trim panel clip retainers with the
wheelhouse rail retainers. INSPECTION
(3) Engage the trim panel end retainers with the Inspect the condition of all the belts and buckles
quarter inner panel slots. (Figs. 33, 34 and 35). Replace any belt or buckle that
(4) Position the rear pillar panel at the hatchgate is damaged in any way. Also, replace the shoulder
pillar panel. Install the screws and tighten to 1 N»m belt if the retractor is inoperative.
(5) Install the spare tire. FRONT SHOULDER BELTS/LAP
BELT/BUCKLES
SPARE TIRE CARRIER
REMOVAL
RETAINER ROD AND STAND-OFF
(1) If necessary, move the front seat(s) all the way
REMOVAL
forward for access.
(2) Disconnect the shoulder belt warning wire har
(1) Remove the spare tire (Fig. 32).
ness connectors.
(3) Bucket seats—detach the covers from the an
chor bolts for the left and right shoulder belt buckles.
(4) Remove the anchor bolts from the anchor plates
on the floor panel.
(5) Remove the buckles and the lap belt from the
floor panel.
• Ram Trucks and Chassis Cabs—Remove the cover
concealing the shoulder belt upper anchor bolt.
• Ramchargers—Remove the quarter window trim
panel. If necessary, refer to the removal procedure.
(6) Remove the upper anchor bolt from the cab in
ner side panel/B-pillar.
• Ram Trucks and Chassis Cabs—Remove the shoul
der belt retractor and lower anchor bolt from the
B-pillar.
• Ramchargers—Remove the screw and belt retrac
tor cover from the side inner panel. Remove the an
chor bolts. Remove the retractor and lower belt from
the side inner panel.
(7) Remove the shoulder belts and retractors from
the vehicle.
INSTALLATION Fig. 33 Ramcharger Bucket Seat Shoulder Belt

(1) Position the shoulder belt retractor and the Buckles
lower end of the shoulder belt at the side inner
panel. Align the anchor bolt holes. Install the anchor SHOULDER ANCHOR LAP
bolts. Tighten the anchor bolts to 40 N*m (350 in.
lbs.) torque.
• Ramchargers—Install the belt retractor cover and
the screw in the side inner panel. Tighten the screw
to 1 N»m (12 in. lbs.) torque.
(2) Position the shoulder belt upper anchor plate
on the trim panel. Install the upper anchor bolts in
#
the side panels. Tighten the anchor bolts to 40 N m
• Ram Trucks and Chassis Cabs—Install the cover
to conceal the shoulder belt upper anchor bolt.
• Ramchargers—Install the quarter window trim
panel. If necessary, refer to the installation proce BELT
dure. BUCKLE . J9123-608
(3) Position the belt buckles on the floor panel.
(4) Install the shoulder belt buckles. Install the lap Fig. 34 Bench Seat Shoulder Belt Buckle & Lap
belt and buckle anchor bolts in the floor panel. Belt/Buckle Anchors
Tighten the anchor bolts to 40 N«m (350 in. lbs.) (2) Remove the anchor bolts from the folding rear
torque. seat frame (Fig. 36).
• Bucket seats—Position the covers over the left and (3) Remove the buckles and the lap belt from the
right shoulder belt buckle anchor bolts. folding seat frame.
(5) Connect the shoulder belt warning wire har (4) Remove the covers concealing the shoulder belt
ness connectors. upper anchor bolt.
(6) If moved all the way forward for access, cor (5) Remove the shoulder belt upper anchor bolts
rectly position the front seat. from the roof inner liner.
REAR SHOULDER BELTS/LAP (6) Remove the shoulder belt lower anchor bolts
BELT/BUCKLES-RAMCHARGER from the floor panel.
(7) Remove the shoulder belt covers from the trim
REMOVAL panel.
(1) If necessary, move the front seat(s) all the way (8) Remove the quarter panel lower trim panels. If
forward for access. necessary, refer to the removal procedure.
• BODY COMPONENTS 23 • 47
SHOULDER COVER REAR

SPACER BELT TRIM FOLDING
"PANEL ANCHOR SEAT
BOLT
INNER
PANEL
SPACER
SHOULDER
PILLER BELT
SHOULDER
BELT RETRACTOR
ANCHOR
BOLT
SHOULDER
BELT FLOOR
PANEL
RETRACTOR
COVER
ANCHOR ANTI-
BOLT SCREW RATTLE
WASHER
ANTI- MODELS 30 & 60
RATTLE ANCHOR]
WASHER B O L T
RAMCHARGER J9123-329
ANCHOR
BOLT
Fig. 35 Shoulder Belt, Anchor Bolts & Retractor
(9) Remove the belt retractor support bracket an
chor bolts from the quarter panels.
(10) Remove the shoulder belts and the retractors
SEAT
from the vehicle. RELEASE J9123-610
INSTALLATION Fig. 36 Rear Folding Seat Shoulder Belt Buckle &

(1) Position the shoulder belt retractor support Lap Belt/Buckle Anchors
brackets at the quarters above the wheelhouse. In
ANCHOR ROOF OUTER
stall the support bracket anchor bolts in the quarter B O L T
LINER
SHOULDER
panels. Tighten the anchor bolts to 40 Nnn (350 in. BELT
lbs.) torque.
(2) Position the other end of the shoulder belt at
the floor panel. Install the lower anchor bolt in the
floor panel. Tighten the anchor bolts to 40 Nnn (350
in. lbs.) torque.
(3) Position the shoulder belt upper anchor plate at
the roof inner liner. Install the upper anchor bolts in
the roof inner liner. Tighten the anchor bolts to 40
Nnn (350 in. lbs.) torque.
(4) Position the covers over the upper anchor bolts.
(5) Install the quarter panel lower trim panel. If COVER •
necessary, refer to the installation procedure. SCREW"
(6) Install the shoulder belt cover on the trim SHOULDER^
BELT
panel. Tighten the screws to 1 Nnn (12 in. lbs.) RETRACTOR
SIDE
torque. INNER
ANCHOR PANEL
(7) Position the buckles and the lap belt on the BOLT
folding seat frame. J9123 -330
(8) Install the anchor bolts in the seat frame.
Tighten the bolts to 40 N-m (350 in. lbs.) torque. Fig. 37 Rear Seat Shoulder Belt—Ramcharger
(9) If applicable, adjust the front seat position.
JUMP SEAT LAP BELT/BUCKLE be bent during removal/installation. Permanent

damage possibly will result.
REMOVAL
(1) If necessary, move the front seat(s) all the way (1) Remove the sunvisors and clips. If necessary,
forward for access. refer to the removal procedure.
(2) Remove the lap belt buckle anchor bolt (Fig. (2) As applicable, remove the dome/cargo lamp
38). and/or the dome/reading lamp.
(3) Remove the lap belt and retractor anchor bolt. (3) Ram Trucks and Chassis Cabs, remove the:
(4) Remove the buckle and the lap belt/retractor • Windshield header trim moulding
from the floor panel. • Door header trim moulding
• Rear corner trim panel or quarter window trim
INSTALLATION panel (club cab)
(1) Position the lap belt/retractor and buckle on • Rear window upper trim moulding.
the floor panel. If necessary, refer to the trim removal procedure.
(2) Install the anchor bolts in the anchor plates. (4) Ramchargers, remove the:
Tighten the anchor bolts to 40 N*m (350 in. lbs.) • Windshield header trim moulding
torque. • Door header trim moulding
• Side trim moulding
• Center trim moulding
• Hatchgate header trim moulding
If necessary, refer to the trim removal procedure.
(5) Remove all other interfering components.
(6) As applicable, remove the headliner retainers
and screws (Fig. 41).
(7) Remove the headliner from the vehicle (Figs.
40 and 41).
INSTALLATION
(1) Position the headliner in the vehicle adjacent
to the roof panel.
(2) As applicable, install the headliner retainers
and screws. Tighten the screws to 1 N*m (12 in. lbs.)
torque.
(3) Install the trim, lamps and all other compo
Fig. 38 Jump Seat Lap Belt/Buckle Anchors
nents t h a t were removed. If necessary, refer to the
HEADLINERS applicable installation procedures.
SERVICE INFORMATION
The base headliner is constructed of molded hard-
board (Fig. 39). A cloth-covered, molded headliner is
used for most applications (Fig, 40).
Ramchargers are equipped with a cloth-covered,
molded two-piece headliner. The separation between
the front and rear headliners is concealed by a
push-on trim moulding (Fig. 41).
To remove a headliner, all of the overlapping trim
must be removed along with (as applicable):
• Sunvisors
• Dome/cargo lamps
• Dome/reading lamp
• Coat hooks
• Any other interfering attached component
Fig. 39 Molded Hardboard Cab Headliner
REMOVAL
C A U T I O N : Headliners are constructed of molded
material. They have limited flexibility. They must not
• ^ ^ — BODY COMPONENTS 23 - 49
ROOF ROOF HEADLINER RETAINER ROOF

INNER INNER v RAIL INNER
HEADLINER PANEL PANEL \ PANEL
ROOF FRONT
INNER HEADLINER REAR
PANEL SIDE HEADLINER
TRIM
MOULDING
SCREW
SIDE OF VEHICLE SCREW
ROOF INNER RETAINER SNAP-ON
PANEL TRIM MOULDING ENDCAP
WINDSHIELD CENTER OF VEHICLE
WEATHERSTRIP FRONT
SEAL ROOF INNER
ROOF HEADLINER PANEL
RAIL REAR
HEADER HEADLINER
TRIM PANEL HEADLINER J9123-353
SCREW
Fig. 40 Cloth-Covered Molded Cab Headliner

WINDSHIELD SCREW
ROOF RETAINER RAIL HEADER SUN VISOR SCREW REAR TRIM
INNER CENTERING TRIM SCREW ARM MOULDING
PANEL HOLE MOULDING REAR OF VEHICLE
FRONT OF VEHICLE J9123-359
REAR
HEADLINER Fig. 43 Ramcharger Sunvisor & Headliner Trim
Moulding
ROOF
INNER
PANEL
BRACKET
TRIM BRACKET
RETAINER 'MOULDING
PERIMETER BULB HEADLINER
RETAINER INSTALLATION J9123-358 HOLDER
Fig. 41 Ramcharger Headliner LENSE

DOME SCREW BULB
INNER LAMP HOLDER
BACK
PANEL DOME LAMP DOME LAMP
ROOF — WITH HEADLINER CLUB CAB
REAR
INNER WINDOW J9123-401
PANEL UPPER TRIM
Fig. 44 Ram Truck/Chassis Cab Dome Lamps
DOME/READING LAMP
REMOVAL
(1) Squeeze the dome lamp lense to remove it from
the bracket.
SUNVISOR DOME LAMP LENSE (2) If applicable, remove t h e lense bracket screws.
SUNVISOR DOME AND WINDOW TRIM
AND WINDSHIELD (3) Remove the lense bracket from the headliner
LAMP
HEADER TRIM L E N S E and roof inner panel.
J9l 23-352
(4) Disconnect the bulb holder wire harness con
Fig. 42 Ram Truck/Chassis Cab Sunvisor & Dome nectors (Fig. 44).
Lamp (5) Remove the lense, bulb holder and bracket
from the roof inner panel.
INSTALLATION
(1) Position the dome/reading lense, bulb holder
and lense bracket to the roof inner panel.
23 - 50 BODY COMPONENTS — < ^ ^ • •
(4) Remove the screw and the clip from the roof in
ner panel.
INSTALLATION
(1) Install the sunvisor clip with the screw.
Tighten the screw to 4 N*m (35 in. lbs.) torque,
(2) Position the sunvisor in the clip. Align the a r m
support bracket holes with the headliner holes.
(3) Install the screws t h a t attach the sunvisor a r m
support bracket to the roof inner panel. Tighten the
screws to 4 N * m (35 in. lbs.) torque.
FLOOR CONSOLE AND REAR STORAGE TRAY

DOME LAMP DOME/READING LAMP
J9123-400 CONSOLE
Fig. 45 Ramcharger Dome Lamp & Dome/Reading REMOVAL

Lamp (1) Open the console lid (Fig. 46).
(2) Connect the bulb holder wire harness connec (2) Remove the console front and rear screws from
tors. the floor panel.
(3) Insert the lense bracket in the headliner hole. (3) Remove the console from the floor.
Install the screws in the roof inner panel. Tighten
#
the screws to 4 N m (35 in. lbs.) torque. INSTALLATION
(4) Install the lamp lense on the bracket. (1) Position the console on the floor.
(2) Install the screws in the floor panel. Tighten
DOME LAMP-CLUB CAB screws to 4 N«m (35 in. lbs.) torque.
(3) Close the console lid.
REMOVAL
(1) Remove the screws and t h e dome lamp lense STORAGE TRAY-STANDARD CAB
from the lamp housing (Fig. 44).
(2) Disconnect the bulb holder wire harness con REMOVAL
nectors. (1) Remove the contents from the storage tray.
(3) Remove the screws and t h e bulb holder bracket (2) Remove the screws from the floor panel and t h e
from the lamp housing. tray (Fig. 47).
(4) Remove the bulb holder and bracket from the (3) Remove the storage tray from the floor panel.
lamp housing.
INSTALLATION
INSTALLATION (1) Position the storage tray on the floor panel.
(1) Position the bulb holder and bracket a t the (2) Install the screws in the tray and floor panel.
lamp housing. Tighten the screws to 4 N«m (35 in. lbs.) torque.
(2) Install the bulb holder bracket screws in the
lamp housing. Tighten the screws to 4 N°m (35 in.
lbs.) torque.
(3) Connect the bulb holder wire harness connec
tors.
(4) Position the lense on the lamp housing. Install
#
the screws. Tighten the screws to 4 N m (35 in. lbs.)
torque.
SUNVISORS
REMOVAL
(1) Remove the screws t h a t attach the sunvisor
arm support bracket to the roof inner panel (Figs. 42
and 43).
(2) Detach the sunvisor from t h e clip.
(3) Remove the sunvisor from t h e roof inner panel. Fig. 46 Floor Console
CAB
Fig. 47 Standard Cab Storage Tray Fig. 48 Carpet Or Mat—Standard Cab

CARPETS AND FLOOR HATS CAB
To remove a carpet/mat, all of the adjacent trim
panels must be removed. Also interfering components
should be removed as well as:
• Seat(s)
• Scuff plates
• Transmission and transfer case floor shift levers,
bezels and boots.
• Floor console
REMOWAL
(1) Remove the protective floor mats (if equipped).
(2) Remove all the interfering components.
(3) Remove the trim panels, retainers, sill-well
covers and scuff plates.
(4) Remove the carpet/mat from the floor panel
Fig. 49 Rear Floor Noise Insulator & Sill-Well
and the vehicle. Cover—Standard Cab
INSTALLATION
(1) Position the carpet/mat on the floor panel. CLUB RETAINER
(2) Install seat(s) and all other necessary compo

nents. If necessary, refer to the applicable installa
tion procedure(s).
(3) Install the trim panels, retainers, sill-well cov
ers and scuff plates.
(4) Place the floor mats (if equipped) on the carpet/
mat.
Fig. 50 Carpet, Scuff Plate, Sill-Well Cover & Rear

Retainer— Club Cab
C
AB WH
EE
LH
OUSE REA
R S
CR
EWRE
AR S
CR
EW
SD
IE RE
TA
NIE
R
TRM
I CA
RPE
T F
LOOR
C
ARPET C
ARP
ET
,1.5 IN
RE
AR A
D H E
SV IE REA
RS EA
T
TR
MI E
SCU
TC
HEO
N
C
ARPET N OS
IE ^ N D
N
IS
U L
ATOR nj
F
RON T ~*
RET
AN
IERS
FR
O NT;
! REA
R *
FL
OOR F
LOO
R
CA
RPET . C
ARP
ET
S D OOR
NOS
IE: S
LIL
N
ISUL
ATO
R PA
NEL PA
N EL
D
ASH \ C
ARP
ET S
CS
UC
U
F
FFF J9
123
-
4 1
3
PANEL X AR
PET PL
AT
E PL
AT
E
Fig. 54 Carpet, Scuff Plate, Rear Seat Striker

Escutcheon & Retainers-Ramcharger
R
EAR
FL
OO R
J
912
3-
378 NOSIE
Fig. 51 Side & Rear Panel Trim Carpet-Club Cab N
IS
ULA
T OR
PA
D
RE
AR R
ETA
N
IE
R
F
L
OOR
MAT
C
ARP
ET
A
DHE
SV
IE
F
RON
T ;WHE
EL
HOU
SE
SL
I
LW
- E L
L NOS
IE
F
L
OOR N
IS
ULAT
O
IN
COVER N
IS
ULA
TOR
MAT F
L
I
LER J
912
3-
412
S
CUF
F PA
D
NOS
IE P
LA
TE
N
IS
ULA
TOR D
O OR Fig. 55 Rear Floor Noise Insulator Pad, Insulation
S L
IL Filler & Carpet—Ramcharger
DA
SH F
L
OOR F
L
OOR F
L
OORJ91
23-
418
P
ANEL MAT 1/2 N
IC
H MAT P
ANE
L
Fig. 52 Floor Mat, Scuff Plate, Si 11-WeiI Cover &
Rear Retainer—Club Cab
C
LU
B R
EAR
CA
B FL
OO R
NOSIE
N
IS
ULA
T OR
PA
D
J9123 416
K52' \ ^ -
Fig. 53 Rear Floor Noise Insulator-Club Cab
BODY COMPONENTS 23 - 53
HOL
E FOR HOL
E FOR TR A
N SF
ERC AS
E
4
S
-PE
ED HOLE FOR A 833O VE
RDR
VIE
T
RANSMS
IS
O
IN TRANSMSIS
OIN SC
RE
W
CA
RPT>QR\
E
RS C R
EWOR MAT PLAT
E
CA
OR F
M
R
P
L
O
A
ET
OR
T S
*
C
"R
E
C
O
W S
V
E
A
E
L SCR
EW ' B
SC
RE
W t
TRANS
FER OO
T
CAS
E F LOO RN ISUL
A1
TO
IN^, SEA
L
S H
FIT LE
VER P ANEL PA
D
C O
VER SH
FIT
LEV
E R
CARP
ET COVER
OR MAT W A
SH
ER
S
CR E
W C ARP
ET
F
LOO R OR MAT
PANE L
T
RANSM
SIS
O
IN
S
HF
IT LE
VE
R NIS
ULAT
O
IN
B
OOTS E
AL PA
D
A
833
4
S
-PE
E DT R AN S
MSIS
O
IN O
VER
DR
VI
E TRANSM
SISO
IN
ANb TRANSFER C
ASE J
912
3 4
-06
Fig. 56 Transmission & Transfer Case Shift

Mechanisms
REFINISHING PROCEDURES
SERVICE INFORMATION ble. For best results, use Mopar®Scratch Filler/
Exterior vehicle body colors are identified on the Primer, Touch-up Paints and Clear Top Coat. Refer
Body Code plate. The plate is attached to the top, to Introduction group of this manual for Body Code
right side of the cowl below the cowl grille. The color Plate information.
code location is described in the manual introduction.
OEM paint colors are generally available from all TOUCH-UP

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19 9 3

REAR WHEEL DRIVE

1993 DODGE TRUCKS

To order the special service tools used and

NO PART OF THIS PUBLICATION MAY BE

Chrysler Corporation reserves the right to make changes in design or to make

Litho in U.S.A. Copyright © 1992 Chrysler Corporation 1 5 M 0 9 9 2

GROUP TAB LOCATOR

0 Lubrication and Maintenance

2 Front S u s p e n s i o n and Axle

3 Rear S u s p e n s i o n and Axles

11 Exhaust S y s t e m and Intake Manifold

21 Transmission and Transfer C a s e

22 Wheels and Tires

24 Heating and Air Conditioning

Component and System Index

Service Manual Comment Forms (Rear of Manual)

DESIGNATIONS, LABELS/PLATES/DECALS, CODES A N D DIMENSIONS/WEIGHTS

VEHICLE DESIGNATIONS VEHICLE CODE DESIGNATIONS

Country Vehicle Type Truck Line Engines Sequential

PRIMARY SECONDARY VINYL R O O F EQUIPMENT IDENTIFICATION PLATE

Fig. 2 Vehicle Code Plate MODELS V.I.N. T.O.N.

Line #2 Digit 1-3 Paint Procedure . ^

Line #3 Digit 1-12 V e h i c l e O r d e r Number

® Driver seat to tailgate.

E N G I N E & SALES CODE TRANSMISSION

D100 2692 mm 2540 kg

D150 2692 mm 2540 kg

W100 2692 mm 2722 kg

S = STANDARD ® = Not available in California.

MODEL/ BODY (3) GVWR

31 2722 kg 6000 lbs 852 kg 1878 lbs 1870 kg 4122 lbs

32 2722 kg 6000 lbs 787 kg 1736 lbs 1934 kg 4264 lbs

32 3357 kg 7400 lbs 1369 kg 3019 lbs 1987 kg 4381 lbs

32 2903 kg 6400 lbs 789 kg 1740 lbs 2114 kg 4660 lbs

32 3402 kg 7500 lbs 1259 kg 2775 lbs 2143 kg 4725 lbs

RAM CHASSIS CAB

MODEL/ BODY(3) PAYLOAD CURB

D250 AD2 62 3357 kg 7400 lbs 1721 kg 3794 lbs

D350 AD3 62 3946 kg 8700 lbs ID 1794 kg 3954 lbs

4581 kg 2032 kg 4479 lbs

W250 AD6 62 3860 kg 8510 lbs 1.) 1886 kg 4158 lbs

W350 AD7 62 3946 kg 8700 lbs ID 2038 kg 4494 lbs

RAMCHARGER - SPORT UTILITY

MODEL/ BODY(3) PAYLOAD CURB

ALLOWABLE TONGUE WEIGHTS

D/W150/150S Ramcharger All 800

GCWR - GROSS COMBINED WEIGHT RATING

MEASUREMENT AND TORQUE SPECIFICATIONS

SPECIFICATION NOTATIONS threads. Reduce the torque value by 10 percent when

Inches x 25.4 « Millimeters (mm) mm x 0.03937 « Inches

STANDARD TORQUE SPECIFICATIONS

J89IN-9 Fig. 1 SAE Bolt Grade Identification

LUBRICATION AND MAINTENANCE

CHASSIS AND BODY 28 ENGINE MAINTENANCE 14

sion controls function correctly. The recommended

It is necessary to schedule maintenance as a time in­

CAUTION: UNLEADED FUEL ONLY must be u s e d in OIL

API SERVICE GRADE — USAGE AND

COMPONENTS REQUIRING NO LUBRICATION • Drive shaft center bearings

LIGHT DUTY CYCLE

X = Scheduled maintenance for all vehicles.

Coolant Condition, Coolant Hoses/Clomps X X X X X X O O O O O O O O o O

It is necessary to schedule maintenance as a time in

C A U T I O N : D o not allow the positive ( + ) and nega ENGINE BATTERY

WARNING: WHEN A SERVICE PROCEDURE R E

CAUTION:lt is not recommended to flat tow a vehi

Drain, flush, and fill the cooling system at the in

The condition of the ATF also should be deter

C A U T I O N : D o not add lubricant to the wheel bear