1 9 9 0

SERVICE
MANUAL

REAR WHEEL DRIVE

RAM TRUCK

^ CHRYSLER
W MOTORS
 CHRYSLER
MOTORS

1990

SERVICE MANUAL

DODGE TRUCKS

^ CHRYSLER
W MOTORS

No p a r t of this p u b l i c a t i o n m a y be reproduced,
stored i n a r e t r i e v a l system or t r a n s m i t t e d i n
any f o r m , or by a n y means, electronic, mechan-
ical, photocopying, recording, or otherwise w i t h -
out t h e p r i o r w r i t t e n permission of Chrysler
Motors.

To order t h e special service tools used a n d i l l u s -

t r a t e d , please refer to t h e instructions on inside
back cover.

Chrysler Motors reserves t h e r i g h t to change

t e s t i n g procedures, specifications, diagnosis, or
repair methods a t a n y t i m e w i t h o u t p r i o r notice
or i n c u r r i n g obligation.

L i t h o i n U.S.A. Copyright ©1989 Chrysler Motors 20M1189

 COMPONENT AND SYSTEM INDEX
Name Group-page Name Group-page

ACCESSORIES 1-1 ELECTRICAL 8A-1

SNOW PLOW 1-1 ALTERNATOR TEST PROCEDURES ON VEHICLE. . . 8A-14
SPECIFICATIONS .1-17 BATTERY TEST PROCEDURES ON VEHICLE 8A-2
ALTERNATOR SERVICE 8C-1 BATTERY/STARTING/CHARGING SYSTEMS
SPECIFICATIONS 8C-2 DIAGNOSTICS 8A-1
BATTERY/STARTER SERVICE 8B-1 DIAGNOSTIC INFORMATION 8A-1
BATTERY SERVICE PROCEDURES . . . . . . 8B-1 GROUP INDEX . . . . . ." 8A-1
SPECIFICATIONS 8B-6 SPECIFICATIONS 8A-19
STARTER SERVICE PROCEDURES 8B-4 STARTER TEST PROCEDURES ON VEHICLE 8A-9
BODY 23-1 EMISSION CONTROL SYSTEMS 25-1
CORPORATE IDENTITY CODE 23-38 AIR INJECTION SYSTEM 25-17
DOOR SYSTEMS 23-20 EVAPORATIVE EMISSION CONTROLS 25-2
EXTERIOR PAINT 23-38 EXHAUST EMISSION CONTROLS 25-9
FIXED GLASS 23-27 SERVICE PROCEDURES 25-22
GLASS SYSTEMS . 23-24 ENGINE . . . 9-1
INTERIOR TRIM 23-1 3.9L ENGINE SERVICE PROCEDURES 9-10
INTERIOR TRIM COLOR 23-38 5.2L75.9L ENGINE SERVICE PROCEDURES 9-39
LATCH AND LOCK SYSTEMS 23-20 ENGINE DIAGNOSIS 9-7
REFilMISHING PROCEDURES 23-32 GENERAL INFORMATION 9-1
SHEET METAL 23-10 STANDARD SERVICE PROCEDURES 9-4
BRAKES 5-42 EXHAUST SYSTEM AND INTAKE MANIFOLD 11-1
11- INCH DRUM BRAKE '* . 5-42 EXHAUST DIAGNOSIS 11-3
12- INCH DRUM BRAKE 5-46 GENERAL INFORMATION 11-1
BENDIX DISC BRAKE 5-32 SERVICE PROCEDURES 11-3
CHRYSLER DISC BRAKE 5-22 FRAME STRUCTURES 13-1
COMPONENT SERVICE . 5-61 INSPECTION PROCEDURES 13-6
GENERAL INFORMATION 5-1 LIGHT DUTY MODELS 13-12
MASTER CYLINDER-COMBINATION SERVICE PROCEDURES 13-11
VALVE-BRAKE LINES 5-10 SPECIFICATIONS 13-12
PARKING BRAKES V 5-52 TIGHTENING REFERENCE 13-12
POWER BRAKE BOOSTER-BRAKE PEDAL 5-20 FRONT SUSPENSION 2-1
REAR WHEEL ANTI-LOCK BRAKE SYSTEM (RWAL) . 5-55 FRONT SUSPENSION COMPONENT
RWAL SERVICE DIAGNOSIS 5-59 SERVICE—2WD VEHICLES 2-7
SERVICE ADJUSTMENTS 5-6 FRONT WHEEL ALIGNMENT 2-3
SERVICE DIAGNOSIS 5-2 GENERAL INFORMATION 2-1
CLUTCH 6-1 MODEL 44 FRONT AXLE SERVICE—4WD VEHICLES . . 2-15
CLUTCH SERVICE 6-11 MODEL 60 FRONT AXLE SERVICE—4WD VEHICLES . . 2-51
GENERAL INFORMATION 6-1 SPECIFICATIONS 2-80
SERVICE DIAGNOSIS 6-2 FUEL SYSTEM 14-1
COOLING SYSTEM . . . . 7-1 ACCELERATOR PEDAL AND THROTTLE CABLE . . . 14-15
ACCESSORY DRIVE BELTS 7-21 DUAL POINT FUEL INJECTION 14-17
COOLING SYSTEM DIAGNOSIS : 7-4 FUEL DELIVERY SYSTEM 14-3
DIAGNOSIS 7-3 FUEL TANKS 14-9
ENGINE BLOCK HEATERS . . . 7-24 GENERAL DIAGNOSIS 14-31
SERVICE PROCEDURES 7-8 SERVICE PROCEDURES 14-47
SPECIFICATIONS 7-25 HEATING AND AIR-CONDITIONING .24-1
DRIVE SHAFTS AND UNIVERSAL JOINTS . . 16-1 AIR-CONDITIONING 24-8
GENERAL INFORMATION 16-1 COMPRESSOR SERVICE 24-29
SERVICE PROCEDURES 16-10 DIAGNOSING AIR-CONDITIONING 24-11
SPECIFICATIONS . 16-27 EVAPORATOR HEATER ASSEMBLY 24-36
ELECTRICAL WIRING DIAGRAMS 8W-1 HEATER 24-1
COMPONENT IDENTIFICATION 8W-7 PERFORMANCE TEMPERATURE CHART 24-18
ELECTRICAL WIRING DIAGRAMS REFRIGERANT SYSTEM SERVICE PROCEDURES . . 24-22
WIRE ROUTING AND COMPONENT LOCATION. . 8W-37 SERVICE PROCEDURES 24-6
SPLICE LOCATION 8W-27 SERVICE PROCEDURES 24-26
WIRING DIAGRAMS 8W-1 TEST PROCEDURES 24-11

k
HORNS 8G-1 TEST PROCEDURES 8N-1
SERVICE PROCEDURES 8G-2 SPEED CONTROL SYSTEM 8H-1
TEST PROCEDURES 8G-1 SERVICE PROCEDURES 8H-9
TEST PROCEDURES 8H-5
IGNITION SYSTEMS 8D-1
SPRINGS/SHOCK ABSORBERS 17-1
COMPONENT IDENTIFICATION 8D-1
GENERAL INFORMATION '. 17-1
DIAGNOSTIC PROCEDURES 8D-9
SERVICE PROCEDURES 17-3
SERVICE PROCEDURES 8D-11 SPECIFICATIONS 17-12
SPECIFICATIONS 8D-15 STEERING 19-1
INSTRUMENT PANEL AND GAUGES 8E-1 GENERAL INFORMATION 19-1
CLUSTER AND GAUGE SERVICE AND TESTING . . . . 8E-4 MANUAL STEERING GEAR SERVICE 19-6
GENERAL INFORMATION 8E-1 POWER STEERING GEAR SERVICE 19-16
SWITCH AND PANEL COMPONENT SERVICE 8E-15 POWER STEERING PUMP SERVICE 19-39
INTRODUCTION . . lntro.-2 SPECIFICATIONS 19-70
CONVERSION TABLES lntro.-12 STEERING COLUMN SERVICE 19-54
CONVERSION TABLES (CONT.) lntro.-13 STEERING LINKAGE SERVICE 19-4
INTRODUCTION lntro.-2 TIRES AND WHEELS 22-1
POWER TEAM AVAILABILITY lntro.-5 GENERAL INFORMATION 22-1
STANDARD TRUCK BODY DIMENSIONS . . . . . . . -Intro.-9 SPECIFICATIONS 22-19
TORQUE REFERENCES Intro.-10 TIRE SERVICE 22-8
TRUCK MODEL LINE-UP AND WEIGHTS lntro.-7 WHEEL SERVICE 22-16
VEHICLE AND COMPONENT IDENTIFICATION. . . . lntro.-2 TRANSMISSION-TRANSFER CASE 21-1
LAMPS 8L-1 A833 MANUAL TRANSMISSION 21-1
EXTERIOR LAMPS . 8L-1 NP2500 MANUAL TRANSMISSION 21-16
EXTERIOR LAMPS SERVICE PROCEDURES . . . 8L-3 NP435 MANUAL TRANSMISSION .21-36
INTERIOR LAMPS 8L-10 SERVICE IN VEHICLE 21-3
SPECIFICATIONS 8L-11 SERVICE IN VEHICLE 21-17
LUBRICATION AND MAINTENANCE 0-1 SERVICE OUT OF VEHICLE 21-5
CHASSIS AND BODY .0-28 SERVICE OUT OF VEHICLE 21-20
DRIVETRAIN . 0-22 A-500/A-518 AUTOMATIC TRANSMISSION 21-111
ENGINE . . . . 0-14 GENERAL INFORMATION 21-111
GENERAL INFORMATION 0-1 A-998/999/727 AUTOMATIC TRANSMISSION 21-43
POWER LOCKS 8P-1 GENERAL INFORMATION 21-43
SERVICE PROCEDURES 8P-2 DIAGNOSIS AND TEST PROCEDURES 21-49
TEST PROCEDURES 8P-1 IN-VEHICLE SERVICE 21-75
POWER MIRRORS 8T-1 MAINTENANCE AND ADJUSTMENTS 21-71
SERVICE PROCEDURES 8T-2 SUBASSEMBLY OVERHAUL 21-93
TEST PROCEDURES 8T-1 TRANSMISSION AND TORQUE CONVERTER
POWER WINDOWS 8S-1 REMOVAL/INSTALLATION 21-87
SERVICE PROCEDURES 8S-4 TRANSMISSION OVERHAUL 21-91
TEST PROCEDURES 8S-1 IN-VEHICLE SERVICE 21-140
RADIO, ANTENNA AND SPEAKERS • 8F-1 NP205 TRANSFER CASE 21-130
SERVICE PROCEDURES 8F-6 NP241 TRANSFER CASE 21-138
TEST PROCEDURES 8F-4 OUT-OF VEHICLE SERVICE 21-142
REAR AXLES 3-1 TURN SIGNALS AND HAZARD WARNING FLASHER . . . 8J-1
8 3/8- AND 9 1/4-INCH DIAMETER RING GEAR SERVICE PROCEDURES : 8J-4
AXLE SERVICE 3-9 TESTING PROCEDURES 8J-2
GENERAL INFORMATION 3-1 WARNING BUZZER/CHIME MODULE 8M-1
MODEL 60, 60M AND 70 AXLES SERVICE 3-33 SERVICE PROCEDURES 8M-3
NOISE DIAGNOSIS 3-2 TEST PROCEDURES 8M-1
REAR AXLE ALIGNMENT 3-8 WINDSHIELD WIPER AND WASHER SYSTEMS 8K-1
SPECIFICATIONS 3-56 INTERMITTENT WINDSHIELD WIPER FUNCTION
TIRE/WHEEL BALANCE 3-8 AND SWITCH TESTING PROCEDURES. 8K-5
REAR WINDOW DEFOGGER 8N-1 TWO SPEED WINDSHIELD WIPER MOTOR AND
REPAIR PROCEDURES (GRID LINES, TERMINALS, SWITCH TESTING PROCEDURES 8K-1
AND PIGTAILS) 8N-3 WINDSHIELD WASHERS 8K-15
SERVICE PROCEDURES 8N-4 WINDSHIELD WIPER SYSTEM SERVICE PROCEDURES. . 8K-7

II
FOREWORD
GROUP TITLE
The i n f o r m a t i o n contained i n t h i s service m a n u a l
has been prepared for t h e professional automotive
technician involved i n d a i l y r e p a i r operations. Infor-
— Introduction
m a t i o n i n t h i s m a n u a l i s divided i n t o groups. Each
group covers a general vehicle system (brakes, steer- 0 Lubrication and Maintenance
i n g , body, etc.). Each group i s f u r t h e r divided t o ad-
dress i n d i v i d u a l components o r systems w i t h i n t h e 1 Accessories
group.

The Component and System Index w i l l assist you 2 Front Suspension

i n locating t h e correct group for t h e component or
system y o u require. 3 Rear Axle
These groups contain general i n f o r m a t i o n , diagno- 5 Brakes
sis, testing, adjustment, removal and i n s t a l l a t i o n , as-
sembly a n d disassembly procedures for t h e
components. 6 Clutch

The diagnosis charts are designed t o help you lo- 7 Cooling System
cate a n d correct problems w i t h a systematic ap-
proach. The t a b locator a t the r i g h t side o f t h i s page
8 Electrical
w i l l help y o u t o q u i c k l y locate t h e first page o f each
group. T h e f i r s t page o f each group contains a n a l -
phabetical index t o assist i n t h e location o f the com- 9 Engine
ponent or system.
1 1 Exhaust System/Intake Manifold
The i n f o r m a t i o n , descriptions, t e s t i n g procedures,
and specifications were i n effect a t t h e t i m e t h i s
1 3 Frame
m a n u a l was released for p r i n t i n g .

I n f o r m a t i o n describing t h e operation a n d use of 1 4 Fuel System

standard a n d optional equipment is included i n t h e
Owner's M a n u a l located i n t h e glove box. 1 6 Propeller Shaft—Universal Joints

1 7 Springs—Shock Absorbers

1 9 Steering

2 1 Transmission

2 2 Wheels and Tires

2 3 Body

2 4 Heati ng and Air Conditioning

2 5 Em issions Control Systems

2 INTRODUCTION •
INTRODUCTION

VEHICLE AND COMPONENT IDENTIFICATION

VEHICLE CODE VEHICLE IDENTIFICATION NUMBER (V.I.N.)
The Dodge R a m Pickup, Chassis Cab a n d Sport The Vehicle I d e n t i f i c a t i o n N u m b e r (V.I.N.) is l o -
U t i l i t y Vehicle Code C h a r t is described below ( F i g . cated o n t h e upper left corner o f the i n s t r u m e n t
1): panel, near t h e w i n d s h i e l d . A l l V I N ' s consist o f 17
characters i n a c o m b i n a t i o n o f letters and numbers
t h a t provide specific i n f o r m a t i o n about t h e vehicle
VEHICLE CODE = AD (DODGE RAM
PICKUP & CHASSIS CAB) (Fig. 2).
The V . I . N . i s also located on t h e Equipment Iden-
VEHICLE t i f i c a t i o n Plate, t h e Vehicle Safety Certification L a -
DESCRIPTION bel a n d o n t h e frame r a i l .
FAMILY LINE

ADl D150 EQUIPMENT IDENTIFICATION PLATE

PICKUP
AD2 D250 4x2
AD3 D350 The equipment i d e n t i f i c a t i o n plate, contains infor-
m a t i o n r e g a r d i n g t h e vehicle: model, wheel base,
AD5 W150 V . I . N . (Vehicle I d e n t i f i c a t i o n Number), T.O.N. (Or-
PICKUP der N u m b e r ) , a n d a l l production or special equip-
AD6 W250 4x4
AD7 W350 m e n t o n t h e vehicle w h e n i t was shipped from t h e
factory (Fig. 3). A l w a y s refer to t h i s plate w h e n or-
AD2 D250 CHASSIS CAB d e r i n g parts.
AD3 D350 4x2
The E q u i p m e n t I d e n t i f i c a t i o n Plate is located o n
t h e under hood panel i n t h e r i g h t front corner.
AD6 W250 CHASSIS CAB
AD7 W350 4x4
VEHICLE SAFETY CERTIFICATION LABEL
AD4 AD 100 SPORT UTILITY A vehicle safety certification label (Fig. 4) is a t -
AD4 AD 150 4x2 tached t o t h e rear f a c i n g o f the driver's door. This la-
bel reflects t h e date o f manufacture (month a n d
AD8 AD 100 SPORT UTILITY year), Gross Vehicle W e i g h t R a t i n g (GVWR), Gross
AD8 AD 150 4x4 A x l e W e i g h t R a t i n g (GAWR) front, Gross A x l e
W e i g h t R a t i n g ( G A W R ) rear and t h e Vehicle I d e n t i -
J90IN-32 fication N u m b e r ( V I N ) . T h e M o n t h , Day and H o u r o f
manufacture is also included on t h i s label.
Fig. 1 Vehicle Code Chart
A l l communications o r i n q u i r i e s regarding t h e ve-
hicle should include t h e Month-Day-Hour and V e h i -
cle I d e n t i f i c a t i o n N u m b e r .

BODY CODE PLATE

T h i s plate is r i v e t e d t o t h e i n n e r panel under t h e
cowl on t h e passenger side.
There a r e seven (7) lines of i n f o r m a t i o n on t h i s
plate. I n f o r m a t i o n reads from left to r i g h t , s t a r t i n g
w i t h l i n e 1 a t the b o t t o m of the plate to line 7 a t the
top (Fig. 5).
 • INTRODUCTION 3

COUNTRY Vehicle Type Truck Line Engines Sequential

1 = United States 4 = Multipurpose E = Ramcharger X - 3.9L (EFI Serial Number
2 = Canada Passenger Ram Chassis Cab Y = 5.2L EFI Six Digit Numbers
3 = Mexico 5 = Bus Ram Pickup 4x2 Z . 5.9L EFP
6 = Incomplete M m Ramcharger 5 = .9L (EFI
7 = Truck Ram Chassis Cab 8 =
Ram Pickup 4x4

Make GVWR
B = Dodge Hydraulic Check Diait
D = 0001 - 3000 Number or Letter
E = 3001 - 4000 Series
F = 4001 - 5000 0 = 150S Job Rated
G = 5001 - 6000 1 = 150 Job Rated
H = 6001 - 7000 2 = 250 Job Rated Body Plant Location
J = 7001 - 8000 3 = 350 Job Rated 3 = Club Cab S as Dodge City
K = 8001 - 9000 6 = Conventional Cab M = Lago Alberto
L = 9001 - 10,000 7 = Sport Utility 2 DR
M = 10,001 - 14,000
W = Bus or Inc. J90IN-33

Fig. 2 Vehicle Identification Number (VIN)

PRIMARY SECONDARY VINYL ROOF

'OOBBMB EQUIPMENT IDENTIFICATION 42is»e PAINT PAINT CODE
I
MODELS V.I.N. T.O.N.
CODE NO. DESCRIPTION CODE N O . DESCRIPTION VEHICLE
VEHICLE MODEL
ORDER- •NUMBER
NUMBER
ENGINE
(3) XXX >XXXXX)X XXX XXXXXX
PAINT- -CODE
PROCEDURE (2) XXX XXXX XXXX XXXX XXX
-INTERIOR
0) XXX X XXXXXXXXXXXXXXXXX TRIM CODE

Fig. 3 Equipment Identification Label TRANSMISSION I VEHICLE IDENTIFICATION

CODE I NUMBER
| GVWR MARKET U-C-B-M
CHRYSLER , U A i t ur MruK.
CODE 90IN-3
GAWR FRONT 1 WITH TIRES i RIMS AT |PSI COLD
Fig. 5 Body Code Plate
a l i n e to punch t h e f u l l 6 digits, t h e balance of t h a t
line w i l l be left b l a n k a n d t h e SEC code w i l l be
VEHICLE NUMBER I VEHICLE TYPE punched on t h e next line.
The last nine positions o f line #7 w i l l contain a
J901N-17 two d i g i t species, when applicable, and a six d i g i t
Fig. 4 Vehicle Safety Certification Label gateline sequence number (the last six numbers of
the V I N ) .
Refer to t h e body code plate c h a r t (lines 1 t h r u 3)
The last code shown o n either plate w i l l be fol-
for detailed i n f o r m a t i o n (Fig. 6).
lowed by E N D . When t w o plates are required, t h e
Lines 4 t h r u 7, o f t h e body code plate, are se-
last code space on the first plate w i l l show C T D (for
quenced on t h e plate as follows:
continued).
• 3 d i g i t sales codes
W h e n a second plate is required, t h e first four
• 3 d i g i t n u m e r i c codes
spaces of each l i n e w i l l not be used due to overlap of
• 6 d i g i t SEC codes
the plates.
W h e n there is a n SEC code t o be punched o n t h e
body code plate and there is not enough room left on
 INTRODUCTION

Transmission Sales Code

TRANSMISSION IDENTIFICATION
Line #1 Digit 1-3
Digit 4 Open Space
Digit 5 Market Code - U-C-B-M Specific l i g h t a n d m e d i u m d u t y vehicles referred t o
Digit 6 Open Space i n t h i s m a n u a l c a n be identified b y p a r t n u m b e r ,
Digit 7-23 Vehicle I d e n t i f i c a t i o n No. model a n d b u i l t date supplied o n t h e Transmission
Line #2 Digit 1-3 Paint Procedure Identification T a g .
Digit 4 Open Space Operation requirements are, i n some instances, dif-
Digit 5-8 Primary Paint
Digit 9 Open Space ferent for each vehicle a n d engine combination a n d
Digit 10-13 Secondary Paint some i n t e r n a l p a r t s w i l l also be different. Therefore,
Digit 14 Open Space w h e n replacing parts, refer t o t h e n u m b e r stamped
Digit 15-18 Trim Code
Digit 19 Open Space on left side o f t h e transmission o i l p a n flange.
Digit 20-22 Engine Sales Code M A N U A L TRANSMISSION: A n aluminum Identi-
Digit 23 Open Space
fication Tag is secured t o t h e power take-off cover.
Line #3 Digit 1-12 Vehicle Order Number Do n o t discard t h i s t a g i f t h e transmission power
Digit 13 Open Space
Digit 14-16 Vinyl Roof Code CDoor Combo take-off cover is removed. O n other transmission
Code - P i l l e t t e ) models, a blue m e t a l identification t a g is perma-
Digit 17 Open Space n e n t l y attached t o t h e left top o f transmission case
Digit 18-23 Model
near t h e case cover.
J901N-20
A U T O M A T I C T R A N S M I S S I O N : A surface pad has
Fig. 6 Body Code Plate Information been provided on t h e r i g h t o f t h e transmission case
to supply identification.
ENGINE SERIAL NUMBER (PARTS REPLACEMENT See Group 2 1 , Transmissions for additional infor-
INFORMATION) mation.
O n t h e 238 C.I.D. (3.9 L i t e r ) 6 c y l i n d e r engine, t h e
engine serial n u m b e r is o n a pad located on the r i g h t
side o f the block.
O n t h e 318 C.I.D. (5.2 L i t e r ) a n d t h e 360 C.I.D.
(5.9 L i t e r ) 8 cylinder engines, t h e engine serial n u m -
ber is located o n the left front corner o f the block, be-
low t h e cylinder head (Fig. 7).

Fig. 7 Engine Serial Number 5.2L and 5.9L

• INTRODUCTION 5

POWER T E A M A V A I L A B I L I T Y
RAM P I C K U P
ENGINIE&SAILES 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 MAN. MAN. 4-SP 3-SP AUTO
EHB ELG EMG EMJ ETA O.D. O.D. MAN. AUTO O.D.
D150 2921 mm 2495 kg S S O o
4x2 (115 in) (5500 lbs)
O s o o o
3327 mm
(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 2722 kg s s o
(133 in) (6000 lbs)
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 3860 kg s s o
(131 in) (8510 lbs)
3/85 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)
o s© o
3327 mm 2903 kg
(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
(131 in)
3402 kg s s© o
(7500 lbs)
3785 mm
(149 in) o s o
3327 mm
(131 in)
3860 kg s s o
(8510 lbs)
3785 mm
(149 in) o s o
W350 3327 mm 3946 kg s s o
4x4 (131 in) \WA
(IQ7AA
O / U U IDS]
o s o
4581 kg S s o
(IU, 1
HA n o IDS}
iu«.\
lUU
o s o
S = STANDARD O = OPTIONAL © = Not available in California J90IN-39
6 INTRODUCTION •
POWER T E A M A V A I L A B I L I T Y (CONT.)
R A M C H A S S I S CAB

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 MAN. MAN. 4-SP 3-SP AUTO
EHB ELG EMG EMJ ETA O.D. O.D. MAN. AUTO O.D.
D250 3327 mm 3357 kg S s
4x2 (131 in) (7400 lbs)
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
4763 kg
(159 in)
(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 o
(135 in) (10,100 lbs)
s
4989 kg o s o
(11,000 IBs)

R A M C H A R G E R S P O R T UTILITY

DlOO 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 S o
4x4 (106 in) S
(6000 lbs) . . . .

2903 kg S s© o
(6400 lbs)
S s o

S = STANDARD © = Not available in California.

O = OPTIONAL © = California Only. J901N-35
• INTRODUCTION 7

TRUCK MODEL LINE-UP AND WEIGHTS

RAM P I C K U P

MODEL/ BODY(3) PAYLOAD CURB

FAMILY STYLE GVWR ALLOWANCE (1) WEIGHT (2)

D150 ADl 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

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

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

32 3357 kg 7400 lbs 1369 kg 3019 lbs 1987 kg 4381 lbs

3860 kg 8510 lbs 1846 kg 4070 lbs 2014 kg 4440 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

62 2903 kg 6400 lbs 966 kg 2131 lbs 1936 kg 4269 lbs

32 2903 kg 6400 lbs 789 kg 1740 lbs 2114 kg 4660 lbs

W250 AD6 62 3402 kg 7500 lbs 1364 kg 3007 lbs 2038 kg 4493 lbs
4x4 3860 kg 8510 lbs 1769 kg 3899 lbs 2092 kg 4611 lbs

32 3402 kg 7500 lbs 1259 kg 2775 lbs 2143 kg 4725 lbs

3860 kg 8510 lbs 1664 kg 3668 lbs 2196 kg 4842 lbs

W350 AD7 62 3946 kg 8700 lbs 1749 kg 3855 lbs 2198 kg 4845 lbs
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 suppfied 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 •

TRUCK MODEL LINE-UP A N D WEIGHTS (CONT.)

R A M C H A S S I S CAB

MODEL/ BODY(3) PAYLOAD CURB

FAMILY STYLE GVWR ALLOWANCE (1) WEIGHT (2)

D250 AD2 62 3357 kg 7400 lbs (1) 1721 kg 3794 lbs

4x2 3860 kg 8510 lbs 1740 kg 3835 lbs

D350 AD3 62 3946 kg 8700 lbs (1) 1794 kg 3954 lbs

4x2

4581 kg 10,100 lbs (1) 1963 kg 4327 lbs

"lit 4763 kg 10,500 lbs 1972 kg 4347 lbs

4581 kg 10,100 lbs (1) 2032 kg 4479 lbs

"12! 4763 kg 10,500 lbs 2043 kg 4505 lbs

W250 AD6 62 3860 kg 8510 lbs (1) 1886 kg 4158 lbs

4x4

W350 AD7 62 3946 kg 8700 lbs (1) 2038 kg 4494 lbs

4x4

4581 kg 10,100 lbs (1) 2136 kg 4709 lbs

63
$ 4990 kg 11,000 lbs 2145 kg 4729 lbs

R A M C H A R G E R - S P O R T UTILITY

MODEL/ BODY(3) PAYLOAD CURB

FAMILY GVWR ALLOWANCES) WEIGHT(2)
STYLE

D100 AD4 71 2540 kg 5600 lbs 603 kg 1330 lbs 1937 kg 4270 lbs
4x2

D150 AD4 71 2540 kg 5600 lbs 606 kg 1336 lbs 1934 kg 4264 lbs
4x2

W100 AD8 71 2722 kg 6000 lbs 618 kg 1363 lbs 2103 kg 4637 lbs
4x4

W150 AD8 71 2722 kg 6000 lbs 621 kg 1369 lbs 2102 kg 4631 lbs
4x4 2903 kg 6400 lbs 796 kg 1755 lbs 2107 kg 4645 lbs

(1) Payload includes maximum weight of driver, passengers, cargo and optional equipment not included in payload or GVW package
Includes base engine
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-38
• INTRODUCTION 9

STANDARD TRUCK BODY DIMENSIONS

STANDARD BODIES AVAILABLE
LOAD SPACE DIMENSIONS (2)
VEHICLE WHEELBASE CAB TO BODY NOMINAL MAX.
FAMILY AVAILABLE AXLE TYPE LENGTH LENGTH WIDTH HEIGHT VOLUME
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 )
3

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

(106 in) Utility (62.5 in) (41.8 in) (105.8 ft ) 3

4x2
AD-8 2692 mm — Sport — 1778 mm 1588 mm 1062 mm 2.99 m 3

(106 in) Utility (62.5 in) (41.8 in) (105.8 ft ) 3

4x4
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 3

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.

© Based on S.A.E. procedure J1100. J901N-34
10 INTRODUCTION •
TORQUE R E F E R E N C E S
I n d i v i d u a l Torque Charts appear a t t h e end o f INCH METRIC
many Groups. Refer t o t h e Standard Torque Specifi-
cations a n d B o l t I d e n t i f i c a t i o n C h a r t i n t h i s Group 5/16-18 M8 X 1.25
for torques not listed i n the i n d i v i d u a l torque charts THREAD NUMBER THREAD DISTANCE
(Fig. 1). MAJOR OF MAJOR BETWEEN
DIAMETER THREADS DIAMETER IN THREADS IN
BOLT T O R Q U E IN INCHES PER INCH MILLIMETERS MILLIMETERS
GRAM 5 GRADE 8
BOLT
SIZE N-rn ft-lbs N'ffti ft-lbs PR606B
(in-lbs) (in-lbs)

1/4-20 11 (95) 14 (125)

Fig. 2 Thread Notation (Metric and SAE)
1/4-28 11 (95) 17 (150)
5/16-18 23 (200) 31 (270)
5/16-24 27 20 34 25
3/8-16 41 30 54 40
3/8-24 48 35 61 45
7/16-14 68 50 ... 88 65
7/16-20 75 55 95 70 METRIC BOLTS—IDENTIFICATION CLASS NUMBERS
1/2-13 136 100 CORRESPOND T O BOLT STRENGTH— INCREASING NUMBERS
102 75
REPRESENT INCREASING STRENGTH. J89IN-10
1/2-20 115 85 149 no
9/16-12 142 105 183 135
9/16-18 156 115 203 150 Fig. 3 Metric Bolt Identification
5/8-11 203 150 264 195
5/8-18 217 160 285 , 210 SAE CLASSIFICATION
3/4-16 237 175 305 225
GRADE 5 GRADE 8

J89IN-9

Fig. 1 Grade 5 and 8 Standard Torque MARKINGS FOUND

Specifications ON TOP OF BOLT
HEAD INDICATE
Note t h a t t h e torque specifications given i n t h e GRADE
chart are based on t h e use o f clean and dry threads.
120° 60°
Reduce the torque by 10% when the threads are l u b r i -
cated w i t h engine o i l and b y 20% i f new plated bolts
are used.
V a r i o u s sizes o f i n t e r n a l a n d e x t e r n a l h e x - l o b -
u l a r ( T o r x ) h e a d f a s t e n e r s a r e u s e d as a t t a c h i n g
h a r d w a r e o n n u m e r o u s c o m p o n e n t s a n d assem-
blies. D u e t o the e v e r - c h a n g i n g usage a n d a p p l i - GRADE 2 GRADES GRADE 8
cation o f automotive fasteners, Torx-head
(SAE) BOLTS—IDENTIFICATION MARKS CORRESPOND
f a s t e n e r s m a y n o t b e i d e n t i f i e d as s u c h t h r o u g h -
TO BOLT STRENGTH—INCREASING NUMBERS
out this manual. REPRESENT INCREASING STRENGTH.
J89IN-11
METRIC THREAD AND GRADE IDENTIFICATION
M e t r i c a n d S A E t h r e a d notations differ slightly. Fig. 4 SAE Bolt Identification
The difference is i l l u s t r a t e d i n F i g . 2.
Common metric fastener strength property classes
are 9.8 a n d 12.9 w i t h t h e class identification em-
bossed on t h e head of each bolt (Fig. 3). Some metric
nuts w i l l be marked w i t h single d i g i t strength iden-
tification numbers on t h e n u t face.
SAE s t r e n g t h classes range from grade 2 to 8 w i t h
line identification embossed on each bolt head. M a r k -
ings corresponding to t w o lines less t h a n the actual
grade (Fig. 4). FOR E X A M P L E - G r a d e 7 bolt w i l l
exhibit 5 embossed lines on the bolt head.
 • INTRODUCTION 11

INTERNATIONAL SYMBOLS h i d e . These symbols are applicable to those controls

w h i c h are displayed on t h e i n s t r u m e n t panel or i n
Some of t h e I n t e r n a t i o n a l Symbols shown below t h e d i a t e v i c i n i t y o f the d r i v e r (Fig. 5).
i m m e

are used t o i d e n t i f y controls a n d displays i n t h i s ve-

INTERNATIONAL SYMBOLS

D CP
WINDHIELD WINDSHIELD
UPPER BEAM LOWER BEAM TURN SIGNAL HAZARD WARNING WASHER
WIPER

I r\

WINDSHIELD WIPER REAR HOOD CHOKE (COLD

VENTILATING FAN PARKING LIGHTS FRONT HOOD (TRUNK) STARTING AID)
AND WASHER

1 4
ENGINE COOLANT BATTERY CHARGING SEAT BELT
HORN FUEL ENGINE OIL
TEMPERATURE CONDITION

(©)
WINDSCREEN
LIGHTER REAR WINDOW REAR WINDOW PARKING BRAKE BRAKE FAILURE DEMISTING
WIPER WASHER AND DEFROSTING
RK230

Fig. 5 International Symbols

METRIC SYSTEM Mega (M) Million Deci (D) Tenth

A r t w o r k , specifications, a n d t i g h t e n i n g references Kilo (K) Thousand Centi (C) Hundreth

i n this Service M a n u a l a r e identified i n the metric
system and i n t h e S A E system. Milli - (m) Thousandth
D u r i n g any maintenance or repair procedures, i t is
important t o salvage m e t r i c fasteners (nuts, bolts, J901N-2
etc.) for reassembly. I f t h e fastener is not salvage-
able, a fastener o f equivalent specification should be Fig. 6 Metric Prefixes
used. The m e t r i c system is based on quantities of one,
ten, one h u n d r e d , one thousand, a n d one m i l l i o n
WARNING: USE OF AN INCORRECT FASTENER (Fig. 6).
MAY RESULT IN COMPONENT DAMAGE OR PER- The f o l l o w i n g Tables w i l l assist you i n conversion
SONAL INJURY. procedures.
12 INTRODUCTION •
CONVERSION T A B L E S
in-lbs to N*m N m to in-lbs
#

in- lb N»m in-lb N»m in-lb N«m in-lb in-lb N»m N»m in-lb N*m in-lb N*m in-lb N*m in-lb
2 .2260 42 4.7453 82 9.2646 122 13.7839 162 18.3032 .2 1.7702 4.2 37.1747 8.2 72.5792 12.2 107.9837 16.2
4 .4519 44 4.9713 84 9.4906 124 14.0099 164 18.5292 .4 3.5404 4.4 38.9449 8.4 74.3494 12.4 109.7539 16.4
6 .6779 46 5.1972 86 9.7165 126 14.2359 166 18.7552 .6 5.3107 4.6 40.7152 8.6 76.1197 12.6 111.5242 16.6
3 .9039 48 5.4232 88 9.9425 128 14.4618 168 18.9811 .8 7.0809 4.8 42.4854 8.8 77.8899 12.8 113.2944 16.8
10 1.12% 50 5.6492 90 10.1685 130 14.6878 170 19.2071 1 8.8511 5 44.2556 9 79.6601 13 115.0646 17
12 1.3558 52 5.8751 92 10.3944 132 14.9138 172 19.4331 1.2 10.6213 5.2 46.0258 9.2 81.4303 13.2 116.8348 17.2
14 19.6590 1.4 12.3916 5.4 47.7961 9.4 83.2006 13.4 118.6051 17.4
1.5818 54 6. ton 94 10.6204 134 15.1397 174
16 1.8077 56 6.3270 96 10.8464 136 15.3657 176 19.8850 1.6 14.1618 5.6 49.5663 9.6 84.9708 13.6 120.3753 17.6
18 2.0337 58 6.5530 98 11.0723 138 15.5917 178 20.1110 1.8 15.9320 5.8 51.3365 9.8 86.7410 13.8 122.1455 17.8
20.3369 2 6 10
17.7022 53.1067 88.5112 14 123.9157 18
20 2.2597 60 6.7790 100 11.2983 140 15.8176 180
22 2.4856 62 . 7.0049 102 11.5243 142 16.0436 182 20.5629 2.2 19.4725 6.2 54.8770 10.2 90.2815 14.2 125.6860 18.5
24 2.7116 64 7.2309 104 11.7502 144 16.2696 184 20.7889 2.4 21.2427 6.4 56.6472 10.4 92.0517 14.4 127.4562 19
21.0148 2.6 6.6 10.6
23.0129 58.4174 93.8219 14.6 129.2264 19.5
26 2.9376 66 7.4569 106 11.9762 146 16.4955 186
28 3.1635 68 7.6828 108 12.2022 148 16.7215 188 21.2408 2.8 24.7831 6.8 60.1876 10.8 95.5921 14.8 130.9966 20
30 3.3895 70 7.9088 110 12.4281 150 16.9475 190 21.4668 3
26.5534 7 61.9579 11 97.3624 15 132.7669 20.5
32 3.6155 72 8.1348 112 12.6541 152 17.1734 192 21.6927 3.2
28.3236 7.2 63.7281 11.2 99.1326 15.2 134.5371 21
34 3.8414 74 8.3607 114 12.8801 154 17.3994 194 21.9187 3.4
30.0938 7.4 65.4983 11.4 100.9028 15.4 136.3073 22
22.1447 3.6 7.6
31.8640 67.2685 11.6 102.6730 15.6 138.0775 23
36 4.0674 76 8.5867 116 13.1060 156 17.6253 196
38 4.2934 78 8.8127 118 13.3320 158 17.8513 198 22.3706 3.8
33.6342 7.8 69.038 11.8 104.4433 15.8 139.8478 24
40 4.5193 80 9.0386 120 13.5580 160 18.0773 200 22.5966 4
35.4045 8 70.8090 12 106.2135 16 141.6180 25

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-lb 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 30.2400 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 45.739 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 88.128] 85 115.2446 5 3.6878 25 18.4391 45 3.1903 65 47.9415 85 62.693
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 90.83% 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 3 40.6745 50 67.7909 70 94.9073 90 122.0236 10 7.3756 30 22.1269 90 36.8781 70 51.6293 90 66.306
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 97.6m 92 124.7352 12 8.8507 32 23.6020 52 3.3532 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 53.843 93 68.593
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 54.573 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 96 130.1586 16 11.8010 36 26.5522 56 41.3035 76 56.0547 96 70.8060
17 23.0489 37 50.1653 57 77.2816 77 104.3980 97 131.5144 17 12.5386 37 27.398 57 42.0410 77 56.7923 97 71.5435
18 24.4047 38 51.5211 58 78.6374 78 105.753 98 132.8702 18 13.2761 38 3.0274 58 42.7786 78 57.5298 98 72.311
19 25.7605 39 52.8769 59 79.9933 79 107.1196 99 134.2260 19 14.0137 39 3.7649 59 43.5162 79 58.2674 99 73.0187
20 27.1164 40 54.2327 60 81.3491 80 108.4654 100 135.5820 20 14.7512 40 29.5025 60 44.2537 80 59.0050 100 73.7562

in. to mm mm to in.
in. mm in. mm in. mm in. mm in. mm mm in. mm in. mm in. mm in. mm in.

.01 .254 .21 5.334 .41 10.414 .61 15.494 .81 3.574 .01 .00039 .21 .0327 .41 .01614 .61 .02402 .81 .3189
.02 .508 .22 5.588 .42 10.668 .62 15.748 .82 3.83 .02 .0379 .22 .00866 .42 .01654 .62 .02441 .82 .0323
.03 .762 .23 5.842 .43 10.922 .63 16.002 .83 21.32 .3 .3118 .23 .00906 .43 .01693 .63 .0243 . 3 .03268
.04 1.016 .24 6.096 .44 11.176 .64 16.256 .84 21.336 .04 .3157 .24 .00945 .44 .01732 .64 .0253 .84 .0337
.05 1.270 .25 6.350 .45 11.43 .65 16.510 .85 21.590 .05 .3197 .25 .00984 .45 .01772 .65 .02559 .85 .03346
.06 1.524 .26 6.604 .46 11.684 .66 16.764 .86 21.844 .06 .00236 .26 .01024 .46 .01811 .66 .0253 .86 .03386
.07 1.778 .27 6.858 .47 11.93 .67 17.018 .87 22.098 .07 .00276 .27 .01063 .47 .01850 .67 .0263 .87 .03425
.OS 2.032 .28 7.112 .48 12.192 .68 17.272 . 3 22.352 .3 .00315 .3 .01102 .48 .01890 .68 .02677 . 3 .03465
.09 2.286 .29 7.366 .49 12.446 .69 17.526 .89 22.606 .09 .0354 .29 .01142 .49 .01929 .69 .02717 .89 .3504
.10 2.540 .3 7.63 .50 12.700 .70 17.73 .90 22.860 .10 .00394 .3 .01181 .3 .01969 .70 .02756 .90 .03543
.11 2.794 .31 7.874 .51 12.954 .71 18.034 .91 23.114 .11 .0043 .31 .0123 .51 .0203 .71 .02795 .91 .0353
.12 3.048 .32 8.13 .52 13.208 .72 18.23 .92 23.368 .12 .00472 .32 .01260 .52 .02047 .72 .02835 .92 .03622
.13 3.32 .33 8.32 .53 13.462 .73 18.542 .93 23.622 .13 .3512 .33 .01299 .53 .0237 .73 .02874 .93 .03661
.14 3.556 .34 8.636 .54 13.716 .74 18.796 .94 3.876 .14 .00551 .34 .01339 .54 .02126 .74 .02913 .94 .3701
.15 3.810 .35 8.890 .55 13.970 .75 19.050 .95 24.13 .15 .3591 .35 .01378 .55 .02165 .75 .02953 .95 .3740
.16 4.064 .36 9.144 .56 14.224 .76 19.304 .96 24.384 .16 .00630 .36 .01417 .56 .0235 .76 .02992 .96 .373
.17 3.318 .37 9.3% .57 14.478 .77 19.558 .97 24.63 .17 .00669 .37 .01457 .57 .02244 .77 .0332 .97 .0319
.18 4.572 .3 9.652 .58 14.732 .78 19.812 .98 24.892 .18 .3709 .3 .01496 .3 .0223 .78 .0371 .98 .03858
.19 4.826 .39 9.906 .59 14.986 .79 3.066 .99 25.146 .19 .3748 .39 .01535 .59 .02323 .79 .3110 .99 .03898
.20 5.080 .40 10.160 .60 15.240 .80 3 . 3 3 1.3 25.400 .3 .3787 .40 .01575 .60 .02362 .3 . 3 1 3 1.3 .03937

J901N-10
• INTRODUCTION 13

CONVERSION TABLES (CONT.)

Multiply By To Get Multiply By To G e t

in.-lbs. x 0.11298 = Newton-Metres (N»m) (N*m) x 8.851 = in.-lbs.
ft.-lbs. x 1.3558 = Newton-Metres (N«m) (NTH) x 0.7376 = ft.-lbs.
inches Hg. (60°F) x 3.377 = Kiiopascals (kPa) (kPa) x 0.2961 Inches Hg.
Pounds/Sq. In. x 6.895 = Kiiopascals (kPa) (kPa) x 0.145 Pounds/Sq. In.

Inches x 25.4 = Millimetres (mm) (mm) x 0.03937 = Inches

Feet x 0.3048 5 = Metres (M) (M) x 3.281 = Feet
Yards x 0.9144 *= Metres (M) (M) x 1.0936 Yards
Miles x 1.6093 = Kilometres (Km) (Km) x 0.6214 = Miles

Miles/Hr. x 1.6093 = Kilometres/Hr. (Km/h) (Km/h) x 0.6214 Miles/Hr.

Feet/Sec. x 0.3048 = Metres/Sec. (M/S) (M/S) x 3.281 Feet/Sec.
Kilometres/Hr. x 0.27778 = Metres/Sec. (M/S) (M/S) x 3.600 Kilometres/Hr.
Miles/Hr. x 0.4470 = Metres/Sec. (M/S) (M/S) x 2.237 Miles/Hr.

C O M M O N METRIC E Q U I V A L E N T S

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

J901N-11
 # LUBRICATION AND MAINTENANCE 0- 1

LUBRICATION AND MAINTENANCE

CONTENTS
Page Page

CHASSIS AND BODY . . 28 ENGINE 14

DRIVETRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1

G E N E R A L INFORMATION
INDEX
Page Page
Assist (Jump) Starting 8 Maintenance Schedule—Heavy Duty Cycle 5
Chassis Lubrication . . . . . . . . . . . . . . . . . . . . . . . . 6 Maintenance Schedule—Light Duty Cycle . . . . . . . . 4
Classification of Lubricants 2 Parts and Lubrication Recommendations 3
Fluid Capacities 8 Parts Requiring No Lubrication 2
Fuel Usage 2 Noise Control Systems 1
Severe Service . . 1
Hoisting Recommendations 9
Towing Recommendations 10
Introduction . . .. 1 Vehicle Storage 12

INTRODUCTION
Maintenance a n d l u b r i c a t i o n service recommenda-
tions have been compiled to provide m a x i m u m pro-
tection for t h e owner's i n v e s t m e n t against a l l
reasonable types o f d r i v i n g conditions.
Since these conditions v a r y w i t h t h e i n d i v i d u a l op-
erator's d r i v i n g habits, the area i n w h i c h the vehicle
is operated and t h e type of service t o w h i c h t h e ve-
hicle is subjected, i t i s necessary t o prescribe lubrica-
t i o n and maintenance service o n a t i m e schedule as
w e l l as a mileage i n t e r v a l basis.
Vehicles w i t h a Gross Vehicle W e i g h t R a t i n g
(GVWR) o f 3 855 k g (8,500 lbs.) or less m u s t meet
l i g h t d u t y emission standards (see L I G H T D U T Y
C Y C L E Maintenance charts). Vehicles w i t h a Gross
Vehicle W e i g h t R a t i n g of (GVWR) 3 856 k g (8,501
lbs.) or more m u s t conform t o the heavy d u t y emis-
sion standards (see H E A V Y D U T Y C Y C L E M a i n t e -
nance charts).
The G V W R for each vehicle appears on the Safety
Certification label, affixed to t h e lock p i l l a r o n t h e
drivers door (Fig. 1).
A d d i t i o n a l i n f o r m a t i o n can be found i n the Owner's
M a n u a l provided w i t h the vehicle.
SEVERE SERVICE
PU625
Fig. 1 Safety Certification Label
(b) 50% or more of t h e vehicle operation i n
heavy city traffic i n h i g h temperatures (32°C or
90°F or higher).
(c) Prolonged i d l i n g .
(d) E x t r e m e l y short r u n operation.
(e) Commercial type operation.
(f) Operated i n water.
A f t e r extended operation i n m u d , sand, water,
or s i m i l a r d i r t y conditions, have your b r a k e drums,
brake linings, and axle j o i n t s inspected and cleaned
as soon as possible. This w i l l prevent a n y abrasive
wear or unpredictable b r a k i n g action.
I t is t h e owner's responsibility t o determine
d r i v i n g conditions (normal or severe service opera-
tion), to have the vehicle serviced according to the
Maintenance Schedule and t o pay for the necessary
parts and labor.

Vehicles operating under one or more of the follow-
i n g conditions w i l l require more frequent service (see
the L u b r i c a t i o n and Maintenance Schedules—Heavy
D u t y Cycle).
(a) I n extremely dusty areas.
NOISE CONTROL SYSTEMS
A l l vehicles b u i l t over 4 535 k g (10,000 lbs.) Gross
Vehicle Weight R a t i n g ( G V W R ) and manufactured
for sale and use i n the U n i t e d States are r e q u i r e d to
0 - 2 LUBRICATION AND MAINTENANCE
comply w i t h t h e Federal Government's E x t e r i o r
Noise Regulations. These vehicles can be identified
by t h e Noise Emissions Control L a b e l located i n t h e
operator's compartment (Fig. 2).
VEHICLE WISE BMS&ON CONTROL ttiFORMATKMI
DATE O F V E H I C L E MANUFACTURE
I CHRYSLER
THIS VEHICLE CONFORMS TO U.S. EPA REGULATIONS FOR NOISE EMISSION
APPLICABLE TO MEDIUM AND HEAVY DUTY TRUCKS.
THE FOLLOWING ACTS OR THE CAUSING THEREOF BY ANY PERSON ARE
PROHIBITED BY THE NOISE CONTROL ACT OF 1972. (A) THE REMOVAL OR
RENDERING INOPERATIVE, OTHER THAN FOR PURPOSES OF MAINTENANCE.
REPAIR, OR REPLACEMENT, OF ANY NOISE CONTROL DEVICE OR ELEMENT OF
DESIGN (LISTED IN THE OWNERS MANUAL) INCORPORATED INTO THK5 VEHICLE
IN COMPLIANCE WITH THE NOISE CONTROL ACT: (B) THE USE OF THIS VEHICLE
AFTER SUCH DEVICE OR ELEMENT OF DESIGN HAS BEEN REMOVED OR
RENDERED INOPERATIVE.
Fig. 2 Vehicle Emission Control Information Label
REQUIRED MAINTENANCE FOR NOISE
CONTROL SYSTEMS
The f o l l o w i n g maintenance services m u s t be per-
formed every 6 months or 9 600 k m (6,000 miles)
whichever occurs first to assure proper operation o f
the noise control systems. Inspection a n d service
should be performed a n y t i m e a m a l f u n c t i o n is ob-
served or suspected. I n addition, proper maintenance
of the e n t i r e vehicle w i l l help t h e effectiveness o f the
noise control systems.
EXHAUST SYSTEM
Inspect t h e entire exhaust system for leaks a n d
damaged parts. Devices such as hangers, clamps a n d
U-bolts should be t i g h t and i n good condition. D a m -
aged components, burned or b l o w n o u t mufflers,
burned or rusted o u t exhaust pipes should be re-
placed according to t h e procedures a n d specifications
outlined i n Group 1 1 , Exhaust system a n d I n t a k e
Manifold.
AIR CLEANER ASSEMBLY
Inspect a i r cleaner housing for proper assembly
and f i t . M a k e certain t h a t the a i r cleaner is properly
positioned a n d indexed o n t h e t h r o t t l e body a n d t h e
cover is t i g h t . Check a l l hoses l e a d i n g t o t h e cleaner
for tightness. The gasket between t h e a i r cleaner
housing a n d t h r o t t l e body must be i n t a c t and i n good
condition. T h e a i r f i l t e r element m u s t also be clean
and serviced according to the i n s t r u c t i o n s o u t l i n e d i n
the Scheduled Maintenance Section o f t h i s m a n u a l .
TAMPERING WITH NOISE CONTROL
PROHIBITED
Federal l a w prohibits t h e f o l l o w i n g acts or t h e
causing thereof:
(1) T h e removal or rendering inoperative b y any
person other t h a n for purposes o f maintenance re-
pair, or replacement o f any device or element o f de-
sign incorporated i n t o any n e w vehicle for t h e
•
purpose of noise control p r i o r t o i t s sale or delivery t o
t h e u l t i m a t e purchaser o r w h i l e i t i s i n use.
(2) The use o f t h e vehicle after such device or ele-
m e n t o f design has been removed or rendered inoper-
ative b y a n y person.
PARTS REQUIRING NO LUBRICATION
There are m a n y parts t h a t should n o t be l u b r i -
cated; some because they a r e p e r m a n e n t l y l u b r i c a t e d ,
some because l u b r i c a n t s w i l l be d e t r i m e n t a l t o t h e i r
operating characteristics, a n d some because l u b r i -
cants w i l l cause component failures. I n p a r t i c u l a r ,
rubber bushings should n o t be l u b r i c a t e d since t h i s
not only w i l l cause t h e m t o f a i l , b u t w i l l destroy
PU626D t h e i r necessary f r i c t i o n a l characteristics. Parts t h a t
should not be l u b r i c a t e d a r e as follows ( F i g . 3):
Air Pumps Rear Spring Shackle Bolts
Alternator Bearings Rear Wheel Bearings on
Clutch Release Bearing D-100 and D-200 Vans
Drive Belts Starter Bearings
Drive Shaft Center Bearing Suspension Strut Bearing
Fan Belt Idler Pulley Throttle Control Cable
Idler Arm Assembly Throttle Linkage
Rubber Bushings Water Pump Bearings
J9000-58
Fig. 3 Parts Not Requiring Lubrication
FUEL USAGE
A l l engines require t h e use o f unleaded fuel t o r e -
duce exhaust emissions, a n d t o protect t h e catalytic
converters. Use fuel h a v i n g a n octane r a t i n g o f a t
least 87, (R + M)/2.
U N L E A D E D G A S O L I N E S O N L Y m u s t be used i n
vehicles equipped w i t h catalyst emission control sys-
tems. A l l vehicles, so equipped, have labels located
on t h e i n s t r u m e n t panel a n d adjacent to t h e fuel
f i l l e r cap or door t h a t state, U N L E A D E D F U E L
O N L Y . These vehicles also have fuel f i l l e r tubes spe-
c i a l l y designed to accept t h e smaller diameter u n -
leaded gasoline dispensing nozzles only.
The exhaust emission system of y o u r vehicle i s de-
signed to meet a l l emission regulations w h i l e , a t t h e
same t i m e , provide excellent fuel economy.
CLASSIFICATION OF LUBRICANTS
Oils, lubricants, a n d greases are classified a n d
SYSTEM graded according t o standards recommended b y t h e
Society of A u t o m o t i v e Engineers (SAE), A m e r i c a n
Petroleum I n s t i t u t e ( A P I ) a n d N a t i o n a l L u b r i c a t i n g
Grease I n s t i t u t e ( N L G I ) .
ENGINE OIL
The S A E grade n u m b e r indicates t h e viscosity of
engine oils, for example, S A E 30, w h i c h is a single
• LUBRICATION AND MAINTENANCE
grade o i l . E n g i n e oils are also identified b y a d u a l
number, for example, S A E 10W-30, w h i c h indicates a
multigrade oil.
GEAR LUBRICANTS
The SAE grade n u m b e r also indicates t h e viscosity
of M u l t i p u r p o s e Gear Lubricants.
The A P I classification system defines gear l u b r i -
cants i n terms o f usage such as A P I GL-4 or A P I GL-
5 etc.
LUBRICANTS/GREASES
Semisolid lubricants, bear t h e N L G I designation
and are f u r t h e r classified as grades 0, 1, 2, 3 etc.
0-3
PARTS AND LUBRICATION RECOMMENDATIONS
Y o u r Chrysler Motors vehicle has been engineered
to perform for y o u for years t o come. Y o u w i l l occa-
sionally require service and maintenance for your ve-
hicle a n d C h r y s l e r M o t o r s r e c o m m e n d s t h e use of
" M O P A R " b r a n d p a r t s a n d accessories.
Each M O P A R p a r t has been specifically designed
to m a i n t a i n top efficiency a n d q u a l i t y b y the same
t e a m o f engineers who designed y o u r vehicle. O n l y
M O P A R can make t h i s c l a i m .
Remember, whenever y o u r vehicle requires a new
p a r t , always request t h e b r a n d name M O P A R , i t ' s
w o r t h t h e effort!
 LIGHT DUTY CYCLE—GASOLINE ENGINES
Inspection and service should be performed any time a malfunction is observed or suspected.
X = Scheduled maintenance for all vehicles.
O = Scheduled maintenance for all vehicles (except California). Recommended for proper vehicle performance for vehicles built for sale in California.

W h e r e both time a n d m i l e a g e Miles (Thousand) 7V 2 15 2 2 V* 30 37V 2 45 5 2 Va 60 67V 2 75 8 2 v% 9 0 97V 2 105 112V2 120
a r e s h o w n , 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/Clamps (12 months) 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 0 0 0 0 0 O 0 0 0

Oil —Change (12 Months) X X X X X X 0 0 0 0 0 0 O 0 0 0

Oil Filter—Change (2nd Oil Change) * X X X 0 0 0 0 0

Drive Belt Tension —Inspect & Adjust 01 X 01 0 0 0 0 0

Drive Belt (V-Type)—Replace 0

Spark Plug —Replace X 0 0 0

Air Filter—Replace X 0 0 0

Fuel Filter—Replace as necessary

Coolant—Flush/Replace (36 months) & 24 months/48 000 km

(30,000 miles) thereafter 0

EGR Valve & Tube —Replace (clean passengers at 60 months) 02 02

PCV Breather—Clean 0 0

PCV Valve —Replace (60 months) 02 Q2

Vacuum Emission Components — Replace (60 months) 0 0

Ignition Timing—Adjust to Specs as necessary 0 0

Ignition Cables, Distributor Cap & Rotor—Replace 0 0

Manifold Heat Control Valve — Lubricate 0 0

Battery—Replace 0

Oxygen Sensor—Replace Q2

* If accumulated mileage is less than 12 000 km (7,500 miles) for 12 months, replace the filter at each oil change.
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.
This maintenance is not allowed on California Durability Vehicles.
2
Requires Emission Maintenance Reminder Light. If so equipped, these parts are to be replaced at the indicated mileage, or when the emissions maintenance
reminder light remains on continuously with the key in the "on" position, whichever occurs first.
J9000-51
 H E A V Y DUTY C Y C L E — G A S O L I N E E N G I N E S
Inspection and service should be performed anytime a malfunction is observed or suspected.

Where both time and mileage are Miles (Thousand) 6 12 18 24 30 36 42 48 54 60 66 72 78 82'/ 3 84 90 96 102 108
shown, 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 (12 months) 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 (12 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 1
X X 1
X X^ X
Drive Belt (V-Type) — Replace X
Air Filter/Air Pump Air Filter — Replace X X X X
Crankcase Inlet Air Filter — Clean X X X X
Spark Plug — Replace X X X
Fuel Filter — Replace as necessary
Coolant — Flush/Replace (36 months) & 24 months/48 000 km
X
(30,000 miles) thereafter
EGR Valve & Tube — Replace X 2

EGR Tube — Clean Passengers X 2

PCV Valve — Replace X 2

Vacuum Emission Components — Replace X

Ignition Timing — Adjust to Specs, as necessary X
Ignition Cables, Distributor Cap & Rotor — Replace X
Manifold Heat Control Valve — Lubricate X
Battery — Replace X
Oxygen Sensor — Replace X 2

* If accumulated mileage is less than 9 600 km (6,000 miles) for 12 months, replace the filter at each oil change.
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. J9000-35
For light duty cycle vehicles G W V rating of 3 855 K g (8,500 lbs.) a n d below.
Component
Center Link
Drag Link Bail Joints
Gearshift Mechanism
Overdrive 4
Parking Brake Ratio
Lever Pivot
Propeller Shaft U-joint
Propeller Shaft Slip Spline
Suspension Ball Joints
Tie Rod Ball Joints
NP-241 Transfer Case Shift
Lever Pivot
Wheel Stop
Constant Velocity Joint
(Front P/shaft)
Truck Models Fittings Service Interval Lubricant
ADl AD2 2 36 000 km (22,500 miles) or 2 years Multi-purpose grease - NGLI grade 2 EP
AD 4 (Multi-Mileage Lubricant)
AWl AW 2 2 12 000 km (7,500 miles) or 6 months Multi-purpose grease - NGLI grade 2 EP
AW 8 (Multi-Mileage Lubricant)
ADl 1 36 000 km (22,500 miles) or 2 years Multi-purpose grease - NGLI grade 2 EP
(Multi-Purpose Lubricant)
ADl AD 2 AD 4 — 36 000 km (22,500 miles) or 2 years Multi-purpose grease - NGLI grade 2 EP
AWl AW 8 (Multi-Purpose Lubricant)
AWl AW2 3 (1 Piece 12 000 km (7,500 miles) or 6 months Multi-purpose grease - NGLI grade 2 EP
rear (Multi-Purpose Lubricant)
AW 8
P/shaft)
ADl AD 2 1 36 000 km (22,500 miles) or 2 years. For severe Multi-purpose grease - NGLI grade 2 EP
(2 piece P/shaft) service, every 4 800 km (3,000 miles) or 3 months. (Multi-Purpose Lubricant)
Daily, if vehicle is operated in water
ADl AD2 4 36 000 km (22,500 miles) or 2 years — every engine Multi-purpose grease - NGLI grade 2 EP
oil change for off-highway operation (Multi-Mileage Lubricant)
ADl AD2 4 36 000 km (22,500 miles) or 2 years Multi-purpose grease - NGLI grade 2 EP
AD4 (Multi-Mileage Lubricant)
AWl AW 2 2 12 000 km (7,500 miles) or 6 months. Daily, if
AW8 vehicle is operated in water
AWl AW 2 — As Required Multi-purpose grease - NGLI grade 2 EP
AW8 (Multi-Purpose Lubricant)
ADl AD 2 AD4 — 36 000 km (22,500 miles) or as required Wax Type Lubricant
AWl AW2 1 12 000 km (7,500 miles) Multi-purpose grease - NGLI grade 2 EP
AW8 (Multi-Purpose Lubricant)
For h e a v y duty cycle vehicles G V W rating of 3 856 K g (8,501 lbs.) a n d a b o v e .

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
(Multi-Mileage Lubricant)

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

1 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
(Multi-Mileage Lubricant)

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
0 - 8 LUBRICATION AND MAINTENANCE

FLUID CAPACITIES
C O O L I N G SYSTEM QUARTS LITERS POWER S T E E R I N G PINTS LITERS

3.9L ENGINE 15.1 14.3 ALL 2.7 1.28

5.2L ENGINE (Except AWl50) 17.0 16.1 REAR A X L E PINTS LITERS

5.2L ENGINE (AWl 50) 16.5 15.6 CHRYSLER BVA Inch (210 mm) 4.4 2.08

5.9L ENGINE (Except AWl 50) 15.5 14.7 CHRYSLER 9VA Inch (235 mm) 4.5 2.13

5.9L ENGINE (AWl 50) 15.0 14.2 DANA 60 6.0 2.84

ENGINE CRANKCASE QUARTS LITERS DANA 70 7.0 3.31

3.9L ENGINE 4.0 3.8 FRONT A X L E PINTS LITERS

5.2L & 5.9L (no Filter change) 4.0 3.8 Spicer 44 FBJ 5.6 2.65

5.2L & 5.9L (with Filter change) 5.0 4.7 Spicer 60 F 6.5 3.07

FUEL T A N K GALLON LITERS TRANSMISSION-AUTOMATIC QUARTS LITERS

STANDARD 3.9L & 5.2L ENGINES 22.0 83.0 A 727 (5.9L ENGINE) 8.4 7.9

OPTIONAL 3.9L & 5.2L ENGINES 30.0 113.0 A 998 (3.9L ENGINE) 8.6 8.1

STANDARD 5.9L ENGINE 30.0 113.0 A 999 (5.2L ENGINE) 8.6 8.1

AD100& AW100 34.0 128.0 TRANSMISSION-MANUAL QUARTS LITERS

TRANSFER CASE PINTS LITERS NP-435 (4 Speed) 3.5 3.3

NP-205 4.5 2.13 NP-2500 (5 Speed) 2.0 1.9

NP-241 6.0 . 2.84

ASSIST (JUMP) STARTING
WARNING: DO NOT ATTEMPT TO PUSH OR TOW A
VEHICLE TO GET IT STARTED. UNBURNED FUEL
COULD ENTER THE CONVERTER AND, ONCE THE
ENGINE HAS STARTED, IGNITE AND CAUSE THE
CONVERTER TO OVERHEAT AND RUPTURE.
BOOSTER BATTERY
WARNING: TO PREVENT PERSONAL INJURY OR
DAMAGE TO CLOTHING, DO NOT ALLOW BAT-
TERY FLUID TO CONTACT EYES, SKIN OR FAB-
RICS. DO NOT LEAN OVER A BATTERY WHEN
CONNECTING JUMPER CABLES OR ALLOW CA-
BLE CLAMPS TO TOUCH EACH OTHER. KEEP
OPEN FLAMES OR SPARKS AWAY FROM BAT-
TERY VENT HOLES. ALWAYS WEAR EYE PROTEC-
TION WHEN WORKING WITH BATTERIES.
J9000-62
(3) Observe charge indicator. I f indicator i s l i g h t or
yellow replace battery. D O N O T a t t e m p t j u m p start-
i n g w h e n indicator is l i g h t or yellow. I f charge i n d i -
cator has a green dot i n the center, f a i l u r e t o s t a r t is
not due t o a discharged battery and the c r a n k i n g sys-
tem should be checked. I f charge indicator appears
dark i n the center, proceed as follows:
(4) A t t a c h one end of one j u m p e r cable t o positive
t e r m i n a l o f booster battery and the other end o f same
cable to positive t e r m i n a l of discharged b a t t e r y (Fig.
4).
POSITIVE
BATTERY NEGATIVE JUMPER
CABLE TERMINAL CABLE
BATTERY

I f i t becomes necessary to use a booster battery,

w i t h j u m p e r cables, t o s t a r t a vehicle's engine be-
cause i t s battery is discharged, t h e following proce-
dure should be followed:
(1) Set p a r k i n g brake and place automatic trans-
mission i n P A R K ( N E U T R A L for manual transmis- §§J9000-37
sion).
(2) T u r n off l i g h t s , heater and other electrical
Fig. 4 Connecting Positive Jumper Cable
loads.
 • LUBRICATION AND MAINTENANCE 0 - 9

WARNING: DO NOT PERMIT VEHICLES TO TOUCH (1) P E R S O N A L I N J U R Y C A U S E D B Y ELECTRO-

EACH OTHER AS THIS COULD ESTABLISH A LYTE SQUIRTING OUT BATTERY VENT.
GROUND CONNECTION AND COUNTERACT BENE- (2) P E R S O N A L I N J U R Y OR PROPERTY D A M -
FITS OF THIS PROCEDURE. A G E D U E TO B A T T E R Y EXPLOSION.
(3) D A M A G E TO C H A R G I N G SYSTEM OF
(5) Connect O N E end of other j u m p e r cable to Neg- BOOSTER V E H I C L E OR O F I M M O B I L I Z E D V E H I -
a t i v e (—) Post of booster battery. Connect O T H E R CLE.
end of the j u m p e r cable to a good engine ground free
from d i r t or grease of vehicle w i t h discharged bat- PORTABLE STARTING UNIT
tery. M a k e sure a good connection is made. There are m a n y types of these u n i t s available. F o l -
low instructions of t h e i r m a n u f a c t u r e r for necessary
precautions a n d operations.

CAUTION: It is very important that their operating

voltage does not exceed 15 volts because damage
to battery, starter motor, alternator or electrical sys-
tem may occur.

HOISTING RECOMMENDATIONS
See the Owner's M a n u a l for Emergency J a c k i n g
procedures.

TWIN POST
L i f t points for t w i n post h o i s t i n g are shown i n F i g .
6. Suitable hoist adaptors are available from hoist
manufacturers.
Fig. 5 Both Jumper Cables Connected
FLOOR JACK
WARNING: DO NOT CONNECT TO NEGATIVE POST
A r e g u l a r floor j a c k m a y be used to raise the vehi-
OF DISCHARGED BATTERY (Fig. 5). cle a t the locations described ( w i t h the exceptions
and precautions). I n a d d i t i o n , a front j a c k i n g point is
(6) Take care t h a t clamps f r o m one cable to not i n -
locating at the center of t h e f r o n t crossmember ( i n -
advertently touch clamps on other cable. D O N O T
board) (Fig. 6).
lean over b a t t e r y w h e n m a k i n g connections. The
negative connection m u s t provide good electrical con-
d u c t i v i t y a n d c u r r e n t c a r r y i n g capacity.

WARNING: DURING COLD WEATHER WHEN TEM-

PERATURES ARE BELOW FREEZING POINT, E L E C -
TROLYTE IN A DISCHARGED BATTERY MAY
FREEZE. DO NOT ATTEMPT JUMP STARTING BE-
CAUSE BATTERY COULD RUPTURE OR EXPLODE.
BATTERY TEMPERATURE MUST BE BROUGHT UP
ABOVE THE FREEZING POINT BEFORE ATTEMPT-
ING JUMP STARTING.

(7) After engine is started or i f engine fails to start,

cables m u s t be disconnected i n f o l l o w i n g order:
(a) Negative cable at engine ground.
(b) Negative cable at negative post on booster
battery.
.(c) Cable between positive post of b o t h batter-
ies.

WARNING: ANY PROCEDURE OTHER THAN

ABOVE COULD RESULT IN:
Fig. 6 Hoisting and Jacking Points
0-10 LUBRICATION AND MAINTENANCE
CAUTION: Do not attempt to lift a vehicle with a
floor jack positioned under the axle housings, body
side sills, steering linkage components, propeller
shafts, engine/transmission oil pans, fuel tank, or
front suspension arms. Use the frame rail lift loca-
tions only.
SINGLE POST HOIST/OUTBOARD TWIN
Frame contact l i f t points for single post hoist are
shown i n F i g . 6.
WARNING: WHEN SERVICE PROCEDURES R E -
QUIRE REMOVING REAR AXLE, FUEL TANK, AND
SPARE TIRE, PLACE ADDITIONAL WEIGHT ON
REAR END OF VEHICLE, ANCHOR VEHICLE TO
HOIST OR PLACE JACK STANDS UNDER VEHICLE
FOR SUPPORT TO PREVENT TIPPING WHEN CEN-
TER OF GRAVITY CHANGES.
HOISTING (4WD MODELS)
A conventional h y d r a u l i c hoist m a y be used after
inspecting and adjusting l i f t i n g arms, pads or ramps
to provide clearance between transfer case o r s k i d
plate d u r i n g l i f t i n g procedure (Fig. 7).
I f a t w i n post hoist is used a 4 x 4 x 12 i n c h wood
spacer may be required under t h e f r o n t axle tube (op-
posite differential housing) to m a i n t a i n a level l i f t i n g
position.
CAUTION: Any blocking or spacer material used for
increasing lift height must be secured in a safe
manner that will not unbalance the vehicle or dam-
age components such as hydraulic tines, exhaust
system or steering linkage.
ADJUSTMENT PAD
Fig. 7 Hoisting (Single Post Hoist Typical)
•
TOWING RECOMMENDATIONS
TOWING EQUIPMENT
W h e n t o w i n g a C h r y s l e r Motors vehicle a S A E ap-
proved sling-type t o w i n g device may be used (Fig. 8).
A crossbeam and spacer blocks may be r e q u i r e d for
proper attachment (Fig. 9). I n most sling-type t o w i n g
POST applications, J-hooks are recommended for a t t a c h i n g
the s l i n g crossbar t o t h e underside o f the vehicle.
W h e n J-hooks cannot be used, T-hooks are r e q u i r e d
(Fig. 10). I f T-hooks are b e i n g used, be sure t h e elon-
gated hole i n t h e chassis is reinforced and t h e T-hook
shank is i n - l i n e w i t h t h e hole (Fig. 11).
WHEEL UFT
FLATBED RR00D29
Fig. 8 Recommended Towing Devices
M a n y of Chrysler M o t o r vehicles are equipped w i t h
a i r dams, spoilers, o r g r o u n d effects s k i r t i n g w h i c h
m a k e sling-type t o w i n g i m p r a c t i c a l . I n these cases
the use o f a w h e e l - l i f t or flat-bed t o w i n g device (Fig.
8) is recommended. W h e n u s i n g a wheel-lift t o w i n g
device, be sure t h e u n l i f t e d end has a m i n i m u m
ground clearance o f 5 inches; i f not, use a t o w i n g
dolly. I f a flat-bed t o w i n g device is used, t h e ap-
proach r a m p angle should not exceed 15°.
ACTUALLY 8- 1/4"X7" CARRIAGE BOLT
MEASURES 8 - 1 / 4 " NUT
3-l/2"X3-l/2" 16- 1/4" WASHER J9000-48
Fig. 9 Crossbeam and Spacer Block Construction
 • LUBRICATION AND MAINTENANCE 0 - 11

Fig. 12 Rear Pickup—AD and AW Vehicles

RROOD18

Fig. 11 T—Hook Usage

LIFTING-GROUND CLEARANCE
Towed vehicle should be raised u n t i l l i f t e d wheels
are a m i n i m u m o f four inches from t h e g r o u n d . Be
sure there i s adequate ground clearance a t t h e oppo-
site end of the vehicle, especially w h e n t o w i n g over
rough t e r r a i n or w h e n crossing s h a r p rises such as
curbs. I f necessary, ground clearance c a n be i n -
creased by r e m o v i n g t h e wheels (secure b r a k e drums
w h e n using rear p i c k u p method) from t h e l i f t e d end
of t h e disabled vehicle a n d c a r r y i n g t h e l i f t e d end
closer to t h e ground. A n eight i n c h g r o u n d clearance
m u s t be m a i n t a i n e d between b r a k e d r u m s o r rotors
FRONT TOWING PICKUP (FIGS. 14 AND 15)
and t h e ground.
Care m u s t be t a k e n w h e n l i f t i n g t h e vehicle from
REAR TOWING PICKUP t h e front so t h a t t h e lower spoiler w i l l n o t be dam-
2 W D vehicles m a y be towed o n t h e f r o n t wheels for aged.
extended distances a t a speed n o t t o exceed 50 km/h M A N U A L T R A N S M I S S I O N vehicles m a y be towed
(30 mph). I t is recommended t h a t t h e r e a r pickup on t h e rear wheels a t speeds u p t o 50 km/h (30 mph)
method be used w h e n possible (Figs. 12 a n d 13). for a distance o f 25 k m (15 miles), provided t h e
4 W D vehicles m a y be towed (transfer case i n neu- transmission is i n n e u t r a l a n d t h e d r i v e l i n e has n o t
t r a l ) on t h e front wheels for distances n o t t o exceed been damaged. T h e p a r k i n g b r a k e must be released.
25 k m (15 miles). F o r extended distances, t h e front A U T O M A T I C T R A N S M I S S I O N vehicles m a y be
propeller shaft should be disconnected. towed on t h e front wheels a t speeds n o t to exceed 40
The steering wheel m u s t be clamped i n t h e km/h (25 mph) for a distance o f 25 k m (15 miles).
straight-ahead position w i t h a s t e e r i n g w h e e l clamp-
i n g device designed for t o w i n g service use. CAUTION: If these limits cannot be met, the front
wheels must be placed on a tow dolly.
CAUTION: Do not use steering column lock to se-
cure front wheel position for towing.
0 - 12 LUBRICATION AND MAINTENANCE
POSITION CENTER BAR AND WOOD BEAM BEHIND
BUMPER AND AHEAD OF STRUTS TO SUPPORT
CHAINS CLEAR OF SWAY BAR RN966
Fig. 14 Front Towing Pickup—2WD Vehicles
Fig. 15 Front Towing Pickup—4WD Vehicles
FLAT TOWING (4 WHEELS ON GROUND)
AUTOMATIC T R A N S M I S S I O N : T o w i n g behind
another vehicle is N O T recommended.
M A N U A L TRANSMISSION: Towing behind an-
other vehicle is allowed provided t h e transmission is
i n N E U T R A L and t h e p a r k i n g b r a k e is released.
IGNITION KEY A MAILABLE
Vehicles may be towed w i t h a l l four wheels on the
ground. Place the transmission i n n e u t r a l . D O N O T
tow more t h a n 24 k m (15 miles) or exceed 56 km/h
(35 m p h ) . I f the transmission i s n o t operative, or the
vehicle is t o be towed more t h a n 24 k m (15 miles),
the driveshaft must be disconnected or t h e vehicle
towed w i t h the rear wheels off t h e ground.
•
IGNITION KEY NOT AVAILABLE
I f the vehicle is locked a n d keys are not available,
place rear wheels on a dolly. L i f t a n d tow from t h e
front. As a n a l t e r n a t i v e ( p r o v i d i n g t h e p a r k i n g b r a k e
is released), a l l vehicles covered i n t h i s section m a y
be towed w i t h t h e rear d r i v e shaft disconnected.
SAFETY PRECAUTIONS
The f o l l o w i n g precautions should be t a k e n w h e n
t o w i n g the vehicle.
(1) Remove exhaust t i p s a n d a n y other optional
equipment except bumper guards, t h a t interfere w i t h
t h e t o w i n g s l i n g . Padding (heavy cloth or carpeting)
should be placed between t h e t o w sling a n d a n y
painted surfaces.
(2) W h e n p l a c i n g the t o w hooks o n the rear axle,
position hooks so as not t o damage brake lines.
(3) Do not allow a n y o f t h e t o w i n g equipment to
bear on the fuel t a n k .
(4) Vehicle i s not to be towed b y hooking o n t h e
front or rear shock absorbers or coil springs.
(5) Do not l i f t or tow t h e vehicle b y a t t a c h i n g to or
w r a p p i n g a r o u n d the bumper.
(6) A safety chain system completely independent
of the p r i m a r y l i f t i n g a n d t o w i n g attachment m u s t
be used.
(7) A n y loose or p r o t r u d i n g parts o f damaged vehi-
cle, such as hoods, doors, fenders, t r i m etc., should be
secured p r i o r t o m o v i n g t h e vehicle.
(8) Operator should r e f r a i n f r o m going u n d e r a ve-
hicle w h i l e i t is l i f t e d b y t h e t o w i n g equipment, u n -
less t h e vehicle is adequately supported b y safety
stands.
(9) Never allow passengers t o ride i n a towed vehi-
cle.
(10) State a n d local rules a n d regulations m u s t be
followed w h e n t o w i n g a vehicle.
(11) Special consideration m u s t be given to vehicles
w i t h optional campers, special bodies, f r o n t t i r e
mounts, t r a i l e r hitches, etc.
(12) H e a v i l y loaded l i g h t t r u c k vehicles have t h e
frame r a i l s designed to flex under heavy loading. I f
the vehicle i s lifted and towed from t h e rear, t h e
frame r a i l flex may be increased enough to a l l o w box
to cab contact and could cause damage to box and/or
cab. A t o w i n g dolly or flatbed carrier is desirable for
heavily loaded vehicles.
VEHICLE STORAGE
Vehicles t h a t may be stored for v a r y i n g i n t e r v a l s
require protection against deterioration. Vehicles
should be d r i v e n a m i n i m u m of 40 h i g h w a y k m (25
h i g h w a y miles) per m o n t h after t h e engine has
reached n o r m a l operating temperature. This w i l l pre-
vent the accumulation o f condensation and f o r m a t i o n
of rust on i n t e r n a l engine components such as c y l i n -
der bores.
• LUBRICATION AND MAINTENANCE
M a i n t a i n t h e fuel level i n t h e m a i n t a n k between
3/4 f u l l and f u l l . T h i s prevents t h e possibility o f car-
buretor g u m f o r m a t i o n w h i c h w i l l cause s t a r t i n g
problems and poor mileage.
N o r m a l maintenance services should be carried o u t
a t t h e t i m e or mileage i n t e r v a l s specified.
I f t h e vehicle cannot be d r i v e n each m o n t h , prepare
t h e vehicle according to the appropriate procedure t o
prevent damage t o t h e engine and chassis.
STORAGE FOR LESS THAN 1 MONTH
Vehicles inoperative for one m o n t h require t h e fol-
l o w i n g maintenance:
(1) A d d one q u a r t of special r u s t preventive o i l ,
M O P A R Engine O i l Supplement or equivalent, for
each five gallons o f gasoline i n the fuel t a n k .
(2) R u n the engine a t the 1000 r p m for five m i n -
utes.
STORAGE FOR 1 TO 3 MONTHS
Vehicles inoperative for one t o three months r e -
q u i r e the following maintenance i n a d d i t i o n t o those
described above.
0-13
(1) D r a i n fuel t a n k and operate engine u n t i l carbu-
retor r u n s dry.
(2) Remove spark plugs a n d pour 2 ounces o f spe-
cial r u s t preventive o i l i n t o each cylinder. C r a n k the
engine. Replace plugs and t i g h t e n t o 4 1 N»m (30 f t .
lbs.) torque.
(3) Remove valve covers a n d coat rocker arms,
rocker a r m shaft, valve springs, push rods and valve
stems w i t h special r u s t preventive o i l .
(4) Check cooling system for leaks and proper a n t i -
freeze protection.
STORAGE FOR MORE THAN 3 MONTHS
Vehicles inoperative for more t h a n 3 months r e -
quire the following maintenance i n a d d i t i o n t o those
described above.
(1) Place the vehicle on blocks or jackstands to re-
move weight f r o m tires. I n f l a t e t i r e s to recommended
pressure.
(2) Check the transmission, rear axle a n d steering
system for proper l u b r i c a n t level.
(4) Disconnect battery cables. Clean a n d coat cable
t e r m i n a l s w i t h grease. Remove b a t t e r y a n d place o n
a t r i c k l e charge.
0 - 14 LUBRICATION AND MAINTENANCE •
ENGINE
INDEX
Page Page
Air Conditioning Compressor 21 Exhaust System 21
Air Injection System 17 Fuel System 19
Battery 20 Hoses and Fittings 16
Cooling System 16 Ignition Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Crankcase Inlet Air Filter 18 Ignition Wires, Distributor Cap and Rotor 19
Manifold Heat Control Valve 17
Crankcase Ventilation System 17
Oxygen ( 0 ) Sensor 19
Engine Air Cleaner 16
2

Rubber and Plastic Component Inspection 20

Engine Oil 14 Spark Plugs 20
Engine Oil and Filter Changes 15 Throttle Control Linkage 16
Engine Oil Filter Selection 15 Vacuum Operated Components 19
Exhaust Gas Recirculation (EGR) System . . . . . . . 19 Vacuum Operated Emission Control Components . 20

ENGINE OIL VISCOSITY

DURING BREAK-IN
The crankcase o i l installed i n the engine at the fac-
t o r y is a h i g h q u a l i t y , energy conserving type l u b r i -
cant. O i l changes should be consistent w i t h
anticipated c l i m a t i c conditions under w h i c h vehicle
operation w i l l occur. The recommended S A E viscosity
grades are shown i n Fig. 1. O n l y oils w i t h the proper
A P I q u a l i t y classification should be used w h e n add-
i n g or changing the crankcase engine o i l .
CAUTION: Nondetergent or straight mineral oils
must never be used.
Frequently a n e w engine w i l l consume some o i l
d u r i n g its first few thousand miles of operation. T h i s
should be considered as a n o r m a l p a r t o f b r e a k - i n
a n d not i n t e r p r e t e d as a n indication o f difficulty.
Multi-viscosity oils protect t h e engine over a wide
range o f operating temperatures and d r i v i n g condi-
tions. Therefore these oils can be used a l l year round.
Select o i l viscosity according t o t h e lowest a i r t e m -
perature expected before the n e x t o i l change (Fig. 1).
L o w viscosity oils make engine s t a r t i n g easier i n cold
weather. Oils o f the S A E 5W-30 grade n u m b e r are
preferred w h e n m i n i m u m temperatures consistently
f a l l below -12°C (10°F).
ENERGY CONSERVING
There are m a n y engine oils c u r r e n t l y available
t h a t could increase the fuel economy o f y o u r vehicle.
They are m a r k e t e d as E N E R G Y C O N S E R V I N G , or
E N E R G Y C O N S E R V I N G I I . Those oils identified as
E N E R G Y C O N S E R V I N G I I provide greater fuel
economy benefits t h a n those i d e n t i f i e d as E N E R G Y
C O N S E R V I N G . I n a d d i t i o n t o selecting t h e proper
A P I q u a l i t y category and viscosity grade, use of E N -
E R G Y C O N S E R V I N G type engine oils are preferred.

10W-30
> ENGINE OIL IDENTIFICATION SYMBOL
A symbol has been developed t o a i d t h e vehicle
<I I
5W-30
I !
owner i n the proper selection o f engine o i l . This sym-
bol is located on the o i l container and i s composed o f
F -20 0 10 20 32 60 80 100 three distinct areas for i d e n t i f y i n g various aspects o f
C -29 -18 -12 -7 0 16 27 38 the o i l (Fig. 2).
ANTICIPATED TEMPERATURE RANGE (1) The top p o r t i o n w i l l i n d i c a t e the q u a l i t y of the
BEFORE NEXT OIL CHANGE J9000-39 o i l , such as " S G " or "SG/CD".
(2) The center portion w i l l show the S A E viscosity
Fig. 1 Recommended Viscosity Grades grade o f the o i l , such as S A E 5W-30 or 10W-30.
SELECTING ENGINE OIL (3) T h e lower portion w i l l show o n l y E N E R G Y
C O N S E R V I N G or E N E R G Y C O N S E R V I N G I I , i f i t
OIL QUALITY is applicable t o t h a t o i l . E n e r g y conserving w h e n
For m a x i m u m engine protection under a l l d r i v i n g shown, indicates, t h a t o i l , offers fuel economy bene-
fits i n gasoline engines.
conditions, use only engine oils t h a t conform to A P I
Service Catagories "SG" or "SG/CD". To assure use o f
ENGINE OIL LEVEL INDICATOR
properly formulated engine oils, i t is recommended The engine o i l level i n d i c a t o r dipstick i s located o n
t h a t M O P A R Oils, or equivalent be used (see the r i g h t front of the engine, left o f t h e alternator.
Chrysler M a t e r i a l Standard MS-6395).
 • LUBRICATION AND MAINTENANCE 0 - 15

(2) Heavy D u t y C y c l e - E v e r y 12 months or 9 600

k m (6,000 miles), whichever occurs first.
(3) Severe Service Cycle—Every 3 months or 4 800
k m (3,000 miles), whichever occurs first, i f the v e h i -
cle is d r i v e n under any of the f o l l o w i n g conditions:
(a) Frequent d r i v i n g i n dusty conditions
(b) Frequent t r a i l e r p u l l i n g
(c) Extensive i d l i n g
(d) F r e q u e n t short t r i p d r i v i n g (less t h a n 8 k m
or 5 miles) a t temperatures below 10°F (-12°C).
(e) M o r e t h a n 50%operation a t sustained h i g h
speeds over 112 km/h (70 mph) d u r i n g hot weather
(above 90°F or 32°C).
ECONOMY
BENEFIT J9000-4 CAUTION: Do not overfill crankcase. This will cause
011 aeration and loss of oil pressure.
Fig. 2 Oil Container Symbol
CHECKING ENGINE OIL LEVEL
To assure proper l u b r i c a n t of y o u r vehicle's engine, ENGINE OIL FILTER
t h e engine o i l m u s t be m a i n t a i n e d a t the correct N O R M A L D R I V I N G — T h e o i l filter should be re-
level. Check the o i l level a t r e g u l a r i n t e r v a l s , such placed w i t h a new filter a t every second engine o i l
as every fuel stop. A d d o i l only w h e n t h e level on the change. E a c h 12 months, i f the mileage is less t h a n
dipstick is a t or below t h e A D D O I L m a r k . 12 000 k m (7,500 miles) L i g h t D u t y Cycle or 9 600
k m (6,000 miles) Heavy D u t y Cycle, replace t h e o i l
CAUTION: Do not overfill crankcase. This will cause f i l t e r a t each o i l change.
oil aeration and loss of oil pressure. S E V E R E S E R V I C E - F o r severe operating condi-
tions as o u t l i n e d above, the o i l filter should be re-
placed a t every second o i l change.
MATERIALS ADDED TO ENGINE OILS
I t is not necessary t o add any m a t e r i a l t o crank-
DISPOSING OF USED ENGINE OIL
case oils for most types of vehicle operation. I n some
instances, such as i n f r e q u e n t operation or short t r i p s
WARNING: TEST RESULTS SUBMITTED TO EPA
o n l y and d u r i n g b r e a k - i n after a major engine over-
HAVE SHOWN THAT LABORATORY ANIMALS DE-
h a u l and/or new p i s t o n i n s t a l l a t i o n , a d d i t i o n o f spe-
VELOP SKIN CANCER AFTER PROLONGED CON-
cial materials c o n t a i n i n g a n t i - r u s t a n d anti-scuff
TACT WITH USED ENGINE OIL. ACCORDINGLY,
additives are beneficial. M O P A R E n g i n e O i l Supple-
THE POTENTIAL EXISTS FOR HUMANS TO DE-
ment, or equivalent, i s a suitable product for t h i s
VELOP A NUMBER OF SKIN DISORDERS, INCLUD-
purpose.
ING CANCER, FROM SUCH EXPOSURE TO USED
ENGINE OIL FILTER SELECTION ENGINE OIL. CARE SHOULD BE TAKEN WHEN
CHANGING ENGINE OIL, TO MINIMIZE THE
A l l engines are equipped w i t h full-flow, t h r o w - AMOUNT AND LENGTH OF EXPOSURE TIME TO
away o i l filters. I t i s possible, p a r t i c u l a r l y i n cold USED ENGINE OIL ON YOUR SKIN. PROTECTIVE
weather, t h a t the vehicle may develop h i g h o i l pres- CLOTHING AND GLOVES, THAT CANNOT BE PEN-
sure for a short d u r a t i o n . ETRATED BY OIL, SHOULD BE WORN. THE SKIN
The q u a l i t y o f replacement f i l t e r s varies consider- SHOULD B E THOROUGHLY WASHED WITH SOAP
ably. Be sure t h a t a n y replacement f i l t e r used i s a AND WATER, OR USE WATERLESS HAND
h i g h q u a l i t y filter, a n d is capable o f w i t h s t a n d i n g a CLEANER, TO REMOVE ANY USED ENGINE OIL.
pressure o f 1765 k P a (256 psi—manufacturer's speci- DO NOT USE GASOLINE, THINNER, OR SOLVENTS.
fications) t o avoid f i l t e r a n d engine damage.
Care should be t a k e n i n disposing o f the used en-
gine o i l f r o m y o u r vehicle. Used o i l , i n d i s c r i m i n a t e l y
ENGINE OIL AND FILTER CHANGES
discarded, can present a problem to the environment.
Contact y o u r dealer or service station, to determine
ENGINE OIL where used o i l can be safely discarded.
Engine o i l should be changed a t t h e f o l l o w i n g i n -
tervals:
(1) L i g h t D u t y Cycle—Every 12 m o n t h s or 12 000
k m (7,500 miles), whichever occurs first.
0-16 LUBRICATION AND MAINTENANCE
COOLING SYSTEM
WARNING: TAKE CARE TO AVOID THE RADIA-
TOR COOLING FAN WHENEVER THE VEHICLE
HOOD IS RAISED. IF YOU MUST WORK NEAR THE
FAN, DISCONNECT THE FAN MOTOR LEAD.
INSPECTION
WARNING: WHEN REMOVING THE RADIATOR
CAP, CARE SHOULD BE TAKEN TO PREVENT
SCALDING FROM HOT PRESSURIZED COOLANT.
Coolant protection checks should be made every 12
months (prior t o the onset of freezing weather, where
applicable). I f coolant i s d i r t y or r u s t y i n appearance,
the system should be drained,flushed a n d refilled
w i t h fresh coolant.
Check r a d i a t o r cap for proper vacuum sealing and
operation. Use caution w h e n r e m o v i n g the radiator
cap t o avoid contact w i t h hot coolant or steam. Place
a cloth over t h e cap, t u r n to t h e first stop, (do n o t
press down), pause t o allow pressure t o release
t h r o u g h the overflow tube,then press down and t u r n
counterclockwise t o remove cap. Check face o f radia-
tor and a i r c o n d i t i o n i n g condenser for any accumula-
t i o n of bugs, leaves, etc. Check t u b i n g a t coolant
reserve t a n k and radiator. Inspect entire system for
leaks.
Y o u r cooling system has a 50/50 solution o f a n t i -
freeze and w a t e r from t h e factory. T h i s is t h e recom-
mended solution for most operating temperatures
and provides good corrosion protection.
F a i l u r e t o follow anti-freeze concentration and re-
placement recommendations or f a i l u r e t o use a n t i -
freeze formulated t o prevent corrosion o f a l l cooling
system metals, may r e s u l t i n r a d i a t o r plugging. The
result is engine overheating or cooling system leaks,
such as a t core hole plugs, r e s u l t i n g i n loss of cool-
ant.
RADIATOR CAP
The r a d i a t o r cap m u s t be f u l l y tightened i n order
to provide a good seal w i t h the radiator f i l l e r neck.
T h i s prevents loss o f coolant and ensures t h a t coolant
w i l l r e t u r n t o the r a d i a t o r f r o m the coolant reserve
t a n k . The v e n t valve and i t s seat can become con-
t a m i n a t e d w i t h coolant sediment etc. The valve and
seat should be carefully cleaned i f :
(1) The system w i l l not go under pressure.
(2) The coolant reserve bottle gains coolant abnor-
mally.
(3) The top r a d i a t o r hose collapses o n cool-down.
DRAIN, FLUSH AND FILL
D r a i n , flush, a n d f i l l the cooling system at t h e
mileage or t i m e i n t e r v a l s specified i n t h e Mainte-
•
nance Schedule i n t h i s Group. I f t h e solution is d i r t y
or r u s t y or contains a considerable amount o f sedi-
m e n t , clean a n d flush w i t h a reliable cooling system
cleaner. Care should be t a k e n i n disposing o f t h e
used engine coolant f r o m y o u r vehicle. Used coolant,
i n d i s c r i m i n a t e l y discarded, can present a p r o b l e m t o
the environment. Contact y o u r dealer, service s t a t i o n
or governmental agency t o f i n d o u t where used cool-
ant can be properly discarded i n y o u r area.
Refer t o Group 7, Cooling System for t h e proper
d r a i n , flush a n d f i l l procedures.
HOSES AND FITTINGS
Inspect t h e hose f i t t i n g s for looseness a n d corro-
sion. Inspect t h e hoses for brittleness and cracks.
T h o r o u g h l y inspect t h e hose ends t h a t are slipped
onto nipples.
E n g i n e performance m a y be adversely affected b y
air leaks i n t o such u n l i k e l y places as the heater a n d
air conditioner control v a c u u m hoses, coolant hoses
or t h e power brake booster v a c u u m hose.
ENGINE AIR CLEANER
The engine a i r cleaner should be replaced every 48
000 k m (30,000 miles) under n o r m a l d r i v i n g condi-
tions. W h e n t h e vehicle is frequently operated i n
dusty conditions t h e a i r cleaner should be replaced
and the wrapper cleaned as required.
Remove cleaner assembly, remove paper element
(Fig. 3). Clean f i l t e r element by b l o w i n g d i r t out gen-
t l y w i t h compressed a i r (Fig. 4). Direct a i r from i n -
side o u t , a n d keep nozzle t w o inches away f r o m
element to avoid damage. I f the f i l t e r element is sat-
u r a t e d w i t h o i l for more t h a n 1/2 i t s circumference
replace t h e f i l t e r element a n d wrapper assembly.
Check t h e rest o f t h e crankcase v e n t i l a t i n g system
for proper operation.
Do not immerse paper element i n l i q u i d .
On vehicles equipped w i t h a heated a i r system, do
not immerse t e m p e r a t u r e sensor (located i n a i r
cleaner housing) i n cleaning solution.
W a s h the cleaner cover and body w i t h cleaning sol-
v e n t and wipe dry.
Replace paper element (and wrapper, i f equipped).
Replace cleaner assembly o n engine.
THROTTLE CONTROL LINKAGE
A l l transmission l i n k a g e pivot p i n areas except
b a l l j o i n t type, should be cleaned of dust a n d d i r t
(Fig. 5). L u b r i c a t e every second o i l change w i t h M u l -
tipurpose Grease N L G I Grade 2 E.P. D o not l u b r i -
c a t e t h r o t t l e b o d y l i n k a g e , throttle l i n k a g e b a l l
j o i n t s , throttle c o n t r o l c a b l e s , o r t r a n s m i s s i o n
k i c k d o w n cables.
 • LUBRICATION AND MAINTENANCE 0-17

HOLD DOWN NUT AIR CLEANER PIVOT AREAS

ASSEMBLY

FRONT

RN965

Fig. 5 Accelerator Linkage Pivot Areas

RROOD26

Fig. 3 Engine Air Cleaner Assembly (Typical)

PAPER ELEMENT

Fig. 6 Manifold Heat Control Valve

AIR INJECTION SYSTEM
A l l valves and switches i n t h e A i r Injection System
and the a i r p u m p should be checked for proper oper-
IF THE PAPER AIR CLEANER ation a n d replaced, i f necessary. Inspect t h e check
ELEMENT IS SATURATED WITH \
valve t u b i n g for corrosion a n d replace, i f excessive
OIL, IT MUST BE REPLACED
AND PCV SYSTEM TESTED RR00D24 corrosion is evident.

Fig. 4 Cleaning Filter Element (Typical) CRANKCASE VENTILATION SYSTEM

MANIFOLD HEAT CONTROL VALVE
O n t h e L E F T H A N D manifold, test the manifold
heat control v a l v e for free operation. W i t h the engine
i d l i n g , accelerate m o m e n t a r i l y . T h e counterweight
should move C L O C K W I S E . I f no movement is ob-
served, shaft i s b i n d i n g or t h e thermostat spring is
weak or broken. Be sure manifold is COOL before
a p p l y i n g M O P A R M a n i f o l d Heat Control Valve Sol-
vent, or equivalent, to each end of t h e shaft a t t h e
bearings (Fig. 6). A l l o w t h e solvent to soak a few
minutes to dissolve deposits. Then, w o r k t h e valve
back and f o r t h u n t i l i t t u r n s freely. I f the spring is
weak or broken, replace t h e spring.
A l l models w i t h gasoline operated engines are
equipped w i t h a closed crankcase v e n t i l a t i o n system
designed t o e l i m i n a t e emission o f residual fumes and
vapors f r o m t h e crankcase b y directing these fumes
back t h r o u g h t h e engine combustion chambers.
VENTILATION SYSTEM OPERATION
The v e n t i l a t i o n system operates by m a n i f o l d vac-
u u m . A i r is d r a w n from t h e a i r cleaner, t h r o u g h t h e
crankcase i n l e t a i r cleaner. T h e n the a i r is circulated
t h r o u g h t h e engine and d r a w n out t h r o u g h t h e P C V
valve, a n d i n t o a passage i n the t h r o t t l e body, becom-
i n g p a r t o f t h e calibrated air/fuel m i x t u r e ( F i g . 7).
This m i x t u r e is d r a w n i n t o t h e combustion chamber
and burned.
 0 - 18 LUBRICATION AND MAINTENANCE •

Fig. 7 Crankcase Ventilation System Operation

(Typical)
FREQUENCY OF SERVICE Fig. 8 Check Vacuum at PCV Valve
The crankcase v e n t i l a t i o n system m u s t be k e p t
(5) C l e a n t h e crankcase i n l e t a i r filter.
clean t o m a i n t a i n good engine performance a n d d u -
(6) Clean or replace t h e engine a i r cleaner.
rability.
Periodic service is required to remove combustion
products f r o m t h e valve, hoses a n d i n t a k e m a n i f o l d
CRANKCASE INLET AIR FILTER
passages. T h e components should be inspected a n d Clean a n d lubricate t h e crankcase i n l e t a i r cleaner
serviced as indicated a t t h e mileage or t i m e i n t e r v a l a t t h e mileage or t i m e i n t e r v a l shown i n t h e L u b r i -
specified i n t h e appropriate L u b r i c a t i o n and M a i n t e - cation a n d Maintenance Schedule.
nance C h a r t . I f a vehicle is used extensively for short (1) Disconnect t h e hoses f r o m t h e crankcase i n l e t
trips w i t h frequent i d l i n g , t h e crankcase v e n t i l a t i o n a i r filter ( F i g . 9).
system m a y require servicing more frequently. (2) Remove t h e crankcase i n l e t a i r filter a n d w a s h
i t t h o r o u g h l y i n kerosene or s i m i l a r solvent.
INSPECTION AND SERVICE PROCEDURE (3) L u b r i c a t e or w e t t h e filter, by i n v e r t i n g t h e
(1) W i t h engine i d l i n g : crankcase i n l e t a i r filter a n d filling w i t h S A E 30 en-
(a) Remove P C V valve. I f t h e valve is n o t gine o i l . Position t h e a i r filter t o allow excess o i l t o
plugged, a h i s s i n g noise w i l l be heard as a i r passes
d r a i n t h o r o u g h l y t h r o u g h t h e vent nipple located o n
t h r o u g h t h e valve, and a strong vacuum should be
t h e top o f t h e a i r filter.
felt w h e n a finger is placed over t h e valve i n l e t
M o r e frequent service m a y be required for vehicles
(Fig. 8).
used i n short r u n , stop a n d go or extended engine
(b) I n s t a l l t h e P C V valve. Remove t h e crank- idle service.
case i n l e t tube f r o m t h e a i r cleaner assembly a n d
loosely h o l d a piece of paper over t h e open end o f
the tube. A f t e r a l l o w i n g about a m i n u t e for t h e
crankcase pressure to reduce, t h e paper should be
sucked against t h e opening w i t h a noticeable
amount o f force.
(2) W i t h engine stopped; remove P C V valve a n d
shake. A c l i c k i n g noise should be heard t o indicate
t h a t t h e valve mechanism is free.
(3) I f t h e crankcase v e n t i l a t i o n system meets t h e
tests i n (1) a n d (2) above, no f u r t h e r service is re-
quired. I f not, t h e P C V valve should be replaced a n d
the system checked again. I n s t a l l a new Mopar P C V
Valve, o r equivalent. D o not a t t e m p t to c l e a n t h e
old P C V valve!
(4) I f test ( l b ) fails when a n e w P C V valve has J9000-52
been i n s t a l l e d , i t w i l l be necessary to replace t h e
PCV hose a n d clean t h e P C V hose intake port. Fig. 9 Crankcase Inlet Air Filter
 • LUBRICATION AND MAINTENANCE
FUEL SYSTEM
Inspect the fuel system cap, lines, hoses a n d con-
nections a t t h e mileage or t i m e i n t e r v a l s specified i n
the L u b r i c a t i o n and Maintenance Schedule.
Use gasoline h a v i n g a m i n i m u m octane r a t i n g o f
87 (R + M)/2.
Should y o u r vehicle develop spark k n o c k (ping),
purchase y o u r gasoline f r o m a different source. V e h i -
cles may respond differently t o gasolines h a v i n g the
same octane r a t i n g . Occasional trace k n o c k a t l o w
engine speeds is n o t h a r m f u l . Continued knock a t
h i g h speeds, however, can damage y o u r engine and
should be reported t o your dealer i m m e d i a t e l y . E n -
gine damage, as t h e r e s u l t o f continued operation of
a vehicle w i t h spark knock, m a y not be covered b y
the new vehicle w a r r a n t y .
I n addition t o choosing t h e proper octane r a t i n g ,
use o f gasolines c o n t a i n i n g h i g h level o f detergent
additives is also recommended. The use o f these h i g h
detergent gasolines w i l l reduced fuel injector and i n -
take system deposit build-up a n d m a i n t a i n t h e excel-
l e n t d r i v e a b i l i t y o f your vehicle. I f i n doubt,
p r e m i u m unleaded gasolines generally c o n t a i n more
detergent additives t h a n t h e lower octane regular
unleaded gasolines.
Unleaded gasolines only, m u s t be used i n vehicles
equipped w i t h catalyst emission control systems. A l l
vehicles so equipped have labels located o n t h e i n -
strument panel and adjacent t o the fuel filler cap or
door t h a t state U N L E A D E D F U E L O N L Y . These ve-
hicles also have fuel filler tubes specially designed t o
accept t h e smaller diameter unleaded gasoline dis-
pensing nozzles only.
The exhaust emission system o f your vehicle is de-
signed to meet a l l emission regulations w h i l e , a t the
same t i m e , p r o v i d i n g excellent fuel economy. Cata-
l y s t systems require t h a t only unleaded gasoline be
used. Use o f leaded fuel w i l l n o t only destroy the ef-
fectiveness o f the catalytic converter used t o reduce
exhaust emissions, b u t w i l l also make p a r t o f t h e
fuel control system inoperative and lead t o h i g h fuel
consumption. D a m a g e r e s u l t i n g from t h e u s e o f
leaded gasoline m a y n o t b e covered b y the n e w
vehicle w a r r a n t y .
GASOLINES CONTAINING ALCOHOL
Some gasolines sold a t service stations contain a l -
cohol, a l t h o u g h they m a y not be so identified. Use o f
fuels containing alcohol is not recommended, unless
t h e nature o f the b l e n d can be determined as being
satisfactory.
G A S O H O L - A m i x t u r e o f 10% ethanol ( g r a i n a l -
cohol) a n d 9 0 % unleaded gasoline m a y be used i n
your vehicle. I f d r i v e a b i l i t y problems are experienced
as a result o f u s i n g G A S O H O L , i t is recommended
t h a t the vehicle be operated o n unleaded gasoline,
only.
0-19
M E T H A N O L - D O N O T use gasoline containing
methanol (wood alcohol). Use of t h i s type of alcohol
can r e s u l t i n vehicle performance deterioration and
damage t o c r i t i c a l parts i n t h e fuel pump, injector
and other fuel system components. F u e l system dam-
age a n d vehicle performance problems, r e s u l t i n g
from the use o f gasoline containing methanol alcohol,
m a y not be covered b y t h e new vehicle w a r r a n t y .
GASOLINES CONTAINING MTBE
Gasoline a n d M T B E blends are a m i x t u r e of u n -
leaded gasoline a n d u p to 15% M T B E ( M e t h y l Ter-
t i a r y B u t y l E t h e r ) . Gasoline blended w i t h M T B E
m a y be used i n y o u r vehicle.
MATERIALS ADDED TO FUEL
I n d i s c r i m i n a t e use o f fuel system cleaning agents
should be avoided. M a n y of these materials intended
for g u m a n d v a r n i s h removal may contain h i g h l y ac-
t i v e solvents or s i m i l a r ingredients t h a t can be
h a r m f u l t o gasket a n d diaphragm materials used i n
fuel system component parts.
FUEL FILTER
A plugged fuel filter can be caused by contami-
nants i n t h e fuel. T h i s can l i m i t t h e speed a t w h i c h a
vehicle c a n be d r i v e n a n d cause hard starting. I f
these conditions occur, the filter should be replaced.
VACUUM OPERATED COMPONENTS
Inspect a l l v a c u u m operated a n d emission related
components t o ensure they are not cracked or broken.
Replace component(s), as necessary.
EXHAUST GAS RECIRCULATION (EGR) SYSTEM
The E G R valve and E G R tube ( i f so equipped) a t
the mileage or t i m e i n t e r v a l specified i n the Lubrica-
t i o n and Maintenance Schedules. For additional i n -
f o r m a t i o n refer t o Group 25, Emission Control
System.
IGNITION WIRES, DISTRIBUTOR CAP AND ROTOR
Replace t h e i g n i t i o n wires, distributor cap and ro-
tor a t t h e mileage i n t e r v a l indicated on the Lubrica-
tion a n d Maintenance Schedule. Check the
d i s t r i b u t o r for excessive wear and proper component
clearances. Replace, i f necessary.
OXYGEN (0 ) SENSOR
2
Replace t h e oxygen sensor a t t h e mileage a n d t i m e
i n t e r v a l specified i n t h e L u b r i c a t i o n a n d M a i n t e -
nance Schedule. Refer to Group 25, Emission Control
System for a d d i t i o n a l i n f o r m a t i o n .
 0 - 20 LUBRICATION AND MAINTENANCE
SPARK PLUGS
Replace t h e spark p l u g s (Fig. 10) a t the mileage or
time i n t e r v a l specified i n t h e L u b r i c a t i o n and M a i n -
tenance Schedule. Refer t o Group 8D, a n d t h e O w n -
er's M a n u a l provided w i t h t h e vehicle for additional
information.
ENGINE SPARK SPARK TORQUE
PLUG PLUG GAP
3.9L RN12YC 0.9 mm 41 Nm
5.2L 0.035 in 30 ft lb
5.9L
J9000-54
Fig. 10 Spark Plug Replacement
IGNITION TIMING
Check a n d adjust t h e i g n i t i o n t i m i n g (and cam t i m -
ing on t h e 2.5L Engine) according t o specifications
shown o n t h e Engine Emission C o n t r o l I n f o r m a t i o n
Label, located i n t h e engine compartment.
BATTERY
A l l vehicles are equipped w i t h maintenance-free
batteries ( F i g . 11). A maintenance-free batterie has
no removable battery cell caps. Water n e v e r needs
to b e a d d e d to a m a i n t e n a n c e - f r e e b a t t e r y . S m a l l
vent holes i n t h e cover allow t h e gases t h a t are pro-
duced to escape. A special chemical composition i n -
side t h e b a t t e r y reduces production o f gas t o a n
extremely s m a l l a m o u n t a t n o r m a l c h a r gin g volt-
ages.
The b a t t e r y contains a V i s u a l T e s t I n d i c a t o r .
When a n adequate charge level exists t h e indicator
is G R E E N . W h e n c h a r g i n g is required t h e indicator
is R E D or B L A C K . W h e n replacement is required
the indicator is Y E L L O W .
VACUUM OPERATED EMISSION CONTROL
COMPONENTS
Replace these components a t t h e t i m e or mileage
intervals indicated i n t h e L u b r i c a t i o n a n d M a i n t e -
nance Schedules. Refer t o Group 25, Emission Con-
trol System for more i n f o r m a t i o n .
RUBBER AND PLASTIC COMPONENT INSPECTION
Variables such as type of vehicle service, geo-
graphic area o f vehicle operation, a n d l e n g t h o f expo-
sure t i m e t o heat a n d contaminants are factors
affecting t h e life of r u b b e r a n d plastic components.
•
INCREASED SEALED TEST
ELECTROLITE VENT CAPS INDICATOR
ENVELOPE HOLD DOWN
SEPARATORS RK92
Fig. 11 Maintenance Free Battery
To provide best vehicle performance a n d avoid a d -
verse effect o n component life, i t is recommended
t h a t t h e f o l l o w i n g components be inspected w h e n
p e r f o r m i n g other under hood services. C o m p o n e n t s
should be replaced immediately i f there is a n y
evidence o f degradation that c o u l d result i n fail-
ure.
HOSES (EXCEPT EMISSION HOSES)
R e f e r t o G r o u p 25, E m i s s i o n s C o n t r o l S y s t e m s
f o r i n s p e c t i o n o f e m i s s i o n hoses.
Inspect surface o f hoses and n y l o n t u b i n g for evi-
dence o f heat a n d mechanical damage. H a r d a n d
b r i t t l e rubber, cracking, checking, tears, cuts, abra-
sion a n d excessive swelling indicate deterioration o f
the rubber. Hose a n d n y l o n t u b i n g located close t o
the exhaust m a n i f o l d or any source of intense heat
should receive special attention. Be certain t h a t n y -
lon t u b i n g i n these areas is not melted or collapsed.
Inspect hose r o u t i n g t o ensure hose does n o t come
i n contact w i t h any heat source or m o v i n g component
w h i c h w i l l cause heat damage or mechanical wear.
Inspect a l l hose connections such as clamps a n d
couplings t o m a k e sure they are secure a n d no leaks
are present. I n m a n y i n s t a n c e s , f l u i d s s u c h as o i l ,
power steering fluid a n d brake fluid are used
d u r i n g a s s e m b l y o f hoses t o c o u p l i n g s . T h e r e -
fore, o i l wetness a t the hose-coupling area i s n o t
necessarily a n i n d i c a t i o n o f leakage. Actual drip-
p i n g o f h o t f l u i d w h e n systems are under pressure
( d u r i n g vehicle operation), should be noted a n d
clamps t i g h t e n e d before hose i s replaced based o n
leakage.
 • LUBRICATION AND MAINTENANCE
DRIVE BELTS
At the mileage indicated i n t h e L u b r i c a t i o n and
Maintenance C h a r t , a l l belts should be checked for
t h e i r condition a n d proper tension. Improper belt t e n -
sion can cause b e l t slippage a n d f a i l u r e .
Belts should be inspected for evidence o f cuts,
cracks, or glazing. Replace t h e belts i f there is a n i n -
dication of damage w h i c h could r e s u l t i n belt f a i l u r e .
I f adjustment i s required, t h e belts m u s t be adjusted
according t o t h e specifications a n d procedures de-
scribed i n Group 7, Cooling System. Special tools are
required t o properly measure tension and t o restore
belt tension t o factory specifications.
ENGINE MOUNTS
Inspect t h e connecting fasteners between the block
and the engine m o u n t bracket a n d those h o l d i n g the
m o u n t t o t h e frame for correct torque (see Group 9,
Engines). T h e rubber i n t h e m o u n t should be i n -
spected for excessive softening and/or swelling caused
by o i l and/or gasoline c o n t a m i n a t i o n . S l i g h t surface
deterioration a n d wear at t h e ends w i l l not adversely
affect performance. I f , however, excessive engine
movement, r u b b e r softening o r swelling, or noise
caused by metal-to-metal contact is observed, the en-
gine mount assembly should be replaced.
CAUTION: Avoid continuous contamination with oil
or gasoline. Such contamination will result in re-
duced engine mount life.
IGNITION WIRES
The i g n i t i o n wires should be kept clean and prop-
e r l y connected. T e r m i n a l s should be f u l l y seated and
t h e nipple assemblies should n o t be removed f r o m
t h e d i s t r i b u t o r or coil towers.
0 - 21
EXHAUST SYSTEM
The exhaust system m u s t be properly aligned to
prevent stress, leakage, and body contact. I f t h e sys-
t e m contacts a n y panel, i t m a y amplify objectionable
noises o r i g i n a t i n g f r o m the engine o r the body.
Inspect the exhaust system a t t h e mileage or t i m e
intervals specified i n the Maintenance Schedule i n
t h i s Group for t h e following conditions. Correct as re-
quired.
(1) Exhaust system leaks, damage, m i s a l i g n m e n t .
(2) Grounding against body sheet m e t a l or frame.
(3) Catalytic converter " b u l g i n g " o r heat damage.
W h e n inspecting a n exhaust system, c r i t i c a l l y i n -
spect for cracked o r loose j o i n t s , stripped screws/bolt
threads, corrosion damage, a n d w o r n or broken hang-
ers. Replace a l l components t h a t are badly corroded
or damaged. Do n o t a t t e m p t repair.
CAUTION: The catalytic converter(s) will become
contaminated if leaded gas is used, or if the engine
or emission controls are not maintained as sched-
uled. If this occurs, the catalyst (the alumina-coated
beads in the converter) or the entire converter must
be replaced.
AIR CONDITIONING COMPRESSOR
The l u b r i c a n t level i n the a i r conditioning compres-
sor should be checked i f there are signs t h a t o i l was
lost (oily shaft seal area, o i l covered f i t t i n g s , etc.).
Loss of o i l u s u a l l y accompanies loss o f refrigerant
charge. The presence of gas bubbles (white foam) as
viewed t h r o u g h t h e filter d r i e r sight glass, w h i l e the
system is i n operation, indicates some loss o f refrig-
erant charge has occurred.
For compressor o i l level check or recharging sys-
tem, see Group 24, H e a t i n g and A i r conditioning.
0 - 22 LUBRICATION AND MAINTENANCE •
DRIVETRAIN

INDEX
Page Page
Automatic Transmission 24 Manual Transmissions NP2500 Overdrive
Axles 25 5-Speed/NP435 Overdrive 4-Speed 22
Clutch and Brake Linkage 22 Propeller Shaft Universal Joints . . . . . . . . . . . . . . 26
Clutch Master Cylinder 22 Transfer C a s e . . 24
Front Axle Universal Drive Joint and Pivot
Bearings . . 26

CLUTCH AND BRAKE LINKAGE (MUSS 116) s t a n d a r d only. M O P A R B r a k e F l u i d or

I f the clutch and brake pedal assembly should s t a r t
to squeak or g r u n t , t h e p i v o t bushings should be l u -
bricated (Fig. 1). Use a m u l t i p u r p o s e ( N L G I Grade 2)
grease, M O P A R Multi-Purpose L u b r i c a n t , or equiva-
lent.
equivalent w i l l provide the best c l u t c h performance.
CAUTION: Do not allow any petroleum base fluids
to contaminate the clutch hydraulic system, seal
damage will result.

CLUTCH MASTER CYLINDER MANUAL TRANSMISSIONS NP2500 OVERDRIVE

5-SPEED/NP435 OVERDRIVE 4-SPEED
The clutch master cylinder f l u i d level should be pe-
riodically inspected w h e n other under hood service is
SHIFTER MECHANISM BOOT
performed. The f l u i d level i n the reservoir should be
Inspect b o t h automatic and m a n u a l shifter boots
up to the bottom of the l i d r e t a i n i n g collar (Fig. 1). I f
for stone o r heat damage. Replace, i f necessary.
the f l u i d level should become low, locate and correct
any possible leaks a n d f i l l the reservoir w i t h clean,
moisture free brake f l u i d conforming to D O T 3,

RESERVOIR

CLUTCH
HOUSING

VIEW IN DIRECTION
OF ARROW Z

23 N i *
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 and Brake Pedal Assembly

 • LUBRICATION AND MAINTENANCE 0 - 23

CHECK FLUID LEVEL DRAIN AND FILL

The NP2500 overdrive 5-speed a n d NP435 over- The NP2500 overdrive 5-speed a n d NP435 over-
drive 4-speed should be inspected for leakage a n d drive 4-speed m a n u a l transmission should be d r a i n e d
proper o i l level whenever general maintenance is and f i l l e d a t the following i n t e r v a l s (Fig. 4).
performed under the vehicle. To check o i l level, r e -
move t h e f i l l e r p l u g (Figs. 2 and 3). I f low, f i l l t o t h e Light Duty Cycle
Normal 60 000 km 37,500miles
b o t t o m o f t h e f i l l e r hole w i t h S A E 10W-30 engine o i l
Service Heavy Duty Cycle
( A P I Classification S G or SG/CD). D e x t r o n I I A T F
58 000 km 36,000 miles
m a y b e u s e d i f h i g h shift effort i s e x p e r i e n c e d
Severe
d u r i n g w a r m - u p i n c o l d w e a t h e r . D r a i n the 10W- 29 000 km 18,000 miles
Service
30 o i l f r o m the t r a n s m i s s i o n a n d fill w i t h t w o 19000-43
q u a r t s o f D e x t r o n I I A T F fluid.
Fig. 4 Manual Transmission—Drain and Fill Intervals
GEARSHIFT LINKAGE (MANUAL
TRANSMISSION)
The gearshift control mechanism should be l u b r i -
cated every 36 000 k m (22,500 miles) or every t w o
years whichever occurs first, or more f r e q u e n t l y i f
h i g h shift effort or noise (mechanism r a t t l i n g ) i s ap-
parent.
The four-speed gearshift control mechanism i s
equipped w i t h a grease f i t t i n g located on t h e left side
(Fig. 5), accessible f r o m the underside of t h e vehicle.
U s i n g a h i g h pressure grease g u n , apply M u l t i p u r -
pose Grease, N L G I , Grade 2 E.P. into t h e control
mechanism u n t i l the grease i s visible on t h e operat-
i n g levers. V e h i c l e m u s t b e i n r e v e r s e g e a r p o s i -
tion, w i t h the engine OFF, w h e n l u b r i c a t i n g this
Fig. 2 NP2500 Manual Transmission mechanism.

Fig. 3 NP435 Manual Transmission

SPECIAL ADDITIVES
Chrysler Motors does not recommend t h e a d d i t i o n
of a n y special additives to t h e transmission other
t h a n special dyes t o aid i n detecting f l u i d leaks.
The use o f transmission sealers should be avoided
Fig. 5 Four-Speed Shift Mechanism
since t h e y may adversely affect t h e seals.
0 - 24 LUBRICATION AND MAINTENANCE •
AUTOMATIC TRANSMISSION DRAIN, FILTER CHANGE, BAND ADJUSTMENT
AND FILL
Change the automatic transmission fluid a n d f i l t e r
CHECK FLUID LEVEL and adjust t h e bands a t t h e f o l l o w i n g i n t e r v a l s ( F i g .
T h e f l u i d level i n t h e automatic transmission 6).
should be checked when performing other underhood
services. Operation w i t h a n improper f l u i d level w i l l
greatly reduce t h e life of the transmission and f l u i d . WAGON NO SERVICE REQUIRED
W h e n t h e f l u i d level is checked, especially o n vehi-
cles operated under conditions of severe service, t h e NORMAL 60 000 km (37,500 miles)
USAGE LIGHT DUTY CYCLE
condition o f t h e f l u i d should be observed. I f severe VAN
d a r k e n i n g o f the f l u i d , accompanied b y a strong odor 38 000 km (24,000 miles)
is noted, t h e f l u i d and f i l t e r should be changed a n d HEAVY DUTY CYCLE
the bands adjusted. A physical change i n t h e f l u i d ,
such as t h i s , m a y be the result of overheating. SEVERE VAN/ 19 200 km (12,000 miles)
USAGE WAGON
To check t h e automatic transmission fluid level, J9000-55
the f o l l o w i n g procedure m u s t be used:
(1) Vehicle m u s t be on level ground. Fig. 6 Automatic Transmission—Service Intervals
(2) E n g i n e should be r u n n i n g a t idle speed.
I f the transmission is disassembled for a n y reason,
(3) A p p l y p a r k i n g brake.
the fluid and f i l t e r should be changed a n d t h e bands
(4) Place gear selector m o m e n t a r i l y i n each gear
adjusted (see Group 2 1 , Transmission for service pro-
position, ending w i t h t h e lever i n N (neutral).
cedures).
(5) Remove dipstick, wipe clean a n d determine i f Trucks do n o t have a torque converter d r a i n p l u g .
f l u i d is hot or w a r m . Hot f l u i d is approximately 82°C No attempt should be made t o d r a i n t h e converter.
(180°F) w h i c h is t h e n o r m a l operating temperature Refer to Group 2 1 , Transmission for t h e proper
after t h e vehicle has been d r i v e n a t least 24 k m (15 D r a i n and Refill procedures.
miles). T h e f l u i d cannot comfortably be h e l d between
the finger tips. W a r m is w h e n fluid is between 29°- TRANSFER CASE
52°C (85°-125°F).
(6) W i p e dipstick clean, insert u n t i l cap seals. Re-
FLUID LEVEL CHECK
move t h e dipstick and note t h e reading.
W i t h vehicle i n level position remove f i l l e r p l u g
(a) I f the fluid is hot, t h e reading should be i n
(Fig. 7 or 8), and check fluid level. I f level i s below
the crosshatched area m a r k e d O K .
bottom of f i l l e r p l u g hole, add sufficient l u b r i c a n t t o
(b) I f the fluid is w a r m , t h e fluid level should restore level to bottom o f f i l l e r hole.
be between t h e t w o dimples.
(7) I f the fluid level checks low, add sufficient fluid
to b r i n g t h e level to w i t h i n t h e m a r k s indicated for
the appropriate temperature. I t is i m p o r t a n t proper
l u b r i c a n t i s used i n t h e transmission. M O P A R A T F
P L U S (Automatic Transmission F l u i d Type 7176)
should be used. Dextron I I automatic transmission
fluid should be used only i f the recommended fluid is
not available.
(8) To prevent d i r t and water f r o m e n t e r i n g t h e
transmission after checking or fluid replacement,
make c e r t a i n t h a t the dipstick cap is seated properly.

CAUTION: Do not overfill the transmission.

SPECIAL ADDITIVES
Chrysler Motors does not recommend t h e addition
of a n y special additives to t h e transmission other
t h a n special dyes to aid i n detecting fluid leaks.
The use o f transmission sealers should be avoided
since they m a y adversely affect t h e seals.
Fig. 7 HP241 Transfer Case Drain and Fill Locations
DRAIN AND FILL
The transfer case should be drained and f i l l e d a t 58
000 k m (36,000 miles) Heavy D u t y Cycle or 60 000
k m (37,500 miles) L i g h t D u t y Cycle. Refer t o Group
2 1 , Transmission for t h e proper procedures.
 • LUBRICATION AND MAINTENANCE 0 - 25

FRONT OF
VEHICLE RY680

Fig. 8 NP205 Transfer Case Drain and Fill Locations

LUBRICANT SELECTION—NP-241 TRANSFER RY682
CASE
Mopar A T F Plus type 7176, or D E X R O N I I A F T or Fig. 10 Gearshift Mechanism Lubrication (NP205
Transfer Case)
equivalent are recommended.
AXLES
LUBRICANT SELECTION-NP-205 TRANSFER
CASE
CONVENTIONAL DIFFERENTIAL (FRONT AND
Engine oils SG or SG/CD may be used i n t h i s
REAR)
transfer case. Use SAE 30 grade motor o i l .
A l l t r u c k rear axles contain SAE 80W-90 m u l t i p u r -
pose type gear l u b r i c a n t w h e n delivered f r o m the fac-
GEAR SHIFT MECHANISM (TRANSFER
tory.
CASE)-NP-241 AND NP-205
The shift mechanism should be cleaned and l u b r i - FREQUENCY OF OIL CHANGE
cated as r e q u i r e d to m a i n t a i n ease of operation. Chrysler Motors does n o t recommend r e g u l a r l y
W h e n mechanism i s cleaned, lubricate pivot a n d scheduled o i l changes for axles i n vehicles whose op-
s l i d i n g contact areas and shift linkage pivot ends e r a t i o n is classified as n o r m a l t r u c k service, unless
w i t h l i g h t engine o i l (Figs. 9 and 10). t h e l u b r i c a n t has become contaminated w i t h water or
GEARSHIFT TRANSFER CASE to provide the correct viscosity grade for the a n t i c i -
TRANSMISSION
ASSEMBLY MECHANISM pated temperature range as follows (Fig. 11):
The presence of water i n t h e gear l u b r i c a n t w i l l re-
s u l t i n corrosion and possible f a i l u r e o f differential

Anticipated Temp. Range Recommended SAE Grade

Above 32°C SAE 140
(90°F) SAE 80W-140
SHIFT ROD
SAE 85W-140
- 2 3 ° C to 32°C SAE 90
( - 1 0 ° F to 90°F) SAE 80W-90
SAE 80W-140
SAE 85W-140
SCREW
SCREWS (2) 80 IN. LBS. Below -23°C SAE 75W
50 FT. LBS. (9 N»m) (-10°F) SAE 75W-90
(68 N*m) SAE 80W
RP1091 SAE 80W-140

Fig. 9 Gearshift Mechanism Lubrication (NP241 J9000-56

Transfer Case)
Fig. 11 Viscosity Grades for Anticipated
Temperature Range
0 - 26 LUBRICATION AND MAINTENANCE •
components. Operation o f the vehicle i n water, as "PRESS-IN" TYPE
may be encountered i n some off-highway, types o f FILLER PLUG
service w i l l r e q u i r e d r a i n i n g a n d f i l l i n g the axle t o
avoid damage.

FLUID LEVEL CHECK

For n o r m a l service, periodic f l u i d level checks are
not required. W h e n the vehicle is serviced for other
reasons, however, the exterior surfaces o f the axle as-
sembly should be inspected for evidence o f gear o i l
leakage. Perform a f l u i d level check t o confirm sus-
pected leakage. W i t h t h e vehicle supported o n a n
axle or wheel type hoist or o n t h e ground, m a i n t a i n
f l u i d level a t t h e bottom o f t h e f i l l e r p l u g opening.
Confirmed leakage should be repaired as soon as pos-
sible.

LUBRICANT SELECTION
Chrysler Motors recommends t h a t M u l t i p u r p o s e
Gear L u b r i c a n t , as defined b y t h e A m e r i c a n Petro-
l e u m I n s t i t u t e GL-5, should be used i n a l l rear axles RK43 %

w i t h conventional differentials. M O P A R H y p o i d L u -
Fig. 13 Rear Axle Fill Plugs (Typical)
bricant, or equivalent, is recommended.
t i o n o f t h i s special friction modifier additive is neces-
FILL PLUGS-TYPE AND LOCATION sary t o a i d i n p r e v e n t i n g t h e occurance o f axle
F r o n t axles (Fig. 12) w i l l have a m e t a l screw i n C H A T T E R i n these units.
type f i l l p l u g . Rear axles w i l l have either the screw
i n f i l l p l u g or a rubber PRESS I N type p l u g (Fig. 13). FRONT AXLE UNIVERSAL DRIVE JOINT AND PIVOT
M a i n t a i n f l u i d level to b o t t o m o f f i l l p l u g opening. BEARINGS
Spicer 60 axles may have a r u b b e r press-in type f i l l
plug. W h e n i n s t a l l i n g rubber f i l l p l u g ensure i n n e r
lip of f i l l p l u g is fully seated i n cover.
MODEL AW3SO (WITH SPICER 60F AXLE
ONLY)
E v e r y 9 600 k m (6,000 miles) Heavy D u t y Cycle or
12 000 k m (7,500 miles) L i g h t D u t y Cycle l u b r i c a t e
the p i v o t bearings w i t h a M u l t i p u r p o s e grease E.P.
No. 2.
D o not u s e h i g h p r e s s u r e to fill front axle u n i -
v e r s a l d r i v e joints.

MODELS AW 100, AW250, AW150 (WITH

SPICER 44-8FD AXLE)
The front axle universal j o i n t and p i v o t bearings
are p e r m a n e n t l y lubricated a n d do not require ser-
vicing.

PROPELLER SHAFT UNIVERSAL JOINTS

Fig. 12 Removing Filler Plug (Front Driving Axle) PROPELLER SHAFT UNIVERSAL
REAR AXLE (LIMITED SLIP DIFFERENTIAL) JOINTS-CROSS TYPE (NOT EQUIPPED WITH
For rear axles equipped w i t h A u b u r n Gear A n t i - GREASE FITTINGS)
Spin or Spicer Power-Loc or Trac-Loc L i m i t e d S l i p L u b r i c a t i o n of cross type u n i v e r s a l j o i n t s t h a t do
Differentials, follow t h e same inspection procedure not have grease fittings i s n o t required. T h e seals
and l u b r i c a n t recommendations as o u t l i n e d for axles should be inspected for e x t e r n a l leaks or damage
w i t h conventional differentials. whenever t h e vehicle is serviced for other reasons
These l i m i t e d slip differentials require the use o f a (Fig. 14). I f external leaks or damage is evident, t h e
friction control additive ( F r i c t i o n Modifier). The addi- u n i v e r s a l j o i n t should be replaced.
 • LUBRICATION AND MAINTENANCE 0 - 27

Fig. 14 Universal Joint Seal Inspection GREASE FITTINGS RK40

PROPELLER SHAFT UNIVERSAL
JOINTS-SLIP SPLINES (EQUIPPED WITH Fig. 15 Universal Joint and Slip Spline with Grease
Fittings (Typical)
GREASE FITTINGS) CONSTANT VELOCITY
JOINT (FIGS. IS AND 16)
U n d e r n o r m a l d r i v i n g conditions ( h i g h w a y type op-
eration) l u b r i c a t e every 12 000 k m (7,500 miles) w i t h
M O P A R M u l t i p u r p o s e L u b r i c a n t , or equivalent. I f
vehicle i s operated i n water, t h e u n i v e r s a l j o i n t s
should be l u b r i c a t e d daily.

Fig. 16 Constant Velocity Universal Joint

Lubrication Points
0 - 28 LUBRICATION AND MAINTENANCE •
C H A S S I S AND BODY
INDEX
Page Page
Body Mechanisms Lubrication 32 Power Steering 29
Brakes 30 Speedometer Cable 31
Front Suspension Ball Joints 28 Steering Linkage 28
Headlights . . . 31 Upper and Lower Control Arm Bushings . 30
Manual Steering Gear 29 Wheel Bearings 29

STEERING LINKAGE FRONT SUSPENSION BALL JOINTS

INSPECTION
Whenever the vehicle is hoisted, a l l steering l i n k -
age j o i n t s should be thoroughly inspected for evi-
dence o f damage (Fig. 1). Damaged seals should be
replaced t o prevent leakage or contamination o f the
grease.
LUBRICATION
Steering l i n k a g e j o i n t s should be lubricated every
36 000 k m (22,500 miles) or every two years w h i c h -
ever occurs first. W h e n l u b r i c a t i n g j o i n t s use only
the special long life chassis grease such as M O P A R
M u l t i - m i l e a g e L u b r i c a n t , or equivalent.
INSPECTION
The front suspension b a l l j o i n t s should be inspected
w h e n ever a vehicle is serviced for other reasons
(Fig. 1). Damaged seals should be replaced to p r e v e n t
leakage or contamination o f t h e grease.
LUBRICATION
B a l l j o i n t s are semi-permanently lubricated a t t h e
factory w i t h a special grease. They should be greased
every 39 000 k m (24,000 miles) for L i g h t D u t y Cycle
operation a n d 36 000 k m (22,500 miles) for H e a v y
D u t y Cycle operation or every t w o years whichever
occurs first. W h e n l u b r i c a t i n g b a l l j o i n t s , use o n l y a
special long life chassis grease intended for t h i s p u r -
pose such as M O P A R M u l t i - m i l e a g e L u b r i c a n t or
equivalent.

LOWER
SUSPENSION DRAG LINK TO
BALL JOINT TIE ROD ENDS TIE ROD END
CENTER LINK
TIE ROD END
PU638

Fig. 1 Steering Linkage Lubrication

 • LUBRICATION AND MAINTENANCE 0 - 29

F r o n t Suspension b a l l j o i n t s o n vehicles used for WHEEL BEARINGS

off-highway operation should be greased a t every en-
gine o i l change.
PROCEDURE
Before l u b r i c a t i o n , clean t h e accumulated d i r t and
grease f r o m t h e outside surface o f the seal to p e r m i t
complete inspection a n d wipe off the outside surface
of the grease fittings t o remove accumulate d i r t f r o m
grease i n l e t area t o avoid grease contamination.
Then fill a n d flush the j o i n t s w i t h lubricant. Stop
filling w h e n grease begins t o flow freely f r o m t h e
bleed areas a t t h e base o f t h e seal, or i f the seal be-
gins to balloon.
After l u b r i c a t i o n , wipe off any excess grease f r o m
exterior surfaces o f b a l l j o i n t s a n d adjacent compo-
nent surfaces.
MANUAL STEERING GEAR
The m a n u a l steering gear is permanently l u b r i -
cated a t t h e factory a n d periodic lubrication is not re-
quired.
INSPECTION/LUBRICATION INTERVALS
FRONT WHEEL BEARINGS
Inspect t h e l u b r i c a n t whenever t h e rotors are re-
moved or service is performed on t h e brake system,
b u t a t least a t t h e f o l l o w i n g intervals.
S p i c e r 4 4 - 8 F D a n d 6 0 F A x l e - E v e r y 19 000 k m
(12,000 miles) Heavy D u t y Cycle or 24 000 k m
(15,000 miles) L i g h t D u t y Cycle.
A l l E x c e p t S p i c e r 4 4 -8 FD a n d 6 0 F A x l e - Every
39 000 k m (24,000 miles) Heavy D u t y Cycle or 36
000 k m (22,500 miles) L i g h t D u t y Cycle.
Wheel bearings i n vehicles equipped w i t h Spicer
44-8FD or 6 0 F axles used for off-highway operation
should be inspected every 1 600 k m (1,000 miles).
Bearings should be cleaned a n d packed every day
w h e n vehicle is operated i n deep m u d or water.
The bearings should be cleaned or packed as re-
q u i r e d a n d whenever t h e disc brake pads are re-
placed (Figs. 3 and 4).

POWER STEERING

WARNING: FLUID LEVEL SHOULD BE CHECKED

WITH THE ENGINE OFF TO PREVENT PERSONAL
INJURY FROM MOVING PARTS.

The power steering fluid level should be checked a t

the power steering p u m p reservoir whenever the ve-
hicle is serviced for other reasons. Before r e m o v i n g
the reservoir cap, wipe t h e outside of the cap and res-
ervoir w i t h a cloth t o remove d i r t t h a t can f a l l i n t o
t h e reservoir. F l u i d level should be m a i n t a i n e d t o the
proper level indicated on cap dipstick (Fig. 2).
Only fluids specially f o r m u l a t e d for m i n i m u m ef-
fect on rubber hoses should be used (MOPAR Power
Steering F l u i d or equivalent).

Fig. 3 Front Wheel Bearings 2WD Vehicles

Fig. 2 Power Steering Pump (Typical)
REAR WHEEL BEARINGS
8-3/8 a n d 9-1/4 I n c h C h r y s l e r A x l e s - These
bearings are n o r m a l l y considered to be permanently
lubricated. C l e a n i n g a n d packing is r e q u i r e d only
w h e n axle shafts are removed or i n cases o f extreme
water or dust contamination.
D a n a 6 0 — Clean and pack as required a n d when-
ever b r a k e l i n i n g s are replaced or brake drums re-
surfaced.
0 - 30 LUBRICATION AND MAINTENANCE •
BRAKES
The vehicle is equipped w i t h disc brakes on t h e
front a n d d r u m brakes on the rear wheels. M a i n t e -
nance a n d service o n t h e brakes is covered under
Group 5, Brakes.

MASTER CYLINDER
The f l u i d i n t h e master cylinders should be checked
w h e n p e r f o r m i n g other underhood services (Fig. 5). I f
necessary, add f l u i d t o b r i n g level t o t h e bottom o f
the s p l i t r i n g s . W i t h disc-brakes, f l u i d level can be
expected t o f a l l as the brake pads wear. However,
low f l u i d level m a y be caused b y a leak, and a
checkup m a y be needed. Only brake f l u i d conforming
to D O T 3 should be used (DOT 3 is Federal, Depart-
ment o f T r a n s p o r t a t i o n specification). M O P A R B r a k e
F l u i d i s a f l u i d of t h i s q u a l i t y and is recommended t o
provide best brake performance.
Fig. 4 Front Wheel and Spindle Bearings 4WD
Vehicles
INSPECTION AND LUBRICATION PROCEDURE
The condition of the grease i n the h u b and b e a r i n g
area on t r u c k s equipped w i t h either d r u m or disc
brakes should be inspected a t the i n t e r v a l s specified
above. The presence o f water, r u s t , or d i r t may i n d i -
cate the necessity of seal replacement. I f i t is found
t h a t the grease has become contaminated, is low or i f
the vehicle has been operated under severe or dusty
conditions, a l l of the l u b r i c a n t should be t h o r o u g h l y
cleaned f r o m the bearings, wheel hubs, dust cap, and/
or covers. A f t e r cleaning, carefully check for evidence
of spalling o f cups, rollers and i n n e r race of cone.
Bearings should be replaced i f any defects exist. A p -
ply grease to the h u b , a n n u l u s area, and dust cap us-
i n g H i g h Temperature M u l t i p u r p o s e Grease (E. P.
M O P A R F r o n t Wheel B e a r i n g Grease), or equivalent.
To a v o i d m i x i n g d i f f e r e n t types o f grease w h i c h
m a y b e i n c o m p a t i b l e , n e v e r a d d grease, l u b r i -
cate c o m p l e t e l y .

UPPER AND LOWER CONTROL ARM BUSHINGS
A n off center condition of i n n e r m e t a l to outer
metal is a sign o f early f a i l u r e of upper and lower
control a r m bushings. T o t a l f a i l u r e is evident b y ex-
cessive movement w i t h i n b u s h i n g and a noise caused
by metal-to-metal contact. S m a l l cracks i n outer,
nonconfined rubber does not constitute f a i l u r e .
Lower control a r m bushings may be v i s u a l l y i n -
spected by l i f t i n g the vehicle on a hoist and inspect-
ing from underneath. Upper control a r m b u s h i n g
may be inspected b y r e m o v i n g the f r o n t wheels. I f
failure exists, replace b u s h i n g (see Group 2, F r o n t
Suspension for the proper procedure).
Fig. 5 Check Master Cylinder Fluid Level (Typical)
CAUTION: Use of a brake fluid that may have a
lower initial boiling point then speified by MVSS
116, DOT 3, may result in sudden brake failure dur-
ing hard, prolonged braking.
Use o n l y b r a k e fluid t h a t has been stored i n a
t i g h t l y closed container, to avoid contamination w i t h
foreign m a t t e r or moisture.
CAUTION: Do not allow petroleum base fluids to
contaminate the brake fluid. Seal damage will re-
sult!
 • LUBRICATION AND MAINTENANCE 0 - 31

PARKING BRAKE (1) Correct length, severe surface cracking, p u l l i n g ,

P i v o t a n d s l i d i n g contact areas should be l u b r i -
cated as required t o m a i n t a i n ease o f operation ( F i g .
6). A p p l y a film of smooth w h i t e body hardware l u -
b r i c a n t to s l i d i n g mechanism, such as M O P A R Spray
W h i t e Lube o r equivalent. Use engine o i l t o lubricate
t h e control lever pivot areas.
scuffing or w o r n spots. Should t h e fabric casing o f
the hose be exposed b y cracks or abrasions i n t h e
rubber hose cover, t h e hose should be replaced.
(2) F a u l t y i n s t a l l a t i o n can cause t w i s t i n g , wheel/
t i r e or chassis interference.
HEADLIGHTS
To assure correct adjustment o f h e a d l i g h t a i m i n g ,
i t is recommended t h a t t h e headlights be checked
and, i f necessary, properly aimed every s i x months.
Changes i n front and rear suspension, such as f r o n t
suspension h e i g h t and/or deflection o f rear springs
due to heavy load, w i l l change t h e h e a d l i g h t beam
p a t t e r n a n d m a y cause unsafe n i g h t d r i v i n g condi-
tions.
I f a vehicle is to be loaded a b n o r m a l l y , t h e head-
l i g h t a i m i n g should be checked and adjusted t o serve
the new conditions. Refer t o Group 8 L , E x t e r i o r
Lamps, for adjusting procedures.

SPEEDOMETER CABLE
Fig. 6 Parking Brake Ratio Lever Lubrication
L u b r i c a t i o n o f speedometer cable is n o t required.
BRAKE HOSES For service o f noisy or erratic operation o f cable see
Inspection o f brake hose and t u b i n g should be i n - Group 8E, I n s t r u m e n t Panel and Gauges.
cluded i n a l l brake service operations and a t each l u -
b r i c a t i o n period. The hoses should be checked for:
0 - 32 LUBRICATION AND MAINTENANCE
BODY MECHANISMS LUBRICATION
Body and other operating mechanisms and l i n k -
ages should be inspected, cleaned and l u b r i c a t e d as
r e q u i r e d to m a i n t a i n ease of operation a n d to provide
protection against rust and wear.
P r i o r to the application of any l u b r i c a n t , the parts
concerned should be wiped clean to remove dust and
g r i t . A f t e r l u b r i c a t i o n , excess o i l or grease should be
removed.
P a r t i c u l a r a t t e n t i o n should also be g i v e n t o hood
l a t c h i n g components to ensure proper function. W h e n
performing other underhood services, t h e hood l a t c h ,
release mechanism, a n d safety catch should be
cleaned and lubricated.
The external lock cylinders should be lubricated
twice a year, preferably i n the f a l l and spring. A p p l y
•
a s m a l l a m o u n t of a h i g h q u a l i t y l u b r i c a n t such as
M o p a r Lock Cylinder L u b r i c a n t , o r equivalent d i -
r e c t l y i n t o t h e lock cylinder. A v o i d excess l u b r i c a n t .
I n s e r t t h e key i n t o the lock c y l i n d e r a n d rotate f r o m
t h e unlocked t o the locked position. W i t h o u t adding
more l u b r i c a n t , repeat t h i s procedure three or four
times. Wipe a l l the l u b r i c a n t off t h e key w i t h a clean
cloth t o avoid subsequent s o i l i n g o f clothing. I f a l u -
b r i c a n t i s used t h a t cannot be dispensed directly i n t o
t h e lock cylinder, apply a s m a l l a m o u n t o f the l u b r i -
cant t o the lock cylinder key. I n s e r t t h e key i n t o the
lock cylinder, t h e n proceed as described above, i n or-
der t o d i s t r i b u t e the l u b r i c a n t w i t h i n the lock c y l i n -
der.
The following mechanisms should be inspected,
cleaned and a l l pivot and s l i d i n g contact areas o f
these components lubricated as r e q u i r e d w i t h t h e
proper l u b r i c a n t (Fig. 7).

COMPONENT SERVICE INTERVAL LUBRICANT

Door Hinges As Required Engine Oil

Door Latches As Required Multi-Purpose Grease (Water Resistant) (1)
Hood Latch Release Mechanism & Safety Catch When Performing Multi-Purpose Grease NLGI Grade 2 EP (2)
Other Underhood
Services
Hood Hinges As Required Engine Oil
Seat Regulator & Track Adjuster As Required Multi-Purpose Grease NLGI Grade 2 EP (2)
Tailgate Hinge (Quick Release Pins) As Required Multi-Purpose Grease NLGI Grade 2 EP (2)
Tailgate Check Arms As Required Engine Oil
Tailgate Latches As Required Smooth White Body Hardware Lubricant (3)
Tailgate Release Handle (Pivot & Slide Contact Surfaces) As Required Multi-Purpose Grease NLGI Grade 2 EP (2)
Window System Components (Regulators, Tracks, Links, As Required Smooth White Body Hardware Lubricant (3)
Channel Areas — Except Glass Run Weatherstrips and
Felt Lubricator, if Equipped)
Lock Cylinders Twice/Year Lock Cylinder Lubricant (4)
Window Regulator Felt Tube Lubricator, if so Equipped As Required Engine Oil
Parking Brake Mechanism As Required Multi-Purpose Grease (1)
1. Mopar Wheel Bearing Grease (High Temperature)
2. Mopar Multi-Mileage Lubricant
3. Mopar Spray White Lube
4. Mopar Lock Cylinder Lubricant

J9000-61

Fig. 7 Lubrication Chart—Body Mechanisms

 • ACCESSORIES 1-1

ACCESSORIES

CONTENTS
Page Page

SNOW PLOW ... 1 SPECIFICATIONS ,. 17

SNOW PLOW

INDEX
Page Page
General Information 1 Snow Plow Wiring Diagrams 9
Service Procedures 9 System Description And Operation 2

GENERAL INFORMATION • m o l d b o a r d (blade) — constructed from h i g h t e n -

sile steel — strong b u t l i g h t w e i g h t ;
A snow plow is optionally available for R a m T r u c k • t r i p s p r i n g s — allow the moldboard (blade) t o t r i p
a n d Ramcharger vehicles. The p r i m a r y mechanical ( t i l t ) forward a n d slide over immovable obstructions
components are i l l u s t r a t e d i n F i g u r e 1. w i t h o u t losing t h e snow load — t h i s function protects
both t h e snow plow and t h e vehicle;
LIFT ARM
• sector — constructed f r o m h i g h s t r e n g t h steel —
used for positioning t h e moldboard (blade) s t r a i g h t
ahead or a n g l i n g i t t o t h e r i g h t or left;
• sector s h e a r p i n — t h i s self-locking p i n locks t h e
moldboard (blade) i n either a s t r a i g h t ahead or a n
HYDRAULIC PUMP angled p l o w i n g position — i f t h e blade impacts ob-
AND MOTOR
structions w i t h strong force, t h e p i n w i l l shear t o
protect t h e snow plow a n d t h e vehicle from damage
— t h e is p i n n o t used w i t h power angle p l o w i n g ;
• p o w e r a n g l i n g c y l i n d e r s — these cylinders en-
SECTOR able t h e operator t o h y d r a u l i c a l l y position t h e mold-
board (blade) either s t r a i g h t ahead or t o t h e r i g h t or
left w h i l e p l o w i n g ;
TRIP SPRINGS
HINGE PIN • hinge p i n s — these pins enable t h e operator t o at-
MOLDBOARD tach or detach t h e snow plow f r o m t h e vehicle i n
m i n u t e s w i t h o u t tools;
SNO-FLO • cutting edge — t h e replaceable steel grader blade
PAINT
edge extends t h e life of the blade;
N
CUTTING • r u n n e r s — t h e adjustable and replaceable runners
EDGE r e t a i n t h e c u t t i n g edge a t t h e proper height;
• S n o - F l o p a i n t — t h i s specifically developed h i g h -
• v i s i b i l i t y , yellow p a i n t provides fast, smooth snow-
r o l l i n g action;
• h y d r a u l i c p u m p a n d motor (Electro-Touch™)
— t h i s u n i t provides the power for h y d r a u l i c a l l y rais-
RUNNERS J9001-2 i n g , lowering a n d a n g l i n g t h e snow plow;
• A - f r a m e — provides t h e means for a t t a c h i n g t h e
Fig. 1 Snow Plow Components snow plow t o t h e vehicle; a n d
COMPONENT DESCRIPTION • lift a r m — raises a n d lowers t h e snow plow.
The p r i m a r y snow plow components (Fig. 1) are de-
scribed w i t h i n t h e following list:
1 - 2 ACCESSORIES
SYSTEM DESCRIPTION AND OPERATION
HYDRAULIC CYLINDER AND MOTOR
The snow plow h y d r a u l i c cylinder a n d m o t o r (pow-
er) u n i t i s a n electrically powered, electrically con-
t r o l l e d h y d r a u l i c mechanism t h a t is specifically
designed t o raise, lower and angle t h e blade.
The power u n i t is comprised o f a high, torque, 12-
v o l t motor t h a t is directly coupled t o a gear-type hy-
draulic p u m p . A driver-actuated, solenoid-controlled
switch located i n t h e engine c o m p a r t m e n t connects
battery voltage to t h e motor. T h e p u m p i s supplied
w i t h h y d r a u l i c fluid f r o m a n i n t e g r a l reservoir,
w h i c h completely surrounds t h e h y d r a u l i c cylinder
t h a t raises and lowers the blade.
The remotely located ( i n s t r u m e n t panel) toggle
switches provide a means to electrically operate t h e
electro-hydraulic solenoid valves. T h e solenoid (elec-
tro-mechanical) h y d r a u l i c valves (designated " A " ,
" B " , and "C"), along w i t h t h e mechanical h y d r a u l i c
check valves, p i l o t check valve a n d crossover r e l i e f
valve, control t h e pressurized h y d r a u l i c f l u i d for
snow plow blade positioning.
SOLENOID (ELECTRO-MECHANICAL) VALVES
Three solenoid (electro-mechanical) hydraulic
valves are used for snow plow h y d r a u l i c f l u i d control.
Each solenoid valve is comprised o f t w o components:
• cartridge — comprised of a valve and a solenoid
armature t h a t enables the h y d r a u l i c valve t o be op-
erated a n d controlled electrically; a n d
• coil — t h e electrical component t h a t retracts t h e
cartridge solenoid a r m a t u r e ( a n d t h e h y d r a u l i c
valve) v i a electromagnetic action.
T h e c a r t r i d g e t h r e a d s into a n d o u t o f the
p o w e r u n i t s i m i l a r to the w a y a s p a r k p l u g i s i n -
stalled a n d r e m o v e d from a n engine.
W i t h power applied, t h e solenoid a r m a t u r e (con-
nected t o the h y d r a u l i c valve) retracts and p u l l s the
spool or poppet valve i n t o the O P E N position.
When t h e current flow ceases (power off), t h e com-
pressed coil spring forces the a r m a t u r e (and t h e hy-
draulic valve) back t o i t s n o r m a l , de-energized
CLOSED position.
SOLENOID VALVE "A"
The solenoid valve " A " cartridge contains a poppet
valve t h a t is n o r m a l l y de-energized i n t h e C L O S E D
position. W h e n closed, t h e valve r e t a i n s pressurized
hydraulic f l u i d i n the l i f t cylinder. W h e n i t is ener-
gized (valve opened), i t allows t h e h y d r a u l i c f l u i d to
flow from t h e l i f t cylinder back t o t h e reservoir,
w h i c h enables the plow blade t o lower v i a g r a v i t y .
Solenoid valve " A " is designed t o r e m a i n energized
(valve open) d u r i n g snow plow operation t o provide a
•
" f l o a t i n g " blade position, w h i c h ensures t h a t t h e
plow blade is guided up-down b y t h e surface devia-
tions.
SOLENOID VALVE "B"
The solenoid valve " B " cartridge contains a spool
valve t h a t i s n o r m a l l y i n t h e de-energized CLOSED
position t o allow t h e pressurized h y d r a u l i c f l u i d to
flow t o solenoid valve " C " . I n t h e energized O P E N
position, t h e pressurized h y d r a u l i c f l u i d is diverted to
the l i f t cylinder, w h i c h causes t h e plow blade to be
raised.
SOLENOID VALVE "C"
The solenoid valve " C " cartridge contains a spool
valve t h a t i s n o r m a l l y i n t h e de-energized CLOSED
position t o allow t h e pressurized h y d r a u l i c f l u i d to
flow to t h e right-side power a n g l i n g cylinder, w h i c h
angles t h e plow blade t o t h e left. A t t h e same t i m e ,
i t allows t h e h y d r a u l i c f l u i d t h a t is being forced from
the r e t r a c t i n g left-side power a n g l i n g cylinder to flow
t h r o u g h t h e " C " cartridge valve and r e t u r n t o t h e
pump reservoir.
E n e r g i z i n g t h e solenoid valve w i l l route pressur-
ized h y d r a u l i c f l u i d to t h e left-side a n g l i n g cylinder,
w h i c h angles the plow blade t o the r i g h t . Also, dur-
i n g t h i s action, the h y d r a u l i c f l u i d is forced from the
r e t r a c t i n g right-side power a n g l i n g cylinder, i t flows
t h r o u g h t h e " C " cartridge valve and i t r e t u r n s to the
pump reservoir.
MECHANICAL HYDRAULIC VALVES
The mechanical h y d r a u l i c valves a l l have the same
function: t h e y control t h e d i r e c t i o n o f the hydraulic
f l u i d flow.
CHECK VALVES
H y d r a u l i c "check" (one-way) valves allow f l u i d to
flow freely i n one direction w h i l e preventing f l u i d
from f l o w i n g i n the opposite direction.
A p u m p "check" valve is used i n a l l applications to
prevent h y d r a u l i c f l u i d f r o m l e a k i n g back t h r o u g h
the p u m p t o the reservoir.
Two a d d i t i o n a l "check" valves are necessary be-
cause solenoid valves " B " a n d " C " (as do a l l spool
valves) have some leakage.
One "check" valve is located between solenoid
valve " B " and t h e l i f t cylinder. I t prevents f l u i d i n
the l i f t cylinder from l e a k i n g back t h r o u g h solenoid
valve " B " , w h i c h could cause the w e i g h t of the plow
to angle t h e plow blade to t h e left by forcing f l u i d
t h r o u g h solenoid valve " C " i n t o t h e right-side power
a n g l i n g cylinder.
The other "check" valve is located between solenoid
valve " B " and solenoid valve " C " . I t prevents the hy-
draulic f l u i d i n either power a n g l i n g cylinder from
being forced t h r o u g h solenoid valve " B " and back to
the l i f t cylinder.
 • ACCESSORIES
PILOT CHECK VALVE
A p i l o t "check" valve is more sophisticated t h a n a
standard "check" valve because i t has a p i s t o n i n a d -
d i t i o n t o a b a l l "seat" a n d s p r i n g . A p i l o t "check"
valve i s located between solenoid-valve " C " a n d t h e
reservoir. I t has t w o functions:
• i t prevents t h e h y d r a u l i c fluid i n either a n g l i n g
c y l i n d e r from l e a k i n g back t o t h e reservoir; a n d
• i t allows t h e h y d r a u l i c fluid f r o m t h e r e t r a c t i n g
a n g l i n g cylinder ( d u r i n g a n a n g l i n g cycle) t o r e t u r n
to t h e reservoir.
T h e valve action i s accomplished b y pressurized h y -
d r a u l i c fluid m o v i n g t h e piston, w h i c h forces t h e
"check" b a l l off i t s "seat".
CROSSOVER RELIEF VALVE
T h e crossover r e l i e f valve has t h e function o f pro-
t e c t i n g against p o t e n t i a l damage t h a t can be caused
1 -3
by a n abnormally h i g h opposite force (from impact)
being applied against t h e end of t h e blade (e.g., w h e n
t h e blade end contacts a curb or other immovable
structure). This type o f action w i l l cause very h i g h
h y d r a u l i c pressure t o accumulate i n one o f t h e a n -
g l i n g cylinders.
W h e n t h e h y d r a u l i c pressure increases sufficiently
to open t h e crossover r e l i e f valve, t h e valve allows
t h e h i g h l y pressurized h y d r a u l i c fluid t o flow directly
to t h e opposite power a n g l i n g cylinder. T h i s function
aids i n cushioning t h e impact a n d results i n only
changing t h e angle position o f the plow blade.
SYSTEM OPERATION
Refer t o Figures 2 t h r o u g h 5 for voltage application
a n d h y d r a u l i c fluid flow for each snow plow function.
Each figure i l l u s t r a t e s t h e components t h a t are actu-
ated and associated for t h e applicable function.
1 - 4 ACCESSORIES

TAN IGNITION SWITCH

BLACK

ANGLING CYLINDER

B B OPERATING PRESSURE
EXHAUST
ESSS3 INTAKE OR DRAIN
METERED FLOW

RB525

Fig. 2 Raise Blade—Voltage Application & Hydraulic Fluid Flow

 ACCESSORIES 1 - 5
•

TAN IGNITION SWITCH

ORANGE
WITH
SWITCH WHITE 6 O
TRACER
ANGLE

BATTERY
ORANGE WITH
WHITE TRACER
F U

}
S E
i
f r—

•o
LIGHT GREEN

ENERGIZED: "A" COIL

SOLENOID SWITCH

r
'B" SOLENOID "C" SOLENOID
"IV PRESSURE
RELIEF f

CHECK VALVE CHECK

VALVE

c FILTER POWER
ANGLING
CYLINDER
PILOT
CHECK
PUMP

LIFT
CYLINDER

" A " SOLENOID

"A" LOWER AND FLOAT

SOLENOID (FORCE APPLIED AGAINST LIFT RAM)
IN
OPERATION

OPERATING PRESSURE
EXHAUST
INTAKE OR DRAIN
U TANK r~—g METERED FLOW

RB526

Fig, 3 Lower & Float Blade—Voltage Application & Hydraulic Fluid Flow
1 - 6 ACCESSORIES •

IGNITION SWITCH
L

BLACK

O H B OPERATING PRESSURE
FZT^I EXHAUST
INTAKE OR DRAIN
METERED FLOW

RB527

Fig. 4 Angle Blade Right— Voltage Application & Hydraulic Fluid Flow
• ACCESSORIES 1- 7

TAN- ORANGE
ORANGE
WITH WHITE
WITH WHITE
TRACER
O TRACER
• IGNITION SWITCH
SWITCH
6

O O SWITCHi ANGLE
RAISE
AND LOWER 0 BATTERY
FUSE
BLACK-
Q
TAN
i

LIGHT
RED- "GREEN

D—c
-SOLENOID SWITCH

a •MOTOR
ENERGIZED: MOTOR

"B" SOLENOID " C " SOLENOID

••H OPERATING PRESSURE

r~—I EXHAUST
ES^ INTAKE OR DRAIN
METERED FLOW

J9001-1

Fig. 5 Angle Blade Left— Voltage Application & Hydraulic Fluid Flow
1 - 8 ACCESSORIES
Condition
PLOW BLADE WILL NOT LIFT OR
LIFTS SLOWLY
PLOW BLADE WILL NOT ANGLE RIGHT-
MOTOR IS OPERATIONAL
PLOW BLADE WILL NOT ANGLE LEFT-
MOTOR IS OPERATIONAL
PLOW BLADE WILL NOT ANGLE-
MOTOR IS OPERATIONAL
PLOW WILL NOT REMAIN IN
ANGLED POSITION
MOTOR DOES NOT OPERATE
PLOW BLADE WILL NOT LOWER
PLOW BLADE CREEPS DOWNWARD
PLOW BLADE WILL NOT
CLEAN SURFACE
BLADE WILL NOT FOLLOW
SURFACE DEVIATIONS
SNOW STICKS TO FACE
OF BLADE
SNOW PLOW DIAGNOSIS
Possible Cause
(a) Low hydraulic fluid level.
(b) Discharged battery.
(c) Leaking or open "A" cartridge.
(d) No voltage at "B" coil.
(e) Inoperative "B" coil.
(f) Malfunctioning motor.
(g) Malfunctioning pump.
(a) Improper coupler engagement.
(b) Mechanical bind or interference.
(c) Malfunctioning coupler.
(d) No voltage at "C" coil.
(e) Inoperative "C" coil.
(f) Inoperative "C" cartridge.
(a) Improper coupler engagement.
(b) Mechanical bind or interference.
(c) Malfunctioning coupler.
(d) Leaking or open crossover relief
valve.
(a) Improper coupler engagement.
(b) Mechanical bind or interference.
(c) Leaking or open crossover relief
valve.
(a) Air in cylinders and hoses.
(b) Leaking "C" cartridge O-ring seals,
c) Leaking or open pilot check valve.
(d) Leaking crossover relief valve.
(e) Crossover relief valve opening
pressure too low.
va) Discharged or defective battery.
(b) Loose or corroded electrical
connections.
(c) Inoperative solenoid switch.
(d) Malfunctioning control switch.
(e) Malfunctioning motor.
(a) No voltage at "A" coil.
(b) "A" cartridge jammed in closed
position.
(c) Inoperative "A" coil.
(a) Leaking "A" cartridge.
(b) Leaking "A" cartridge O-ring seal.
(c) Leaking B-Check Valve.
(d) Leaking Ram Packing Cup.
(e) Leaking O-ring seal at bottom of
cylinder.
(a) Runner height incorrect.
(b) Cutting edge unevenly worn.
(a) Not in "Lower Float Position".
(b) Insufficient slack in lift chain.
(a) Sno-Flo paint worn off.
Correction
(a) Add fluid to proper level.
(b) Recharge battery.
(c) Clean or replace "A" cartridge.
(d) Locate malfunction and repair.
(e) Replace "B" coil.
(f) Repair or replace motor.
(g) Replace pump.
(a) Engage coupler properly.
(b) Eliminate mechanical bind or
interference.
(c) Repair or replace coupler.
(d) Locate malfunction and repair.
(e) Replace "C" coil.
(f) Clean or replace "C" cartridge.
(a) Engage coupler properly.
(b) Eliminate mechanical bind or
interference.
(c) Repair or replace coupler.
(d) Clean or replace crossover relief
valve.
(a) Engage coupler properly.
(b) Eliminate mechanical bind or
interference.
(c) Clean or replace crossover relief
valve.
(a) Purge cylinders and hoses.
(b) Replace O-ring seals.
(c) Clean or replace pilot check valve.
(d) Clean or replace crossover relief
valve.
e) Replace crossover relief valve.
^a) Recharge or replace battery.
(b) Clean and tighten electrical
connections.
(c) Replace solenoid switch.
(d) Replace control switch.
(e) Repair or replace motor.
(a) Locate malfunction and repair.
(b) Clean or replace "A" cartridge.
c) Replace "A" coil.
(a) Clean or replace "A" cartridge.
(b) Replace O-ring seal.
(c) Clean or replace Pump Check Valve.
(d) Replace Ram Packing Cup.
(e) Replace O-ring seal.
(a) Adjust runners.
(b) Replace.
(a) Position switch at "Lower Float"
(b) Adjust lift chain.
(a) Refinish.
J9001-3
 • ACCESSORIES 1-9

SNOW PLOW WIRING DIAGRAMS (1) H o l d a steel screwdriver blade approximately 1/

8 inch above t h e r e t a i n i n g n u t o n t h e coil t o be
Refer to Figures 6, 7 a n d 8 for w i r i n g d i a g r a m s for tested.
the snow plow power u n i t , t h e controls a n d t h e aux- (2) Have a helper position t h e control switch t h a t
iliary lighting.
energizes t h e applicable coil (e.g., place t h e RAISE/
For electric motor a n d solenoid specifications, refer
L O W E R s w i t c h i n the L O W E R and F L O A T positions
to Snow Plow Specifications c h a r t a t e n d o f t h i s
to energize solenoid valve " A " coil).
group.
CAUTION: Do not connect an ohm meter to a sole-
SERVICE PROCEDURES noid coil when voltage is applied to the coil. This
can cause internal damage to the ohmmeter.
DIAGNOSIS
W h e n malfunctions a r e encountered, refer t o t h e (3) I f t h e coil has voltage applied a n d current is
Snow Plow Diagnosis c h a r t a n d t h e Voltage Applica- flowing t h r o u g h t h e coil, t h e electromagnetic action
t i o n & H y d r a u l i c F l u i d F l o w i l l u s t r a t i o n s before dis- w i l l p u l l (attract) t h e screwdriver d o w i i to the r e t a i n -
assembling t h e u n i t . i n g n u t . Absence o f electromagnetic attraction i n d i -
cates a m a l f u n c t i o n . A n ohmmeter or continuity
SOLENOID VALVE COIL FUNCTIONAL TEST tester should t h e n be used t o determine whether t h e
Test the solenoid valve coils t o determine i f they coil has c o n t i n u i t y .
are functioning properly, according t o t h e f o l l o w i n g
procedure.
1 - 10 ACCESSORIES

TO TURN FUSE # 5
SIGNAL FLASHER < (20 AMP)
-Dl 18RD/YL
(SEE SHEET 27) y

Dl 18RD/YL

TO R.W.A.L
{ 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*
PLOW
CONTROL Dl 18RD/YL*
SWITCH
-SP3 18 WT/RD*
UP & DOWN

-SP3 18WT/RD*-
-SP1 18WT/BK*-

Dl -SP418WT/BR*]
18RD -SP4 18WT/BR*
YL*

-Dl 18RD/YL*
PLOW — S P 4 18WT/BR*
CONTROL
SWITCH Dl 18RD/YL*
LEFT TO
— S P 5 18WT/LG*
RIGHT
L I

-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

 FUSE *5
(15 AMP)
TO BATTERY , NATURAL
CABLE Al
43(REAR OF 6RD

BATTERY)
NATURAL -Al 6RD- -Al 6RD-
IGNITION TO CHARGING
-SP4 18WT/BR*-
ACCESSORY SYSTEM
(REAR OF SNOW PLOW MOTOR
FEED BATTERY) SOLENOID (LEFT
WHEELHOUSE)
-Ml 6 R D - G 3 ©

1
—Ml 6RD-
BODY
GROUND SNOW PLOW MOTOR
(FRONT SNOW (FRONT SNOW
PLOW FRAME) PLOW FRAME)
-SP4 18WT/BR*
i— G9 6BK h
SP4 18WT/BR*
SP4 18WT/BR*
UP J BLACK SNOW PLOW
i #
DOWN
SP1 18WT/BK* (FRONT SNOW UP SOLENOID
UP
Dl 18RD/YL* PLOW FRAME) (FRONT SNOW
DOWN
SP3 18WT/RD* PLOW FRAME)
PLOW -SP3 18WT/RD*—HOZ 16RD—FW\ "L
CONTROL
SWITCH -SP1 18WT/BK* -Ifl I i6bk—pm " l
UP & DOWN
-SP3 18WT/RD*- BLACK SNOW PLOW DOWN
(FRONT SNOW SOLENOID (FRONT
SP1 18WT/BK*- PLOW FRAME) SNOW PLOW FRAME)

SP4 18WT/BR*
SP4 18WT/BR
L
- S P 5 18WT/LG*$ 16LG-p5F|
SP4 18WT/BR
Dl 18RD/YL*
SNOW PLOW
SP5 18WT/LG* BLACK O
RIGHT SOLENOID
PLOW (FRONT SNOW (FRONT SNOW O
CONTROL PLOW FRAME) PLOW FRAME)
m
GO
SWITCH W
LEFT TO o
RIGHT TRANSMISSION OIL
-SP5 18WT/LG* TEMPERATURE SWITCH m
w
T2 18LG/RD* (RIGHT SIDE
TRANSMISSION OIL BELOW RADIATOR) 8901-4
TEMPERATURE LAMP

Fig. 7 Snow Plow Control Wiring Diagram (Cont'd)

1-12 ACCESSORIES

TO FRONT
TO FRONT END WIRING
END WIRING TO HEADLAMP $~ -L2 14LG (SEE SH 22)
(SEE SH 21) SWITCH
(SEE SH 25) y

BLACK
BLACK

(RIGHT
SIDE
RADIATOR
YOKE
PANEL)

BLACK (RIGHT
UPPER
SNOW
PLOW
FRAME)

BLACK

LEFT AUXILIARY RIGHT AUXILIARY

PARK AND TURN PARK AND TURN
LEFT AUXILIARY RIGHT AUXILIARY
SIGNAL LAMP SIGNAL LAMP
HEADLAMP HEADLAMP
8901-2

Fig. 8 Snow Plow Auxiliary Lighting Wiring Diagram

• ACCESSORIES 1 - 13

RB530

Fig. 9 Power Unit—Exploded View

1 - 14 ACCESSORIES

1. Plastic Washer 16. Pump Housing 31. Valve Block 46. 3-Way Coil
2. Locknut 17. Poppet 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 and Seal 20. Retainer 35. Strainer 50. Valve Block
6. O-Ring 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 Seal 30. Base and Strainer 45. 3-Way Valve
J9001-6

LEGEND FOR FIG. 9

POWER UNIT DISASSEMBLY/INSPECTION B o t h Prestolite a n d A m e r i c a n Bosch motors
(1) Remove t h e d r a i n p l u g (Fig. 9). D r a i n t h e u n i t . a r e u s e d i n s n o w p l o w p o w e r unit. A P r e s t o l i t e
(2) Extend t h e r a m a n d piston r o d completely t o motor c a n be identified b y a d o m e d t o p c o v e r
d r a i n t h e r e m a i n i n g o i l from t h e cylinder. a n d t h e trade n a m e s t a m p e d o n the b o d y . A m e r -
(3) Remove t h e cover locknuts ( F i g . 9) and remove i c a n B o s c h motors h a v e a flat top c o v e r a n d n o
t h e cover. identifying n a m e o r m a r k s .
(4) Inspect t h e casting for damage a n d cracks, a n d (12) Remove the pump drive shaft seal ( i f damaged)
t h e seal for cuts ( F i g . 9). w i t h a pointed tool.
(5) Remove t h e r a m and t h e piston. Inspect t h e n y - (13) Verify t h a t t h e seal k i t replacement compo-
l o n sleeve, t h e piston, and t h e piston follower for ex- nents are correct for t h e u n i t .
cessive wear (Fig. 10). (14) D i p t h e replacement seal i n o i l a n d i n s t a l l i t
over t h e pump shaft w i t h t h e seal l i p facing down.
TANK
COVER (15) Position t h e seal i n t h e p u m p h o u s i n g s l i g h t l y
ASSEMBLY RESERVOIR
CYLINDER below t h e boss face.
(16) Remove solenoid valve " A " coil f r o m t h e base
and test i t for electrical c o n t i n u i t y . The n o r m a l coil
DC resistance is 9.0 ohms ±10%.
(17) Remove solenoid valve " A " cartridge (two-way
valve) w i t h a 1 1/8-inch diameter deep socket wrench
and inspect for external damage.
(18) Remove t h e filters and clean t h e screens w i t h

(E cleaning solvent a n d compressed air. Discard t h e O-

O-RING
RAM WASHER
PISTON
FOLLOWER
RB531
Fig. 10 Lift Cylinder Components
(6) Inspect t h e cylinder for p i t t i n g a n d scoring i n
t h e bore (Fig. 10).
(7) Inspect t h e r a m for nicks, scratches, a n d rust/
corrosion (Fig. 10).
(8) Inspect t h e piston packing cup for wear a n d
sealing l i p cut (Fig. 10).
(9) Clean a n d inspect t h e base strainer.
(10) Replace a l l t h e O-ring seals d u r i n g assembly.
(11) Loosen t h e motor a t t a c h i n g bolts. Do n o t re-
move the bolts from t h e motor. Retain or secure t h e
motor end plate in-place d u r i n g removal, t h e n t e m -
p o r a r i l y i n s t a l l two 1/4-20 nuts on t h e motor attach-
i n g bolts to r e t a i n t h e motor intact.
r i n g seals and t h e n y l o n r e t a i n i n g rings.
(19) Remove t h e pump housing (Fig. 9), a n d t h e n
remove t h e insert valve, t h e b a l l , t h e s p r i n g , and t h e
retainer from t h e pump housing (Fig. 11). Inspect a l l
the components for damage a n d contamination. Dis-
card t h e O-ring seals.
(20) Remove t h e socket-head screws a n d remove
the valve block from t h e p u m p housing ( F i g . 9). Dis-
card the O-ring seals.
(21) Remove solenoid valve " B " (three-way valve)
w i t h special tool J-25399 (Fig. 9).
(22) Remove the b a l l and t h e spring f r o m t h e valve
block (Fig. 9). Clean t h e solenoid valve a n d inspect i t
for external damage.
(23) Disassemble t h e three-way valve ( F i g . 9). Dis-
card t h e O-ring seal.
(24) Remove and clean solenoid valve " C " (four-way
valve) w i t h special tool J-25399 (Fig. 9). Inspect t h e
solenoid valve for external damage.
• ACCESSORIES 1 - 15

(25) Disassemble t h e four-way valve (Fig. 12). Dis-

card the O - r i n g seals (Fig. 12).
(26) Test solenoid valve " B " and " C " coils for elec-
t r i c a l c o n t i n u i t y . T h e n o r m a l coil D C resistance i s
3.7 ohms.
(27) Remove t h e p i l o t "check" valve p l u g , t h e
spring a n d t h e b a l l from t h e bottom of t h e valve
block.
(28) Inspect t h e s p r i n g for damage and t h e b a l l
BASE seat for nicks.
f| RETAINER

P
(29) Remove t h e acorn n u t for access t o t h e cross-
over valve components (Fig. 9).
(30) Remove t h e crossover valve components (Fig.
SPRING 13). Inspect for e x t e r n a l damage. Discard the O - r i n g
O-RING
seals.
BALL (31) W i t h a l l t h e components removed from t h e
block, clean t h e block w i t h compressed a i r to remove
INSERT
VALVE
a l l foreign m a t e r i a l .

O-RING POWER UNIT ASSEMBLY

RB532
Before assembly, ensure t h a t a l l components are
thoroughly clean a n d free o f a l l foreign m a t e r i a l . Use
Fig. 11 Insert Valve—Exploded View replacement gaskets and seals d u r i n g assembly. Pe-
t r o l e u m j e l l y (or a n equivalent l u b r i c a n t ) m a y be
used as a n a i d i n positioning and i n s t a l l i n g t h e r u b -
BRASS NUT LOCK NUT ber O-ring seals.

COIL ALLEN
HEAD
SCREW

BALL
VALVE CARTRIDGE PILOT CHECK
SPRING
O-RING
PRESSURE PLUG
CAGE
GUIDE O-RING
O-RINGS SPRING SPACER POPPET
"*>N^f > WASHER
PLUNGER * SPRING
O-RING v. DISC

SNAP RING
O-RINGS
O-RING
NOTE: NYLON WASHERS
AND O-RINGS SHOULD
TAPER DOWN TO VALVE SHAPE
FROM VALVE DOWN.
Fig. 12 Solenoid Valve
Valve—Exploded
* ADJUSTMENT SCREW
VALVE ACORN NUT
RB534
NYLON WASHER Fig. 13 Crossover Relief Valve—Disassembled
(1) I n s t a l l t h e crossover valve components i n t h e
valve block w i t h replacement O-ring seals (Fig. 13)
NYLON WASHER
(2) I n s t a l l t h e b a l l , spring and pressure p l u g w i t h a
replacement O - r i n g seal i n t h e bottom of the valve
NYLON WASHER block (Fig. 13)
(3) Assemble solenoid valve " C " (four-way valve)
RB533 w i t h replacement O - r i n g seals a n d n y l o n r e t a i n e r
rings (Fig. 12).
"C"/Four-Way (4) I n s t a l l solenoid valve " C " (four-way valve) w i t h
View
Tool J-25399 (Fig. 9).
1 - 16 ACCESSORIES
(5) Assemble solenoid valve " B " (three-way valve)
w i t h replacement O - r i n g seals.
(6) I n s t a l l t h e b a l l , s p r i n g and solenoid valve " B "
w i t h Tool J-25399 (Fig. 9).
(7) I n s t a l l the v a l v e block and the replacement O-
r i n g seals on the p u m p base.
(8) I n s t a l l the retainer, the spring, t h e b a l l , the i n -
sert valve and t h e p u m p housing w i t h replacement
O - r i n g seals (Fig. 11). T i g h t e n the p u m p housing-to-
base n u t s w i t h 11.3 Nma (100 in-lbs) torque.
(9) I n s t a l l t h e f i l t e r s and t h e plugs w i t h replace-
m e n t O-ring seals (Fig. 9).
(10) I n s t a l l solenoid valve " A " cartridge (two-way
valve) i n t h e p u m p base w i t h replacement O-ring
seals (Fig. 9).
(11) I n s t a l l solenoid valve " A " coil (Fig. 9).
(12) I n s t a l l the motor on the p u m p h o u s i n g (Fig. 9).
Engage the gear shaft t a n g w i t h the notch i n the mo-
' GLAND NUT
ROD PACKING
WIPER PACKING
Fig. 14 Angling Cylinder—Exploded View
t o r o u t p u t shaft. T i g h t e n t h e motor-to-housing cap
screws w i t h 5 N»m (45 in-lbs) torque.
(13) I n s t a l l t h e r a m and piston w i t h replacement
O-ring seals (Fig. 9).
(14) Position t h e cover on the reservoir and secure
i t w i t h l o c k n u t s (Fig. 9). T i g h t e n t h e locknuts w i t h
11.3 N*m (100 in-lbs) torque.
POWER ANGLING CYLINDER SERVICE
I f a n g l i n g cylinder f l u i d leakage occurs (a s l i g h t
w e t t i n g i s n o r m a l ) , t h e cause could be a loose gland
n u t (Fig. 14). T i g h t e n the gland n u t .
CAUTION: Over-tightening the gland nut can "lock"
the cylinder. Leakage will not cease immediately be-
cause fluid has accumulated between the packing
and the gland nut. If the leakage persists after con-
tinued usage, replace the rod packing (Fig. 14).
POWER ANGLING CYLINDER
SPLIT BEARING
RN886
 SPECIFICATIONS
SNOW PLOW SPECIFICATIONS
ELECTRICAL SPECIFICATIONS SOLENOID VALVES A , B, ANP C SPECIFICATIONS
MOTOR SPECIFICATIONS A Coll
American Bosch M0551046A Applied Voltage — 12 Volts DC
No load (motor not attached to pump) operation: Current — 0.83 Amperes
CAUTION: Do not operate motor continuously for more Nominal resistance (one ohmmeter probe to coil wire, other
than 30 seconds. to metal coil cover)—9.0 ± 10% ohms.
Applied Voltage — 12 Volts DC B and C Colls
Max. Current — 24 Amperes Applied Voltage — 12 Volts DC
Speed (Min.) — 5900 rpm Current — 1.24 Amperes
With load (pump operating): Nominal resistance (one ohmmeter probe to coil wire, other
CAUTION: Do not operate motor continuously for more to metal coil cover)—3.5 ± 1 0 % ohms.
than 5 seconds.
Applied Voltage — 12 Volts DC SOLENOID SWITCH
Max. Current — 230 Amperes Applied Voltage — 12 Volts DC
Prestolite MGL4105 Max. Current — 5 Amperes
No load (motor not attached to pump) operation: Nominal resistance (one ohmmeter probe to coil wire, other
CAUTION: Do not operate motor continuously for more to metal foot)—2.65-4.5 ohms.
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 (36.5 oz.)
Pressure Output (pump relief valve opening pressure Hoses & 2 x 12 Cylinders 28 oz.
1650±50psi Total 2 qt., 5 oz.
(64.5 oz.)
CROSSOVER RELIEF VALVE
Opening Pressure 3800 ± 400 psi J9001-4

TORQUE SPECIFICATIONS

COMPONENT SET-TO-TORQUE RECHECK TORQUE

11.3 N*m (100 in-lbs) 11-14 N » m (100-125 in-lbs)

11.3 N*m (100 in-lbs) 11-14 N » m (100-125 in-lbs)

11 N » m (95 in-lbs) 11-12 N « m (95-105 in-lbs)

5 N » m (45 in-lbs) 5-6 N*m (45-55 in-lbs)

J9001-5
 • FRONT SUSPENSION 2 - 1

FRONT SUSPENSION
CONTENTS
Page Page

FRONT SUSPENSION COMPONENT MODEL 44 FRONT AXLE SERVICE-4WD

SERVICE—2WD VEHICLES 7 VEHICLES ...15
FRONT WHEEL ALIGNMENT 3 MODEL 60 FRONT AXLE SERVICE—4WD
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1 VEHICLES 51
SPECIFICATIONS 80

G E N E R A L INFORMATION
INDEX
Page Page
Description—2WD Vehicles 1 Service Information 2
Description—4WD Vehicles 2

DESCRIPTION—2WD VEHICLES
A l l two-wheel d r i v e (2WD) R a m T r u c k and Ram- SHOCK
charger vehicles are equipped w i t h a coil-spring op-
erated (independent) f r o n t suspension system a t each
side o f t h e vehicle (Fig. 1). T h e coil springs are lo-
cated between t h e frame side r a i l bracket and t h e
lower suspension a r m . T h e lower suspension arms
are attached to a stationary crossmember. A 0.3 i n c h
(7.6 m m ) ozone-resistant, r u b b e r noise isolation pad
is located between t h e upper end of t h e coil spring
and the frame bracket. T h i s pad dampens noise t h a t
w o u l d otherwise be t r a n s m i t t e d v i a t h e metal-
to-metal contact o f t h e s p r i n g a n d the frame bracket.
A shock absorber i s located inside each spring coil
and i t i s attached t o the f r a m e side r a i l bracket and
to the lower suspension a r m .
STABILIZER BAR J9017-28
B o t h suspension arms have replaceable bushings a t
t h e i n b o a r d ends a n d replaceable b a l l studs a t t h e Fig. 1 Front Suspension—2WD Vehicles
outboard ends. T h e lower suspension arms are
equipped w i t h tension-type b a l l studs. The upper sus-
pension a r m s also control t h e caster a n d camber an- Refer t o Group 17—Springs A n d Shock Absorbers
gles v i a adjustable eccentric (cam) bolts located a t for service i n f o r m a t i o n i n v o l v i n g the coil springs, the
t h e i n b o a r d ends. shock absorbers a n d t h e stabilizer b a r . Refer t o
The suspension a r m b a l l studs and t h e tie-rod end Group 19—Steering f o r service i n f o r m a t i o n i n v o l v i n g
b a l l studs are semi-permanently lubricated d u r i n g the steering linkage.
manufacture.
2 - 2 FRONT SUSPENSION
DESCRIPTION—4WD VEHICLES
A l l four-wheel drive (4WD) R a m T r u c k a n d Ram-
charger vehicles are equipped w i t h a leaf-spring op-
erated f r o n t suspension system ( F i g . 2). T h e leaf
springs are t h e fixed-rate type a n d are attached t o
the frame side r a i l brackets a n d t o t h e front axle.
The f r o n t l e a f springs are attached to t h e axle
shaft tubes a t t h e s p r i n g pads b y U-bolts a n d n u t s
(Fig. 2).
The housing for Model 44 and Model 60 front axles
consists o f a n i r o n center casting (differential hous-
ing) w i t h axle shaft tubes e x t e n d i n g from either side.
The axle shaft tubes are pressed i n t o and welded t o
the d i f f e r e n t i a l housing t o f o r m a one-piece axle
housing. B o t h axles have a h y p o i d gear differential
and t h e centerline of t h e drive p i n i o n gear shaft is
located below t h e centerline o f t h e r i n g gear. The re-
movable, stamped steel cover located a t t h e front o f
the d i f f e r e n t i a l housing provides a means for inspec-
tion and for d i f f e r e n t i a l service w i t h o u t removing t h e
complete f r o n t axle from t h e vehicle.
A s m a l l , stamped m e t a l axle gear ratio identifica-
Fig. 2 Front Suspension—4 WD Vehicles (Typical)
•
t i o n t a g is attached t o t h e housing cover v i a one o f
the cover bolts. T h i s t a g also identifies t h e n u m b e r o f
r i n g gear a n d d r i v e p i n i o n gear teeth.
Refer t o G r o u p 17—Springs A n d Shock Absorbers
for service i n f o r m a t i o n i n v o l v i n g the leaf springs and
the shock absorbers.
SERVICE INFORMATION
The lower b a l l studs ( 2 W D vehicles) should be r e -
placed i f more t h a n 0.020 i n c h "end p l a y " exists.
The tie-rod e n d b a l l stud seals are serviced sepa-
r a t e l y a n d s h o u l d be inspected for damage a t t h e
same t i m e t h e engine o i l is changed. Refer t o Group
19—Steering f o r a d d i t i o n a l service i n f o r m a t i o n .
A l l front s u s p e n s i o n components t h a t c o n t a i n
r u b b e r (e.g., b u s h i n g s ) s h o u l d b e tightened w h i l e
the s u s p e n s i o n i s a t the n o r m a l height a b o v e t h e
s u r f a c e (refer t o t h e Specifications c h a r t ) a n d
w i t h t h e full w e i g h t of the vehicle s u p p o r t e d b y
the wheels/tires.
R u b b e r bushings should never be lubricated.
 • FRONT SUSPENSION 2-3

FRONT WHEEL ALIGNMENT

INDEX
Page Page
General Alignment Information . 3 Wheel Alignment Measurements/Adjustments . . . . . 6
Pre-Alignment Inspection 4

GENERAL ALIGNMENT INFORMATION HEIGH"r

F r o n t wheel a l i g n m e n t involves t h e correct adjust-

ment or positioning o f a l l the i n t e r r e l a t e d suspension
angles and l i n e a r distances t h a t affect the r o t a t i o n
and the steering o f the vehicle f r o n t wheels. The i m -
portance of front wheel a l i g n m e n t a n d wheel/tire bal-
ancing is essential t o m a i n t a i n ease o f steering, good
directional s t a b i l i t y and t o prevent a b n o r m a l t i r e A 1 TOE-IN J
tread wear. POSITIVE NEGATIVE STEERING AXIS INCLINATION

R o u t i n e i n s p e c t i o n o f t h e f r o n t s u s p e n s i o n sys- CASTER CASTER

t e m and the steering components is a good pre-
v e n t a t i v e m a i n t e n a n c e p r a c t i c e a n d also h e l p s t o FRONT OF VEHICLE
e n s u r e safe o p e r a t i o n o f t h e v e h i c l e .
The method o f measuring the f r o n t wheel a l i g n -
ment w i l l vary depending on the type of a l i g n m e n t
PIVOT^^^^^^
equipment being used. The i n s t r u c t i o n s provided b y
the manufacturer of the equipment should always be POSITIVE NEGATIVE TOE-OUT ON TURNS
followed, w i t h the exception t h a t t h e a l i g n m e n t spec- CAMBER CAMBER

--^
" I
ifications contained i n t h i s m a n u a l (or a subsequent
service b u l l e t i n ) should always have precedence.
There are six suspension system a n d steering l i n k -
WHEELS TURN
age measurements t h a t are used t o determine i f the Q \ A B O U T COMMON
front wheel a l i g n m e n t is correct (Fig. 1): M \ ^ CENTER
• vehicle height,
• caster angle,
X
RN1047
• camber angle,
Fig. 1 Wheel Alignment Measurements
• wheel "toe" position,
• steering axis i n c l i n a t i o n , and The measurements a n d adjustments should be
• wheel "toe-out" on t u r n s ( t u r n i n g radius). made i n the following sequence:
A l l the angles a n d linear distances are mechani- • vehicle h e i g h t differential (not adjustable),
cally adjustable except the vehicle height, the steer- • caster angle,
i n g axis i n c l i n a t i o n and the wheel "toe-out" position • camber angle (adjustable for 2 W D vehicles only),
on turns ( t u r n i n g radius). A l t h o u g h not adjustable, • wheel "toe" position,
the measurements are valuable i n d e t e r m i n i n g i f • steering axis i n c l i n a t i o n (not adjustable), and
there are bent or damaged components involved, par- • wheel "toe-out" on t u r n s (not adjustable).
t i c u l a r l y w h e n the camber and the caster angles can- The h e i g h t d i f f e r e n t i a l between the left side and
not be adjusted t o be w i t h i n t h e recommended the r i g h t side o f the vehicle should be zero. The ve-
specifications. hicle should be on a level surface, or on an a l i g n m e n t
Do not attempt t o modify a n y suspension o r rack, w i t h a f u l l t a n k o f fuel and no luggage or pas-
steering component b y heating a n d b e n d i n g i t . senger load. The tires m u s t a l l have the same recom-
mended pressure.
 2 - 4 FRONT SUSPENSION
The c a s t e r angle i s the n u m b e r o f degrees of for-
w a r d or r e a r w a r d t i l t of t h e steering k n u c k l e (wheel
spindle support a r m ) f r o m t h e v e r t i c a l (i.e., from 0
degrees). F o r w a r d t i l t f r o m t h e v e r t i c a l i s negative
caster. Rearward t i l t f r o m t h e v e r t i c a l i s positive
caster (Fig. 1, F i g . 2).
RN1030
Fig. 2 Caster & Camber Adjustment Location—2WD
Vehicles
The c a m b e r angle is t h e n u m b e r of degrees t h e
top of the wheel is t i l t e d i n w a r d or o u t w a r d from the
vertical plane (i.e., f r o m 0 degrees). I n w a r d t i l t of the
top of t h e wheel f r o m the v e r t i c a l plane i s a negative
camber angle. O u t w a r d t i l t o f the t o p of the wheel
from t h e v e r t i c a l plane is a positive camber angle.
A n excessive camber angle w i l l cause abnormal t i r e
tread wear. A n excessive negative camber angle w i l l
cause t h r e a d wear a t the inside of the t i r e , w h i l e a n
excessive positive camber angle w i l l cause thread
wear a t t h e outside o f the t i r e (Fig. 1, F i g . 2).
The w h e e l " t o e " p o s i t i o n is t h e l i n e a r distance
differential between t h e l e a d i n g inside edges of the
front tires and t h e t r a i l i n g inside edges o f the front
tires. Incorrect wheel "toe" position i s the most seri-
ous cause for excessive t i r e t h r e a d wear. The wheel
"toe" position is t h e f i n a l f r o n t wheel a l i g n m e n t ad-
justment.
The s t e e r i n g a x i s i n c l i n a t i o n is measured i n de-
grees a n d is t h e angle t h a t t h e steering k n u c k l e
(wheel spindle support) is t i l t e d f r o m t h e vertical
•
plane (i.e., f r o m 0 degrees). I t has a fixed r e l a t i o n -
ship w i t h the camber angle a n d w i l l not change ex-
cept w h e n t h e spindle or b a l l stud is damaged or
bent. T h e angle i s not adjustable and the damaged
components m u s t be replaced to correct m i s -
alignment.
The w h e e l " t o e - o u t " o n t u r n s ( t u r n i n g radius) is
measured i n degrees and i s t h e difference between
the t w o front w h e e l t u r n i n g angles. T h i s t u r n i n g a n -
gle difference i s provided b y t h e design o f the steer-
i n g l i n k a g e a n d i s based o n t h e wheelbase o f t h e
vehicle. I t is n o t adjustable. W h e n t h e wheel "toe-
out" o n t u r n s ( t u r n i n g radius) i s not w i t h i n t h e rec-
ommended specification, inspect for possible bent or
damaged components.
PRE-ALIGNMENT INSPECTION
Before i n i t i a t i n g front wheel alignment, the follow-
i n g inspection a n d the necessary corrections m u s t be
completed for those components t h a t interact w i t h
the steering o f t h e vehicle.
(1) Check a n d i n f l a t e a l l t h e tires w i t h t h e same
recommended pressure. A l l t h e tires should be t h e
same size, i n good condition a n d have approximately
the same t h r e a d wear. I f abnormal, note the type o f
t i r e t r e a d wear, w h i c h w i l l a i d i n the diagnosis (refer
to Group 2 2 - T i r e s A n d Wheels).
(2) Inspect a n d adjust ( i f necessary) the front wheel
bearings.
(3) Inspect t h e f r o n t wheels/tires for evidence o f ex-
cessive r a d i a l a n d l a t e r a l " r u n o u t " (refer to Group
22—Tires A n d Wheels for measurement procedures).
(4) Inspect t h e wheels/tires for evidence of " u n b a l -
ance". B o t h static and dynamic unbalance can affect
the vehicle steering.
(5) Inspect t h e b a l l studs and a l l the steering l i n k -
age p i v o t locations for excessive looseness.
(6) Inspect t h e shock absorbers for leaks and jounce
the vehicle to determine i f the shock absorbers prop-
erly dampen vehicle body movement.
(7) Inspect t h e steering gear operation for r o u g h -
ness, b i n d i n g or a " s t i c k i n g " condition. Adjust/repair
as necessary.
(8) Inspect t h e rear springs for cracked or b r o k e n
leaves, a n d t h e U-bolt n u t s for correct tightness
(torque).
• FRONT SUSPENSION 2-5

FRONT SUSPENSION DIAGNOSIS

I - a r II m H I FRONT WHEEL
SHIMMY

H VEHICLE
INSTABILITY
I I
I I
DIFFICULT
STEERING
I
I
I
I
VEHICLE
PULLS TO
O N E SIDE

i
LOOSE OR WORN LOOSE OR WORN LOOSE OR WORN LOW OR UNEVEN LOW OR UNEVEN LOW OR UNEVEN
FRONT WHEEL FRONT WHEEL TIRE AIR PRESSURE TIRE AIR!PRESSURE TIRE PRESSURE
BEARINGS WHEEL BEARINGS
BEARINGS

LOOSE OR WORN
SHOCK ABSORBER LOOSE OR WORN LOOSE, WORN OR WHILE BRAKING-
TIRE/WHEEL LOOSE GLAZED P/S REFER TO
MOUNTING HARD- STEERING COLUMN
OUT OF BALANCE WHEEL BEARINGS PUMP BELT BRAKES SERVICE
WARE OR SHAFT COUPLING
SHOCK ABSORBER

UNEVEN TIRE TREAD

LOOSE STEERING LOOSE STEERING WEAR, OR EX- LOW
BROKEN OR WEAK BROKEN OR WEAK
GEAR-TO-FRAME GEAR-TO-FRAME CESSIVELY WORN POWER STEERING
REAR SPRING REAR SPRING
RAIL BOLTS RAIL BOLTS TIRE TREAD FLUID LEVEL

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 OR WORN LOOSE OR WORN STEERING GEAR

LOOSE LOWER
UPPER SUSPENSION SUSPENSION ARM LUBRICANT LEVEL
SUSPENSION ARM
ARM BALL STUDS BUSHINGS LOW

WORN ISOLATOR INCORRECT FRONT-

INCORRECT FRONT INCORRECT
PAD BETWEEN COIL WHEEL ALIGNMENT STEERING GEAR
SPRING AND (PARTICULARLY WHEEL ALIGNMENT
ADJUSTMENT
FRAME BRACKET CASTER)

STEERING
GEAR
MALFUNCTION

INCORRECT FRONT
WHEEL ALIGNMENT
(PARTICULARLY
CASTER)
J9002-97
2 - 6 FRONT SUSPENSION
WHEEL ALIGNMENT
MEASUREMENTS/ADJUSTMENTS
The f r o n t wheel a l i g n m e n t positions m u s t be re-
tained w i t h i n the specified l i m i t s t o prevent abnor-
m a l t i r e t r e a d wear, and t o ensure steering ease and
safe operation of the vehicle.
T h e equipment m a n u f a c t u r e r ' s r e c o m m e n d a -
tions for u s e o f t h e i r e q u i p m e n t s h o u l d a l w a y s
be followed. A l l d a m a g e d front s u s p e n s i o n s y s -
tem components s h o u l d b e r e p l a c e d . D o not at-
tempt to straighten a n y bent c o m p o n e n t .
CAMBER AND CASTER ANGLES
2WD VEHICLES
For 2 W D vehicles, camber and caster angle adjust-
ments involve repositioning t h e upper suspension
a r m eccentric (cam) adjustment bolts. T h e eccentric
(cam) bolts are inserted i n t o " s l o t t e d " holes i n a
frame-mounted bracket (Fig. 2). A l i g n m e n t adjust-
ments are accomplished b y loosening t h e r e t a i n i n g
nuts and changing the position o f t h e eccentric (cam)
bolt.
(1) Remove a l l foreign m a t e r i a l f r o m t h e eccentric
(cam) adjustment bolt threads.
(2) Record the camber and caster measurements be-
fore loosening the eccentric (cam) adjustment bolt re-
t a i n i n g nuts.
(3) The camber angle should be adjusted as near as
possible to the "preferred" angle. T h e caster should
be the same at both sides of the vehicle. Refer t o the
Specifications chart.
4WD VEHICLES
For 4 W D vehicles, the correct wheel camber ( v e r t i -
cal t i l t ) angle is factory "preset" a t positive one de-
gree ( + 1 ° ) and cannot be altered b y adjustment.
CAUTION: Do not attempt to adjust the camber an-
gle by heating or bending the axle or any suspen-
sion component. If the camber angle is incorrect,
the component(s) causing an incorrect camber an-
gle must be replaced.
(1) I t is i m p o r t a n t t h a t the camber (vertical t i l t )
angle be t h e same for both front wheels.
(2) The camber angle should be measured w i t h ac-
curate wheel alignment equipment. T h e acceptable
range is +1/2° to + 1 1/2°. Refer to t h e Specifications
chart.
I f the caster angle appears to be correct a n d t h e
axle is not bent or twisted, a satisfactory test for as-
surance can be made b y road t e s t i n g t h e vehicle a n d
observing the steering wheel " r e t u r n - t o - c e n t e r " posi-
tion.
•
Before r o a d testing, c h e c k a n d c o r r e c t the tire
inflation p r e s s u r e s . B e p a r t i c u l a r l y c a r e f u l to i n -
flate b o t h o f the front t i r e s w i t h e x a c t l y t h e
same pressure.
D u r i n g the road test, t u r n t h e steering wheel from
side-to-side and make vehicle t u r n s t o both the left
and r i g h t . I f the wheels t u r n easily t o either side and
the steering wheel r e t u r n s t o w a r d t h e center position
unassisted, t h e caster angle is correct. However, i f
the wheels t u r n to either side easily b u t the steering
wheel does not r e t u r n t o w a r d t h e center position u n -
assisted, a n incorrect caster angle i s probable.
(1) The caster angle is factory "preset" a t positive
two degrees ( + 2°). The acceptable range is +1/2° to
+ 3 1/2°.
(2) The caster angle should be measured w i t h accu-
rate wheel a l i g n m e n t equipment.
(3) I f the caster angle is incorrect, i t can be ad-
justed b y i n s t a l l i n g appropriate size, tapered shims
between t h e front axle pads a n d t h e s p r i n g brackets.
The caster angle should be adjusted as near as possi-
ble t o the "preferred" angle.
(4) Record the caster measurement before removing
the o r i g i n a l shims f r o m the s p r i n g pads.
(5) The caster should be t h e same a t b o t h sides of
the vehicle. Refer to the Specifications chart.
WHEEL "TOE" POSITION
The wheel "toe" position adjustment should be the
f i n a l f r o n t wheel a l i g n m e n t adjustment. I n a l l i n -
stances, follow the equipment manufacturer's recom-
mended procedure.
(1) Secure the steering wheel w i t h the front wheels
i n the straight-ahead position. For vehicles equipped
w i t h power steering, s t a r t the engine before straight-
ening the wheels.
With p o w e r steering, the e n g i n e s h o u l d be op-
e r a t i n g d u r i n g the w h e e l " t o e " position adjust-
ment.
(2) Loosen t h e t i e r o d adjustment sleeve clamp
bolts (Fig. 3).
TIE RODS
CLAMP RN1036
Fig. 3 'Toe" Position Adjustment
(3) A d j u s t the wheel "toe" position b y r o t a t i n g the
tie rod adjustment sleeve (Fig. 3).
 • FRONT SUSPENSION 2 -7

To avoid a b i n d i n g condition a t either tie r o d , (5) Position t h e adjustment sleeve clamps so t h a t

also rotate each t i e - r o d e n d i n t h e d i r e c t i o n o f
s l e e v e r o t a t i o n d u r i n g t h e a d j u s t m e n t ( F i g . 3).
T h i s w i l l ensure t h a t b o t h tie-rod ends are a t t h e
center o f their travel w h e n t h e adjustment
sleeve clamps a r e t i g h t e n e d .
(4) I f applicable, t u r n the i g n i t i o n switch off.
the clamp ends a r e n o t l o c a t e d a t t h e sleeve slot
and t i g h t e n the clamp bolt nuts w i t h 18 N»m (160 i n -
lbs) torque. T i g h t e n Model D350 and a l l 4WD vehicle
(i.e.,"heavy d u t y " t i e rods) tie-rod sleeve clamp b o l t
nuts w i t h 34 N*m (25 ft-lbs) torque. Ensure t h a t t h e
clamp bolts are located a t t h e underside o f t h e
sleeve.

FRONT S U S P E N S I O N COMPONENT SERVICE—2WD VEHICLES

INDEX
Page Page
Lower Ball Stud Replacement . 9 Steering Knuckle Removal/Installation 13
Lower Suspension Arm Bushing Replacement . . . 11 Upper Ball Stud Replacement . . 12
Lower Suspension Arm Removal/Installation 7 Upper Suspension Arm Bushing Replacement . . . 12
Lower Suspension Arm Strut Removal/Installation . . 7 Upper Suspension Arm Removal/Installation . . . . . 11

LOWER SUSPENSION ARM STRUT REMOVAL/ l a t i o n (Fig. 1). I n s t a l l the jounce bumper a n d t h e
INSTALLATION rear attaching bolts. T i g h t e n the bolts w i t h 129 N»m
(95 ft-lbs) torque.
(3) I n s t a l l the front bushing, the front r e t a i n e r a n d
REMOVAL the n u t a t the front end of the s t r u t (Fig. 1). T i g h t e n
(1) Raise and support the vehicle.
t h e n u t w i t h 68 N»m (50 ft-lbs) torque.
(2) Use a s m a l l d r i f t and a h a m m e r to d r i v e t h e
(4) I n s t a l l t h e spring p i n .
s p r i n g p i n from t h e f r o n t o f the s t r u t . Remove t h e
(5) Remove the supports and lower the vehicle.
s p r i n g p i n , t h e n u t , t h e r e t a i n e r and t h e b u s h i n g
f r o m the end of the s t r u t (Fig. 1).
LOWER SUSPENSION ARM
NUT REMOVAL/INSTALLATION

REMOVAL
(1) Block t h e brake pedal i n t h e " u p " (non-
depressed) position. Raise the vehicle o n a hoist. Po-
sition supports a t t h e extreme front ends o f t h e
frame r a i l s and lower the hoist. Remove t h e applica-
ble wheel cover and wheel/tire.
(2) Remove the brake caliper retainer a n d the a n t i -
r a t t l e spring. Remove the brake caliper f r o m the disc
rotor by s l i d i n g i t out and t h e n away f r o m the rotor.
I f necessary, refer to Group 5 — B r a k e s for removal
information. Support t h e brake caliper o u t -
of-the-way. D o n o t a l l o w t h e c a l i p e r t o h a n g f r o m
FRO NT RETAINER STRUT J9002-120 o r b e s u p p o r t e d b y t h e b r a k e f l u i d h o s e . Remove
the inboard brake pad.
Fig. 1 Lower Suspension Arm Strut Removal/
(3) Remove t h e dust cap, t h e cotter p i n , t h e n u t
Installation
lock, the adjustment n u t , the washer, a n d the outer
(3) Remove the s t r u t rear a t t a c h i n g bolts a n d t h e wheel bearing.
jounce bumper f r o m t h e bracket. Remove t h e s t r u t (4) Carefully slide the hub/rotor from t h e steering
f r o m the vehicle (Fig. 1). k n u c k l e spindle. D o n o t a l l o w t h e s e a l o r t h e i n -
ner wheel bearing to contact t h e steering
INSTALLATION k n u c k l e spindle threads, otherwise t h e threads,
(1) Position t h e rear r e t a i n e r and the rear b u s h i n g t h e b e a r i n g , a n d t h e seal c o u l d b e d a m a g e d .
on t h e front end of the s t r u t (Fig. 1). (5) Remove t h e attaching screws a n d t h e b r a k e
(2) Carefully slide the s t r u t i n t o position for i n s t a l - splash shield.
 2 - 8 FRONT SUSPENSION •
(6) Remove t h e shock absorber f r o m t h e vehicle BOLT • JOLT
and t h e shock absorber upper bushing f r o m t h e WASHER
bracket (Fig. 2). I f necessary, refer t o t h e r e m o v a l
procedure.

INSULATOR

RETAINER

-RETAINER

-WASHER

"LOCKNUT
J9002-121

Fig. 3 Stabilizer Bar

1—Nut 6—Coil Spring 10—Capscrew

2— Retainer 7— Shock Absorber 11—Lower Suspension
3— Bushing 8—Washer Arm
4— Bolt 9— Bushing
J9002-119
5— Nut

Fig. 2 Coil Spring Suspension—2WD Vehicles

(7) Remove the s t r u t bar (Fig. 1). I f necessary, refer
to t h e r e m o v a l procedure. I f equipped, disconnect t h e
stabilizer b a r from t h e lower suspension a r m (Fig. 3).
(8) I n s t a l l S p r i n g Compressor Tool DD-1278 i n t h e
spring (Fig. 4) and t i g h t e n the n u t " f i n g e r - t i g h t " , and
t h e n loosen the n u t 1/2 of-a-turn.
(9) Remove the cotter pins and t h e lower a n d upper
b a l l stud n u t s at the steering k n u c k l e .
(10) I n s t a l l B a l l S t u d Loosening Tool C-3564-A on
the lower b a l l stud (Fig. 4). T u r n the threaded por-
t i o n o f t h e tool and " l o c k " the tool securely against
the lower s t u d (Fig. 4). SPECIAL
(11) E x p a n d the tool sufficiently enough t o place TOOL DD-1278 RH192
force on t h e lower b a l l stud and t h e n s t r i k e t h e steer-
Fig. 4 Spring Compressor & Ball Stud Loosening
i n g k n u c k l e sharply w i t h a h a m m e r t o loosen t h e Tools Installed
stud. D o n o t a t t e m p t t o f o r c e t h e s t u d o u t o f t h e
(14) Remove the s p r i n g compressor tool a n d t h e
steering k n u c k l e w i t h the loosening tool.
spring w i t h the rubber isolation pad (Fig. 4).
(12) Remove the loosening tool a n d remove t h e b a l l
(15) Remove the lower suspension a r m hex-head at-
stud f r o m t h e steering k n u c k l e w i t h a n appropriate
t a c h i n g b o l t from t h e frame crossmember bracket
tool.
(Fig. 2).
(13) Slowly loosen t h e coil spring compressor tool
(16) Remove the lower suspension a r m f r o m the ve-
(Fig. 4) u n t i l a l l tension is relieved f r o m the spring.
hicle (Fig 2).
 • FRONT SUSPENSION
INSTALLATION
(1) Position t h e lower suspension a r m a t the frame
crossmember bracket (Fig. 2 ) .
(2) I n s t a l l t h e hex-head a t t a c h i n g bolt and t i g h t e n
" f i n g e r - t i g h t " (Fig. 2 ) .
(3) A f t e r t h e vehicle has been lowered t o t h e sur-
face a n d w i t h t h e wheels/tires supporting the vehicle
w e i g h t , t i g h t e n t h e hex head a t t a c h i n g bolt w i t h 305
N*m (225 ft-lbs) torque.
( 4 ) Position t h e s p r i n g ( w i t h t h e rubber isolation
pad) o n t h e suspension a r m ( F i g . 2 ) a n d i n s t a l l t h e
s p r i n g compressor tool (Fig. 4 ) . Compress t h e s p r i n g
u n t i l t h e lower suspension a r m b a l l s t u d can be prop-
erly positioned i n t h e steering k n u c k l e bore.
(5) I n s t a l l t h e r e t a i n i n g n u t s o n the b a l l stuck a n d
t i g h t e n t h e upper n u t w i t h 142 N * m (105 ft-lbs)
torque a n d the lower n u t , i f a 11/16-16 bolt, w i t h 183
N-m (135 ft-lbs) torque or, i f a 3 / 4 - 1 6 bolt, w i t h 237
N«m (175 ft-lbs) torque. I n s t a l l replacement cotter
pins.
(6) I n s t a l l t h e s t r u t (Fig. 1). T i g h t e n t h e strut-to-
lower suspension a r m bolts w i t h 136 N*m (100 ft-lbs)
torque. T i g h t e n t h e s t r u t front n u t w i t h 70 N m (50 #
ft-lbs) torque. I n s t a l l t h e s p r i n g p i n .
(7) Connect t h e stabilizer b a r ( i f equipped) a n d
t i g h t e n t h e l i n k w i t h 11 N»m (100 in-lbs) torque (Fig.
3). Remove t h e s p r i n g compressor tool (Fig. 4).
(8) I n s t a l l t h e shock absorber b u s h i n g i n the frame
r a i l bracket. Place t h e lower retainer o n the s t u d a n d
position t h e shock absorber inside t h e coil s p r i n g
(Fig. 2). I n s t a l l a n d t i g h t e n t h e upper s t u d n u t a n d
the lower r e t a i n i n g bolts " f i n g e r - t i g h t " .
A f t e r t h e vehicle has been lowered t o t h e sur-
f a c e a n d w i t h t h e wheels/tires s u p p o r t i n g t h e v e -
hicle weight, tighten the shock absorber stud
n u t w i t h 3 4 N * m ( 2 5 ft-lbs) t o r q u e a n d t h e l o w e r
r e t a i n i n g b o l t s w i t h 2 3 N*m ( 1 7 ft-lbs/200 in-lbs).
(9) ^ Position t h e brake splash shield o n the steering
k n u c k l e , i n s t a l l a n d t i g h t e n t h e a t t a c h i n g screws
w i t h 23 N i n (200 in-lbs) torque.
( 1 0 ) C a r e f u l l y i n s t a l l t h e hub/rotor o n t h e steering
k n u c k l e spindle, followed b y the outer wheel bearing,
t h e washer a n d t h e adjustment n u t . T i g h t e n t h e ad-
j u s t m e n t n u t w i t h 4 8 N T A ( 3 5 ft-lbs) torque w h i l e ro-
t a t i n g hub/rotor. Stop t h e hub/rotor r o t a t i o n a n d
loosen t h e adjustment n u t t o completely release t h e
wheel b e a r i n g "preload". N e x t , t i g h t e n t h e adjust-
m e n t n u t " f i n g e r - t i g h t " , and i n s t a l l n u t lock and cot-
t e r p i n . T h e r e s u l t o f t h e adjustment should be
0.0001 t o 0.003 i n c h (0.0025 t o 0.76 m m ) "end play".
Clean- t h e dust cap, apply a l i g h t coat o f wheel bear-
i n g l u b r i c a n t t o t h e inside surface a n d i n s t a l l i t o n
the hub.
( 1 1 ) Position t h e inboard brake pad on t h e b r a k e
caliper adapter w i t h t h e p a d flanges engaged w i t h
t h e adapter r a i l s . Slowly slide t h e caliper i n t o posi-
t i o n i n t h e adapter a n d over t h e brake rotor. A l i g n
2 - 9
t h e caliper on t h e adapter r a i l s . Use care t o avoid
p u l l i n g t h e protective dust boot f r o m t h e grooves as
the caliper piston a n d boot slide over t h e i n b o a r d
b r a k e pad.
I f necessary, refer t o G r o u p 5 — B r a k e s f o r a d -
ditional installation information.
(12) I n s t a l l t h e a n t i - r a t t l e springs and t h e r e t a i n e r
clips, a n d t i g h t e n w i t h 20 N i n (15 ft-lbs/180 in-lbs)
torque.
T h e i n b o a r d shoe a n t i - r a t t l e s p r i n g m u s t a l -
ways be installed o n t o p o f the retainer spring
plate.
(13) I n s t a l l t h e wheel/tire a n d t h e wheel cover.
Raise t h e vehicle, remove t h e supports, lower t h e ve-
hicle a n d remove t h e block from t h e b r a k e pedal.
(14) T i g h t e n t h e shock absorber n u t a n d bolts w i t h
s t u d n u t w i t h 34 N n n (25 ft-lbs) torque a n d t h e lower
r e t a i n i n g bolts w i t h 23 N - m (17 ft-lbs/200 in-lbs)
torque. T i g h t e n t h e suspension a r m hex-head a t t a c h -
i n g b o l t w i t h 305 N»m (225 ft-lbs) torque (Fig. 2).
(15) Test the vehicle brakes and t h e suspension for
proper operation.
LOWER BALL STUD REPLACEMENT
REMOVAL
(1) Block t h e b r a k e pedal i n t h e " u p " (non-
depressed) position. Raise t h e vehicle o n a hoist. Po-
s i t i o n supports a t t h e extreme f r o n t ends o f t h e
frame r a i l s and lower the hoist. Remove t h e applica-
ble wheel cover and wheel/tire.
(2) Remove t h e b r a k e caliper r e t a i n e r and t h e a n t i -
r a t t l e spring. Remove t h e brake caliper from t h e disc
rotor b y s l i d i n g i t o u t a n d t h e n away from t h e rotor.
I f necessary, refer t o Group 5—Brakes for removal
information. Support t h e brake caliper o u t -
of-the-way. D o n o t a l l o w t h e c a l i p e r t o h a n g from
o r b e s u p p o r t e d b y t h e b r a k e fluid h o s e . Remove
t h e inboard b r a k e pad.
(3) Remove t h e dust cap, t h e cotter p i n , t h e n u t
lock, t h e adjustment n u t , t h e washer, a n d t h e outer
wheel bearing.
(4) Carefully slide t h e hub/rotor f r o m t h e steering
k n u c k l e spindle. D o n o t a l l o w t h e s e a l o r t h e i n -
ner wheel bearing t o contact t h e steering
k n u c k l e spindle threads, otherwise the threads,
t h e b e a r i n g , a n d t h e seal c o u l d b e d a m a g e d .
(5) Remove t h e a t t a c h i n g screws a n d t h e b r a k e
splash shield.
( 6 ) Remove t h e shock absorber f r o m t h e vehicle
a n d t h e shock absorber upper b u s h i n g from t h e
frame r a i l bracket (Fig. 2). I f necessary, refer t o t h e
r e m o v a l procedure.
(7) Remove t h e s t r u t b a r (Fig. 1). I f necessary, refer
to t h e removal procedure. I f equipped, disconnect t h e
stabilizer bar f r o m t h e lower suspension a r m (Fig. 3).
2 - 10 FRONT SUSPENSION
(8) I n s t a l l Spring Compressor Tool DD-1278 i n t h e
s p r i n g (Fig. 4) and t i g h t e n the n u t " f i n g e r - t i g h t " , a n d
t h e n loosen t h e n u t 1/2 of-a-turn.
(9) Remove the cotter pins and the lower a n d upper
b a l l stud n u t s a t the steering knuckle.
(10) I n s t a l l B a l l Stud Loosening Tool C-3564-A o n
the lower b a l l stud (Fig. 4). T u r n the threaded por-
t i o n o f t h e tool and " l o c k " t h e tool securely against
the lower s t u d (Fig. 4).
(11) E x p a n d t h e tool sufficiently enough t o place
force on t h e lower b a l l s t u d and t h e n s t r i k e t h e steer-
i n g k n u c k l e sharply w i t h a h a m m e r to loosen t h e
stud. D o n o t a t t e m p t t o f o r c e t h e s t u d o u t o f t h e
steering k n u c k l e w i t h the loosening tool.
(12) Remove the loosening tool and remove t h e b a l l
stud f r o m t h e steering k n u c k l e bore w i t h a n appro-
p r i a t e tool.
(13) Slowly loosen t h e coil spring compressor tool
(Fig. 4) u n t i l a l l tension is relieved from t h e spring.
(14) Remove the b a l l stud seal. Use assembled Tool
C-4212 to force the b a l l stud out of the lower suspen-
sion a r m bore (Fig. 5).
Fig. 5 Lower Ball Stud Removal
INSTALLATION
(1) Force t h e replacement b a l l stud i n t o t h e lower
suspension a r m bore w i t h assembled Tool C-4212
(Fig. 6).
(2) Position t h e seal over t h e b a l l stud ( i f neces-
sary, use a replacement seal), force the r e t a i n i n g por-
tion of t h e seal downward o n t h e b a l l stud h o u s i n g
w i t h a n appropriate size socket wrench u n t i l i t i s se-
curely locked in-place.
(3) Compress the spring w i t h the spring compressor
•
Fig. 6 Lower Ball Stud Installation
tool (Fig. 4) u n t i l the lower suspension a r m b a l l stud
can be properly positioned i n t h e steering k n u c k l e
bore.
(4) I n s t a l l the r e t a i n i n g nuts on the b a l l studs and
t i g h t e n t h e upper n u t w i t h 142 N * m (105 ft-lbs)
torque a n d t h e lower n u t , i f a 11/16-16 bolt, w i t h 183
N - m (135 ft-lbs) torque or, i f a 3/4-16 bolt, w i t h 237
N » m (175 ft-lbs) torque. I n s t a l l replacement cotter
pins.
(5) I n s t a l l t h e s t r u t (Fig. 1). T i g h t e n t h e s t r u t - t o -
lower suspension a r m bolts w i t h 136 N « m (100 ft-lbs)
torque. T i g h t e n the s t r u t front n u t w i t h 70 N T H (50
ft-lbs) torque. I n s t a l l the spring p i n .
(6) Connect t h e stabilizer bar ( i f equipped) a n d
t i g h t e n t h e l i n k w i t h 11 N * m (100 in-lbs) torque (Fig.
3). Remove the s p r i n g compressor tool (Fig. 4).
(7) I n s t a l l the shock absorber b u s h i n g i n t h e frame
r a i l bracket. Place the lower retainer on the s t u d and
position t h e shock absorber inside t h e coil s p r i n g
(Fig. 2). I n s t a l l and t i g h t e n the upper stud n u t and
t h e lower r e t a i n i n g bolts " f i n g e r - t i g h t " .
A f t e r the vehicle has been l o w e r e d t o t h e sur-
f a c e a n d w i t h t h e wheels/tires s u p p o r t i n g t h e v e -
hicle weight, tighten the shock absorber s t u d
n u t w i t h 34 N»m (25 ft-lbs) t o r q u e a n d t h e l o w e r
r e t a i n i n g b o l t s w i t h 23 N n n (17 ft-lbs/200 i n - l b s ) .
(8) Position the brake splash shield on the steering
k n u c k l e , i n s t a l l a n d t i g h t e n t h e a t t a c h i n g screws
w i t h 23 N * m (200 in-lbs) torque.
(9) Carefully i n s t a l l t h e hub/rotor o n t h e steering
k n u c k l e spindle, followed by the outer wheel bearing,
t h e washer and the adjustment n u t . T i g h t e n the ad-
j u s t m e n t n u t w i t h 48 N T H (35 ft-lbs) torque w h i l e ro-
t a t i n g hub/rotor. Stop t h e hub/rotor, r o t a t i o n a n d
 • FRONT SUSPENSION 2-11

loosen the adjustment n u t t o completely release t h e UPPER SUSPENSION ARM

wheel bearing "preload". N e x t , t i g h t e n t h e adjust- REMOVAL/INSTALLATION
m e n t n u t " f i n g e r - t i g h t " , and i n s t a l l n u t lock and cot-
ter p i n . The r e s u l t of t h e adjustment should be
REMOVAL
0.0001 to 0.003 i n c h (0.0025 t o 0.76 m m ) "end play".
(1) Raise the vehicle. Position support stands under
Clean the dust cap, apply a l i g h t coat o f wheel bear-
the frame r a i l and lower t h e front o f t h e hoist. Re-
i n g l u b r i c a n t t o t h e inside surface and i n s t a l l i t o n move the wheel/tire.
the h u b . (2) Remove t h e upper bushing, t h e sleeve and t h e
(10) Position t h e inboard b r a k e pad o n t h e brake shock absorber (Fig. 2).
caliper adapter w i t h t h e p a d flanges engaged w i t h (3) I n s t a l l S p r i n g Compressor Tool DD-1278 ( F i g .
the adapter r a i l s . Slowly slide t h e caliper into posi- 4), t i g h t e n t h e n u t " f i n g e r - t i g h t " and t h e n loosen i t
t i o n i n the adapter and over t h e brake rotor. A l i g n 1/2 of-a-turn.
the caliper o n t h e adapter r a i l s . Use care to avoid (4) Remove t h e cotter pins and the b a l l stud r e t a i n -
p u l l i n g the protective dust boot f r o m the grooves as i n g nuts.
the caliper p i s t o n a n d boot slide over t h e inboard (5) I n s t a l l B a l l Stud Loosening Tool C-3564-A (Fig.
brake pad. 7), t u r n the threaded p o r t i o n of the tool t o " l o c k " i t
I f necessary, r e f e r t o G r o u p 5—Brakes f o r a d - securely against the upper b a l l stud (Fig. 7). Spread
ditional installation information. t h e tool enough t o apply force against the upper b a l l
(11) I n s t a l l t h e a n t i - r a t t l e springs and t h e retainer stud, t h e n s t r i k e the steering knuckle sharply w i t h a
clips, and t i g h t e n w i t h 20 N*m (15 ft-lbs/180 in-lbs) h a m m e r to loosen t h e upper b a l l stud. Do n o t a t -
torque. t e m p t t o force t h e b a l l stud o u t o f t h e steering
The i n b o a r d shoe a n t i - r a t t l e s p r i n g m u s t a l - k n u c k l e bore w i t h the loosening tool.
ways be installed o n t o p o f the retainer spring
plate.
(12) I n s t a l l t h e wheel/tire a n d t h e wheel cover.
Raise the vehicle, remove t h e supports, lower the ve-
hicle and remove t h e block f r o m the brake pedal.
(13) T i g h t e n t h e shock absorber stud n u t w i t h 34
N»m (25 ft-lbs) torque and t h e lower a t t a c h i n g bolts
w i t h 23 N*m (17 ft-lbs/200 in-lbs) torque.
(14) Test t h e vehicle brakes a n d the front suspen-
sion for proper operation.

LOWER SUSPENSION ARM BUSHING

REPLACEMENT
REMOVAL
(1) Remove t h e lower suspension a r m according to
instructions provided w i t h i n t h e removal procedure.
(2) Use a n arbor press a n d a n appropriate size
sleeve to force t h e o r i g i n a l b u s h i n g from t h e lower
suspension a r m bore.

INSTALLATION
(1) Use a n arbor press a n d a n appropriate size Fig. 7 Ball Stud Loosening Tool Installed
sleeve to force t h e replacement b u s h i n g i n t o t h e (6) Remove t h e loosening tool from t h e steering
lower suspension a r m bore. Ensure t h a t i t is com- knuckle.
pletely "seated" i n the bore. (7) Remove t h e upper b a l l stud from t h e steering
(2) I n s t a l l t h e lower suspension a r m according t o k n u c k l e bore w i t h a n appropriate tool.
instructions provided w i t h i n t h e i n s t a l l a t i o n proce-
dure.
2 - 12 FRONT SUSPENSION •
(8) Remove t h e r e t a i n i n g nuts, t h e eccentric (cam) (3) Remove the b a l l stud nuts. Use B a l l S t u d Loos-
bolts and the upper suspension a r m from the vehicle e n i n g Tool C-3564-A to loosen t h e upper b a l l s t u d
(Fig. 8). (Fig. 7).
(4) Use Tool C-3561 t o u n - t h r e a d t h e upper b a l l
stud f r o m the upper suspension a r m (Fig. 8).

INSTALLATION
(1) T h r e a d the replacement b a l l stud i n t o t h e upper
suspension a r m bore as far as possible b y h a n d , t h e n
use Tool C-3561 t o t i g h t e n t h e b a l l stud w i t h 169
N»m (125 ft-lbs) torque. Ensure t h a t the b a l l stud i s
completely "seated" against the a r m .
(2) I n s t a l l a n d "seat" t h e replacement b a l l stud
seal.
(3) I n s e r t the upper b a l l stud into steering k n u c k l e
FRONT and i n s t a l l b a l l stud nuts. T i g h t e n the n u t s w i t h 183
STRAIGHT PART
OF SUSPENSION ARM N m (135 ft-lbs) torque. I n s t a l l replacement cotter
#

MUST BE FORWARD pins.

(4) I n s t a l l the wheel/tire. Raise the vehicle, remove
1— Nut 7— Upper Suspension Arm the support and lower the vehicle t o t h e surface.
2— Lockwasher 8— Upper Ball Joint Seal
3— Cam 9— Bumper
4— Bushing 10— Sleeve UPPER SUSPENSION ARM BUSHING
5— Ball Joint 11—Cam and Bolt REPLACEMENT
6— Locknut
J9002-118
REMOVAL
Fig. 8 Upper Suspension Arm Removal/Installation
(1) Remove the upper suspension a r m according t o
INSTALLATION the instructions provided i n the removal procedure.
(1) Position t h e upper suspension a r m a t the frame (2) Place the upper suspension a r m i n a vise a n d
r a i l bracket a n d i n s t a l l t h e eccentric (cam) bolts (Fig. assemble Tool C-3962 a n d Adaptor Tool SP-3953
8). I n s t a l l a n d t i g h t e n t h e r e t a i n i n g nuts "finger- (Fig. 9) over the bushing. T i g h t e n the n u t s and force
tight". the b u s h i n g out o f the a r m bore.
(2) I n s t a l l t h e r e t a i n i n g nuts on the b a l l studs and
t i g h t e n t h e m w i t h 183 (135 ft-lbs) torque. I n s t a l l
replacement cotter pins.
(3) Remove t h e s p r i n g compressor tool (Fig. 4). SP-3952A
(4) I n s t a l l t h e shock absorber upper bushing a n d
sleeve (Fig. 2). Position the shock absorber inside the BUSHING
coil s p r i n g , i n s t a l l the upper retainer and n u t and i n -
s t a l l t h e lower a t t a c h i n g bolts. T i g h t e n the shock ab-
sorber stud n u t w i t h 34 N * m (25 ft-lbs) torque a n d
the lower a t t a c h i n g bolts w i t h 23 N-m (17 ft-lbs/200
in-lbs) torque.
(5) I n s t a l l t h e wheel/tire. Raise the vehicle, remove
the support stands and lower the vehicle to the sur-
face.
(6) A d j u s t t h e caster and camber angles. I f neces-
sary, refer to t h e procedure (also refer to the Specifi- UPPER SUSPENSION
ARM RH393
cations chart). T i g h t e n the eccentric (cam) r e t a i n i n g
nuts w i t h 95 N*m (70 ft-lbs) torque. Fig. 9 Upper Suspension Arm Bushing Removal

UPPER BALL STUD REPLACEMENT

INSTALLATION
When installing a replacement bushing i n t h e
REMOVAL
u p p e r suspension a r m bore, ensure t h e suspen-
(1) Raise the vehicle, position a support under the
sion a r m is supported f i r m l y a t the area w h e r e
outer end of t h e lower suspension a r m and lower the
the b u s h i n g is being forced i n the bore. D o n o t
vehicle so t h a t t h e support compresses t h e coil
use o i l o r a n y o t h e r l u b r i c a n t t o a i d t h e i n s t a l l a -
spring.
tion.
(2) Remove t h e wheel/tire.
 • FRONT SUSPENSION 2 - 13

(1) Position t h e flange end of t h e replacement
b u s h i n g i n Tool C-3962, support suspension a r m
f i r m l y , and force the b u s h i n g i n t h e suspension a r m
bore (from outside) u n t i l t h e flanged end is "seated"
on the a r m (Fig. 10).
(7) I n s t a l l Puller Tool C-3894A (Fig. 11) and apply
sufficient force w i t h the tool t o loosen the tie-rod end
b a l l stud f r o m the steering k n u c k l e a r m bore.

Fig. 10 Upper Suspension Arm Bushing Installation

(2) I n s t a l l t h e upper suspension a r m according t o
t h e instructions provided i n t h e i n s t a l l a t i o n proce-
dure.

STEERING KNUCKLE REMOVAL/INSTALLATION Fig. 11 Tie-Rod End Ball Stud Removal

REMOVAL
(1) Block t h e brake pedal i n t h e " u p " (non-
depressed) position. Raise t h e vehicle o n a hoist. Po-
s i t i o n supports at t h e extreme f r o n t ends o f t h e
frame r a i l s and lower t h e hoist. Remove t h e applica-
ble wheel cover and wheel/tire.
(2) Remove the brake caliper retainer and the a n t i -
r a t t l e spring. Remove the brake caliper f r o m the disc
rotor b y s l i d i n g i t out and t h e n away f r o m the rotor.
I f necessary, refer to Group 5—Brakes for r e m o v a l
information. Support t h e brake caliper o u t -
of-the-way. D o n o t a l l o w t h e c a l i p e r t o h a n g f r o m per
o r b e s u p p o r t e d b y t h e b r a k e f l u i d hose. Remove
t h e inboard brake pad.
(3) Remove t h e dust cap, t h e cotter p i n , t h e n u t
lock, t h e adjustment n u t , t h e washer, and t h e outer
wheel bearing.
(4) Carefully slide t h e hub/rotor f r o m t h e steering
k n u c k l e spindle. D o n o t a l l o w t h e s e a l o r t h e i n -
ner wheel bearing t o contact t h e steering
knuckle spindle threads, otherwise t h e threads,
t h e b e a r i n g , a n d t h e seal c o u l d b e d a m a g e d .
(5) Remove t h e a t t a c h i n g screws a n d . the b r a k e
splash shield. Remove a n d discard t h e dust seal.
(6) Remove the cotter p i n and the n u t f r o m t h e t i e -
rod end b a l l stud.
(8) Remove t h e shock absorber f r o m t h e vehicle
and t h e shock absorber upper b u s h i n g f r o m t h e
frame r a i l bracket (Fig. 2). I f necessary, refer t o t h e
removal procedure.
(9) Remove the s t r u t bar (Fig. 1). I f necessary, refer
to the removal procedure. I f equipped, disconnect t h e
stabilizer bar from the lower suspension a r m (Fig. 3).
(10) I n s t a l l Spring Compressor Tool DD-1278 i n the
s p r i n g (Fig. 4) and t i g h t e n the n u t " f i n g e r - t i g h t " , and
t h e n loosen t h e n u t 1/2 of-a-turn.
(11) Remove t h e cotter pins and t h e lower a n d up-
b a l l stud nuts a t the steering k n u c k l e .
(12) I n s t a l l B a l l Stud Loosening Tool C-3564-A o n
t h e lower b a l l stud (Fig. 4). T u r n t h e threaded por-
t i o n of the tool a n d " l o c k " t h e tool securely against
t h e lower stud (Fig. 4).
(13) Expand t h e tool sufficiently enough t o place
force on the lower b a l l stud and t h e n s t r i k e the steer-
i n g k n u c k l e sharply w i t h a h a m m e r to loosen t h e
stud. D o n o t a t t e m p t t o f o r c e t h e b a l l s t u d o u t o f
the steering k n u c k l e bore w i t h the loosening
tool.
(14) Remove t h e loosening tool a n d remove t h e
lower b a l l stud from t h e steering k n u c k l e bore w i t h
an appropriate tool.
2 - 14 FRONT SUSPENSION
(15) Reverse t h e position o f B a l l Stud Loosening
Tool C-3564-A (Fig. 12), t u r n the threaded p o r t i o n o f
t h e tool to "lock" i t securely against t h e upper b a l l
s t u d . Spread t h e tool enough t o apply force against
t h e upper b a l l stud, t h e n s t r i k e t h e steering k n u c k l e
s h a r p l y w i t h a h a m m e r to loosen t h e b a l l stud. Do
not a t t e m p t t o force t h e stud o u t o f t h e steering
k n u c k l e bore w i t h t h e loosening tool.
Fig. 12 Loosening Upper Ball Stud
(16) Remove the loosening tool.
(17) Remove the upper b a l l stud from the steering
k n u c k l e bore w i t h a n appropriate tool.
(18) Slowly loosen t h e coil s p r i n g compressor tool
(Fig. 4) u n t i l a l l tension is relieved from the spring.
(19) Separate the steering k n u c k l e and the steering
k n u c k l e a r m from the b a l l studs and position i t o n a
bench or other w o r k surface.
(20) Remove t h e brake adapter a n d steering
k n u c k l e attaching bolts from t h e steering k n u c k l e .
Separate the components.
INSTALLATION
(1) I n s t a l l t h e brake adaptor on t h e steering
k n u c k l e a n d t i g h t e n t h e a t t a c h i n g bolts w i t h 136
N»m (100 ft-lbs) torque.
(2) A l i g n the steering k n u c k l e a r m bolt holes w i t h
t h e steering k n u c k l e bolt holes. I n s t a l l the a t t a c h i n g
bolts and t i g h t e n w i t h 291 N*m (215 ft-lbs) torque.
(3) Position the steering k n u c k l e between t h e sus-
pension arms.
(4) Compress t h e coil spring w i t h t h e s p r i n g com-
pressor tool (Fig. 4) u n t i l t h e suspension a r m b a l l
studs can be inserted i n the steering k n u c k l e bores.
I n s e r t the b a l l studs i n the bores. I n s t a l l the r e t a i n -
i n g nuts. T i g h t e n t h e upper n u t w i t h 142 N»m (105
•
ft-lbs) torque and t h e lower n u t , i f a 11/16-16 bolt,
w i t h 183 N*m (135 ft-lbs) torque or, i f a 3/4-16 bolt,
w i t h 237 N»m (175 ft-lbs) torque. I n s t a l l replacement
cotter pins.
(5) Connect the tie-rod end b a l l s t u d t o t h e steering
k n u c k l e a r m bore. I n s t a l l a n d t i g h t e n t h e r e t a i n i n g
n u t w i t h 6 1 N*m (45 ft-lbs) torque. I n s t a l l a replace-
ment cotter p i n .
(6) Position a replacement dust seal on t h e steering
knuckle. I n s t a l l the splash shield a n d t i g h t e n t h e at-
taching bolts w i t h 25 N m (220 in-lbs) torque.
#
(7) I n s t a l l t h e s t r u t (Fig. 1). T i g h t e n t h e strut-to-
lower suspension a r m bolts w i t h 136 N*m (100 ft-lbs)
torque. T i g h t e n t h e s t r u t f r o n t n u t w i t h 70 N»m (50
ft-lbs) torque. I n s t a l l the s p r i n g p i n .
(8) Connect t h e stabilizer b a r ( i f equipped) a n d
t i g h t e n the l i n k n u t w i t h 11 N»m (100 in-lbs) torque
(Fig. 3). Remove the s p r i n g compressor tool (Fig. 4).
(9) I n s t a l l the shock absorber b u s h i n g i n the frame
r a i l bracket. Place the lower r e t a i n e r on t h e s t u d and
position t h e shock absorber inside t h e coil s p r i n g
(Fig. 2). I n s t a l l and t i g h t e n the upper s t u d n u t and
the lower r e t a i n i n g bolts " f i n g e r - t i g h t " .
After the vehicle has been l o w e r e d t o the sur-
face a n d w i t h t h e wheels/tires s u p p o r t i n g t h e v e -
hicle weight, tighten t h e shock absorber stud
n u t w i t h 34 N*m (25 ft-lbs) t o r q u e a n d t h e l o w e r
r e t a i n i n g b o l t s w i t h 23 N - m (17 ft-lbs/200 i n - l b s ) .
(10) Carefully i n s t a l l the hub/rotor o n t h e steering
knuckle spindle, followed b y t h e outer wheel bearing,
the washer and the adjustment n u t . T i g h t e n the ad-
j u s t m e n t n u t w i t h 48 N»m (35 ft-lbs) torque w h i l e ro-
t a t i n g hub/rotor. Stop t h e hub/rotor r o t a t i o n a n d
loosen t h e adjustment n u t to completely release t h e
wheel bearing "preload". Next, t i g h t e n t h e adjust-
ment n u t " f i n g e r - t i g h t " , and i n s t a l l n u t lock and cot-
ter p i n . The result of t h e adjustment should be
0.0001 to 0.003 i n c h (0.0025 t o 0.76 m m ) "end play".
Clean the dust cap, apply a l i g h t coat o f wheel bear-
i n g l u b r i c a n t to t h e inside surface and i n s t a l l i t on
the hub.
(11) Position t h e inboard b r a k e pad o n t h e brake
caliper adapter w i t h t h e pad flanges engaged w i t h
the adapter rails. Slowly slide t h e caliper i n t o posi-
t i o n i n t h e adapter and over t h e brake rotor. A l i g n
the caliper on the adapter r a i l s . U s e c a r e t o a v o i d
pulling the protective dust boot f r o m the
g r o o v e s as t h e c a l i p e r p i s t o n a n d b o o t s l i d e o v e r
the i n b o a r d brake pad.
I f necessary, r e f e r t o G r o u p 5 — B r a k e s f o r a d -
ditional installation information.
(12) I n s t a l l the a n t i - r a t t l e springs and the retainer
clips, and t i g h t e n w i t h 20 N*m (15 ft-lbs/180 in-lbs)
torque.
T h e i n b o a r d shoe a n t i - r a t t l e s p r i n g m u s t a l -
ways be installed o n t o p o f the retainer spring
plate.
 • FRONT SUSPENSION
(13) I n s t a l l t h e wheel/tire a n d t h e wheel cover.
Raise the vehicle, remove t h e supports, lower the ve-
hicle and remove the block f r o m t h e brake pedal.
MODEL 4 4 FRONT A X L E S E R V I C E — 4 W D V E H I C L E S
Complete Axle Removal/Installation . . . . . . . . . . .
Differential Service . . . . . . . . . . . . . . . . . . . . . . .
Disconnect Axle Vacuum Control System Service
Drag Link Removal/Installation . . . . . . . . . . . . . .
General Information
Left (Disconnect) Axle Shaft Service
Lubricant
GENERAL INFORMATION
The Model 44 front axle used for Ram T r u c k and
Ramcharger vehicles equipped for standard duty
4 W D operation has a hypoid gear differential and the
centerline of the drive p i n i o n gear shaft is located be-
low the centerline of the r i n g gear. The differential
housing is a n i r o n casting w i t h tubes "pressed" into
and welded t o i t to produce a one-piece axle housing.
A removable stamped steel cover is attached to the
differential housing to allow v i s u a l inspection of the
differential w i t h o u t r e m o v i n g t h e complete axle from
t h e vehicle.
A small m e t a l t a g is attached t o t h e differential
housing (by one of the cover screws) to identify the
axle ratio. T h i s t a g is stamped w i t h the number of
teeth on the drive p i n i o n and r i n g gear, and the axle
ratio.
The drive p i n i o n gear shaft is supported by t w o
"preloaded", tapered roller bearings. The i n n e r bear-
i n g has a t i g h t "press-fit" on t h e drive p i n i o n gear
shaft. The outer bearing has a l i g h t "press-fit"-to-a
close " s l i d i n g - f i t " on the shaft. T h e outer and inner
bearing cups are "press-fitted" against a shoulder
t h a t is recessed i n the d i f f e r e n t i a l housing.
The drive p i n i o n gear depth o f mesh ( w i t h the r i n g
gear) adjustment is controlled b y shims, w h i c h are
installed between the i n n e r d r i v e p i n i o n gear shaft
bearing cup and the differential housing shoulder.
The drive p i n i o n gear shaft b e a r i n g "preload"
torque is m a i n t a i n e d b y p l a c i n g appropriate thick-
ness of shims between the d i f f e r e n t i a l housing shoul-
der and the outer bearing.
The differential case is supported b y t w o tapered,
roller bearings t h a t are "press-fitted" on t h e differen-
t i a l case hubs. The shims placed between the bearing
and the differential case h u b shoulder provide three
functions:
2 - 15
(14) T i g h t e n the shock absorber stud n u t w i t h 34
N*m (25 ft-lbs) torque and the lower attaching bolts
w i t h 23 N-m (17 ft-lbs/200 in-lbs) torque.
(15) Test the vehicle brakes and the front suspen-
sion for proper operation.
INDEX
Page Page
. 31 Right Axle Shaft Removal/Installation 20
. 32 Rotor/Hub and Bearing Service . . . . . . . . . . . . . . . 15
. 25 Shift Motor Service 29
. 30 Stabilizer Bar Removal/Installation 31
15 Steering Knuckle Arm Removal/Installation 29
Steering Knuckle, Spindle and Ball Stud Service . 16
21
Tie-Rod End Replacement . . . . . . . . . . . . . . . . . . 30
50 U-Joint Service 20
• they eliminate the differential case "side play";
• they adjust and m a i n t a i n t h e "backlash" between
the r i n g gear and the drive p i n i o n gear; and
• they establish a means for obtaining and t h e n re-
t a i n i n g the differential bearing "preload" torque.
The axle shaft disconnect housing is welded t o the
left axle shaft tube between t h e differential housing
and the spring pad. A splined, two-piece axle shaft is
located on t h e left side and i t is mechanically en-
gaged or disengaged b y a shift collar t h a t is moved
by a vacuum shift motor controlled shift fork. The
shift motor is operated b y v a c u u m t h a t is controlled
by a vacuum switch located a t the transfer case.
CAUTION: Whenever front axle service is neces-
sary, or when the axle is being rotated via the en-
gine or other means, raise all four wheels off the
surface.
R0T0R/HUB AND BEARING SERVICE
REMOVAL/DISASSEMBLY
(1) Block t h e brake pedal i n t h e " u p " (non-
depressed) position. Raise the vehicle on a hoist. Po-
sition supports a t t h e extreme front ends o f the
frame rails and lower the hoist. Remove the applica-
ble wheel cover and wheel/tire.
(2) Remove the brake caliper retainer and t h e anti-
r a t t l e spring. Remove the brake caliper from the disc
rotor by s l i d i n g i t out and t h e n away from the rotor.
I f necessary, refer t o Group 5—Brakes for removal
information. Support t h e brake caliper out-
of-the-way. D o n o t a l l o w t h e c a l i p e r t o h a n g f r o m
o r b e s u p p o r t e d b y t h e b r a k e f l u i d h o s e . Remove
the inboard brake pad.
(3) Remove the dust cap and the d r i v i n g h u b snap
ring.
2 - 16 FRONT SUSPENSION •
(4) Remove the d r i v i n g h u b a n d t h e r e t a i n i n g t i o n i n t h e h u b and, u s i n g Tool D-359 a n d C-4171
spring. Handle, i n s t a l l t h e b e a r i n g seal.
(5) Use Tool C-4170-A t o remove t h e wheel bearing (3) Position t h e rotor/hub o n t h e steering k n u c k l e
n u t lock (Fig. 1). Remove t h e r e t a i n i n g washer a n d spindle and i n s t a l l t h e "re-packed" i n n e r wheel bear-
the wheel bearing adjusting n u t (Fig. 2). ing.
(4) I n s t a l l t h e adjusting n u t a n d , u s i n g Tool C-
4170, t i g h t e n i t w i t h 68 N * m (50 ft-lbs) torque t o
"seat" t h e wheel bearings. Loosen adjusting n u t a n d
re-tighten i t w i t h 41-54 NVm (30-40 ft-lbs) torque
w h i l e r o t a t i n g rotor/hub. Loosen t h e adjusting n u t
135° t o 150°. Position t h e r e t a i n i n g washer on t h e ad-
j u s t i n g n u t b y r o t a t i n g t h e n u t so t h a t the a l i g n m e n t
p i n pressed i n t o t h e n u t w i l l enter t h e nearest hole
i n the r e t a i n i n g washer. I n s t a l l a n d t i g h t e n t h e n u t
lock w i t h 68 N«m (50 ft-lbs) torque. T h e wheel bear-
i n g "end p l a y " after t h e f i n a l b e a r i n g adjustment
should be w i t h i n 0.001 i n c h t o 0.010 i n c h (0.03 t o
0.25 mm).
(5) I n s t a l l t h e r e t a i n i n g spring, t h e d r i v i n g h u b
and the r e t a i n i n g r i n g .
(6) A p p l y R T V sealant t o t h e sealing edge o f t h e
dust cap and i n s t a l l i t on t h e h u b .
(7) Position t h e i n b o a r d brake p a d o n t h e brake
caliper adapter w i t h t h e p a d flanges engaged w i t h
the adapter r a i l s . Slowly slide t h e caliper i n t o posi-
Fig. 1 Wheel Bearing Nut Lock Removal t i o n i n t h e adapter a n d over t h e brake rotor. A l i g n
the caliper o n t h e adapter r a i l s . U s e c a r e t o a v o i d
p u l l i n g t h e p r o t e c t i v e d u s t b o o t from t h e
g r o o v e s as t h e c a l i p e r p i s t o n a n d b o o t s l i d e o v e r
the i n b o a r d b r a k e pad.
I f necessary, refer t o G r o u p 5 — B r a k e s f o r a d -
ditional installation information.
(8) I n s t a l l t h e a n t i - r a t t l e springs and t h e r e t a i n e r
clips, and t i g h t e n w i t h 20 N T H (15 ft-lbs/180 in-lbs)
ADJUSTING NUT RETAINING WASHER RY702B torque.
The i n b o a r d shoe a n t i - r a t t l e s p r i n g m u s t a l -
Fig. 2 Wheel Bearing Adjusting Nut, Retaining ways be installed o n t o p o f t h e retainer spring
Washer & Nut Lock plate.
(6) Remove rotor/hub. The outer wheel bearing and (9) I n s t a l l t h e wheel/tire. T i g h t e n the l u g n u t s w i t h
the r e t a i n e r spring plate w i l l slide out as rotor/hub is 149 N « m (110 ft-lbs). I n s t a l l t h e wheel cover. Raise
removed. the vehicle, remove t h e supports, lower t h e vehicle
(7) P r y t h e inner wheel b e a r i n g seal from h u b and and remove t h e block f r o m t h e b r a k e pedal.
remove t h e inner wheel bearing.
(8) Remove the i n n e r and outer bearing cups.
STEERING KNUCKLE, SPINDLE AND BALL STUD
SERVICE
INSPECTION
(1) W a s h the bearings i n clean m i n e r a l spirits. I n - REMOVAL/DISASSEMBL Y
spect a n d "re-pack" t h e bearings. I f necessary, refer (1) Block t h e brake pedal i n t h e " u p " (non-
to Group 0 — L u b r i c a t i o n A n d Maintenance for addi- depressed) position. Raise t h e vehicle on a hoist. Po-
t i o n a l information. sition supports a t t h e extreme f r o n t ends o f t h e
frame rails a n d lower the hoist. Remove the applica-
ASSEMBL Y/INSTALLA TION ble wheel cover and wheel/tire.
(1) I n s t a l l inner and outer b e a r i n g cups i n t h e ro- (2) Remove the brake caliper r e t a i n e r and the a n t i -
tor/hub. r a t t l e spring. Remove the brake caliper from t h e disc
(2) Place the "re-packed" i n n e r bearing i n t o posi- rotor by s l i d i n g i t out and t h e n away from t h e rotor.
I f necessary, refer to Group 5—Brakes for removal
 • FRONT SUSPENSION 2 - 17

information. Support t h e b r a k e caliper out-

of-the-way. D o n o t a l l o w t h e c a l i p e r t o h a n g f r o m
o r b e s u p p o r t e d b y t h e b r a k e f l u i d h o s e . Remove
the' inboard brake pad.
(3) Remove the dust cap and t h e d r i v i n g h u b snap
ring.
(4) Remove t h e d r i v i n g h u b a n d t h e r e t a i n i n g
spring.
(5) Use Tool C-4170-A to remove the wheel bearing
n u t lock (Fig. 1). Remove the r e t a i n i n g washer and
the wheel b e a r i n g adjusting n u t (Fig. 2).
(6) Remove rotor/hub. The outer wheel b e a r i n g and
t h e r e t a i n e r spring plate w i l l slide out as rotor/hub is
removed.
(7) Remove brake caliper adaptor f r o m t h e steering
knuckle.
Fig. 4 Needle Bearing Removal (Right-Side Spindle)
(8) Remove t h e six "torque r e t a i n i n g " n u t s a n d k n u c k l e a r m t o loosen i t f r o m t h e steering k n u c k l e .
washers f r o m the spindle-to-steering k n u c k l e attach- Remove steering k n u c k l e a r m .
i n g bolts. (16) Remove the cotter p i n f r o m the upper b a l l stud
(9) Remove the brake splash shield. n u t . Remove the upper a n d lower b a l l stud nuts. Dis-
(10) Use a soft-faced hammer t o l i g h t l y s t r i k e t h e card the lower n u t .
spindle and loosen i t from the steering k n u c k l e (Fig. (17) Use a brass d r i f t and a h a m m e r to separate
3). the steering k n u c k l e f r o m t h e axle shaft tube yoke.
Use Tool C-4169 to remove the sleeve f r o m t h e axle
shaft tube upper yoke a r m . Discard the sleeve.
(18) Clamp the steering k n u c k l e upside down i n a
vise and remove t h e " s n a p " r e t a i n i n g r i n g f r o m t h e
lower b a l l stud w i t h Snap R i n g Pliers Tool C-4020
(Fig. 5).

Fig. 3 Spindle Removal From Steering Knuckle

(11) Clamp t h e spindle i n a "soft-jawed" vise. Do
not clamp a t t h e bearing contact surfaces. Remove
t h e b e a r i n g seal.
(12) Use Tool D-131 t h e remove needle bearings
f r o m the spindle (Fig. 4).
(13) Carefully remove the axle shaft f r o m the axle
shaft tube. Remove the seal f r o m the axle shaft.
(14) R i g h t side only: disconnect the tie-rod end b a l l
stud f r o m t h e steering k n u c k l e a r m bore. Left side:
disconnect t h e drag l i n k b a l l stud from t h e steering
k n u c k l e a r m bore. I f necessary, refer to t h e removal
procedures w i t h i n t h i s section o f Group 2.
(15) Left side only: remove t h e nuts and t h e wash- Fig. 5 "Snap" Retaining Ring Removal/Installation
ers f r o m t h e steering k n u c k l e a r m . Tap t h e steering
2 - 18 FRONT SUSPENSION
(19) Use Tool C-4212-L and Adaptor Tool Set C-
4288 (positioned as i l l u s t r a t e d i n F i g u r e 6) to force
the lower b a l l stud from t h e steering k n u c k l e bore.
Re-position t h e tools as i l l u s t r a t e d i n F i g u r e 7 a n d
force t h e upper b a l l stud from t h e steering k n u c k l e
bore. Replace the b a l l studs i f any looseness or " e n d
p l a y " exists.
Fig. 7 Upper Ball Stud Removal
(20) Clean a l l the components w i t h a n appropriate
cleaning solvent and a i r d r y t h e m w i t h compressed
air. Inspect a l l the components for burrs, chips, ex-
cessive wear and cracks. Replace components as nec-
essary d u r i n g assembly.
ASSEMBL Y/INSTALLA TION
(1) C l a m p t h e steering k n u c k l e r i g h t side up i n a
vise. Use Tool C-4212-L and Adaptor Tool Set C-4288
•
(positioned as i l l u s t r a t e d i n F i g u r e 8) t o carefully
force t h e lower b a l l stud i n t o t h e steering k n u c k l e
bore. I n s t a l l t h e " s n a p " r e t a i n i n g r i n g w i t h Snap
R i n g Pliers Tool C-4020.
Fig. 8 Lower Ball Stud Installation
(2) Use Tool C-4212-L and Adaptor Tool Set C-4288
(positioned as i l l u s t r a t e d i n F i g u r e 9) t o carefully
force t h e upper b a l l stud i n t o t h e steering k n u c k l e
bore. I n s t a l l replacement r u b b e r boots over both ball
studs. Remove the steering k n u c k l e f r o m t h e vise.
Fig. 9 Upper Ball Stud Installation
(3) T h r e a d a replacement sleeve into the axle shaft
tube yoke upper a r m bore. A l l o w approximately two
threads to r e m a i n exposed a t the top of the a r m .
 • FRONT SUSPENSION
(4) Position the steering knuckle on the axle shaft
tube yoke arms and i n s t a l l a replacement lower b a l l
s t u d n u t . T i g h t e n t h e n u t w i t h 108 N T H (80 ft-lbs)
torque.
(5) Use Tool C-4169 and a torque wrench to t i g h t e n
t h e sleeve i n the yoke upper a r m bore w i t h 54 N » (40
ft-lbs) torque. I n s t a l l t h e upper b a l l stud n u t a n d
t i g h t e n i t w i t h 136 N T H (100 ft-lbs) torque.
(6) Continue to t i g h t e n the n u t u n t i l the cotter p i n
hole i n t h e stud and t h e slot i n castellated n u t are
aligned. Do not loosen the n u t to a l i g n the hole a n d
t h e slot. I n s t a l l a replacement cotter p i n .
(7) Left side: position t h e steering k n u c k l e a r m
over t h e studs o n t h e steering k n u c k l e . I n s t a l l t h e
washer and the n u t s . T i g h t e n the n u t s w i t h 122 N»m
(90 ft-lbs) torque. Connect the drag l i n k b a l l s t u d t o
t h e steering k n u c k l e a r m bore. I n s t a l l t h e r e t a i n i n g
n u t and t i g h t e n i t w i t h 81 N T H (60 ft-lbs) torque. I n -
s t a l l a replacement cotter p i n .
(8) Connect the tie-rod end b a l l s t u d t o the steering
k n u c k l e a r m bore. I n s t a l l t h e r e t a i n i n g n u t a n d
t i g h t e n i t w i t h 61 NTH (45 ft-lbs) torque. I n s t a l l a re-
placement cotter p i n .
(9) I n s t a l l the seal on the axle shaft shield w i t h t h e
l i p facing toward the axle shaft splines (Fig. 10). L u -
bricate the complete circumference o f the seal ( F i g .
11) w i t h multi-purpose l u b r i c a n t ( N L G I Grade 2, E P
or a n equivalent l u b r i c a n t ) .
Fig. 10 Seal Installation On Axle Shaft Shield
(10) Right side only: carefully insert the axle shaft
i n t o the axle shaft tube and avoid d a m a g i n g t h e dif-
f e r e n t i a l housing seal.
(11) Left side only—proceed w i t h t h e f o l l o w i n g i n -
structions:
• remove the shift motor housing cover;
• position t h e shift collar on the splined end o f the
i n n e r axle shaft;
• insert the intermediate (outer) axle shaft t h r o u g h
axle shaft seal (use care to avoid d a m a g i n g t h e seal
d u r i n g this step);
2 - 19
RN328
Fig. 11 Lubricating Seal
• i n s t a l l t h e shift motor housing gasket and cover
(ensure t h a t the shift fork is correctly guided into the
shift collar groove);
• i n s t a l l the shift motor housing cover shield a n d
bolts, and t i g h t e n t h e bolts w i t h 14 N T H (10 ft-lbs)
torque; and
• connect the vacuum hoses to the shift motor ports
and t h e w i r e connector to the 4 W D indicator switch
(wrap the r e t a i n i n g clip securely around switch con-
nector).
(12) I n s t a l l replacement needle bearings i n t h e
spindle w i t h I n s t a l l a t i o n Tool D-122 and Handle Tool
C-4171.
(13) Use Tool D-155 and Handle Tool C-4171 to i n -
s t a l l t h e replacement brake h u b seal. Lubricate t h e
complete circumference of the seal and t h e contact
surface on t h e spindle w i t h multi-purpose l u b r i c a n t
( N L G I Grade 2, E P or a n equivalent lubricant).
(14) Position t h e replacement spacer on t h e axle
shaft, a n d i n s t a l l the spindle a n d brake splash
shield.
(15) I n s t a l l replacement n u t s a n d t i g h t e n t h e m
w i t h 34-41 N T H (25-35 ft-lbs) torque.
(16) Position t h e rotor/hub a n d t h e outer wheel
b e a r i n g o n the spindle.
(17) I n s t a l l t h e adjusting n u t and, using Tool C-
4170, t i g h t e n i t w i t h 68 N T H (50 ft-lbs) torque t o
"seat" t h e wheel bearings. Loosen adjusting n u t and
r e - t i g h t e n i t w i t h 41-54 N - m (30-40 ft-lbs) torque
w h i l e r o t a t i n g rotor/hub. Loosen t h e adjusting n u t
135° t o 150°. Position the r e t a i n i n g washer on the ad-
j u s t i n g n u t by r o t a t i n g the n u t so t h a t the a l i g n m e n t
p i n pressed into t h e n u t w i l l enter the nearest hole
i n t h e r e t a i n i n g washer. I n s t a l l and t i g h t e n the n u t
lock w i t h 68 N T H (50 ft-lbs) torque. The wheel bear-
i n g " e n d p l a y " after the f i n a l bearing adjustment
should be w i t h i n 0.001 i n c h to 0.010 inch (0.03 to
0.25 m m ) .
(18) I n s t a l l t h e r e t a i n i n g spring, t h e d r i v i n g h u b
and the r e t a i n i n g r i n g .
2 - 20 FRONT SUSPENSION •
(19) A p p l y R T V sealant to the sealing edge o f the INSTALLATION
dust cap a n d i n s t a l l i t on the h u b . (1) I n s t a l l t h e seal on t h e axle shaft stone shield
(20) Position t h e inboard brake pad o n t h e brake w i t h the l i p facing t o w a r d t h e axle shaft splines.
caliper adapter w i t h t h e pad flanges engaged w i t h (2) Carefully insert t h e axle shaft i n t o t h e axle
t h e adapter r a i l s . Slowly slide t h e caliper i n t o posi- shaft tube and avoid damaging t h e d i f f e r e n t i a l hous-
t i o n i n t h e adapter and over t h e b r a k e rotor. A l i g n i n g seal.
t h e caliper o n the adapter r a i l s . U s e c a r e to a v o i d (3) I n s t a l l the spindle a n d t h e splash shield. I n s t a l l
p u l l i n g t h e protective d u s t boot from the the n u t s and t i g h t e n t h e m w i t h 34-41 N*m (25-30 f t -
g r o o v e s a s t h e c a l i p e r piston a n d boot s l i d e o v e r lbs) torque.
t h e inboard b r a k e pad. (4) Position the rotor/hub a n d t h e outer w h e e l bear-
I f n e c e s s a r y , r e f e r to G r o u p 5 — B r a k e s for a d -
i n g on the spindle.
d i t i o n a l i n s t a l l a t i o n information. (5) I n s t a l l t h e adjusting n u t a n d , u s i n g Tool C-
(21) I n s t a l l the a n t i - r a t t l e springs and t h e retainer
4170, t i g h t e n i t w i t h 68 N * m (50 ft-lbs) t o r q u e t o
clips, a n d t i g h t e n w i t h 20 N-rn (15 ft-lbs/180 in-lbs) "seat" the wheel bearings. Loosen a d j u s t i n g n u t and
torque. re-tighten i t w i t h 41-54 N»m (30-40 ft-lbs) torque
The i n b o a r d shoe a n t i - r a t t l e s p r i n g m u s t a l -w h i l e r o t a t i n g rotor/hub. Loosen t h e a d j u s t i n g n u t
w a y s b e i n s t a l l e d o n top of the r e t a i n e r s p r i n g 135° to 150°. Position the r e t a i n i n g washer o n t h e ad-
plate. j u s t i n g n u t by r o t a t i n g t h e n u t so t h a t the a l i g n m e n t
p i n pressed into the n u t w i l l enter t h e nearest hole
(22) I n s t a l l t h e wheel/tire. T i g h t e n t h e l u g n u t s
w i t h 149 N»m (110 ft-lbs). I n s t a l l t h e wheel cover. i n the r e t a i n i n g washer. I n s t a l l a n d t i g h t e n t h e n u t
Raise t h e vehicle, remove the supports, lower the ve- lock w i t h 68 N*m (50 ft-lbs) torque. The w h e e l bear-
hicle and remove the block from t h e brake pedal. i n g "end p l a y " after t h e f i n a l b e a r i n g adjustment
should be w i t h i n 0.001 i n c h t o 0.010 i n c h (0.03 t o
RIGHT AXLE SHAFT REMOVAL/INSTALLATION 0.25 mm).
(6) I n s t a l l t h e r e t a i n i n g spring, t h e d r i v i n g h u b
and the r e t a i n i n g r i n g .
REMOVAL
(7) A p p l y R T V sealant t o t h e sealing edge o f the
(1) Block t h e brake pedal i n t h e " u p " (non-
dust cap and i n s t a l l i t on the h u b .
depressed) position. Raise the vehicle o n a hoist. Po-
(8) Position t h e inboard brake p a d o n t h e b r a k e
s i t i o n supports a t t h e extreme f r o n t ends o f t h e
frame r a i l s and lower the hoist. Remove the applica- caliper adapter w i t h t h e pad flanges engaged w i t h
ble wheel cover and wheel/tire. the adapter r a i l s . Slowly slide t h e caliper i n t o posi-
t i o n i n the adapter and over the b r a k e rotor. A l i g n
(2) Remove the brake caliper r e t a i n e r and the a n t i -
r a t t l e spring. Remove the brake caliper f r o m the disc t h e caliper o n the adapter r a i l s . U s e c a r e to a v o i d
rotor b y s l i d i n g i t out and t h e n away f r o m t h e rotor. p u l l i n g the protective d u s t boot f r o m t h e
I f necessary, refer t o Group 5—Brakes for removal grooves a s the c a l i p e r p i s t o n a n d boot s l i d e o v e r
information. Support the b r a k e caliper o u t - t he inboard brake pad.
of-the-way. D o n o t a l l o w t h e c a l i p e r t o h a n g f r o m I f n e c e s s a r y , refer to G r o u p 5 — B r a k e s f o r a d -
or be s u p p o r t e d b y the b r a k e fluid hose. Remove ditional installation information.
the i n b o a r d brake pad. (9) I n s t a l l the a n t i - r a t t l e springs a n d the r e t a i n e r
(3) Remove the dust cap and t h e d r i v i n g h u b snap clips, and t i g h t e n w i t h 20 N*m (15 ft-lbs/180 in-lbs)
ring. torque.
(4) Remove t h e d r i v i n g h u b a n d t h e r e t a i n i n g T h e i n b o a r d shoe a n t i - r a t t l e s p r i n g m u s t a l -
spring. w a y s be installed o n top o f the r e t a i n e r s p r i n g
(5) Use Tool C-4170-A to remove the wheel bearing plate.
n u t lock (Fig. 1). Remove the r e t a i n i n g washer and (10) I n s t a l l t h e wheel/tire. T i g h t e n t h e l u g n u t s
the wheel b e a r i n g adjusting n u t (Fig. 2). w i t h 149 N»m (110 ft-lbs). I n s t a l l t h e wheel cover.
(6) Remove the rotor/hub. The outer wheel bearing Raise the vehicle, remove the supports, lower t h e ve-
and the r e t a i n e r s p r i n g plate w i l l slide out as rotor/ hicle and remove the block f r o m t h e brake pedal.
h u b is removed.
U-J0INT SERVICE
(7) Remove t h e s i x nuts t h a t attach t h e splash
shield and the spindle to the steering k n u c k l e .
(8) Remove the splash shield a n d the spindle. DISASSEMBLY
(9) Remove t h e brake caliper adaptor f r o m t h e (1) Remove t h e "snap" r e t a i n i n g rings f r o m t h e
steering k n u c k l e . yoke a r m bores.
(10) Carefully remove the axle shaft from the axle (2) Position the U-joint between open vise j a w s
shaft tube. Remove t h e seal a n d t h e stone shield w i t h one yoke horizontal and supported b y t h e top o f
from the shaft. the vise jaws (Fig. 12). Do not t i g h t e n the vise.
 • FRONT SUSPENSION 2 - 21

Fig. 12 Bearing Cap Removal

(3) Use a m a l l e t t o t a p t h e v e r t i c a l yoke upper a r m
several times and drive t h e v e r t i c a l yoke d o w n w a r d
(Fig. 12). T h i s w i l l force t h e upper needle b e a r i n g
and cap out o f the yoke.
(4) Reverse the position o f the vertical yoke and re-
move opposite needle b e a r i n g and cap (Fig. 12).
(5) Remove the yoke f r o m t h e spider.
(6) To complete the disassembly, position the open
ends o f t h e spider i n a "soft-jawed" vise and repeat
steps 3 and 4 (above) t o remove r e m a i n i n g bearings
and caps.
(7) Remove the spider f r o m t h e yoke.
(8) Clean a n d inspect a l l t h e components. Clean
any r u s t f r o m t h e axle shaft splines. Retain each
bearing and cap separate. I f any component is exces-
sively w o r n or damaged, a complete replacement U -
j o i n t should be installed.
(9) Re-pack t h e U - j o i n t w i t h M O P A R M u l t i -
Mileage L u b r i c a n t , or a n equivalent lubricant. Fig. 14 Bearing Cap & Spider Installation
ASSEMBLY LEFT (DISCONNECT) AXLE SHAFT SERVICE
(1) Insert t h e needle b e a r i n g and cap i n one yoke
a r m bore. REMOVAL AND DISASSEMBLY
(2) Place the yoke i n a vise (Fig. 13) and force t h e (1) Block t h e brake pedal i n t h e " u p " (non-
needle bearing and cap i n t o t h e correct position. I n - depressed) position. Raise the vehicle on a hoist. Po-
stall the " s n a p " r e t a i n i n g r i n g . s i t i o n supports a t t h e extreme front ends of t h e
(3) Remove t h e yoke f r o m t h e vise and insert one frame r a i l s and lower the hoist. Remove the applica-
end o f the spider i n t o t h e bearing. Insert opposite ble wheel cover a n d wheel/tire.
bearing a n d cap i n t h e yoke a r m bore b y h a n d a n d (2) Remove the brake caliper retainer and the a n t i -
a l i g n i t w i t h the spider. r a t t l e spring. Remove the brake caliper from the disc
(4) Place the yoke i n a vise and force the cap i n t o rotor b y s l i d i n g i t out and t h e n away from the rotor.
the yoke a r m bore and onto t h e spider (Fig. 14). I f necessary, refer t o Group 5—Brakes for removal
(5) Use a short p l u g or a socket wrench to force the information. Support t h e brake caliper o u t -
bearing cap i n t o the correct position and i n s t a l l t h e of-the-way. D o n o t a l l o w t h e c a l i p e r t o h a n g f r o m
"snap" r e t a i n i n g r i n g . o r b e s u p p o r t e d b y t h e b r a k e f l u i d hose. Remove
(6) Repeat t h e instructions i n steps 1 t h r o u g h 5 for the i n b o a r d brake pad.
i n s t a l l i n g r e m a i n i n g bearings, caps and yoke. (3) Remove the dust cap and the d r i v i n g hub snap
ring.
2 - 22 FRONT SUSPENSION •

Fig. 15 Left (Disconnect) Axle

(4) Remove t h e d r i v i n g h u b a n d t h e r e t a i n i n g (15) Remove t h e needle bearing from intermediate
spring. axle shaft w i t h Tool D-330 (Figs. 16 a n d 17).
(5) Use Tool C-4170-A to remove the wheel bearing
n u t lock (Fig. 1). Remove t h e r e t a i n i n g washer and
the wheel b e a r i n g adjusting n u t (Fig. 2).
(6) Remove t h e rotor/hub. The outer wheel bearing INTERMEDIATE
and t h e retainer s p r i n g plate w i l l slide o u t as rotor/ AXLE SHAFT
h u b is removed.
(7) Remove t h e six n u t s t h a t attach t h e splash
shield and t h e spindle t o t h e steering k n u c k l e .
(8) Remove t h e splash shield and t h e spindle.
(9) Remove t h e brake caliper adaptor f r o m t h e
steering k n u c k l e .
(10) Disconnect t h e v a c u u m hoses from t h e shift
motor ports a n d t h e w i r e connector from t h e 4 W D i n -
dicator switch.
(11) Remove t h e shift motor housing cover, gasket
and shield ( F i g . 15). RK 724
(12) Carefully remove t h e intermediate axle shaft
Fig. 16 Intermediate Shaft Bearing Removal
from t h e axle shaft tube. Carefully slide t h e axle
shaft t h r o u g h axle shaft seal to avoid damage t o t h e
seal.
D-354-4 D-354-2
(13) Remove t h e shift collar from t h e shift motor
housing.
D-354-1 D-328
(14) Remove t h e i n n e r axle shaft seal f r o m t h e axle
shaft tube a n d remove i t from the shift motor hous- D-330
ing. C e r t a i n vehicles could also have a seal guard;
discard both components. The guard is n o t used w i t h
5041-3 RR02E35
a replacement seal. A l w a y s replace t h e i n n e r axle 5041 5041-2
shaft seal whenever t h e axle shaft is removed from
the axle shaft tube. Fig. 17 Right (Disconnect) Axle Housing Service
Tools
 • FRONT SUSPENSION
(16) Remove t h e differential housing coyer screws
and the cover. D r a i n t h e l u b r i c a n t into a clean con-
tainer.
(17) Force t h e i n n e r axle shaft t o w a r d the center of
t h e vehicle a n d remove t h e " C " lock f r o m t h e re-
cessed groove i n the shaft.
(18) Use Tool D-354-4 and A d a p t o r Tool D-354-3 to
remove the i n n e r axle shaft (Fig. 18).
Fig. 18 Inner Axle Shaft Removal/Installation
(19) Use Tool D-354-4, Tool D-354-1, a n d Puller
Tool C-637 t o remove t h e i n n e r axle shaft bearing
(Figs. 16 and 18).
ASSEMBL Y/INSTALLA TION
(1) Use Tool D-354-4, Tool 354-2 and Tool C-637 to
i n s t a l l the i n n e r axle shaft b e a r i n g (Figs. 16 and 18).
(2) Insert t h e i n n e r axle shaft i n t o t h e axle shaft
tube w i t h Tool D-354-4 a n d Adaptor Tool D-354-3
(Fig. 18). Carefully slide t h e axle shaft i n t h e side
gear and i n s t a l l t h e " C " lock i n t h e axle shaft re-
cessed groove.
(3) Inspect the i n n e r axle shaft seal contact surface
and remove a n y m a t e r i a l t h a t could have remained
i n the axle shaft tube bore after t h e o r i g i n a l seal was
removed. Clean t h e outer axle shaft tube bore w i t h
crocus cloth a n d remove t h e r u s t from t h e area
where the seal i n s t a l l a t i o n tool w i l l be located.
(4) I n s t a l l t h e replacement axle shaft seal on Tool
5041-1 and position i t i n the s h i f t motor housing. I n -
sert Threaded B a r Tool 5041-2 t h r o u g h t h e seal
t h r e a d i t i n t o Tool 5041-1. I n s t a l l Tool 5041-3 and
t h e r e t a i n i n g n u t on the end o f t h e threaded bar tool
and t i g h t e n t h e n u t u n t i l t h e tool contacts t h e
threaded bar shoulder.
(5) I n s t a l l t h e shift collar o n t h e splined end of the
i n n e r axle shaft.
2 - 23
(6) I n s t a l l t h e needle bearing i n the end of the i n -
termediate shaft w i t h Tool D-328 and Handle Tool C-
4171 (Fig. 19).
UK 727
Fig. 19 Intermediate Shaft Bearing Installation
(7) Lubricate t h e splined end of the i n t e r m e d i a t e
axle shaft w i t h a l i b e r a l amount of multi-purpose l u -
bricant and insert i t t h r o u g h inner axle shaft seal.
Use c a r e t o a v o i d d a m a g i n g t h e seal.
(8) I n s t a l l t h e shift motor housing gasket a n d
cover. E n s u r e t h a t t h e s h i f t f o r k i s c o r r e c t l y
guided i n t o the shift collar groove.
(9) I n s t a l l t h e shift motor housing cover shield a n d
bolts. T i g h t e n t h e bolts w i t h 14 N - m (10 ft-lbs)
torque.
(10) Connect t h e v a c u u m hoses to t h e shift motor
ports and t h e w i r e connector t o the 4 W D indicator
switch. W r a p t h e r e t a i n i n g clip securely a r o u n d t h e
4 W D indicator switch connector.
(11) I n s t a l l t h e splash shield and t h e spindle. I n -
stall the washers and replacement nuts. T i g h t e n t h e
nuts w i t h 34-41 N n n (25-30 ft-lbs) torque.
(12) Position t h e rotor/hub a n d t h e outer wheel
bearing on t h e spindle.
(13) I n s t a l l t h e adjusting n u t and, u s i n g Tool C-
4170, t i g h t e n i t w i t h 68 N«m (50 ft-lbs) torque t o
"seat" the wheel bearings. Loosen adjusting n u t and
re-tighten i t w i t h 41-54 N i n (30-40 ft-lbs) torque
w h i l e r o t a t i n g rotor/hub. Loosen the adjusting n u t
135° to 150°. Position the r e t a i n i n g washer on the ad-
j u s t i n g n u t b y r o t a t i n g the n u t so t h a t the a l i g n m e n t
p i n pressed i n t o t h e n u t w i l l enter the nearest hole
i n the r e t a i n i n g washer. I n s t a l l and t i g h t e n the n u t
lock w i t h 68 N»m (50 ft-lbs) torque. The wheel bear-
i n g "end p l a y " after t h e f i n a l bearing adjustment
should be w i t h i n 0.001 i n c h to 0.010 i n c h (0.03 t o
0.25 m m ) .
(14) I n s t a l l t h e r e t a i n i n g spring, t h e d r i v i n g h u b
and the r e t a i n i n g r i n g .
(15) A p p l y R T V sealant to the sealing edge of t h e
dust cap and i n s t a l l i t on the hub.
(16) Position t h e inboard brake pad on t h e brake
caliper adapter w i t h t h e pad flanges engaged w i t h
the adapter r a i l s . Slowly slide t h e caliper into posi-
t i o n i n t h e adapter and over t h e brake rotor. A l i g n
2 - 24 FRONT SUSPENSION
the caliper o n the adapter r a i l s . U s e c a r e to a v o i d
p u l l i n g t h e p r o t e c t i v e d u s t b o o t from t h e
grooves as the caliper p i s t o n a n d boot slide over
the i n b o a r d b r a k e p a d .
I f necessary, refer t o G r o u p 5—Brakes f o r ad-
ditional installation information.
(17) I n s t a l l the a n t i - r a t t l e springs and the retainer
clips, a n d t i g h t e n w i t h 20 N*m (15 ft-lbs/180 in-lbs)
torque.
T h e i n b o a r d shoe a n t i - r a t t l e s p r i n g m u s t a l -
ways be installed o n t o p o f the retainer spring
plate.
(18) Remove the r e s i d u a l gasket m a t e r i a l from t h e
differential housing a n d t h e cover, thoroughly clean
the contact surfaces w i t h m i n e r a l spirits (or a n
equivalent solution) a n d d r y t h e surfaces completely.
(19) A p p l y a 1/16-inch t o 3/32-inch (1.6-mm t o 2.4-
m m ) t h i c k "bead" o f M O P A R Silicone Rubber Seal-
ant (or a n equivalent sealant) around the bolt circle
on the housing cover (Fig. 20).
SEALANT
(TYPICAL) J9003-85
Fig. 20 Sealant On Housing Cover
•
A l l o w the sealant t o " c u r e " f o r f e w minutes.
I f f o r a n y reason the housing cover is n o t i n -
s t a l l e d w i t h i n 20 m i n u t e s a f t e r a p p l y i n g t h e seal-
ant, t h e sealant m u s t b e r e m o v e d a n d a n o t h e r
" b e a d " o f sealant applied.
(20) I n s t a l l t h e h o u s i n g cover o n t h e d i f f e r e n t i a l
housing w i t h t h e a t t a c h i n g bolts. I n s t a l l t h e axle
gear r a t i o i d e n t i f i c a t i o n t a g w i t h one o f t h e cover
bolts. T i g h t e n the cover bolts w i t h 47 N*m (35 ft-lbs)
torque.
(21) I n s t a l l t h e wheel/tire. T i g h t e n t h e l u g n u t s i n
the correct sequence (Fig. 21) w i t h 149 N»m (110 ft-
lbs). I n s t a l l t h e wheel cover. Raise t h e vehicle, re-
move the supports a n d raise or lower t h e hoist u n t i l
the vehicle i s level. Remove the block f r o m the b r a k e
pedal.
Fig. 21 Wheel Lug Nut Tightening Sequence
(22) Remove the f i l l hole p l u g and f i l l the differen-
t i a l h o u s i n g a n d the axle tubes w i t h l u b r i c a n t (refer
to the Specifications c h a r t for the type a n d the quan-
t i t y ) . I n s t a l l t h e f i l l hole p l u g .
(23) Lower t h e vehicle a n d test the brakes a n d the
axle for correct operation.
 • FRONT SUSPENSION
DISCONNECT AXLE VACUUM CONTROL SYSTEM
SERVICE
DESCRIPTION
The disconnect axle v a c u u m control system consists
of a vacuum control s w i t c h o n t h e transfer case, a n
a i r vent f i l t e r , a v a c u u m shift motor (located on the
left front axle tube), a 4 W D indicator l i g h t and vac-
u u m switch, t w o v a c u u m check valves, a reservoir
and a n interconnecting v a c u u m harness (Fig. 22).
FILTER
J8902-52
Fig. 22 Disconnect Axle Vacuum Control System
Refer t o G r o u p 21 f o r a d d i t i o n a l service infor-
m a t i o n i n v o l v i n g t h e d i s c o n n e c t a x l e c o n t r o l sys-
tem.
AXLE SHIFT MOTOR FUNCTIONAL TEST
(1) Raise and support t h e vehicle. Disconnect t h e
vacuum harness f r o m t h e axle shift motor and con-
nect a v a c u u m pump t o the v a c u u m shift motor front
port (Fig. 23).
(2) A p p l y 5 1 kPa (15 i n . H g ) o f v a c u u m t o the front
port and rotate the left front wheel to f u l l y disengage
the inner and intermediate axle shafts (i.e., shift t o
two-wheel drive operation).
(3) T h e shift motor should m a i n t a i n t h e vacuum
applied t o t h e front port for a m i n i m u m o f 30 sec-
onds. I f t h e motor does not m a i n t a i n the vacuum, re-
place i t . I f t h e motor does m a i n t a i n t h e vacuum,
proceed t o the next step.
(4) Disconnect the vacuum p u m p f r o m t h e vacuum
shift motor front p o r t (Fig. 23). Connect t h e vacuum
2 - 25
REAR
PORT
MOTOR J8902-57
Fig. 23 Axle Vacuum Shift Motor
p u m p t o t h e v a c u u m s h i f t motor rear port, cap t h e
port for t h e 4 W D indicator l a m p switch, and apply 51
k P a (15 i n . H g ) of v a c u u m t o the rear port.
(5) T h e shift motor should m a i n t a i n t h e vacuum
applied t o the rear p o r t for a m i n i m u m o f 30 seconds.
I f t h e shift motor does not m a i n t a i n the vacuum, re-
place i t . I f the motor does m a i n t a i n the vacuum, pro-
ceed t o t h e n e x t step.
(6) Remove t h e cap f r o m t h e port for t h e 4 W D i n -
dicator l a m p s w i t c h a n d determine i f vacuum was
present a t t h i s port. I f v a c u u m was present, the shift
motor functions n o r m a l l y . I f vacuum was n o t
present, proceed t o t h e n e x t step.
(7) A p p l y 5 1 k P a (15 i n . H g ) o f vacuum to the shift
motor rear port. Rotate t h e left front wheel as neces-
sary and ensure t h a t t h e i n n e r and intermediate axle
shafts are completely engaged. T h e axles m u s t be
completely engaged (i.e., shifted to 4 W D operation) t o
open the p o r t for the 4 W D indicator lamp switch.
(8) Determine i f v a c u u m is present a t the port for
the 4 W D indicator l a m p switch again. I f vacuum was
present a t t h e port, t h e shift motor functions nor-
m a l l y . I f v a c u u m was not present a t the port, replace
the shift motor.
(9) Connect t h e v a c u u m harness t o the shift motor
(Fig. 24), remove t h e supports and lower the vehicle.
2 - 26 FRONT SUSPENSION

DISCONNECT AXLE/SHIFT MOTOR DIAGNOSIS

TWO-WHEEL DRIVE O P E R A T I O N D I A G N O S I S

FOUR-WHEEL DRIVE
INDICATOR LIGHT WILL
NOT G O O U T W H E N
TRANSFER C A S E SELECTOR
IS MOVED FROM 4H TO
2H P O S I T I O N .

YES '

START E N G I N E DEPRESS BRAKE TEST COMPLETE

RAISE VEHICLE S O ALL
FOUR W H E E L S ARE
FREE TO ROTATE.
INSPECT INDICATOR PEDAL. PLACE TRANSFER
SWITCH A N D W I R I N G O N C A S E SELECTOR IN 2H POSITION
SHIFT MOTOR H O U S I N G A N D T R A N S M I S S I O N IN
FOR DAMAGE A N D DRIVE (AUTOMATIC) OR FIRST
SHORT-CIRCUIT. G E A R (MANUAL). E A S E O F F FROM
REPAIR A S NECESSARY. BRAKE A N D LET W H E E L S ROTATE
SLOWLY.

FRONT DRIVE FRONT DRIVE

SHAFT D O E S SHAFT ROTATES.
NOT ROTATE.

INSPECT TRANSFER
FOUR-WHEEL DRIVE CASE LINKAGE.
INDICATOR 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 VACUUM
IN VACUUM H O S E
• THAT C O N N E C T S TO
INBOARD SHIFT
DISCONNECT T H E MOTOR PORT.
SHIFT MOTOR VACUUM (VACUUM S H O U L D BE
HOSES. B E T W E E N 10-20 IN. HG.)

VACUUM O K
N O VACUUM
OR LOW VACUUM.

STOP E N G I N E

INSPECT INTAKE M A N I F O L D
VACUUM SUPPLY H O S E C O N N E C T I O N ,
TRANSFER C A S E VACUUM SWITCH
CONNECT A VACUUM
C O N N E C T I O N , VACUUM RESERVOIR,
PUMP TO THE INBOARD
A N D SHIFT SYSTEM VACUUM H O S E S
SHIFT MOTOR PORT.
FOR PROPER C O N N E C T I O N , RESTRICTION, APPLY 15 IN. HG
AIR LEAKS, A N D DAMAGE. REPAIR OR REPLACE VACUUM AND ROTATE
AS NECESSARY. LEFT WHEEL.

FRONT AXLE FRONT AXLE

DISCONNECTS. D O E S NOT
DISCONNECT.

INSPECT VACUUM
H O S E S FOR AIR LEAKS, K I N K S , ETC.
REPAIR AS NECESSARY. REMOVE SHIFT MOTOR
H O U S I N G COVER. C O N N E C T
VACUUM PUMP TO
SHIFT MOTOR PORT. FRONT AXLE
REPLACE SHIFT MOTOR WILL NOT DISCONNECT.
IF ARMATURE D O E S
NOT MOVE IN A N D OUT
FREELY.
REMOVE SHIFT MOTOR H O U S I N G
C O V E R . INSPECT SHIFT FORK,
COLLAR, A N D AXLE SHAFTS.
REPAIR OR REPLACE A S
J9002-95 NECESSARY.
 FRONT SUSPENSION 2 - 27

DISCONNECT AXLE/SHIFT MOTOR DIAGNOSIS (CONT'D)

FOUR-WHEEL DRIVE OPERATION D I A G N O S I S

FOUR-WHEEL DRIVE INDICATOR

LIGHT D O E S NOT LIGHT WHEN
TRANSFER CASE SELECTOR IN
4H O R 4 L POSITION.

RAISE VEHICLE SO ALL FOUR

WHEELS ARE FREE TO ROTATE.

START E N G I N E , DEPRESS BRAKE PEDAL.

PLACE TRANSFER CASE SELECTOR IN 4H
POSITION A N D TRANSMISSION LEVER IN
DRIVE (AUTOMATIC) OR IN FIRST GEAR
(MANUAL) TO CONFIRM TRANSFER CASE
ENGAGEMENT IN 4H. LET WHEELS
ROTATE SLOWLY.

FRONT DRIVE FRONT DRIVE

SHAFT DOES SHAFT TURNS.
NOT ROTATE.

INSPECT TRANSFER FRONT AXLE RECOMMENDATION:

CHECK VACUUM PLACE TRANSMISSION FRONT AXLE
CASE LINKAGE. CONNECTS. LEVER IN NEUTRAL DOES NOT
SHIFT SYSTEM
FOR PROPER POSITION. CONNECT.
OPERATION.
CHECK TRANSFER FOUR-WHEEL DRIVE
CASE. REPAIR AS INDICATOR LIGHT
NECESSARY. D O E S NOT LIGHT. REMOVE VACUUM HOSES
FROM AXLE SHIFT
MOTOR PORTS.

INSPECT FWD INDICATOR

SWITCH, WIRING, A N D START ENGINE. TEST FOR VACUUM
LAMP FOR DAMAGE. AT HOSE REMOVED FROM OUT-
REPAIR A S NECESSARY. BOARD PORT O N SHIFT MOTOR,
SHOULD BE BETWEEN 10-20 IN HG.

N O VACUUM STOP ENGINE VACUUM OK

OR LOW VACUUM.

CONNECT A VACUUM PUMP

INSPECT INTAKE MANIFOLD TO THE OUTBOARD
VACUUM SUPPLY HOSE C O N N E C T I O N , SHIFT MOTOR PORT.
TRANSFER CASE VACUUM SWITCH APPLY 15 INCHES HG. VACUUM
C O N N E C T I O N , VACUUM RESERVOIR, A N D SHIFT AND ROTATE LEFT WHEEL.
SYSTEM VACUUM H O S E S FOR PROPER C O N N E C T I O N
RESTRICTION, LEAKS, AND DAMAGE.
REPAIR OR REPLACE AS NECESSARY.

FRONT AXLE FRONT AXLE

N O VACUUM
CONNECTED. DOES NOT
CONNECT.

CHECK TRANSFER CASE

VACUUM SWITCH. REPLACE INSPECT VACUUM HOSES
OR REPAIR IF SWITCH FOR LEAKS, KINKS, ETC. REMOVE SHIFT MOTOR
PLUNGER IS DIFFICULT TO REPAIR AS 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 DOES
NOT MOVE IN AND OUT
FREELY.

REMOVE SHIFT MOTOR HOUSING t

COVER. INSPECT SHIFT FORK,
FRONT AXLE
COLLAR, AND AXLE SHAFTS.
WILL NOT CONNECT.
REPAIR OR REPLACE AS
NECESSARY.
J9002-96
 TORQUE
LET. POUNDS NEWTON
METRES
RESERVOIR
ASSEMBLY FULLY SEATED
<£> HAND TIGHTENED
<B> 55 IN. 6
LEFT ENGINE MOUNT
<€> 15 FT. 20

CLIP
STONE
SHIELD

NUT A N D / ,
WASHER <C>

ALIGN WHITE TAPE

TRANSFER TO END OF CLIP
CASE VIEW IN DIRECTION SHIFT MOTOR VIEW IN DIRECTION
OF ARROW W OF ARROW Z

ROUTE HOSE TO
CLIP
VIEW IN DIRECTION REAR OF DISTRIBUTOR
OF ARROW X

WHITE TAPE RESERVOIR

ON HARNESS ASSEMBLY
MUST BE INSIDE VIEW IN DIRECTION
OF CLIP OF ARROW Y
6 CYLINDER
(SAME AS 8 CYL
EXCAS SHOWN)

FILTER MUST BE
IN DOWNWARD POSITION

/TRANSFER
FILTER MUST BE v
CASE VENT
IN DOWNWARD POSITION TUBE
TRANSFER CASE
VENT TUBE 8 CYLINDER
RK722

Fig. 24 Disconnect Axle Vacuum Hose Routing

 • FRONT SUSPENSION
SHIFT MOTOR SERVICE
REMOVAL/DISASSEMBLY
(1) Raise and support the vehicle a t a comfortable
w o r k i n g height.
(2) Disconnect the v a c u u m hoses f r o m t h e shift mo-
t o r ports a n d the w i r e connector f r o m the 4 W D i n d i -
cator switch.
(3) Remove t h e s h i f t motor housing cover, gasket
and shield f r o m the housing.
(4) Remove the E-clips from t h e shift motor hous-
i n g and shaft, and remove shift motor and shift fork
from the housing (Fig. 25).
Fig. 25 Shift Motor & Axle Disconnect Components
(5) Remove t h e O - r i n g seal f r o m t h e shift motor
shaft (Fig. 25).
(6) Clean and inspect a l l the components (Fig. 25).
I f any component i s excessively w o r n or damaged, i t
should be replaced.
ASSEMBL Y/INSTALLA TION
(1) I n s t a l l a replacement O - r i n g seal o n t h e shift
motor shaft (Fig. 25).
(2) Insert t h e shift motor shaft t h r o u g h the hole i n
the housing and t h r o u g h t h e hole i n t h e shift fork
(Fig. 25). T h e shift f o r k offset should be t o w a r d t h e
differential.
(3) I n s t a l l the E-clips o n the shift motor shaft and
housing.
(4) I n s t a l l t h e shift motor housing gasket and cover
(Fig. 25). E n s u r e t h a t t h e s h i f t f o r k i s c o r r e c t l y
guided into the shift collar groove.
(5) I n s t a l l t h e shift motor housing shield and a t -
taching bolts. T i g h t e n the bolts w i t h 14 N*m (10 f t -
lbs) torque.
2 - 29
STEERING KNUCKLE ARM
REMOVAL/INSTALLATION
REMOVAL
The d r a g - l i n k b a l l stud seals should be inspected
for damage w h e n the engine o i l i s changed.
(1) Raise and support the vehicle a t a comfortable
w o r k i n g height. Remove the wheel cover and wheel/
tire.
(2) T u r n t h e front wheels t o t h e left. Remove t h e
cotter p i n and t h e r e t a i n i n g n u t from the d r a g - l i n k
b a l l stud.
R e m o v a l o f a d r a g - l i n k b a l l s t u d from t h e
steering k n u c k l e a r m b y methods other t h a n us-
i n g T o o l C-4150 c o u l d d a m a g e t h e seal.
(3) I n s t a l l P u l l e r Tool C-4150 o n the drag-link b a l l
s t u d (Fig. 26). A p p l y sufficient force w i t h the tool t o
loosen t h e d r a g - l i n k b a l l stud from t h e steering
knuckle arm.
TOOL C-4150 RH4Q4
Fig. 26 Drag-Link Ball Stud Removal With Tool
C-4150
(4) Remove t h e three steering knuckle a r m -
to-steering k n u c k l e n u t s and washers (Fig. 27). T a p
the steering k n u c k l e a r m to loosen i t from the steer-
i n g k n u c k l e . P r y u p w a r d a n d remove t h e steering
k n u c k l e a r m from the vehicle.
INSTALLATION
(1) Position the steering k n u c k l e a r m on the steer-
i n g k n u c k l e . I n s t a l l the washers and attaching nuts.
T i g h t e n the nuts w i t h 122 N-m (90 ft-lbs).
(2) Connect the d r a g - l i n k b a l l stud to the steering
k n u c k l e a r m . I n s t a l l t h e r e t a i n i n g n u t and t i g h t e n i t
w i t h 8 1 N T H (60 ft-lbs). I n s t a l l a replacement cotter
pin.
(3) Remove the supports, lower the vehicle and test
t h e vehicle steering.
2 - 30 FRONT SUSPENSION
Fig. 27 Steering Knuckle Arm Removal
DRAG LINK REMOVAL/INSTALLATION
SERVICE INFORMATION
T h e d r a g - l i n k b a l l s t u d seals s h o u l d b e i n -
spected f o r damage w h e n t h e engine o i l is
changed.
A damaged seal requires removal of the seal and
inspection o f the d r a g - l i n k b a l l stud a t t h e throat
opening. I f a l l t h e l u b r i c a n t has n o t escaped (or is
not contaminated) or t h e b a l l s t u d is not excessively
w o r n or rusted, i n s t a l l a replacement seal. Otherwise
a replacement complete drag l i n k should be installed.
Lubricate t h e b a l l studs after i n s t a l l a t i o n w i t h MO-
P A R M u l t i - M i l e a g e L u b r i c a n t or an equivalent l u b r i -
cant.
REMOVAL
Removal o f a drag-link ball stud from the
steering k n u c k l e a r m o r t h e p i t m a n (steering
g e a r ) a r m b y m e t h o d s o t h e r t h a n u s i n g T o o l C-
4150 c o u l d d a m a g e t h e seal.
(1) Raise a n d support the vehicle a t a comfortable
w o r k i n g height. Remove t h e applicable wheel cover
and wheel/tire.
(2) T u r n the front wheels i n t h e direction t h a t w i l l
provide the best possible access t o the drag l i n k . Re-
move the cotter pins a n d t h e r e t a i n i n g nuts from the
d r a g - l i n k b a l l studs.
(3) I n s t a l l Puller Tool C-4150 on each drag-link
b a l l stud ( F i g . 26). A p p l y sufficient force w i t h the
tool t o loosen the d r a g - l i n k b a l l stud from the steer-
i n g k n u c k l e a r m and the p i t m a n (steering gear) arm.
Remove the drag l i n k f r o m the vehicle.
INSTALLATION
(1) Position the d r a g l i n k a t steering knuckle a r m
(Fig. 28) so t h a t the distance " A " to the bend i n the
•
l i n k is the shortest distance to the steering k n u c k l e
a r m and the distance " B " is the closest t o the p i t m a n
(steering gear) a r m .
Fig. 28 Correct Drag Link Installation
(2) I n s t a l l a n d t i g h t e n the b a l l stud r e t a i n i n g n u t s
w i t h 8 1 N * m (60 ft-lbs) torque. I n s t a l l replacement
cotter pins.
(3) I n s t a l l the wheel/tire and the wheel cover. Re-
move the supports a n d lower the vehicle.
TIE-ROD END REPLACEMENT
SERVICE INFORMATION
T h e t i e - r o d b a l l s t u d seals s h o u l d b e i n s p e c t e d
for damage w h e n the engine oil is changed.
A damaged seal requires removal o f t h e seal a n d
inspection o f the tie-rod b a l l stud a t the t h r o a t open-
i n g . I f a l l t h e l u b r i c a n t has n o t escaped (or i s n o t
contaminated) or t h e b a l l stud is n o t excessively
w o r n or rusted, i n s t a l l a replacement seal. Otherwise
a replacement complete tie-rod end should be i n -
stalled. Lubricate t h e b a l l studs after i n s t a l l a t i o n
w i t h M O P A R M u l t i - M i l e a g e L u b r i c a n t or a n equiva-
lent l u b r i c a n t .
REMOVAL
Removal o f a tie-rod e n d ball stud f r o m the
steering k n u c k l e a r m b y methods other t h a n us-
i n g T o o l C-3894-A c o u l d d a m a g e t h e seal.
(1) Raise and support the vehicle a t a comfortable
w o r k i n g height. Remove t h e applicable wheel cover
and wheel/tire.
(2) T u r n the front wheels i n the direction t h a t w i l l
provide t h e best possible access to t h e tie-rod end.
Remove the cotter p i n and the r e t a i n i n g n u t f r o m the
tie-rod end b a l l stud.
(3) I n s t a l l P u l l e r Tool C-3894-A on the tie-rod end
b a l l stud (Fig. 29). A p p l y sufficient force w i t h t h e
tool to loosen the tie-rod end b a l l stud from the steer-
ing knuckle arm.
(4) Measure and record t h e approximate distance
from the end o f the t i e rod to the outside edge o f the
tie-rod end. Loosen t h e adjustment sleeve clamp n u t
 • FRONT SUSPENSION 2 - 31

INSULATOR

LINK
ASSEMBLY
RH406

Fig. 29 Tie-Rod End Removal SHAFT ASSEMBLY NUT

and bolt. U n - t h r e a d t h e tie-rod end from the adjust- BUSHING
m e n t sleeve a n d remove i t from t h e vehicle. BOLT ASSEMBLY
RETAINER
INSTALLATION VIEW D RN1034
(1) T h r e a d t h e replacement tie-rod end i n t o the ad-
j u s t m e n t sleeve so t h a t the l e n g t h approximates the Fig. 30 Stabilizer Bar—4WD Vehicles
distance previously measured and recorded. and the n u t on each l i n k (Fig. 30). T i g h t e n t h e n u t s
(2) Connect the tie-rod end b a l l s t u d to the steering w i t h 11 N«m (100 in-lbs) torque.
k n u c k l e a r m and i n s t a l l the r e t a i n i n g n u t . T i g h t e n (3) Remove the supports and lower the vehicle.
the n u t w i t h 6 1 N»m (45 ft-lbs) torque.
(3) Remove t h e supports and lower vehicle t o t h e COMPLETE AXLE REMOVAL/INSTALLATION
surface.
(4) A d j u s t the "toe" position. Refer t o the procedure SERVICE INFORMATION
and the Specifications chart. Position the adjustment
I t is n o t necessary t o remove t h e complete f r o n t
sleeve clamp bolt a t t h e bottom o f the tie-rod end.
axle f r o m the vehicle for r o u t i n e service. However, i f
T i g h t e n t h e clamp b o l t and n u t w i t h 34-41 N»m (25-
the differential housing or the axle shaft tubes are
30 ft-lbs) torque. Test the vehicle steering.
damaged, the complete axle can be removed a n d i n -
STABILIZER BAR REMOVAL/INSTALLATION stalled v i a the following procedures.

REMOVAL
(1) Raise a n d support the vehicle a t a comfortable
working height.
(2) Remove t h e n u t , t h e outer retainer a n d t h e
outer i n s u l a t o r f r o m the l i n k a t each side of the ve-
hicle (Fig. 30).
(3) Remove t h e a t t a c h i n g nuts, bolts, and the re-
t a i n e r f r o m each frame r a i l (Fig. 30). Lower the sta-
bilizer bar a n d remove i t from t h e vehicle.
INSTALLATION
(1) Position the stabilizer bar a t t h e frame rails. I n -
s t a l l the r e t a i n e r , t h e bolts and t h e nuts a t each side
of the vehicle (Fig. 30). T i g h t e n t h e nuts w i t h 102 N «
(75 ft-lbs) torque.
(2) Position the ends o f the stabilizer bar over the
l i n k s . I n s t a l l t h e outer insulator, t h e outer retainer
REMOVAL
(1) Block t h e brake pedal i n t h e " u p " position.
Raise and support the vehicle a t a comfortable w o r k -
i n g height.
(2) Remove the front wheels/tires.
(3) M a r k the front drive shaft and the drive p i n i o n
gear shaft (axle) yoke for i n s t a l l a t i o n a l i g n m e n t ref-
erence.
(4) Disconnect the f r o n t drive shaft f r o m t h e axle
yoke. A t t a c h the drive shaft to the frame r a i l w i t h
wire.
(5) Remove t h e cotter p i n , t h e r e t a i n i n g n u t , a n d
disconnect t h e drag l i n k from t h e steering k n u c k l e
a r m (left side only). Discard the cotter p i n .
(6) Disconnect flexible brake f l u i d hose f i t t i n g s a t
the frame crossmember. P l u g t h e hoses a t t h e f i t -
tings.
2 - 32 FRONT SUSPENSION
(7) Remove the shock absorber lower attaching n u t
and detach t h e stud f r o m the axle shaft tube bracket.
Remove t h e r e t a i n i n g n u t s and disconnect the stabi-
lizer b a r l i n k s from the spring brackets (Fig. 30).
(8) Disconnect the vacuum hoses from the shift mo-
t o r ports a n d t h e w i r e connector from 4 W D indicator
l a m p s w i t c h o n the shift motor housing.
(9) Remove nuts and t h e washers from t h e spring
U-bolts. Remove the complete front axle from the ve-
hicle.
INSTALLATION
(1) Position the front axle under the front o f the ve-
hicle w i t h t h e axle spring pads under t h e springs.
Place t h e s p r i n g brackets over t h e springs w i t h t h e
stabilizer b a r l i n k bolt holes facing toward the rear
of t h e vehicle (Fig. 30).
(2) I n s t a l l t h e spring U-bolts, washers and r e t a i n -
i n g n u t s . T i g h t e n the n u t s w i t h 149 N*m (110 ft-lbs)
torque.
(3) I n s e r t t h e shock absorber lower studs i n t h e
axle shaft tube brackets. I n s t a l l t h e attaching nuts
and t i g h t e n t h e m w i t h 75 N T H (55 ft-lbs) torque.
(4) Connect t h e stabilizer b a r l i n k s to t h e spring
brackets w i t h t h e bolts and n u t s (Fig. 30). T i g h t e n
the n u t s w i t h 271 N r n (200 ft-lbs) torque.
(5) Remove plugs and connect t h e brake hose fit-
tings. T i g h t e n the f i t t i n g s w i t h 9-17 N-m (80-150 i n -
lbs) torque.
(6) Connect the d r a g - l i n k b a l l stud to the steering
k n u c k l e a r m . I n s t a l l the r e t a i n i n g n u t and t i g h t e n i t
w i t h 8 1 N T H (60 ft-lbs) torque. To a l i g n t h e cotter
p i n hole i n the b a l l stud w i t h t h e slot i n the castel-
lated n u t ( i f the slot and t h e hole are n o t aligned),
continue to t i g h t e n t h e n u t u n t i l they are aligned.
Do not loosen the n u t to a l i g n the hole and the slot.
I n s t a l l a replacement cotter p i n .
(7) Connect the drive shaft to the drive p i n i o n gear
shaft (axle) yoke w i t h t h e i n s t a l l a t i o n reference
m a r k s aligned. I n s t a l l the washers and the n u t s and
t i g h t e n w i t h 34 N T H (300 in-lbs) torque.
(8) Connect t h e vacuum hoses to the shift motor
ports a n d t h e w i r e connector t o t h e 4 W D indicator
lamp s w i t c h .
(9) Remove the supports, lower the vehicle and re-
move t h e block from the brake pedal.
(10) Raise the vehicle, bleed and adjust the brakes,
lubricate a l l the b a l l stud f i t t i n g s , inspect the differ-
e n t i a l housing l u b r i c a n t level. Refer to the Specifica-
tions c h a r t .
(11) L o w e r t h e vehicle and test t h e axle and sus-
pension operation.
•
DIFFERENTIAL SERVICE
SERVICE INFORMATION
I t i s n o t necessary t o remove t h e complete f r o n t
axle f r o m t h e vehicle for r o u t i n e axle or d i f f e r e n t i a l
service. To replace t h e differential side gears, i t i s
necessary t o remove only the axle shafts, t h e differ-
e n t i a l h o u s i n g cover, t h e l u b r i c a n t and the differen-
t i a l case. T o replace t h e differential bearings, i t is
necessary t o remove only t h e axle shafts, t h e differ-
e n t i a l h o u s i n g cover, t h e l u b r i c a n t , t h e d i f f e r e n t i a l
case and t o adjust the r i n g gear "backlash".
REMOVAL/DISASSEMBLY
(1) Raise a n d support the vehicle a t a comfortable
working height.
(2) Remove t h e front wheels/tires.
(3) M a r k t h e f r o n t drive shaft and the d r i v e p i n i o n
gear shaft (axle) yoke for i n s t a l l a t i o n a l i g n m e n t ref-
erence.
(4) Disconnect t h e front drive shaft from t h e axle
yoke. A t t a c h t h e drive shaft t o t h e frame r a i l w i t h
wire.
(5) T h o r o u g h l y clean the outer area of the differen-
t i a l housing a n d axle shaft tubes w i t h an appropriate
cleaning solvent and blow d r y w i t h compressed air.
(6) Loosen t h e differential housing cover bolts and
d r a i n t h e l u b r i c a n t into a container. Remove t h e
bolts and t h e differential housing cover.
A close e x a m i n a t i o n o f t h e d i f f e r e n t i a l p r i o r t o
disassembly c a n often reveal valuable informa-
t i o n c o n c e r n i n g the extent a n d type o f repairs o r
adjustments t h a t w i l l be necessary. Because t h e
m o s t f r e q u e n t causes o f a x l e n o i s e a r e i m p r o p e r
" b a c k l a s h " o r differential bearing "preload", o r
both, a f e w m i n o r adjustments could be a l l that
is necessary t o correct the defect.
Therefore, before disassembly, t h e f o l l o w i n g infor-
m a t i o n should be available:
• r i n g gear " b a c k l a s h " measurement,
• d r i v e p i n i o n gear shaft bearing "preload" torque
measurement, and
• r i n g gear/drive p i n i o n gear teeth contact patterns.
T h e results (above) s h o u l d b e r e c o r d e d a n d an-
alyzed. I t i s expected t h a t these measurements
w i l l be h e l p f u l w h e n m a k i n g necessary r e p a i r s
to the differential. Refer t o the applicable proce-
dures w i t h i n t h i s section f o r instructions.
If, after t h e measurements a n d adjustments, t h e
defect s t i l l exists, proceed w i t h t h e following disas-
sembly, inspection and assembly procedures.
(7) T h o r o u g h l y flush a n d clean t h e d i f f e r e n t i a l
gears, bearings and the other differential components
w i t h a n appropriate solvent.
(8) I n s t a l l a p i l o t stud i n t h e differential housing
and a t t a c h D i a l Indicator Tool C-3339 to t h e housing
(Fig. 31) w i t h the indicator plunger s l i g h t l y "loaded"
 • FRONT SUSPENSION 2 - 33

DIAL INDICATOR

39
Fig. 31 Ring Gear "Runout Measurement
and a t a r i g h t angle (i.e., perpendicular) to the back
side of t h e r i n g gear. "Zero" t h e d i a l indicator
pointer.
(9) Measure the r i n g gear " r u n o u t " b y r o t a t i n g the
r i n g gear several complete revolutions and observing
the d i a l indicator pointer. M a r k both t h e r i n g gear
and t h e differential case flange at t h e location o f
maximum "runout".
T h e m a r k o n t h e d i f f e r e n t i a l case f l a n g e w i l l
be very useful w h e n m e a s u r i n g the differential
case " r u n o u t " . T h e d i f f e r e n t i a l case f l a n g e
" r u n o u t " measurement procedure is described
below.
I f t h e c o m b i n e d r i n g g e a r " r u n o u t " (i.e., p e a k -
t o - p e a k ) e x c e e d s o f 0.006 i n c h (0.150 m m ) , p o s s i -
b l e causes c o u l d b e t h a t t h e r i n g g e a r i s n o t
t i g h t l y a t t a c h e d t o t h e d i f f e r e n t i a l case flange o r
t h e d i f f e r e n t i a l case i s d a m a g e d .
(10) Determine i f the clearance between the differ- Fig. 33 Differential Housing Separation
e n t i a l bearing caps and bearing cups is excessive b y the l o c a t i n g holes ( F i g . 33). I n s t a l l t h e holddown
a t t e m p t i n g t o insert a 0.003- inch (0.076-mm) t h i c k clamps a n d t i g h t e n t h e tool turnbuckle "finger-
feeler gauge blade between t h e m . N o r m a l l y , a 0.003-
tight".
i n c h (0.076-mm) t h i c k feeler gauge blade should be
(14) I n s t a l l a p i l o t stud a t the left side of the dif-
too t h i c k t o be inserted between a bearing cap and
f e r e n t i a l housing. A t t a c h D i a l Indicator Tool C-3339
cup.
to the differential housing (via the pilot stud) w i t h
I f t h e c l e a r a n c e i s m o r e t h a n 0.003 i n c h (0.076
the i n d i c a t o r plunger s l i g h t l y "loaded" against t h e
m m ) , t h e cause c o u l d b e t h a t t h e applicable
opposite side of the differential housing (Fig. 33).
bearing cup rotated i n t h e differential housing
"Zero" t h e d i a l indicator pointer.
" s e a t " a n d caused excessive wear.
(11) Note the i n s t a l l a t i o n reference letters stamped CAUTION: Do not exceed the specified separation
into the differential bearing caps and i n t o the differ-
distance when separating the differential housing. If
e n t i a l housing machined sealing surface (Fig. 32).
the housing is over-separated, it could be distorted
The letters are stamped horizontally on the left side
or damaged, which would necessitate replacement.
and are stamped v e r t i c a l l y on the r i g h t side of the
differential housing. A l w a y s match the reference let- (15) T i g h t e n the spreader tool t u r n b u c k l e (Fig. 33)
ters when i n s t a l l i n g the differential bearing caps. and separate the differential housing only enough to
(12) Remove the differential bearing caps. remove the differential case from the housing. Sepa-
(13) Position Spreader Tool W-291-A on the differ- rate t h e differential housing a maximum dis-
e n t i a l housing w i t h the tool dowel pins "seated" i n
 2 - 34 FRONT SUSPENSION •
t a n c e o f 0.38 m m (0.015 i n ) w i t h t h e s p r e a d e r FLANGE FACE DIAL INDICATOR
t o o l . Measure t h e separation distance w i t h t h e d i a l
indicator (Fig. 33) as t h e housing is being separated.
(16) Remove t h e d i a l indicator (Fig. 33) w h e n t h e
differential h o u s i n g has been separated sufficiently
to remove t h e differential case f r o m t h e housing.
(17) P r y t h e differential case loose from t h e hous-
ing. A l i g h t p r y i n g action w i t h a small p r y b a r or
pinch bar w i l l loosen the case sufficiently for easy re-
moval. To prevent damage, p r y t h e differential case
outward t o w a r d t h e opening w i t h t h e p r y b a r pivot-
i n g on t h e differential h o u s i n g a n d w i t h t h e end o f
the p r y b a r against t h e differential case.
(18) Remove t h e differential case from t h e differen-
t i a l housing. I f they are reusable, r e t a i n t h e differen-
t i a l bearing cups and bearings together as "matched
sets".
(19) Remove t h e inner seal f r o m the right-side axle
shaft tube w i t h a long r o d o r a non-reusable axle
shaft.
(20) Clamp t h e differential case i n a vise equipped
w i t h soft j a w s a n d remove ( a n d d i s c a r d ) t h e r i n g
gear bolts. " T a p " the r i n g gear w i t h a rawhide m a l l e t
to loosen i t f r o m t h e d i f f e r e n t i a l case flange. Remove
the r i n g gear.
(21) I f the r i n g gear " r u n o u t " exceeded 0.006 inch
(0.15 m m ) w h e n measured (above), t h e differential
case flange " r u n o u t " should be measured a t t h i s
time.
(22) I n s t a l l t h e differential case ( w i t h t h e o r i g i n a l
bearing cups) i n t h e differential housing.
(23) Remove t h e holddown clamps and t h e spreader
tool from t h e differential housing (Fig. 33).
(24) I n s t a l l t h e differential bearing caps a n d
t i g h t e n t h e bolts " f i n g e r - t i g h t " u n t i l each bolt head
is l i g h t l y "seated" on t h e b e a r i n g cap.
(25) I n s t a l l a p i l o t stud a t t h e r i g h t side o f the dif-
ferential housing. A t t a c h D i a l Indicator Tool C-3339
to t h e differential housing ( v i a t h e pilot stud) w i t h
the indicator plunger s l i g h t l y "loaded" against t h e
inner face o f t h e flange (Fig. 34). "Zero" t h e d i a l i n -
dicator pointer.
(26) Measure t h e differential case flange " r u n o u t "
by r o t a t i n g t h e flange several complete revolutions
and observing t h e d i a l indicator pointer. M a r k t h e Fig. 36 Drive Pinion Gear Shaft Yoke Removal
flange a t t h e location of m a x i m u m " r u n o u t " . T h e
and H o l d i n g Tool C-3281 to remove t h e drive p i n i o n
flange m a x i m u m " r u n o u t " should not exceed 0.003
gear shaft (axle) yoke (Fig. 36).
inch (0.076 m m ) .
(28) Use Removal Tool C-748 to remove the drive
When installing t h e r i n g gear o n the differen-
p i n i o n gear shaft seal (Fig. 37).
t i a l case, i t i s o f t e n p o s s i b l e t o r e d u c e excessive
(29) Remove the o i l slinger, t h e shaft front bearing
r i n g gear " 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 gear
a n d t h e " p r e l o a d " torque shims (Fig. 37). Record t h e
w i t h i t s m a x i m u m " r u n o u t " m a r k l o c a t e d 180 de-
thickness o f the shims. T h i s w i l l save t i m e i f t h e y
grees o p p o s i t e t h e flange m a x i m u m " r u n o u t "
should become misplaced.
mark.
(30) Use a n appropriate tool to force t h e drive p i n -
(27) Remove t h e drive p i n i o n gear shaft (axle) yoke
i o n gear shaft ( w i t h t h e rear bearing) from t h e dif-
n u t a n d washer (Fig. 35). Use Removal Tool C-452
 4 FRONT SUSPENSION 2 - 35

1. DIFFERENTIAL CASE 10. SEAL 19. THRUST WASHERS

2. DIFFERENTIAL BEARING SHIMS 11. YOKE 20. RING GEAR
3. DIFFERENTIAL BEARING 12. DUST CAP 21. COVER
4. BEARING CUP 13. DRIVE PINION GEAR SHAFT FRONT BEARING 22. PLUG
5. DRIVE PINION GEAR SHAFT 14. DRIVE PINION GEAR BEARING PRELOAD SHIMS 23. LOCKPIN
6. DRIVE PINION GEAR DEPTH SHIMS 15. DRIVE PINION GEAR SHAFT REAR BEARING 24. PINION MATE SHAFT
7. DIFFERENTIAL HOUSING 16. THRUST WASHERS 25. SLINGER
8. DRIVE PINION GEAR SHAFT FRONT BEARING CUP 17. DIFFERENTIAL SIDE GEAR 26. REAR BEARING CUP
9. SLINGER 18. DIFFERENTIAL PINION GEAR J90Q2-33

Fig. 37 Model 44 Axle L ial—Exploded View

ferential housing bore (Fig. 37).
(31) Use Removal Tool D-158 and Handle Tool C-
4171 to remove t h e drive p i n i o n gear shaft front
bearing cup f r o m t h e differential housing bore ( F i g .
37).
(32) Use Removal Tool D-162 and Handle Tool C-
4171 to remove t h e drive p i n i o n gear shaft rear bear-
i n g cup from t h e differential housing bore (Fig. 37).
(33) Remove t h e drive p i n i o n gear depth shims
f r o m t h e differential housing bore (Fig. 37). Record
t h e thickness o f t h e depth shims.
(34) Remove t h e i n n e r b e a r i n g from the drive p i n -
i o n gear shaft w i t h Removal Tool C-293-PA a n d
Plate Tools C-293-39 (Fig. 38).
(35) Clamp t h e differential case i n a vise equipped
w i t h soft jaws. Use a p i n p u n c h to force t h e p i n i o n
gear mate shaft lock p i n f r o m t h e differential case
bore (Fig. 39).
(36) Remove t h e differential p i n i o n gear mate shaft Fig. 38 Inner Bearing Removal
f r o m the d i f f e r e n t i a l case bores, remove the differen-
(39) Remove the bearings f r o m the differential case
t i a l pinion gears a n d remove the t h r u s t washers (lo-
w i t h Press Tool C-293-PA, P l u g Tool C-293-3, Plate
cated adjacent t o t h e differential case i n t e r n a l
Tools C-293-18 and a vise (Fig. 40).
surface) from t h e differential case.
Use c a r e a n d e n s u r e t h a t t h e a d a p t e r r i n g s a r e
(37) Remove t h e differential side gears a n d t h e s i t u a t e d so t h a t t h e y d o n o t cause f o r c e t o b e ex-
t h r u s t washers (located adjacent t o t h e differential erted o n the b e a r i n g race.
case i n t e r n a l surface) f r o m t h e differential case.
(40) Remove t h e differential bearing shims from
(38) Remove t h e differential case f r o m the vise. each of t h e differential case hubs a n d m a r k t h e m
2 - 36 FRONT SUSPENSION
DIFFERENTIAL
( w i t h hub i d e n t i t y ) for assembly reference. Record
the thickness o f the shims.
CLEANING/INSPECTION
(1) Wash and clean a l l the differential components
(Fig. 37) w i t h a n appropriate cleaning solvent and,
w i t h t h e exception o f t h e bearings, d r y w i t h com-
pressed air.
Do n o t steam clean the differential compo-
nents.
(2) To clean t h e axle shaft tubes, insert a stiff w i r e
into each tube, attach a clean cloth t o t h e w i r e a t the
differential housing opening and w i t h d r a w t h e w i r e
•
(and cloth) f r o m t h e housing o u t w a r d t h r o u g h t h e
tube.
(3) Inspect t h e differential bearings and t h e drive
p i n i o n gear shaft bearings, and the differential case
and housing (Fig. 37):
• the d i f f e r e n t i a l bearings a n d the drive p i n i o n gear
shaft f r o n t and rear bearings and cups should have a
smooth appearance w i t h no broken/dented surfaces
on the b e a r i n g rollers or t h e roller contact surfaces;
• the b e a r i n g races m u s t n o t be distorted or cracked;
I f a differential bearing must be replaced, t h e
c u p a n d t h e b e a r i n g m u s t b e r e p l a c e d as a
"matched set" only.
• a l l t h e machined contact surfaces i n t h e differen-
t i a l housing a n d on t h e differential bearing caps
should be smooth and w i t h o u t any raised edges;
• the drive p i n i o n gear shaft front and rear bearing
cup bores i n t h e differential housing should be
smooth; and
• i f i t exists, raised m e t a l on t h e shoulders o f the
bearing cup bores i n c u r r e d d u r i n g removal o f t h e
cups should be removed w i t h a h a n d stone.
(4) E x a m i n e t h e differential p i n i o n gear mate
shaft, p i n i o n gears, side gears a n d t h r u s t washers
(Fig. 37) for wear and damage. Replace a l l defective
components.
I f either o f the d i f f e r e n t i a l p i n i o n gears is n o t
r e u s a b l e , b o t h g e a r s m u s t b e r e p l a c e d as a
"matched s e t " only. D o n o t replace only one
gear.
(5) E x a m i n e t h e r i n g gear a n d t h e drive p i n i o n
gear shaft (Fig. 37) for excessively w o r n and chipped
teeth. E x a m i n e t h e r i n g gear for damaged bolt
threads.
I f r e p l a c e m e n t o f either gear is necessary, b o t h
the r i n g gear a n d t h e d r i v e p i n i o n gear shaft
m u s t b e r e p l a c e d b e c a u s e t h e y a r e a v a i l a b l e as
a "matched set" only.
(6) Inspect t h e drive p i n i o n gear shaft (axle) yoke
(Fig. 37) for cracks, excessively w o r n splines, " p i t t e d "
areas, and a rough/corroded seal contact surface. Re-
p a i r or replace the yoke as necessary.
(7) Inspect t h e drive p i n i o n gear shaft bearing "pre-
load" torque shims (Fig. 37) for cracks, damage and
distortion. I n s t a l l replacement shims ( i f necessary)
for the " p r e l o a d " torque adjustment.
ASSEMBLY
(1) L u b r i c a t e a l l t h e differential components w i t h
hypoid gear l u b r i c a n t .
(2) I n s t a l l t h e differential side gears and t h r u s t
washers, p i n i o n gears and t h r u s t washers and p i n i o n
gear mate shaft i n the differential case (Fig. 37).
(3) A l i g n t h e lock p i n hole i n the p i n i o n gear mate
shaft w i t h the hole i n the differential case (Fig. 37).
Insert a n d "seat" t h e lock p i n i n t h e case a n d t h e
shaft.
 • FRONT SUSPENSION
I f replacement gears a n d t h r u s t w a s h e r s w e r e
installed, i t is n o t necessary t o measure t h e gear
" b a c k l a s h " . T h e g e a r m e s h i n g w i l l b e c o r r e c t be-
cause " c l o s e " m a c h i n i n g tolerances a r e used
d u r i n g manufacture o f the gears.
(4) Position t h e r i n g gear o n t h e differential case
flange a n d a l i g n t h e r i n g gear threaded holes w i t h
those i n the differential case flange (Fig. 37).
(5) Insert r e p l a c e m e n t r i n g gear bolts ( F i g . 37)
t h r o u g h the differential case flange a n d t h r e a d t h e m
i n t o the r i n g gear.
After a l l t h e bolts a r e initially correctly
t h r e a d e d i n t o the r i n g gear b o l t holes, " t a p " the
r i n g gear w i t h a non-metallic mallet a n d ensure
t h a t i t is flush against the flange.
(6) Clamp t h e differential case i n a vise equipped
w i t h soft jaws and alternately t i g h t e n each r i n g gear
bolt w i t h 61-81 N*m (45-60 ft-lbs) torque.
(7) Place Master D i f f e r e n t i a l B e a r i n g Tools D-135
on the differential case hubs (Fig. 41).
MASTER BEARING
MASTER BEARING
RY652
Fig. 41 Master Bearing Tools On Hubs
(8) Position Spreader Tool W-129-A on the differen-
t i a l housing w i t h the tool dowel pins "seated" i n the
locating holes (Fig. 42). I n s t a l l the holddown clamps
and t i g h t e n the tool t u r n b u c k l e " f i n g e r - t i g h t " .
(9) I n s t a l l a p i l o t stud a t t h e left side o f t h e differ-
e n t i a l housing. A t t a c h D i a l Indicator Tool C-3339 t o
the differential housing ( v i a the p i l o t stud) w i t h the
indicator plunger s l i g h t l y "loaded" against the oppo-
site side of the differential housing (Fig. 42). "Zero"
the d i a l indicator pointer.
CAUTION: Do not exceed the specified separation
distance when separating the differential housing. If
2 - 37
TOOL
C-3339
RH411A
Fig. 42 Differential Housing Separation
the housing is over-separated, it could be distorted
or damaged, which would necessitate replacement.
(10) Tighten the spreader tool t u r n b u c k l e (Fig. 42)
and separate the differential housing only enough t o
i n s t a l l the differential case i n the housing. S e p a r a t e
the differential housing a m a x i m u m distance o f
0.38 m m (0.015 i n ) w i t h t h e s p r e a d e r t o o l . Mea-
sure t h e separation distance w i t h the d i a l indicator
(Fig. 42) as the housing is being separated.
(11) Remove t h e d i a l indicator tool and t h e pilot
stud (Fig. 42) when the differential housing has been
separated sufficiently to i n s t a l l t h e differential case
i n the housing.
(12) I n s t a l l the differential case i n the differential
housing.
(13) Remove the holddown clamps and the spreader
tool from the differential housing (Fig. 42).
(14) Observe the assembly reference marks and po-
sition t h e bearing caps a t t h e i r o r i g i n a l locations.
T i g h t e n the bearing cap bolts " f i n g e r - t i g h t " .
(15) I n s t a l l a p i l o t stud a t the r i g h t side o f the dif-
ferential housing. A t t a c h D i a l Indicator Tool C-3339
to t h e differential housing ( v i a t h e pilot stud) w i t h
the indicator plunger s l i g h t l y "loaded" against t h e
back of the r i n g gear (Fig. 43), —
(16) Insert a small p r y bar between the bearing cap
and the left side o f t h e differential case. P r y the dif-
ferential case as far as possible toward the r i g h t side
of the differential housing (Fig. 43). "Zero" t h e d i a l
indicator pointer.
(17) Pry the differential case t o w a r d the left side of
the housing w i t h t h e pry bar and r e c o r d the t r a v e l
distance indicated b y the d i a l indicator pointer.
The measurement above indicates t h e shim
t h i c k n e s s n e c e s s a r y f o r d i f f e r e n t i a l case " z e r o "
" e n d - p l a y " (i.e., t o e l i m i n a t e t h e space/gap t h a t
2 - 38 FRONT SUSPENSION
Fig. 43 Differential Case "End Play" Measurement
exists b e t w e e n the d i f f e r e n t i a l b e a r i n g s a n d t h e
d i f f e r e n t i a l case). T h e a c t u a l t o t a l s h i m t h i c k -
ness w i l l b e d e t e r m i n e d d u r i n g t h e r i n g g e a r
" b a c k l a s h " adjustment (after i n s t a l l a t i o n o f the
d r i v e p i n i o n gear shaft).
(18) Remove the d i a l indicator tool and the p i l o t
stud f r o m the differential housing.
(19) Remove the differential bearing caps.
(20) Position Spreader Tool W-129-A on the differ-
e n t i a l housing w i t h the tool dowel pins "seated" i n
the locating holes ( F i g . 42). I n s t a l l t h e holddown
clamps a n d t i g h t e n t h e tool t u r n b u c k l e "finger-
tight".
(21) I n s t a l l a pilot stud a t the left side of the dif-
ferential housing. A t t a c h D i a l Indicator Tool C-3339
to the differential housing (via the p i l o t stud) w i t h
the indicator plunger s l i g h t l y "loaded" against t h e
opposite side of the differential housing (Fig. 42).
"Zero" the d i a l indicator pointer.
CAUTION: Do not exceed the specified separation
distance when separating the differential housing. If
the housing is over-separated, it could be distorted
or damaged, which would necessitate replacement.
(22) T i g h t e n the spreader tool t u r n b u c k l e (Fig. 42)
and separate the differential housing only enough t o
remove t h e differential case from the housing. Sepa-
rate t h e differential h o u s i n g a m a x i m u m dis-
t a n c e o f 0.38 m m (0.015 i n ) w i t h t h e s p r e a d e r
t o o l . Measure the separation distance w i t h the d i a l
indicator (Fig. 42) as the housing is being separated.
•
(23) Remove t h e d i a l indicator tool a n d the p i l o t
stud (Fig. 42) w h e n t h e differential h o u s i n g has been
separated sufficiently t o remove the differential case
from the housing.
(24) Remove t h e differential case f r o m the differen-
t i a l housing.
(25) Remove t h e holddown clamps a n d the spreader
tool from the differential housing (Fig. 42).
(26) I n s t a l l a replacement seal i n t h e right-side
axle shaft tube w i t h Tool DD-1243-B.
DRIVE PINION GEAR DEPTH INFORMATION
D r i v e p i n i o n gear shafts and r i n g gears are sup-
plied as "matched sets" only. T h e i d e n t i f y i n g n u m -
bers for both the drive p i n i o n gear a n d t h e r i n g gear
are etched i n t o t h e face o f each gear (Fig. 44). I n ad-
dition, either a plus (" + ") number, a m i n u s ("-")
number or a zero ("0") is also etched i n t o the face o f
the drive p i n i o n gear. T h i s n u m b e r indicates t h e
amount ( i n thousandths o f a n inch) t h a t t h e drive
pinion gear depth o f mesh varies f r o m t h e standard
depth " s e t t i n g " o f 2.625 inches (66.68 m m ) for Model
44 axles. The standard depth of mesh provides t h e
best teeth contact between t h e d r i v e p i n i o n gear
teeth and the r i n g gear teeth. The d e p t h variance of
a drive p i n i o n gear can be either greater ( + ), zero (0)
or less t h a n (-) the standard depth.
DRIVE PINION
Fig. 44 Drive Pinion Gear ID Numbers
The standard depth is the distance (Fig. 45) f r o m
the centerline o f t h e axle shaft/ring gear to the face
of the drive p i n i o n gear. F o r a Model 4 4 axle, t h e
standard depth/distance is 2.625 inches (66.68 m m ) .
Compensation for the depth variance i s achieved by
shims placed adjacent t o the drive p i n i o n gear shaft
rear bearing cup (Fig. 46).
For Example:
• one complete " p a c k " o f d e p t h shims is re-
q u i r e d i f the d e p t h variance is " 0 " ;
• i f t h e d e p t h v a r i a n c e i s " + 3 " ( m + 8), t h e d r i v e
 • FRONT SUSPENSION 2 - 39

AXLE PINION • b y r e d u c i n g t h e t h i c k n e s s o f t h e s h i m s 0.003

MODEL
Fig. 46 Shim Locations
p i n i o n g e a r w o u l d r e q u i r e 0.003 i n c h (0.08 m m )
less i n s h i m t h i c k n e s s t h a n a d e p t h v a r i a n c e o f
" 0 " (i.e., o n e c o m p l e t e s h i m " p a c k " m i n u s 0.003
i n c h o r 0.08 m m ) ;
SETTING i n c h (0.08 m m ) , t h e d e p t h p o s i t i o n o f t h e d r i v e
p i n i o n g e a r w i l l b e d e c r e a s e d f r o m 2.628 i n c h e s
(66.76 m m ) t o t h e s t a n d a r d d e p t h o f 2.625 i n c h e s
(66.68 m m ) ; o r
• i f t h e d e p t h v a r i a n c e i s " - 3 " (m-8), t h e d r i v e
p i n i o n g e a r w o u l d r e q u i r e 0.003 i n c h (0.08 m m )
more i n shim thickness t h a n a depth variance o f
" 0 " (i.e., o n e c o m p l e t e s h i m " p a c k " p l u s 0.003
i n c h o r 0.08 m m ) ;
• b y i n c r e a s i n g t h e t h i c k n e s s o f t h e s h i m s 0.003
i n c h (0.08 m m ) , t h e d e p t h p o s i t i o n o f t h e d r i v e
p i n i o n g e a r w i l l b e i n c r e a s e d f r o m 2.622 i n c h e s
(66.60 m m ) t o t h e s t a n d a r d d e p t h o f 2.625 i n c h e s
(66.68 m m ) .
I f t h e o r i g i n a l drive p i n i o n gear shaft a n d r i n g
gear set w i l l be installed b u t t h e depth shims must
be replaced, measure t h e thickness of the o r i g i n a l
depth shims a n d " b u i l d " a replacement " p a c k " of
depth shims w i t h the same thickness.
I f equipped, the oil slinger located between the
r e a r b e a r i n g a n d the t h r u s t face o f d r i v e p i n i o n
gear must be measured a n d t h e thickness i n -
cluded w i t h the t o t a l s h i m " p a c k " thickness.
I f the o r i g i n a l drive pinion/ring gear set is n o t re-
usable, the depth s h i m thickness for the replacement
drive p i n i o n gear m u s t be determined before i n s t a l l -
i n g the differential case i n t h e housing.
I f a replacement gear set i s being installed, note
t h e depth variance etched i n t o b o t h the o r i g i n a l and
the replacement drive p i n i o n gear, a n d a l t e r t h e
thickness o f the o r i g i n a l depth shims to compensate
for the difference i n the depth variances. Refer t o the
D r i v e P i n i o n Gear D e p t h Variance chart.
For Example:
• i f the o r i g i n a l drive p i n i o n gear has a d e p t h
v a r i a n c e o f " 4 - 2 " ( m + 5) a n d t h e r e p l a c e m e n t
d r i v e p i n i o n gear h a s a d e p t h variance o f " - 2 "
(m-5), a d d 0.004-inch (0.10-mm) t h i c k n e s s t o t h e
o r i g i n a l depth shims.
I n d i v i d u a l depth shims are available i n 0.003-inch,
0.005-inch, 0.010-inch, a n d 0.030-inch (0.08-mm,
0.13-mm, 0.25-mm, and 0.76-mm) thicknesses.
2 - 40 FRONT SUSPENSION •
DRIVE PINION GEAR DEPTH VARIANCE

Original Pinion leplacement Pinion Gear Depth Variance

Sear Depth
Variance -4 -3 -2 -1 0 +1 +2 +3 4-4

+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. 0 0 4

-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 -0.0O6

-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

DRIVE PINION GEAR DEPTH MEASUREMENT (1) Insert Master P i n i o n Block Tool D-139 i n t o t h e
AND ADJUSTMENT WITH TOOL SET D-271 drive p i n i o n gear shaft bore i n t h e differential hous-
The f o l l o w i n g drive p i n i o n gear depth (i.e., t h e i n g (Fig. 48).
depth o f t h e gear teeth mesh between t h e drive p i n -
ion gear and t h e r i n g gear) measurement a n d adjust-
ment procedure involves u s i n g Tool Set D-271 ( F i g .
47).

D-139 D-115-1 D-115-2

Fig. 48 Pinion Block Tool Inserted In Shaft Bore

(2) Place A r b o r Disc Tools D-115-4 on A r b o r Tool
D-115-3 a n d position t h e tool set i n t h e d i f f e r e n t i a l
housing w i t h t h e disc tools located i n t h e d i f f e r e n t i a l
bearing cradles (Fig. 49). T h i s is t h e centerline o f t h e
r i n g gear/axle shaft.
(3) Place P i n i o n H e i g h t Block Tool D-115-1 o n top
of the master p i n i o n block tool and against t h e arbor
D-115-3
tool (Fig. 50).
(4) Place Gauge Block Tool D-115-2 a n d D i a l I n d i -
RK 784
cator Tool D-106-5 on t h e l o w e s t step o f t h e p i n i o n
Fig. 47 Pinion Gear Depth Gauge Tool Set D-271 h e i g h t block tool (Fig. 51). Ensure t h a t t h e gauge
 • FRONT SUSPENSION
Fig. 50 Pinion Height Block Tool Against Arbor Tool
Fig. 51 Drive Pinion Gear Depth Measurement
block tool is r e s t i n g f i r m l y on t h e lowest step o f p i n -
ion height block tool a n d "zero" t h e d i a l indicator
pointer.
2 - 41
(5) W i t h t h e d i a l indicator pointer "zeroed", move
t h e gauge block tool toward the arbor tool u n t i l t h e
t i p o f t h e d i a l indicator plunger contacts t h e arbor
tool ( F i g . 51). Slide t h e gauge block tool ( w i t h t h e
d i a l indicator) across and back and f o r t h along t h e
arbor tool w h i l e observing the d i a l indicator pointer.
Record t h e longest plunger t r a v e l distance, whether
i n w a r d (oq-") or o u t w a r d (" + "), indicated b y t h e
pointer.
The longest plunger t r a v e l distance indicated,
plus o r m i n u s the depth variance etched i n t o the
face o f t h e d r i v e p i n i o n gear, is t h e r e q u i r e d
thickness f o r the drive p i n i o n gear d e p t h shims.
(6) Measure the thickness o f each depth s h i m sep-
arately w i t h a micrometer a n d combine t h e shims
necessary t o obtain t h e t o t a l required depth s h i m
" p a c k " thickness. I f e q u i p p e d , t h e o i l s l i n g e r l o -
cated between t h e rear bearing a n dt h e thrust
face o f d r i v e p i n i o n gear m u s t b e m e a s u r e d a n d
the thickness included w i t h the total shim
" p a c k " thickness.
(7) Remove the measurement tools from the differ-
e n t i a l housing.
(8) Place the depth shims into the drive p i n i o n gear
shaft rear bearing bore i n t h e differential housing
and t h e n force t h e rear bearing cup i n t o t h e bore
w i t h B e a r i n g Cup I n s t a l l a t i o n Tool D - l l l and D r i v e r
H a n d l e Tool C-4171. Ensure t h a t t h e cup is correctly
"seated".
(9) Use Bearing Cup I n s t a l l a t i o n Tool C-4203 and
D r i v e r Handle Tool C-4171 to force the drive p i n i o n
gear shaft front bearing cup i n t o t h e differential
housing bore (Fig. 52).
BEARING CUP DRIVER
INSTALLATION TOOL C-4203 HANDLE
Fig. 52 Shaft Front Bearing Cup Installation
(10) Force t h e rear bearing onto t h e drive p i n i o n
gear shaft u n t i l i t is completely "seated" w i t h Bear-
i n g I n s t a l l a t i o n Tool C-3095-A (Fig. 53).
(11) I n s t a l l t h e drive p i n i o n gear shaft i n t h e dif-
f e r e n t i a l housing.
2 - 42 FRONT SUSPENSION
Fig. 53 Shaft Rear Bearing Installation
(12) I n s t a l l t h e drive p i n i o n gear shaft front bear-
i n g , o i l slinger, (axle) yoke, washer and n u t . Use I n -
s t a l l a t i o n Tool C-3718 and H o l d i n g Tool 3281 t o
i n s t a l l t h e yoke (Fig. 54).
Fig. 54 Drive Pinion Gear Shaft (Axle) Yoke
Installation
D o n o t install t h e " p r e l o a d " torque shims o r
t h e d r i v e p i n i o n g e a r s h a f t seal a t t h i s t i m e .
(13) "Seat" t h e shaft bearings by t i g h t e n i n g t h e
(axle) yoke n u t u n t i l i t requires 1 N«m (10 in-lbs)
torque t o rotate the drive p i n i o n gear shaft (Fig. 55).
Use a Newton-meter or an inch-pound torque wrench
to measure the torque.
(14) Measure t h e drive p i n i o n gear depth of mesh
•
Fig. 55 Rotating Drive Pinion Gear Shaft
( w i t h t h e r i n g gear). Place t h e p i n i o n h e i g h t block
tool o n t h e face o f the drive p i n i o n gear ( F i g . 49).
Place t h e arbor and disc tools i n t o t h e d i f f e r e n t i a l
b e a r i n g cradles i n the differential housing (Fig. 50).
Place t h e gauge block tool w i t h t h e d i a l i n d i c a t o r
tool on the lowest step of the p i n i o n h e i g h t block tool
(Fig. 51). Ensure t h a t the gauge block tool is r e s t i n g
f i r m l y o n the lowest step of the p i n i o n h e i g h t block
tool and "zero" the d i a l indicator pointer.
(15) W i t h the d i a l indicator pointer "zeroed", move
the gauge block tool toward the arbor tool u n t i l t h e
t i p o f t h e d i a l indicator plunger contacts t h e arbor
tool ( F i g . 51). Slide t h e gauge block tool ( w i t h t h e
d i a l indicator) across and back and f o r t h along t h e
arbor tool w h i l e observing the d i a l indicator pointer.
Record t h e longest plunger t r a v e l distance (whether
i n w a r d or outward) indicated b y t h e pointer.
The dial indicator pointer should indicate a n
i n w a r d ("-") o r o u t w a r d (" + ") m a x i m u m t r a v e l
distance t h a t closely a p p r o x i m a t e s t h e d e p t h
v a r i a n c e e t c h e d i n t o t h e face o f t h e d r i v e p i n i o n
gear.
(16) I f the measurement indicates t h a t t h e actual
depth variance is w i t h i n 0.002 i n c h (0.05 m m ) o f the
depth variance etched into the d r i v e p i n i o n gear face,
i t is acceptable.
(17) I f the drive p i n i o n gear actual depth variance
is w i t h i n t h e specified tolerance, continue w i t h t h e
differential assembly. I f the actual depth variance is
not w i t h i n t h e specified tolerance, correct t h e s h i m
thickness accordingly and then re-measure t h e depth
variance.
F i g u r e 56 d e p i c t s a n a r r o w p o i n t i n g o u t w a r d
a n d i n w a r d w i t h i n t h e drive p i n i o n gear shaft.
The o u t w a r d direction (pointing t o w a r d t h e
yoke) indicates t h a t i f the drive p i n i o n gear
shaft d e p t h shim thickness is decreased, the dis-
tance/depth f r o m t h e centerline o f the axle/ring
gear t o t h e drive p i n i o n gear face w o u l d b e i n -
 • FRONT SUSPENSION 2 - 43

c r e a s e d (i.e., i t w o u l d i n c r e a s e the d i a l i n d i c a t o r
C-4171 HANDLE
p l u n g e r o u t w a r d (" + ") t r a v e l d i s t a n c e ) . T h e
shaft b e a r i n g " p r e l o a d " torque s h i m t h i c k n e s s
does n o t affect t h e depth o f m e s h adjustment.
T h e a r r o w o n the r i n g gear i n d i c a t e s t h e m e t h o d
of increasing o r decreasing shim thickness a t
t h e a p p l i c a b l e s i d e o f the differential c a s e to i n -
c r e a s e o r d e c r e a s e the r i n g g e a r " b a c k l a s h " a n d
t h e differential b e a r i n g " p r e l o a d " t o r q u e .

PINION SEAL
BEARING INSTALLER
PRELOAD
SHIM PACK

PINION
LOCATING
SHIM PACK
RY659A

Fig. 57 Drive Pinion Gear Shaft Seal Installation

DIFFERENTIAL BEARING
SHIM PACKS RY660
Fig. 56 Shim Locations
(18) Remove the measurement tools f r o m t h e differ-
e n t i a l housing.
(19) Remove t h e drive p i n i o n gear shaft n u t ,
washer, (axle) yoke, o i l slinger, and f r o n t bearing.
(20) I n s t a l l the bearing "preload" torque shims t h a t
were removed d u r i n g disassembly (Fig. 56), t h e shaft
front b e a r i n g and t h e o i l slinger on t h e d r i v e p i n i o n
gear shaft.
(21) A p p l y a l i g h t coating o f hypoid gear l u b r i c a n t
on the l i p o f drive p i n i o n gear shaft seal, position i t
over the end of the shaft and i n s t a l l i t i n t h e differ-
e n t i a l housing bore w i t h Seal I n s t a l l a t i o n Tool W-
147 and D r i v e r H a n d l e Tool C-4171 (Fig. 57).
(22) I n s t a l l the d r i v e p i n i o n gear shaft (axle) yoke,
washer, and a replacement n u t on t h e shaft. T i g h t e n
the n u t w i t h 271 t o 298 N*m (200 t o 220 ft-lbs)
torque.
(23) Use a Newton-meter or a n i n c h pound torque
wrench (Fig. 55) to rotate the drive p i n i o n gear shaft
and observe the indicated bearing " p r e l o a d " torque.
The torque necessary to rotate the d r i v e p i n i o n gear
shaft should be between 2 to 5 N m (20 t o 40 in-lbs)
#
w i t h replacement bearings. T h e torque necessary t o
rotate t h e drive p i n i o n gear shaft should be between
1 to 3 N»m (10 t o 20 in-lbs) w i t h o r i g i n a l bearings.
I f the d r i v e p i n i o n g e a r shaft b e a r i n g " p r e -
l o a d " torque i s n o t w i t h i n t h e specified toler-
ance, c o r r e c t the s h i m t h i c k n e s s a c c o r d i n g l y . T o
i n c r e a s e the " p r e l o a d " torque, d e c r e a s e the s h i m
t h i c k n e s s ; to decrease the " p r e l o a d " torque, i n -
crease the shim thickness. Shims are available
i n the following t h i c k n e s s e s : 0.003, 0.005, 0.010,
a n d 0.030 i n c h (0.076, 0.127, 0.254, a n d 0.762 mm).
DRIVE PINION GEAR DEPTH MEASUREMENT
AND ADJUSTMENT WITH TOOL SET C-3715-B
The following drive p i n i o n gear depth (i.e., t h e
depth o f t h e gear teeth mesh between the drive p i n -
ion gear and t h e r i n g gear) alternate measurement
and adjustment procedure involves u s i n g A x l e Mea-
surement Gauge Tool Set C-3715-B. Tool Set C-3715-
B is also used t o i n s t a l l t h e drive p i n i o n gear shaft
bearing cups.
(1) Position each drive p i n i o n gear shaft b e a r i n g
cup i n the applicable differential housing bore.
(2) Begin assembling Tool Set C-3715-B b y posi-
t i o n i n g D r i v e P i n i o n Gear Shaft Locating Spacer
Tool SP-5586 over t h e p r i m a r y body o f Screw Tool
5385.
(3) Position the drive p i n i o n gear shaft rear (inner)
bearing on the tool screw a n d i n s e r t t h e tool screw
( w i t h t h e bearing) i n t o and t h r o u g h t h e differential
housing bore.
(4) Position Shaft Locating Sleeve Tool SP-5585
and the drive p i n i o n gear shaft f r o n t (outer) bearing
2 - 44 FRONT SUSPENSION
on the t o o l screw a t the opposite side o f t h e differen-
t i a l housing. Then i n s t a l l Compression Sleeve Tool
SP-3194-B, C e n t r a l i z i n g Washer Tool SP-534 a n d
Compression N u t Tool SP-3193 o n t h e tool screw.
(5) L u b r i c a t e the drive p i n i o n gear shaft outer and
inner bearings w i t h M O P A R H y p o i d Gear L u b r i c a n t
(or a n equivalent product).
(6) T i g h t e n the compression n u t tool, w h i l e r e t a i n -
i n g t h e compression sleeve tool w i t h Tool C-3281,
and force t h e drive p i n i o n gear shaft b e a r i n g cups
into t h e differential housing bearing cup bores. A l -
low the compression tool t o rotate several revo-
l u t i o n s d u r i n g t h e tightening p r o c e s s t o p e r m i t
the b e a r i n g rollers t o properly a l i g n a n d prevent
" b r i n e l l i n g " o f t h e b e a r i n g cups.
Do n o t remove t h e tool after i n s t a l l i n g t h e
drive p i n i o n gear shaft bearing cups. T h e drive
pinion gear depth o f mesh m u s t b e measured
next.
(7) Loosen the n u t tool and t h e n r e - t i g h t e n i t suf-
ficiently to obtain 1 t o 3 N*m (10 t o 30 in-lbs) o f
bearing "preload" torque. W h i l e tightening t h e n u t ,
rotate t h e t o o l t o a l i g n the b e a r i n g rollers.
(8) I n s t a l l Gauge Block Tool SP-3250 on t h e end of
Screw Tool SP-5385 and t i g h t e n the r e t a i n i n g screw
securely w i t h a n A l l e n wrench.
(9) Position Cross Bore A r b o r Tool SP-5183 ( F i g .
58) i n t h e differential bearing cradles ( i n t h e differ-
ential housing). Center the arbor tool i n t h e cradles
so t h a t a n approximately equal space exists a t both
ends.
(10) Observe t h e i n s t a l l a t i o n reference letters and
position t h e differential bearing caps o n t h e arbor
tool (Fig. 58). I n s t a l l the cap bolts and t i g h t e n t h e m
w i t h 14 N»m (10 ft-lbs) torque.
(11) T o measure t h e drive p i n i o n gear depth of
mesh, select and insert a feeler gauge blade t h a t
" s n u g l y " fits between t h e arbor tool and t h e gauge
block tool (Fig. 58). T h e " f i t " m u s t be " s n u g " b u t not
excessively t i g h t . R e c o r d t h e t h i c k n e s s o f t h e
feeler g a u g e b l a d e so t h a t i t c a n b e u s e d w h e n
determining the correct drive p i n i o n gear depth
shim thickness.
(12) Observe t h e depth variance etched i n t o t h e
end o f t h e drive p i n i o n gear (e.g., 0, - 1 , -2, + 1 , + 2 ,
etc.). I f t h e etched depth variance is a "-" (minus)
value, add i t to the thickness measured a n d recorded
i n step (11) above. I f the etched depth variance i s a
" + " (plus) value, subtract i t from the thickness mea-
sured a n d recorded i n step (11) above.
(13) Remove t h e arbor tool from t h e differential
housing c a v i t y a n d t h e other tools ( w i t h t h e outer
and i n n e r bearings) from the housing bore.
(14) Use Removal Tool D-162 and D r i v e r Handle
Tool C-4171 to remove the drive p i n i o n gear shaft i n -
ner (rear) bearing cup from the differential housing
bore.
•
Fig. 58 Drive Pinion Gear Depth Measurement
(15) Position t h e depth shims i n t h e differential
housing I n n e r (rear) b e a r i n g cup bore and i n s t a l l t h e
bearing cup according t o t h e method previously de-
scribed i n steps (1) t h r o u g h (6) above. W h e n t h e
bearing cup is correctly "seated" i n t h e housing bore,
remove t h e tools a n d t h e d r i v e p i n i o n gear shaft
bearings.
(16) I f t h e drive p i n i o n gear d e p t h o f mesh w i t h t h e
r i n g gear has been correctly established according t o
the instructions and i n f o r m a t i o n provided i n the pro-
cedure above, good gear t e e t h contact should exist.
(17) Lubricate t h e d r i v e p i n i o n gear shaft i n n e r
(rear) bearing w i t h M O P A R H y p o i d Gear L u b r i c a n t
(or a n equivalent product) a n d i n s t a l l the bearing o n
the drive p i n i o n gear shaft w i t h Tool W-262. Use a n
arbor press w i t h the i n s t a l l a t i o n tool (Fig. 59).
(18) I n s t a l l t h e d r i v e p i n i o n gear shaft w i t h t h e
bearing i n the differential h o u s i n g bore.
(19) I n s t a l l t h e o r i g i n a l d r i v e p i n i o n gear shaft
bearing "preload" torque shims followed b y the outer
(front) bearing. D o n o t i n s t a l l t h e s h a f t o i l s l i n g e r
o r seal a t t h i s t i m e .
(20) I n s t a l l the drive p i n i o n gear shaft (axle) yoke,
washer a n d n u t . T i g h t e n t h e n u t w i t h 2 7 1 to 298
N-m (200 to 220 ft-lbs) torque. W h i l e t i g h t e n i n g , r o -
tate drive p i n i o n gear shaft several complete revolu-
tions t o "seat" the b e a r i n g rollers.
(21) Use a Newton-meter or a n inch-pound torque
wrench to rotate t h e d r i v e p i n i o n gear shaft a n d
measure t h e bearing " p r e l o a d " torque (Fig. 60). Ro-
tate the shaft several complete revolutions before r e -
cording t h e torque. W i t h o r i g i n a l bearings, t h e
correct bearing "preload" torque is 1 to 3 N«m (10 t o
20 in-lbs) torque. W i t h replacement bearings, t h e
correct bearing "preload" torque i s 2 t o 5 N T H (20 t o
40 in-lbs) torque.
I f the drive p i n i o n gear shaft bearing " p r e -
 • FRONT SUSPENSION
Fig. 59 Shaft Rear Bearing Installation
Fig. 60 Bearing "Preload" Measurement
l o a d " torque i s not w i t h i n t h e specified toler-
ance, c o r r e c t the s h i m t h i c k n e s s a c c o r d i n g l y . T o
i n c r e a s e the " p r e l o a d " torque, d e c r e a s e the s h i m
thickness; to d e c r e a s e t h e " p r e l o a d * • torque, i n -
crease the s h i m t h i c k n e s s . S h i m s a r e a v a i l a b l e
i n the following t h i c k n e s s e s : 0.003, 0.005, 0.010,
a n d 0.030 i n c h (0.076, 0.127, 0.254, a n d 0.762 mm).
(22) After t h e correct d r i v e p i n i o n gear shaft bear-
i n g "preload" torque has been established, remove
the yoke, n u t and washer.
(23) I n s t a l l t h e o i l slinger a n d t h e seal o n the drive
pinion gear shaft. A p p l y a l i g h t coating o f hypoid
gear l u b r i c a n t on t h e l i p o f d r i v e p i n i o n gear shaft
seal, position i t over t h e e n d o f t h e shaft and i n s t a l l
2 - 45
Fig. 61 Drive Pinion Gear Shaft Seal Installation
i t i n t h e differential housing bore w i t h Seal I n s t a l l a -
t i o n Tool W-147 a n d D r i v e r Handle Tool C-4171 (Fig.
61).
(24) I n s t a l l t h e drive p i n i o n gear shaft (axle) yoke,
washer, and a replacement n u t on t h e shaft. T i g h t e n
the n u t w i t h 2 7 1 t o 298 N n n (200 t o 220 ft-lbs)
torque.
RING GEAR "BACKLASH" ADJUSTMENT
(1) Position Spreader Tool W-129-A on the differen-
t i a l housing w i t h t h e tool dowel pins "seated" i n t h e
locating holes ( F i g . 62). I n s t a l l t h e holddown clamps
and t i g h t e n t h e tool t u r n b u c k l e "finger-tight".
(2) I n s t a l l a p i l o t stud a t t h e left side of the differ-
e n t i a l housing. A t t a c h D i a l Indicator Tool C-3339 t o
the differential housing ( v i a t h e pilot stud) w i t h t h e
indicator plunger s l i g h t l y "loaded" against the oppo-
site side of the differential housing (Fig. 62). "Zero"
the d i a l indicator pointer.
CAUTION: Do not exceed the specified separation
distance when separating the differential housing. If
the housing is over-separated, it could be distorted
or damaged, which would necessitate replacement.
(3) T i g h t e n t h e spreader tool turnbuckle (Fig. 62)
and separate t h e differential housing only enough t o
i n s t a l l t h e differential case i n t h e housing. S e p a r a t e
the d i f f e r e n t i a l h o u s i n g a m a x i m u m distance o f
0.38 m m (0.015 i n ) w i t h t h e s p r e a d e r t o o l . Mea-
sure t h e separation distance w i t h the d i a l indicator
(Fig. 62) as t h e housing is being separated.
2 - 46 FRONT SUSPENSION
Fig. 62 Differential Housing, Separation
(4) Remove t h e d i a l indicator tool and t h e pilot
stud (Fig. 62) when the differential housing has been
separated sufficiently t o i n s t a l l the differential case
i n the housing.
(5) I n s t a l l Master B e a r i n g Tools D-135 on the dif-
ferential case hubs and position the case i n the dif-
ferential housing w i t h the r i n g gear teeth "meshed"
w i t h the drive p i n i o n gear teeth. I f necessary, " r o c k "
the r i n g gear t o " m e s h " the gear teeth.
(6) I n s t a l l a pilot stud a t the r i g h t side of the dif-
ferential housing. A t t a c h D i a l Indicator Tool C-3339
to the differential housing ( v i a the p i l o t stud) w i t h
the indicator plunger s l i g h t l y "loaded" against t h e
back o f the r i n g gear (Fig. 63). Ensure t h a t the r i n g
gear teeth and the drive p i n i o n gear t e e t h are t i g h t l y
"meshed" and "zero" the d i a l indicator pointer.
(7) Insert a small p r y bar between the bearing cap
and the left side of the differential case. Pry the dif-
ferential case/ring gear as far as possible toward the
r i g h t side o f the differential housing and away from
the drive p i n i o n gear (Fig. 63). Observe the d i a l i n -
dicator plunger t r a v e l distance indicated by t h e
pointer.
(8) Repeat the measurement several times u n t i l the
indicated plunger t r a v e l distance is consistently the
same for each measurement a n d t h e n record* t h e
t r a v e l distance.
The measurement above indicates t h e shim
thickness necessary t o eliminate t h e r i n g gear
" b a c k l a s h " . S u b t r a c t t h i s t h i c k n e s s f r o m t h e dif-
f e r e n t i a l case " z e r o " " e n d - p l a y " s h i m t h i c k n e s s .
The r i n g gear " b a c k l a s h " shims must be placed
o n the h u b a t the r i n g gear side o f the differen-
t i a l case b e t w e e n t h e d i f f e r e n t i a l case a n d t h e
differential bearing.
(9) Remove t h e d i a l indicator tool and t h e pilot
stud (Fig. 63) from the differential housing.
•
Fig. 63 Ring Gear "Backlash" Measurement
(10) Remove the differential bearing caps.
(11) Position Spreader Tool W-129-A on the differ-
e n t i a l housing w i t h t h e tool dowel pins "seated" i n
the locating holes ( F i g . 62). I n s t a l l t h e holddown
clamps a n d t i g h t e n t h e tool t u r n b u c k l e "finger-
tight".
(12) I n s t a l l a p i l o t stud a t the left side o f the dif-
ferential housing. A t t a c h D i a l Indicator Tool C-3339
to the differential housing (via the p i l o t stud) w i t h
the indicator plunger s l i g h t l y "loaded" against t h e
opposite side of the differential housing ;(Fig. 62).
"Zero" the d i a l indicator pointer.
CAUTION: Do not exceed the specified separation
distance when separating the differential housing. If
the housing is over-separated, it could be distorted
or damaged, which would necessitate replacement.
(13) T i g h t e n the spreader tool t u r n b u c k l e (Fig. 62)
and separate the differential housing only enough t o
remove the differential case from the housing. Sepa-
rate t h e differential housing a m a x i m u m dis-
t a n c e o f 0.38 m m (0.015 i n ) w i t h t h e s p r e a d e r
t o o l . Measure the separation distance w i t h the d i a l
indicator (Fig. 62) as t h e housing is being separated.
(14) Remove t h e d i a l indicator tool and t h e p i l o t
stud (Fig. 62) when the differential housing has been
separated sufficiently t o remove the differential case
from the housing.
(15) Remove the differential case from the differen-
t i a l housing.
(16) Remove the holddown clamps and the spreader
tool from the differential housing (Fig. 62).
 • FRONT SUSPENSION
(17) Remove t h e master bearing tools from the dif-
ferential case hubs.
(18) Position t h e "backlash" shims ( w i t h t h e re-
quired thickness determined above) o n t h e differen-
t i a l case hub ( r i n g gear side). Place the differential
bearing o n the h u b and i n s t a l l i t w i t h B e a r i n g I n -
stallation Tool C-4028-A and D r i v e r H a n d l e Tool C-
4171 (Fig. 64).
BEARING
INSTALLER TOOL
Fig. 64 Differential Bearing Installation
(19) Position the r e m a i n i n g "zero" "end-play" shims
on t h e h u b a t t h e opposite side of the differential
case. Include a n additional 0.015-in (0.38-mm) t h i c k
s h i m on t h i s h u b to provide the required differential
bearing "preload" torque.
(20) I n s t a l l t h e other differential b e a r i n g on t h e
h u b w i t h B e a r i n g I n s t a l l a t i o n Tool C-4028-A a n d
D r i v e r Handle Tool C-4171 (Fig. 64).
(21) M a t c h each bearing cap w i t h i t s differential
bearing (original) counterpart and i n s t a l l t h e caps on
the bearings.
(22) Position Spreader Tool W-129-A o n t h e differ-
e n t i a l housing w i t h the tool dowel pins "seated" i n
t h e locating holes ( F i g . 62). I n s t a l l t h e holddown
clamps a n d t i g h t e n t h e tool t u r n b u c k l e "finger-
tight".
(23) I n s t a l l a p i l o t stud a t the left side o f the dif-
ferential housing. A t t a c h D i a l Indicator Tool C-3339
to the differential housing (via the p i l o t stud) w i t h
the indicator plunger s l i g h t l y "loaded" against t h e
opposite side o f the differential housing (Fig. 62).
"Zero" the d i a l indicator pointer.
CAUTION: Do not exceed the specified separation
distance when separating the differential housing. If
the housing is over-separated, it could be distorted
or damaged, which would necessitate replacement.
2 - 47
(24) T i g h t e n the spreader t o o l t u r n b u c k l e (Fig. 62)
and separate the differential h o u s i n g only enough to
i n s t a l l the differential case i n the housing. S e p a r a t e
the differential housing a m a x i m u m distance o f
0.38 n u n (0.015 i n ) w i t h t h e s p r e a d e r t o o l . Mea-
sure the separation distance w i t h t h e d i a l indicator
(Fig. 62) as the housing is b e i n g separated.
(25) Remove the d i a l i n d i c a t o r tool and t h e p i l o t
stud (Fig. 62) w h e n the d i f f e r e n t i a l housing has been
separated sufficiently to i n s t a l l t h e differential case
i n the housing.
(26) I n s t a l l the differential case i n the differential
housing.
(27) Remove the holddown clamps and the spreader
tool from the differential h o u s i n g (Fig. 62).
(28) I n s t a l l t h e differential b e a r i n g caps. Ensure
t h a t the i n s t a l l a t i o n reference l e t t e r stamped i n each
cap corresponds t o the letter stamped i n the differen-
t i a l housing (Fig. 65). T i g h t e n t h e bearing cap bolts
w i t h 95 t o 122 N*m (70 to 90 ft-lbs) torque.
Fig. 65 Differential Bearing Cap Reference Letters
(29) Measure t h e r i n g gear " b a c k l a s h " a t four
equally spaced locations a r o u n d the perimeter of the
r i n g gear w i t h a d i a l indicator (Fig. 66).
T h e r i n g g e a r " b a c k l a s h " m u s t b e w i t h i n 0.005
- 0.009 i n c h (0.13 - 0.23 m m ) a n d i t c a n n o t v a r y
m o r e t h a n 0.003 i n c h (0.08 m m ) a t a n y o f t h e
measurement locations.
(30) Excessive "backlash" is corrected b y moving
the r i n g gear teeth closer t o t h e drive p i n i o n gear
teeth. Insufficient "backlash" is corrected by moving
the r i n g gear teeth away f r o m the drive p i n i o n gear
teeth. " B a c k l a s h " correction is accomplished by
t r a n s f e r r i n g shims from one side of the differential
case to the other (Fig. 56).
RING GEAR TEETH CONTACT PATTERNS
I f the drive p i n i o n gear depth o f mesh and the r i n g
gear "backlash" have been correctly established ac-
2 - 48 FRONT SUSPENSION •
PATTERNS CLOSE TO CENTER

HEEL END-DRIVE HEEL END-COAST

SIDE (CONVEX) SIDE (CONCAVE)
J9003-74

Fig. 67 Desired Teeth Contact Patterns (With Light

Fig. 66 Ring Gear "Backlash" Measurement Load)
cording t o t h e instructions and i n f o r m a t i o n provided
gear. This condition w i l l cause t h e contact patterns
i n t h e procedures above, good gear teeth contact pat-
to be " h i g h " o n t h e " d r i v e " side a n d near t h e " h e e l "
terns should exist.
of the tooth, and " h i g h " o n t h e "coast" side and near
(1) A p p l y a t h i n coat of H y d r a t e d Ferric Oxide
the " t o e " o f t h e tooth. To correct for t h i s type teeth
(commonly referred to as Yellow Oxide of Iron), or a n
contact patterns, increase t h e thickness of the depth
equivalent product, t o b o t h t h e " d r i v e " side a n d t h e
s h i m (located between t h e drive p i n i o n gear and t h e
"coast" side o f the r i n g gear teeth.
drive p i n i o n gear shaft inner/rear bearing). This w i l l
(2) Rotate t h e r i n g gear one complete revolution i n
cause t h e " h i g h " contact p a t t e r n o n t h e " d r i v e " side
both directions w h i l e a load is b e i n g applied w i t h a
to be lowered a n d t o move t o w a r d t h e "toe" o f t h e
round b a r or screwdriver inserted between t h e differ-
tooth, a n d t h e " h i g h " contact p a t t e r n on t h e "coast"
ential housing and t h e differential case flange. This
side to be lowered and t o move t o w a r d the " h e e l " of
action w i l l produce a d i s t i n c t contact p a t t e r n o n both
the tooth ( F i g . 69).
the " d r i v e " side and t h e "coast" side o f the r i n g gear
teeth.
THICKER SHIM REQUIRED
T h e g e a r teeth c o n t a c t p a t t e r n w i l l disclose
w h e t h e r o r not the d r i v e p i n i o n g e a r shaft r e a r
b e a r i n g depth s h i m h a s t h e c o r r e c t t h i c k n e s s
a n d w h e t h e r o r not the r i n g g e a r " b a c k l a s h " h a s
been adjusted correctly. T h e " b a c k l a s h " be-
tween t h e r i n g g e a r a n d the d r i v e p i n i o n gear
must b e m a i n t a i n e d w i t h i n t h e specified limits
until t h e c o r r e c t teeth c o n t a c t p a t t e r n i s ob-
tained.
(3) E x a m i n e t h e contact patterns on t h e r i n g gear
teeth a n d compare t h e m w i t h those i n Figures 67
t h r o u g h 7 1 to determine i f the patterns are correct. HEEL END-DRIVE HEEL END-COAST
W i t h t h e drive p i n i o n gear depth o f mesh correct and SIDE (CONVEX) SIDE (CONCAVE)
the r i n g gear "backlash" adjusted correctly, t h e teeth J9003-75
contact patterns should closely resemble the patterns
i l l u s t r a t e d i n F i g . 67. Notice t h a t t h e i l l u s t r a t e d Fig. 68 Incorrect Teeth Contact Patterns—Increase
teeth contact patterns are w e l l centered on both the Depth Shim Thickness
" d r i v e " side and t h e "coast" side o f the teeth. (5) If, after e x a m i n i n g t h e contact patterns, i t is de-
W h e n t h e teeth c o n t a c t p a t t e r n s a r e obtained t e r m i n e d t h a t t h e patterns resemble those i l l u s t r a t e d
by the method d e s c r i b e d above, they a r e likely i n F i g . 70, t h e drive p i n i o n gear is too close to t h e
to be r a t h e r small. With a n a c t u a l operating centerline o f the r i n g gear. T h i s condition w i l l cause
load, h o w e v e r , the c o n t a c t a r e a i n c r e a s e s . the contact patterns to be " l o w " o n t h e " d r i v e " side
(4) If, after e x a m i n i n g t h e r i n g gear contact pat- and near t h e "toe" of the tooth, a n d " l o w " on "coast"
terns, i t is determined t h a t t h e patterns resemble side a n d near t h e " h e e l " o f t h e tooth. To correct for
those i l l u s t r a t e d i n F i g . 68, the d r i v e p i n i o n gear is t h i s type o f teeth contact patterns, decrease the
separated too much f r o m t h e centerline of t h e r i n g thickness o f t h e depth s h i m (located between t h e
 FRONT SUSPENSION 2 - 49

PATTERNS MOVE TOWARD CENTER

ANDDOWN PATTERNS MOVE INWARD AND UP

HEEL END-DRIVE HEEL END-COAST HEEl JNP-PRIVE HEEL END-COAST

SIDE (CONVEX) SIDE (CONCAVE) SIDE (CONVEX) SIDE (CONCAVE)

J9003-76 J9003-78

Fig. 69 Teeth Contact Patterns After Depth Shim Fig. 71 Teeth Contact Patterns After Depth Shim
Thickness Is Increased Thickness Is Decreased
SEALANT
THINNER SHIM REQUIRED 1/16-TO
3/32-INCH
(1.59-TO
2.38-MM)
k

THICK BEAD

HEEL END-DRIVE HEEL END-COAST

SIDE (CONVEX) SIDE (CONCAVE)
J9003-77

Fig. 70 Incorrect Teeth Contact Patterns—Decrease

Depth Shim Thickness
drive p i n i o n gear and t h e drive p i n i o n gear shaft i n -
ner/rear bearing). This w i l l cause t h e " l o w " contact
p a t t e r n on t h e " d r i v e " side to be raised a n d t o move
t o w a r d t h e "heel" of the tooth, a n d t h e " l o w " contact
p a t t e r n on t h e "coast" side to be raised a n d to move
t o w a r d t h e "toe" of the tooth ( F i g . 71).
INSTALLATION
(1) I n s t a l l the axle shafts i n t h e axle shaft tubes. I f
necessary, refer to t h e i n s t a l l a t i o n procedures.
(2) Remove any residual R T V sealant/gasket mate-
r i a l from t h e differential housing a n d cover m a t i n g
surfaces, thoroughly clean t h e surfaces w i t h m i n e r a l
spirits (or a n equivalent cleaning solution) a n d d r y
the surfaces completely.
(3) A p p l y a t h i n "bead" of M O P A R R T V Sealant (or
an equivalent sealant) around t h e bolt circle on t h e
housing and on t h e cover (Fig. 72). A l l o w t h e seal-
ant to " c u r e " f o r a few minutes.
I f f o r a n y reason the differential housing cover
i s n o t i n s t a l l e d w i t h i n 20 m i n u t e s a f t e r a p p l y i n g
DIFFERENTIAL
HOUSING
COVER
(TYPICAL) J9003-85
Fig. 72 Sealant On Housing Cover.
the sealant, t h e sealant m u s t be r e m o v e d a n d
another " b e a d " o f sealant applied.
(4) I n s t a l l t h e housing cover on t h e differential
housing w i t h t h e attaching bolts. I n s t a l l t h e a x l e
gear ratio identification t a g under one o f the
c o v e r b o l t s . T i g h t e n t h e cover bolts w i t h 47 N»m (35
ft-lbs) torque.
(5) Remove t h e supports a n d raise or lower the
hoist u n t i l t h e vehicle is level.
(6) Remove t h e f i l l hole p l u g and f i l l t h e differen-
t i a l housing w i t h t h e specified q u a n t i t y of M O P A R
Hypoid Gear L u b r i c a n t (or a n equivalent product).
I n s t a l l t h e f i l l hole p l u g and t i g h t e n w i t h 34 N»m (25
ft-lbs) torque.
(7) Lower t h e vehicle and test t h e brakes and the
axle for proper operation.
2 - 50 FRONT SUSPENSION
LUBRICANT
Multi-purpose, hypoid gear l u b r i c a n t , as defined b y
MIL-L-2105-B and b y A P I G L 5 q u a l i t y specifica-
tions, should be used for Model 44 f r o n t axles. M O -
PAR H y p o i d Gear L u b r i c a n t conforms w i t h b o t h o f
these specifications and is h i g h l y recommended for
use w i t h b o t h R a m T r u c k and Ramcharger vehicles.
Each t i m e a 4 W D vehicle is serviced for other rea-
sons (e.g., a n engine o i l change), inspect the f r o n t
axle for evidence o f l u b r i c a n t leakage. I f leakage ex-
ists, observe t h e l u b r i c a n t level i n t h e differential
housing t h r o u g h t h e f i l l hole. W h e n observing t h e
level, ensure t h a t the vehicle is level o n the hoist.
The l u b r i c a n t level should be m a i n t a i n e d a t the bot-
t o m o f f i l l hole.
CAUTION: If the front axle is submerged in water,
the axle lubricant must be replaced immediately to
avoid the possibility of premature axle failure re-
sulting from water contamination of the lubricant.
•
DRAIN AND REFILL
(1) D r i v e the vehicle w i t h t h e f r o n t axle shafts en-
gaged (i.e., i n 4WD) u n t i l the gear l u b r i c a n t i n the
axle a t t a i n s the n o r m a l operating temperature.
(2) Raise and support the vehicle.
(3) Remove the l u b r i c a n t f i l l holie p l u g f r o m the dif-
ferential housing cover.
(4) Remove the differential housing cover and allow
the o r i g i n a l l u b r i c a n t to completely d r a i n from the
housing and the axle shaft tubes.
(5) F l u s h the differential a n d t h e h o u s i n g cavity
w i t h a " f l u s h i n g " o i l (or l i g h t engine oil) t o remove
residual l u b r i c a n t and foreign matter.. D o n o t u s e
water, steam, kerosene o r gasoline f o r f l u s h i n g .
(6) I n s t a l l t h e differential housing cover a n d
t i g h t e n the bolts w i t h 47 N*m (35 ft-lbs) Torque.
(7) Refill the differential housing w i t h t h e specified
q u a n t i t y of M O P A R Hypoid Gear L u b r i c a n t . Refer t o
the Specifications chart.
(8) I n s t a l l and t i g h t e n the f i l l hole p l u g w i t h 34
N-m (25 ft-lbs) torque.
(9) Remove the supports and lower t h e vehicle.
 • FRONT SUSPENSION 2 - 51

MODEL 60 FRONT A X L E SERVICE—4WD VEHICLES

INDEX
Page Page
Axle Shaft and U-Joint Service 54 Lubricant 78
Complete Axle Removal/Installation . . . . . . . . . . . . 60 Rotor/Hub and Wheel Bearing Service . . . . . . . . . 52
Differential Service 61 Steering Knuckle Arm Removal/Installation 58
Drag Link Removal/Installation 59 Steering Knuckle Service 56
Dualmatic Locking Hub Service 51 Tie-Rod End Replacement 60
General Information . . . . . . . . . . . . . . . . . . . . . . . 51 Wheel Bearing Adjustment 52

GENERAL INFORMATION • to establish a means for o b t a i n i n g a n d t h e n r e t a i n -

R a m T r u c k and Ramcharger vehicles equipped for
heavy d u t y 4 W D operation have a Model 60 front
axle. The housing for Model 60 f r o n t axles consists o f
a n i r o n center casting (differential housing) w i t h
axle shaft tubes extending from either side. The axle
shaft tubes are pressed i n t o and welded to the differ-
e n t i a l housing t o f o r m a one-piece axle housing. The
removable, stamped steel cover located at the front of
t h e differential housing provides a means for inspec-
t i o n and for differential service w i t h o u t removing the
complete f r o n t axle f r o m the vehicle. The axle has a
hypoid gear differential and t h e centerline o f the
d r i v e p i n i o n gear shaft is located below the center-
l i n e o f the r i n g gear.
A small, stamped m e t a l axle gear r a t i o identifica-
t i o n t a g is attached t o the housing cover v i a one o f
t h e cover bolts. This t a g also identifies the number of
r i n g gear and drive p i n i o n gear teeth.
The drive p i n i o n gear shaft rotates w i t h i n two t a -
pered, roller bearings. The drive p i n i o n gear shaft
rear bearing is t i g h t l y "press-fitted" on the drive p i n -
i o n gear shaft. T h e drive p i n i o n gear shaft front
b e a r i n g is very l i g h t l y "press-fitted" (which is s i m i l a r
to a "close, sliding f i t " ) on t h e drive p i n i o n gear
shaft. T h e drive p i n i o n gear shaft inner and outer
b e a r i n g cups are "press-fitted" i n t h e differential
housing bore and against a recessed shoulder. The
drive p i n i o n gear shaft depth o f mesh adjustment is
controlled b y the use o f metal depth shims t h a t are
i n s t a l l e d between the drive p i n i o n gear shaft inner
bearing and the differential housing.
The drive p i n i o n gear shaft bearing "preload"
torque is provided v i a metal shims t h a t are located
between t h e drive p i n i o n gear shaft outer bearing
cup and the differential housing.
The differential case hubs rotate i n the differential
housing v i a t w o tapered, roller bearings t h a t are
"press-fitted" on the case hubs. T h e shims t h a t are
i n s t a l l e d between t h e bearings a n d the hub shoulder
provide three functions:
• t o adjust and m a i n t a i n the " b a c k l a s h " between the
r i n g gear and the drive p i n i o n gear;
i n g the differential bearing " p r e l o a d " torque; a n d
• to eliminate the differential "side play".the differ-
e n t i a l housing and axle shaft tubes (the axle hous-
ing), the differential case and t h e drive p i n i o n gear
shaft.
A Model 60 f r o n t axle has " l o c k i n g " hubs t h a t
m u s t be engaged for 4 W D operation.
CAUTION: Whenever front axle service is neces-
sary, or when the axle is being rotated via the en-
gine or other means, raise all four wheels off the
surface.
DUALMATIC LOCKING HUB SERVICE
REMOVAL/DISASSEMBLY
(1) T u r n the shift knob to the E N G A G E position
(Fig. 1).
(2) A p p l y pressure to the face o f t h e shift knob and
remove the three r e t a i n i n g screws located nearest to
the flange (Fig. 1).
(3) P u l l o u t w a r d and remove t h e shift knob from
the base (Fig. 1).
(4) Remove t h e "snap" r i n g f r o m t h e axle shaft
(Fig.l).
(5) Remove t h e capscrews and lockwashers f r o m
the base flange.
(6) Separate and remove l o c k i n g h u b f r o m the ro-
tor/hub. Remove and discard the gasket.
INSPECTION
(1) Wash a l l t h e components (Fig. 1) i n m i n e r a l
spirits and blow t h e m dry w i t h compressed a i r .
(2) Examine the splines, the s h i f t knob, t h e cam,
the s l i d i n g gear, the drive shaft gear, and t h e base
for damage (Fig. 1). Replace as necessary.
ASSEMBL Y/INSTALLA TION
(1) Lubricate the components (Fig. 1) l i g h t l y w i t h
M O P A R Multi-Purpose L u b r i c a n t (or a n equivalent
lubricant).
(2) Position a replacement gasket and the l o c k i n g
hub onto rotor/hub (Fig. 1).
2 - 52 FRONT SUSPENSION •

Fig. 1 Dualirn ic Locking Hub

(3) I n s t a l l the lockwashers and the a t t a c h i n g cap-
screws. T i g h t e n the capscrews w i t h 41-54 N m (30-40#

ft-lbs) torque.
(4) I n s t a l l the axle shaft "snap" r i n g (Fig. 1).
(5) Position the shift knob on the base. A l i g n t h e
splines b y pushing i n w a r d on the shift knob a n d ro-
t a t i n g i t clockwise to "lock" i t in-place.
(6) I n s t a l l and t i g h t e n the three shift knob r e t a i n -
i n g screws.

WHEEL BEARING ADJUSTMENT

(1) Raise and support the vehicle.
(2) Remove t h e h u b cap. Use Tool C-4020 t o r e -
move the "snap" r i n g .
(3) Remove t h e flange nuts and t h e lockwashers.
Remove t h e drive flange and discard t h e gasket, or
( i f equipped) remove t h e locking hub. I f necessary,
refer to t h e Dualmatic locking h u b removal/
disassembly procedure.
(4) Straighten the lock r i n g tangs and use Tool D D -
1241-JD (Fig. 2) to remove the outer locknut and the
lock r i n g .
(5) Use Tool DD-1241-JD a n d Tool C-3952 t o
t i g h t e n t h e inner locknut w i t h 68 N*m (50 ft-lbs)
torque to seat the wheel bearings. Loosen the l o c k n u t
and t h e n re-tighten w i t h 41-54 N*m (30-40 ft-lbs)
torque w h i l e r o t a t i n g rotor/hub. Loosen t h e l o c k n u t
135° t o 150°.
(6) I n s t a l l t h e lock r i n g a n d t h e outer l o c k n u t .
T i g h t e n t h e locknut w i t h 88 N«m (65 ft-lbs) torque
m i n i m u m . Bend one lock r i n g t a n g over t h e i n n e r
l o c k n u t and one t a n g over the outer locknut.
(7) The wheel bearing adjustment should produce
an "end-play" of 0.001 to 0.010 inch (0.025 t o 0.254
mm).
Fig. 2 Outer Locknut Removal/Installation
(8) I n s t a l l a replacement gasket o n the h u b . I n s t a l l
the drive flange, t h e lockwashers a n d t h e nuts.
T i g h t e n the n u t s w i t h 41 to 54 N«m (30 to 40 ft-lbs)
torque.
(9) Use Tool C-4020 to i n s t a l l t h e "snap" r i n g .
(10) I n s t a l l the h u b cap, or ( i f equipped) i n s t a l l the
D u a l m a t i c l o c k i n g h u b . I f necessary, refer to t h e
D u a l m a t i c l o c k i n g h u b assembly/installation proce-
dure.
(11) Remove t h e supports, lower t h e vehicle a n d
test drive the vehicle.
R0T0R/HUB AND WHEEL BEARING SERVICE
REMOVAL/DISASSEMBL Y
(1) Block the brake pedal i n the " u p " position.
(2) Raise and support the vehicle.
(3) Remove the applicable wheel/tire.
(4) Remove t h e brake caliper-to-adaptor hex-head
screw (Fig. 3).
 • FRONT SUSPENSION
Fig. 3 Hex-Head Screw Removal/Installation
(5) T a p t h e adaptor lock and s p r i n g w i t h a punch
to remove t h e m from between the brake caliper and
the adaptor (Fig. 4).
Fig. 4 Caliper Lock & Spring Removal
(6) Carefully separate t h e brake caliper from t h e
adaptor. Support the caliper out o f the way. D o n o t
allow the caliper to h a n g o r be supported b y the
b r a k e f l u i d h o s e . T h e inner brake pad "will r e m a i n
on the adaptor.
(7) Remove t h e h u b cap. Use Tool C-4020 to re-
move t h e " s n a p " r i n g .
(8) Remove t h e flange nuts and t h e lockwashers.
Remove t h e d r i v e flange and discard t h e gasket, or
( i f equipped) remove t h e locking h u b . I f necessary,
refer t o t h e D u a l m a t i c locking h u b removal/
disassembly procedure.
(9) S t r a i g h t e n the lock r i n g tangs and use Tool D D -
1241-JD (Fig. 2) t o remove the outer l o c k n u t and the
lock r i n g . Remove t h e i n n e r locknut and t h e outer
wheel bearing. Carefully slide the rotor/hub from the
steering k n u c k l e spindle.
(10) Remove t h e seal and the i n n e r wheel bearing
from the hub.
2 - 53
CLEANING/INSPECTION
(1) Thoroughly clean t h e wheel bearings a n d t h e
i n t e r i o r o f t h e h u b . Remove a l l t h e old l u b r i c a n t .
Soak t h e wheel bearings i n cleaning solvent t o loosen
the l u b r i c a n t . S t r i k e t h e f l a t of the wheel bearings
against a wooden block several times and immerse
t h e m i n t h e solvent between blows to j a r loose a n d
wash particles of hardened l u b r i c a n t from each w h e e l
bearing. Repeat the procedure u n t i l the wheel bear-
ings are clean.
(2) D r y the wheel bearings w i t h compressed a i r b u t
do not spin t h e m w i t h the air.
(3) A f t e r cleaning and d r y i n g , apply engine o i l t o
the wheel bearings.
(4) T u r n the wheel bearings slowly w h i l e a p p l y i n g
pressure to inspect t h e m for p i t t i n g and roughness.
Replace a l l excessively w o r n a n d defective wheel
bearings. I f a wheel bearing is p i t t e d and/or r o u g h ,
replace b o t h the wheel bearing and the cup.
(5) I f the wheel bearings are acceptable for addi-
t i o n a l use, remove t h e engine o i l and "pack" t h e m
w i t h M O P A R M u l t i - Mileage L u b r i c a n t (or a n equiv-
alent l u b r i c a n t ) and place t h e m i n a clean covered
container u n t i l ready for i n s t a l l a t i o n . I f a wheel
b e a r i n g "packer" is not available, h a n d "pack" l u b r i -
cant i n t o a l l t h e cavities between t h e cage and t h e
rollers.
(6) I f t h e wheel bearings a n d cups m u s t be r e -
placed, remove t h e cups f r o m t h e hub w i t h a brass
d r i f t or use a n appropriate removal tool.
(7) Replace t h e wheel bearing cups w i t h a a n ap-
propriate i n s t a l l a t i o n tool.
ASSEMBL Y/INSTALLA TION
(1) A p p l y a coat of M O P A R M u l t i - M i l e a g e L u b r i -
cant (or a n equivalent l u b r i c a n t ) to the hub bore. I n -
s t a l l t h e i n n e r wheel bearing i n the l u b r i c a n t coated
h u b bore and i n s t a l l a replacement seal w i t h a n ap-
propriate seal i n s t a l l a t i o n tool. E x e r c i s e e x t r e m e
c a r e t o a v o i d d a m a g i n g t h e seal d u r i n g i n s t a l l a -
tion.
(2) A p p l y a coat of M O P A R M u l t i - M i l e a g e L u b r i -
cant (or a n equivalent lubricant) to t h e spindle.
Carefully i n s t a l l t h e rotor/hub onto t h e l u b r i c a n t
coated spindle. I n s t a l l t h e outer wheel bearing a n d
the i n n e r locknut.
(3) Use Tool DD-1241-JD a n d Tool C-3952 t o
t i g h t e n t h e i n n e r locknut w i t h 68 N«m (50 ft-lbs)
torque t o seat the wheel bearings. Loosen the l o c k n u t
and t h e n re-tighten w i t h 41-54 N*m (30-40 ft-lbs)
torque w h i l e r o t a t i n g rotor/hub. Loosen t h e l o c k n u t
135° t o 150°.
(4) I n s t a l l the lock r i n g and the outer locknut (Fig.
2). T i g h t e n t h e locknut w i t h 88 N*m (65 ft-lbs)
torque m i n i m u m . Bend one lock r i n g t a n g over t h e
i n n e r l o c k n u t and one t a n g over the outer l o c k n u t .
2 - 54 FRONT SUSPENSION
(5) T h e wheel bearing adjustment should produce
an "end-play" o f 0.001 t o 0.010 i n c h (0.025 t o 0.254
mm).
(6) I n s t a l l a replacement gasket on t h e h u b . I n s t a l l
the d r i v e flange, t h e lockwashers a n d t h e nuts.
T i g h t e n t h e n u t s w i t h 4 1 t o 54 N - m (30 to 40 ft-lbs)
torque.
(7) Use Tool C-4020 t o i n s t a l l t h e "snap" r i n g .
(8) I n s t a l l t h e h u b cap, or ( i f equipped) i n s t a l l t h e
D u a l m a t i c l o c k i n g h u b . I f necessary, refer to t h e
D u a l m a t i c l o c k i n g h u b assembly/installation proce-
dure.
(9) Carefully position t h e brake caliper on t h e
adaptor. Position t h e adaptor lock a n d spring be-
tween t h e caliper a n d t h e adaptor and t a p t h e m i n -
place ( F i g . 5). I n s t a l l hex-head screw a n d t i g h t e n i t
w i t h 16 t o 24 N«m (12 t o 18 ft-lbs) torque.
•
(7) Remove t h e h u b cap. Use Tool C-4020 to r e -
move t h e " s n a p " r i n g .
(8) Remove t h e flange n u t s a n d t h e lockwashers.
Remove t h e d r i v e flange a n d discard t h e gasket, or
( i f equipped) remove t h e l o c k i n g h u b . I f necessary,
refer t o t h e D u a l m a t i c l o c k i n g h u b removal/
disassembly procedure.
(9) S t r a i g h t e n t h e lock r i n g tangs and use Tool D D -
1241-JD (Fig. 2) t o remove t h e outer l o c k n u t and t h e
lock r i n g . Remove t h e i n n e r locknut a n d t h e outer
wheel bearing. Carefully slide t h e rotor/hub f r o m t h e
steering k n u c k l e spindle.
(10) Remove t h e i n n e r brake pad from t h e adaptor.
(11) Remove t h e n u t s and washers t h a t a t t a c h t h e
brake splash shield, t h e brake adaptor a n d t h e spin-
dle t o steering k n u c k l e (Fig. 6).

Fig. 6 Spindle & Splash Shield Removal/Installation

Fig. 5 Caliper Lock & Spring Installation
(10) I n s t a l l t h e wheel/tire. T i g h t e n t h e l u g nuts
w i t h 102 N*m (75 ft-lbs) torque.
(11) L u b r i c a t e a l l t h e f i t t i n g s . Remove t h e supports
and lower t h e vehicle. Remove block from brake
pedal a n d test drive t h e vehicle.
(12) Remove t h e spindle f r o m t h e steering k n u c k l e .
Slide t h e i n n e r a n d outer axle shaft w i t h t h e bronze
spacer, seal and slinger from t h e axle shaft tube a n d
the steering k n u c k l e (Fig. 7).

AXLE SHAFT AND U-J0INT SERVICE

REMOVAL
(1) Block t h e brake pedal i n t h e " u p " position.
(2) Raise and support t h e vehicle.
(3) Remove t h e applicable wheel/tire.
(4) Remove t h e brake caliper-to-adaptor hex-head
screw (Fig. 3).
(5) T a p t h e adaptor lock a n d spring w i t h a punch
to remove t h e m from between the brake caliper a n d
the adaptor (Fig. 4).
(6) Carefully separate t h e brake caliper from t h e
adaptor. Support t h e caliper o u t of the way. D o n o t
allow the caliper to hang o r be supported b y the Fig. 7 Axle Shaft & U-Joint Removal/Installation
b r a k e f l u i d hose. The i n n e r brake pad w i l l r e m a i n
on t h e adaptor.
 • FRONT SUSPENSION 2 - 55

DISASSEMBLY
(1) Remove t h e " s n a p " r e t a i n i n g r i n g s from t h e
yoke a r m bores. *
(2) Position t h e U - j o i n t between open vise j a w s
w i t h one yoke h o r i z o n t a l and supported b y the top o f
the vise jaws (Fig. 8). D o not t i g h t e n t h e vise.

Fig. 9 Bearing Cap Installation

Fig. 8 Bearing Cap Removal

(3) Use a m a l l e t t o t a p t h e vertical yoke upper a r m
several times a n d d r i v e t h e vertical yoke downward
(Fig. 8). This w i l l force t h e upper needle bearing and
cap out of t h e yoke.
(4) Reverse t h e position o f the v e r t i c a l yoke and re-
move opposite needle b e a r i n g and cap (Fig. 8).
(5) Remove the yoke f r o m the spider.
(6) To complete the disassembly, position t h e open
ends of the spider i n a "soft-jawed" vise and repeat
steps 3 and 4 (above) t o remove r e m a i n i n g bearings
and caps.
(7) Remove t h e spider f r o m the yoke.
(8) Clean a n d inspect a l l t h e components. Clean
any rust f r o m t h e axle shaft splines. Retain each
bearing and cap separate. I f any component is exces-
sively w o r n or damaged, a complete replacement U -
j o i n t should be installed.
(9) Re-pack t h e U - j o i n t w i t h M O P A R M u l t i -
Mileage L u b r i c a n t , or a n equivalent l u b r i c a n t .
ASSEMBLY
(1) Insert t h e needle b e a r i n g and cap i n one yoke
a r m bore.
(2) Place the yoke i n a vise (Fig. 9) and force t h e
needle bearing and cap i n t o the correct position. I n -
s t a l l the " s n a p " r e t a i n i n g r i n g .
(3) Remove t h e yoke f r o m the vise and insert one
end of the spider i n t o t h e bearing. I n s e r t opposite
bearing and cap i n t h e yoke a r m bore b y hand and
a l i g n i t w i t h t h e spider.
(4) Place the yoke i n a vise and force the cap i n t o
the yoke a r m bore and onto the spider (Fig. 10).
Fig. 10 Bearing Cap & Spider Installation
(5) Use a short p l u g or a socket wrench t o force t h e
b e a r i n g cap i n t o t h e correct position and i n s t a l l t h e
"snap" retaining ring.
(6) Repeat t h e instructions i n steps 1 t h r o u g h 5 for
i n s t a l l i n g r e m a i n i n g bearings, caps and yoke.
INSTALLATION
(1) Position t h e bronze spacer on t h e axle shaft
w i t h chamfer facing t o w a r d t h e U-joint. Slide t h e
axle shaft i n t o t h e steering k n u c k l e a n d t h e axle
shaft t u b e (Fig. 7).
(2) I n s t a l l t h e spindle, t h e brake adaptor and t h e
b r a k e splash shield. I n s t a l l washers a n d nuts a n d
t i g h t e n t h e m w i t h 68 to 95 N - m (50 to 70 ft-lbs)
torque.
(3) Position the i n n e r brake pad on the adaptor.
(4) C a r e f u l l y i n s t a l l rotor/hub on the spindle. I n -
s t a l l t h e outer wheel bearing a n d the inner locknut.
(5) Use Tool DD-1241-JD a n d Tool C-3952 to
t i g h t e n t h e i n n e r locknut w i t h 68 N«m (50 ft-lbs)
2 - 56 FRONT SUSPENSION
torque to "seat" the wheel bearings. Loosen the lock-
n u t and t h e n r e - t i g h t e n w i t h 41-54 N»m (30-40 ft-lbs)
torque w h i l e r o t a t i n g rotor/hub. Loosen t h e locknut
135° t o 150°.
(6) I n s t a l l the lock r i n g and t h e outer l o c k n u t (Fig.
2). T i g h t e n the l o c k n u t w i t h 88 N*m (65 ft-lbs)
torque m i n i m u m . B e n d one lock r i n g t a n g over t h e
inner l o c k n u t and one t a n g over t h e outer locknut.
(7) T h e wheel b e a r i n g adjustment should produce
an "end-play" of 0.001 t o 0.010 i n c h (0.025 to 0.254
mm).
(8) I n s t a l l a replacement gasket on the h u b . I n s t a l l
the drive flange, t h e lockwashers a n d t h e nuts.
T i g h t e n t h e nuts w i t h 4 1 to 54 N - m (30 t o 40 ft-lbs)
torque.
(9) Use Tool C-4020 t o i n s t a l l t h e "snap" r i n g .
(10) I n s t a l l the h u b cap, or ( i f equipped) i n s t a l l the
Dualmatic l o c k i n g h u b . I f necessary, refer to t h e
Dualmatic locking h u b assembly/installation proce-
dure.
(11) Carefully position t h e brake caliper on t h e
adaptor. Position t h e adaptor lock a n d s p r i n g be-
tween t h e caliper a n d t h e adaptor and t a p t h e m i n -
place (Fig. 5). I n s t a l l hex-head screw and t i g h t e n i t
w i t h 16 t o 24 N«m (12 to 18 ft-lbs) torque.
(12) I n s t a l l the wheel/tire. T i g h t e n t h e l u g nuts
w i t h 102 N«m (75 ft-lbs) torque.
(13) Remove t h e supports a n d lower t h e vehicle.
Remove block from b r a k e pedal a n d test drive the ve-
hicle.
STEERING KNUCKLE SERVICE
REMOVAL/DISASSEMBLY
(1) Block the brake pedal i n t h e " u p " position.
(2) Raise and support the vehicle.
(3) Remove the applicable wheel/tire.
(4) Remove the b r a k e caliper-to-adaptpr hex-head
screw (Fig. 3).
(5) Tap t h e adaptor lock and spring w i t h a punch
to remove t h e m f r o m between t h e brake caliper and
the adaptor (Fig. 4).
(6) Carefully separate t h e brake caliper from t h e
adaptor. Support t h e caliper out of the way. D o n o t
allow the caliper t o hang o r be supported b y the
b r a k e f l u i d hose. T h e inner brake pad w i l l r e m a i n
on the adaptor.
(7) Remove the h u b cap. Use Tool C-4020 to re-
move t h e "snap" r i n g .
(8) Remove the flange n u t s a n d t h e lockwashers.
Remove t h e drive flange a n d discard t h e gasket, or
(if equipped) remove t h e l o c k i n g hub. I f necessary,
refer t o t h e D u a l m a t i c l o c k i n g h u b removal/
disassembly procedure.
(9) S t r a i g h t e n the lock r i n g tangs and use Tool D D -
1241-JD (Fig. 2) to remove the outer l o c k n u t and the
•
lock r i n g . Remove t h e i n n e r locknut a n d t h e outer
wheel b e a r i n g . Carefully slide the rotor/hub f r o m t h e
steering k n u c k l e spindle.
(10) Remove the i n n e r b r a k e pad from t h e adaptor.
(11) Remove the n u t s a n d washers t h a t a t t a c h t h e
brake splash shield, t h e brake adaptor and t h e spin-
dle t o steering k n u c k l e (Fig. 6).
(12) Remove the spindle f r o m the steering k n u c k l e .
Slide t h e i n n e r and outer axle shaft w i t h t h e bronze
spacer, seal and slinger f r o m the axle shaft tube and
t h e steering k n u c k l e (Fig. 7).
(13) Remove t h e cotter p i n and t h e r e t a i n i n g n u t
from t h e t i e - rod end b a l l stud. Use Tool C-3894-A t o
loosen t h e b a l l stud a n d remove the tie-rod end from
t h e steering knuckle. Left side only, remove t h e cot-
t e r p i n a n d t h e r e t a i n i n g n u t from drag l i n k b a l l
stud. Use Tool C-4150 t o loosen the b a l l stud a n d re-
move t h e d r a g l i n k f r o m t h e steering k n u c k l e a r m .
(14) Remove the n u t s a n d the steering k n u c k l e u p -
per cap (left side steering k n u c k l e arm). Discard t h e
gasket. Remove the s p r i n g a n d the upper socket
sleeve.
(15) Remove t h e capscrews from t h e steering
k n u c k l e lower cap. Dislodge t h e cap from t h e steer-
i n g k n u c k l e and the axle shaft tube yoke.
(16) To remove the steering knuckle from t h e axle
shaft tube yoke, swing i t out a t the bottom, t h e n l i f t
i t u p a n d off the upper socket p i n .
(17) Use Tool D-192 t o loosen and remove t h e up-
per socket p i n from t h e axle shaft tube upper a r m
bore (Fig. 11). Remove t h e seal.
RH431
Fig. 11 Upper Socket Pin Removal/Installation
(18) Use Tools C-4212-1, C-4366-1 a n d C-4366-2
(positioned as i l l u s t r a t e d i n Figure 12) to force t h e
lower b a l l socket from t h e axle shaft tube yoke lower
a r m bore.
(19) C l e a n a l l the components w i t h a n appropriate
solvent a n d blow t h e m d r y w i t h compressed a i r . I n -
spect a l l t h e components for burrs, chips, excessive
wear, flat spots and cracks. Replace t h e components
as necessary d u r i n g steering knuckle assembly.
 • FRONT SUSPENSION 2 - 57

Fig. 12 Lower Ball Socket Removal

ASSEMBLY/INSTALLATION
(1) Lubricate t h e lower b a l l socket w i t h M O P A R
M u l t i - M i l e a g e L u b r i c a n t (or a n equivalent l u b r i -
cant).
(2) Use Tools C-4212-L, C-4366-3, a n d C-4366-4
(positioned as i l l u s t r a t e d i n F i g u r e 13) t o force t h e
seal and t h e lower b e a r i n g c u p into t h e axle shaft
tube yoke lower a r m bore.
(3) Reposition Tools C-4212-L, C-4366-3 a n d C-
4366-5 (as i l l u s t r a t e d i n F i g u r e 14) a n d force t h e
lower bearing a n d seal i n t o axle shaft t u b e yoke
lower a r m bore.
(4) Use Tool D-192 and Torque W r e n c h Tool D D -
994 to i n s t a l l the upper socket p i n i n t h e axle shaft
tube yoke upper a r m bore. T i g h t e n t h e socket p i n
w i t h 668 to 813 N - m (500 t o 600 ft-lbs) torque. I n -
s t a l l the seal over t h e socket p i n .
(5) Position t h e steering k n u c k l e over t h e socket
p i n . F i l l the socket lower c a v i t y w i t h M O P A R M u l t i -
Mileage L u b r i c a n t (or a n e q u i v a l e n t l u b r i c a n t ) . M a -
neuver t h e lower cap i n t o place on t h e steering
k n u c k l e and the axle shaft t u b e yoke. I n s t a l l t h e cap-
screws and t i g h t e n t h e m w i t h 95 to 122 N m (70 to #

90 ft-lbs) torque.
(6) L i b e r a l l y lubricate upper socket p i n w i t h M O -
P A R M u l t i - M i l e a g e L u b r i c a n t (or a n e q u i v a l e n t l u -
bricant). A l i g n the upper socket sleeve k e y w a y w i t h
t h e steering k n u c k l e (Fig. 15) a n d slide i t i n t o posi-
tion.
Fig. 14 Lower Bearing & Seal Installation
2 - 58 FRONT SUSPENSION
Fig. 15 Sleeve Keyway Alignment On Steering
Knuckle
(7) I n s t a l l a replacement gasket over t h e steering
k n u c k l e upper studs. Position t h e s p r i n g over t h e
sleeve. I n s t a l l t h e cap (left side steering knuckle
arm). I n s t a l l t h e n u t s and t i g h t e n t h e m w i t h 96 to
122 N*m (70 to 90 ft-lbs) torque.
(8) A t the left side only, connect the d r a g - l i n k b a l l
stud t o t h e steering k n u c k l e a r m and i n s t a l l t h e re-
t a i n i n g n u t . T i g h t e n t h e n u t w i t h 8 1 N n n (60 ft-lbs)
torque. I n s t a l l a replacement cotter p i n .
(9) Connect the tie-rod end b a l l stud to the steering
knuckle and install the retaining nut. Tighten the
n u t w i t h 61 N«m (45 ft-lbs) torque. I n s t a l l a replace-
ment cotter p i n .
(10) Position t h e bronze spacer o n t h e axle shaft
w i t h chamfer facing t o w a r d t h e U-joint. Slide t h e
axle shaft i n t o t h e steering k n u c k l e a n d t h e axle
shaft tube (Fig. 7).
(11) I n s t a l l t h e spindle, the brake adaptor and the
brake splash shield. I n s t a l l washers a n d nuts a n d
t i g h t e n t h e m w i t h 68 to 95 N*m (50 to 70 ft-lbs)
torque.
(12) Position the i n n e r brake pad on t h e adaptor.
(13) Carefully i n s t a l l rotor/hub o n t h e spindle. I n -
s t a l l the outer wheel bearing and t h e inner locknut.
(14) Use Tool DD-1241-JD a n d Tool C-3952 to
t i g h t e n t h e inner l o c k n u t w i t h 68 N T H (50 ft-lbs)
torque to "seat" the wheel bearings. Loosen the lock-
n u t and t h e n re-tighten w i t h 41-54 N » m (30-40 ft-lbs)
•
torque w h i l e r o t a t i n g rotor/hub. Loosen t h e locknut
135° t o 150°.
(15) I n s t a l l t h e lock r i n g a n d t h e outer locknut
(Fig. 2). T i g h t e n t h e l o c k n u t w i t h 88 N - m (65 ft-lbs)
torque m i n i m u m . Bend one lock r i n g t a n g over t h e
inner l o c k n u t and one t a n g over t h e outer locknut.
(16) T h e wheel b e a r i n g adjustment should produce
an "end-play" o f 0.001 t o 0.010 i n c h (0.025 t o 0.254
mm).
(17) I n s t a l l a replacement gasket o n t h e h u b . I n -
stall t h e drive flange, t h e lockwashers and the nuts.
T i g h t e n t h e n u t s w i t h 4 1 t o 54 N«m (30 to 40 ft-lbs)
torque.
(18) Use Tool C-4020 t o i n s t a l l t h e "snap" r i n g .
(19) I n s t a l l the h u b cap, or ( i f equipped) i n s t a l l t h e
D u a l m a t i c l o c k i n g h u b . I f necessary, refer to t h e
D u a l m a t i c l o c k i n g h u b assembly/installation proce-
dure.
(20) Carefully position t h e brake caliper on t h e
adaptor. Position t h e adaptor lock a n d spring be-
tween t h e caliper and t h e adaptor and t a p t h e m i n -
place (Fig. 5). I n s t a l l hex-head screw and t i g h t e n i t
w i t h 16 to 24 N»m (12 t o 18 ft-lbs) torque.
(21) I n s t a l l t h e wheel/tire. T i g h t e n t h e l u g nuts
w i t h 102 N*m (75 ft-lbs) torque.
(22) A p p l y l u b r i c a n t t o a l l the f i t t i n g s . Remove the
supports a n d lower t h e vehicle. Remove block from
brake pedal a n d test d r i v e t h e vehicle.
STEERING KNUCKLE ARM
REMOVAL/INSTALLATION
REMOVAL
The d r a g - l i n k b a l l s t u d seals should be inspected
for damage w h e n t h e engine o i l is changed.
(1) Raise and support t h e vehicle a t a comfortable
w o r k i n g height. Remove t h e wheel cover and wheel/
tire.
(2) T u r n t h e front wheels to t h e left. Remove t h e
cotter p i n and t h e r e t a i n i n g n u t from t h e d r a g - l i n k
b a l l stud.
Removal of a drag-link ball stud from the
steering k n u c k l e a r m b y methods other t h a n us-
i n g T o o l C-4150 c o u l d d a m a g e t h e seal.
(3) I n s t a l l P u l l e r Tool C-4150 on t h e d r a g - l i n k b a l l
stud (Fig. 16). A p p l y sufficient force w i t h the tool t o
loosen t h e d r a g - l i n k b a l l stud f r o m t h e steering
knuckle arm.
(4) Remove t h e t h r e e steering k n u c k l e a r m -
to-steering k n u c k l e n u t s a n d washers (Fig. 17). Tap
the steering k n u c k l e a r m to loosen i t from the steer-
i n g k n u c k l e . P r y u p w a r d a n d remove t h e steering
k n u c k l e a r m f r o m t h e vehicle.
 • FRONT SUSPENSION 2 - 59

A damaged seal requires removal o f the seal and

inspection o f t h e d r a g - l i n k b a l l stud a t t h e t h r o a t
opening. I f a l l t h e l u b r i c a n t has n o t escaped (or is
not contaminated) or t h e b a l l stud is not excessively
w o r n or rusted, i n s t a l l a replacement seal. Otherwise
a replacement complete drag l i n k should be installed.
Lubricate the b a l l studs after i n s t a l l a t i o n w i t h M O -
P A R M u l t i - M i l e a g e L u b r i c a n t or a n equivalent l u b r i -
cant.

REMOVAL
R e m o v a l o f a d r a g - l i n k b a l l s t u d from t h e
steering k n u c k l e a r m o r t h e p i t m a n (steering
gear) a r m b y m e t h o d s other t h a n u s i n g T o o l C-
4150 c o u l d d a m a g e the seal.
(1) Raise a n d support the vehicle a t a comfortable
w o r k i n g height. Remove t h e applicable wheel cover
and wheel/tire.
(2) T u r n the f r o n t wheels i n t h e direction t h a t w i l l
provide the best possible access t o the drag l i n k . Re-
move the cotter pins a n d the r e t a i n i n g nuts f r o m the
d r a g - l i n k b a l l studs.
(3) I n s t a l l P u l l e r Tool C-4150 o n each d r a g - l i n k
b a l l stud (Fig. 16). A p p l y sufficient force w i t h t h e
t o o l t o loosen t h e d r a g - l i n k b a l l stud from the steer-
i n g k n u c k l e a r m and the p i t m a n (steering gear) a r m .
Remove the d r a g l i n k f r o m the vehicle.

INSTALLATION
(1) Position t h e d r a g l i n k at steering k n u c k l e a r m
(Fig. 18) so t h a t t h e distance " A " to the bend i n the
l i n k is the shortest distance t o the steering k n u c k l e
a r m and the distance " B " is the closest to t h e p i t m a n
(steering gear) a r m .

Fig. 17 Steering Knuckle Arm Removal

INSTALLATION
(1) Position the steering k n u c k l e a r m on the steer-
i n g k n u c k l e . I n s t a l l t h e washers and a t t a c h i n g nuts.
T i g h t e n the nuts w i t h 122 N*m (90 ft-lbs).
(2) Connect the d r a g - l i n k b a l l stud to the steering
k n u c k l e a r m . I n s t a l l t h e r e t a i n i n g n u t and t i g h t e n i t
w i t h 81 N*m (60 ft-lbs). I n s t a l l a replacement cotter
pin.
(3) Remove the supports, lower the vehicle and test
t h e vehicle steering. Fig. 18 Correct Drag Link Installation
DRAG LINK REMOVAL/INSTALLATION (2) I n s t a l l a n d t i g h t e n the b a l l stud r e t a i n i n g n u t s
w i t h 8 1 N m (60 ft-lbs) torque. I n s t a l l replacement
#

cotter pins.
SERVICE INFORMATION (3) I n s t a l l t h e wheel/tire and the wheel cover. Re-
T h e drag-link ball stud seals should be i n -
move the supports and lower the vehicle.
s p e c t e d for d a m a g e w h e n the engine o i l i s
changed.
2 - 60 FRONT SUSPENSION
TIE-ROD END REPLACEMENT
SERVICE INFORMATION
T h e t i e - r o d b a l l s t u d seals s h o u l d b e i n s p e c t e d
for damage w h e n the engine o i l is changed.
A damaged seal requires removal o f t h e seal and
inspection o f the tie-rod b a l l stud a t t h e t h r o a t open-
i n g . I f a l l t h e l u b r i c a n t has n o t escaped (or is n o t
contaminated) or t h e b a l l stud is n o t excessively
w o r n or rusted, i n s t a l l a replacement seal. Otherwise
a replacement complete tie-rod end should be i n -
stalled. Lubricate t h e b a l l studs after i n s t a l l a t i o n
w i t h M O P A R M u l t i - M i l e a g e L u b r i c a n t o r a n equiva-
lent l u b r i c a n t . ,->-
REMOVAL
Removal o f a tie-rod e n d ball stud from the
steering k n u c k l e a r m b y methods o t h e r t h a n us-
i n g T o o l C-3894-A c o u l d d a m a g e t h e seal.
(1) Raise and support the vehicle a t a comfortable
w o r k i n g height. Remove t h e applicable wheel cover
and wheel/tire.
(2) T u r n the f r o n t wheels i n the direction t h a t w i l l
provide t h e best possible access to t h e tie-rod end.
Remove the cotter p i n and the r e t a i n i n g n u t from the
tie-rod end b a l l stud.
(3) I n s t a l l P u l l e r Tool C-3894-A on t h e tie-rod end
b a l l stud (Fig. 19). A p p l y sufficient force w i t h t h e
tool t o loosen the tie-rod end b a l l stud f r o m the steer-
ing knuckle arm.
Fig. 19 Tie-Rod End Removal
(4) Measure and record t h e approximate distance
from the end of the t i e rod t o the outside edge of the
tie-rod end. Loosen the adjustment sleeve clamp n u t
and bolt. U n - t h r e a d the tie-rod end f r o m the adjust-
ment sleeve and remove i t f r o m the vehicle.
•
INSTALLATION
(1) T h r e a d t h e replacement tie-rod end i n t o the ad-
j u s t m e n t sleeve so t h a t the l e n g t h approximates t h e
distance previously measured and recorded.
(2) Connect t h e tie-rod end b a l l stud t o the steering
knuckle a r m and install t h e retaining nut. Tighten
t h e n u t w i t h 6 1 N m (45 ft-lbs) torque.
#
(3) Remove t h e supports a n d lower vehicle t o t h e
surface.
(4) A d j u s t t h e " t o e " position. Refer t o the procedure
and t h e Specifications chart. Position the adjustment
sleeve clamp bolt a t t h e b o t t o m o f the tie-rod end.
T i g h t e n t h e clamp bolt and n u t w i t h 34-41 N T H (25-
30 ft-lbs) torque. Test the vehicle steering.
COMPLETE AXLE REMOVAL/INSTALLATION
SERVICE INFORMATION
I t i s n o t necessary to remove t h e complete f r o n t
axle from t h e vehicle for r o u t i n e service. However, i f
the d i f f e r e n t i a l housing or t h e axle shaft tubes a r e
damaged, t h e complete axle can be removed and i n -
stalled v i a t h e f o l l o w i n g procedures.
REMOVAL
(1) B l o c k t h e brake pedal i n t h e " u p " position.
Raise a n d support the vehicle a t a comfortable w o r k -
i n g height.
(2) Remove the front wheels/tires.
(3) M a r k the f r o n t drive shaft and the drive p i n i o n
gear shaft (axle) yoke for i n s t a l l a t i o n a l i g n m e n t ref-
erence.
(4) Disconnect t h e front drive shaft f r o m the axle
yoke. A t t a c h t h e drive shaft t o t h e frame r a i l w i t h
wire.
(5) Remove t h e cotter p i n , t h e r e t a i n i n g n u t , a n d
disconnect t h e d r a g l i n k f r o m t h e steering k n u c k l e
a r m (left side only). Discard the cotter p i n .
(6) Disconnect flexible brake fluid hose f i t t i n g s a t
t h e frame crossmember. P l u g t h e hoses a t t h e fit-
tings.
(7) Remove the shock absorber lower a t t a c h i n g n u t
and detach t h e stud f r o m t h e axle shaft tube bracket.
(8) Remove n u t s and the washers from the s p r i n g
U-bolts. Remove the complete front axle from the ve-
hicle.
INSTALLATION
(1) Position the front axle under the front of the ve-
hicle w i t h t h e axle spring pads under t h e springs.
Place t h e s p r i n g brackets over the springs.
(2) I n s t a l l t h e s p r i n g U-bolts, washers and r e t a i n -
i n g n u t s . T i g h t e n the nuts w i t h 149 N T H (110 ft-lbs)
torque.
(3) I n s e r t t h e shock absorber lower studs i n t h e
axle shaft tube brackets. I n s t a l l t h e attaching n u t s
and t i g h t e n t h e m w i t h 75 N * m (55 ft-lbs) torque.
 • FRONT SUSPENSION
(4) Remove plugs and connect t h e brake hose f i t -
tings. T i g h t e n the f i t t i n g s w i t h 9-17 N»m (80-150 i n -
lbs) torque.
(5) Connect the d r a g - l i n k b a l l stud t o the steering
k n u c k l e a r m . I n s t a l l the r e t a i n i n g n u t and t i g h t e n i t
w i t h 8 1 N«m (60 ft-lbs) torque. To a l i g n t h e cotter
p i n hole i n the b a l l stud w i t h t h e slot i n t h e castel-
lated n u t ( i f the slot and t h e hole are n o t aligned),
continue t o t i g h t e n t h e n u t u n t i l t h e y are aligned.
Do not loosen the n u t t o a l i g n t h e hole a n d t h e slot.
I n s t a l l a replacement cotter p i n .
(6) Connect the drive shaft t o the d r i v e p i n i o n gear
shaft (axle) yoke w i t h t h e i n s t a l l a t i o n reference
m a r k s aligned. I n s t a l l the washers a n d the n u t s and
t i g h t e n w i t h 34 N n n (300 in-lbs) torque.
(7) Remove the supports, lower the vehicle a n d re-
move the block from the brake pedal.
(8) Raise t h e vehicle, bleed and adjust the brakes,
l u b r i c a t e a l l the b a l l stud f i t t i n g s , inspect t h e differ-
e n t i a l housing l u b r i c a n t level. Refer t o the Specifica-
tions chart.
(9) Lower t h e vehicle and test t h e axle a n d front
suspension operation.
DIFFERENTIAL SERVICE
SERVICE INFORMATION
I t is n o t necessary t o remove t h e complete f r o n t
axle f r o m t h e vehicle for r o u t i n e axle or differential
service. To replace t h e differential side gears, i t is
necessary t o remove only the axle shafts, t h e differ-
e n t i a l housing cover, the l u b r i c a n t and the differen-
t i a l case. To replace t h e differential bearings, i t is
necessary t o remove only the axle shafts, t h e differ-
e n t i a l h o u s i n g cover, t h e l u b r i c a n t , t h e differential
case and t o adjust the r i n g gear "backlash".
REMOVAL/DISASSEMBLY
(1) Raise and support the vehicle a t a comfortable
w o r k i n g height.
(2) Remove the f r o n t wheels/tires.
(3) M a r k t h e front drive shaft and the drive p i n i o n
gear shaft (axle) yoke for i n s t a l l a t i o n a l i g n m e n t ref-
erence.
(4) Disconnect t h e f r o n t drive shaft from t h e axle
yoke. A t t a c h t h e drive shaft t o t h e frame r a i l w i t h
wire.
(5) T h o r o u g h l y clean the outer area o f the differen-
t i a l housing and axle shaft tubes w i t h a n appropriate
cleaning solvent and blow dry w i t h compressed air.
(6) Loosen t h e differential housing cover bolts and
d r a i n t h e l u b r i c a n t i n t o a container. Remove t h e
bolts and t h e differential housing cover.
A close e x a m i n a t i o n o f the d i f f e r e n t i a l p r i o r t o
disassembly c a n often reveal valuable informa-
t i o n concerning the extent a n d type o f repairs o r
adjustments t h a t w i l l be necessary. Because t h e
2 - 61
m o s t f r e q u e n t causes o f a x l e n o i s e a r e i m p r o p e r
"backlash" o r differential bearing "preload"
torque, o r both, a few m i n o r adjustments could
be a l l t h a t is necessary t o c o r r e c t a defect.
Therefore, before disassembly, t h e f o l l o w i n g infor-
m a t i o n should be available:
• r i n g gear "backlash" measurement,
• drive p i n i o n gear shaft b e a r i n g " p r e l o a d " torque
measurement, and
• r i n g gear/drive p i n i o n gear t e e t h contact patterns.
T h e r e s u l t s (above) s h o u l d b e r e c o r d e d a n d a n -
alyzed. I t is expected t h a t these measurements
w i l l be helpful w h e n m a k i n g necessary repairs
to the differential. Refer t o t h e applicable proce-
dures w i t h i n this section f o r i n s t r u c t i o n s .
If, after t h e measurements a n d adjustments, t h e
defect s t i l l exists, proceed w i t h t h e f o l l o w i n g disas-
sembly, inspection and assembly procedures.
(7) Thoroughly flush a n d clean t h e differential
gears, bearings and the other differential components
w i t h a n appropriate solvent.
(8) I n s t a l l a p i l o t stud i n t h e differential h o u s i n g
and attach D i a l Indicator Tool C-3339 t o the h o u s i n g
(Fig. 20) w i t h the indicator plunger s l i g h t l y "loaded"
and a t a r i g h t angle (i.e., perpendicular) to the back
side o f t h e r i n g gear. "Zero" t h e d i a l indicator
pointer.
DIAL INDICATOR
Fig. 20 Ring Gear "Runout" Measurement
(9) Measure the r i n g gear " r u n o u t " b y r o t a t i n g t h e
r i n g gear several complete revolutions and observing
the d i a l indicator pointer. M a r k b o t h t h e r i n g gear
and t h e differential case flange a t t h e location o f
maximum "runout".
T h e m a r k o n t h e d i f f e r e n t i a l case f l a n g e w i l l
be v e r y useful w h e n measuring t h e differential
case " r u n o u t " . T h e d i f f e r e n t i a l case f l a n g e
" r u n o u t " measurement procedure is described
below.
I f t h e c o m b i n e d r i n g g e a r " r u n o u t " (i.e., p e a k -
t o - p e a k ) exceeds o f 0.006 i n c h (0.150 m m ) , p o s s i -
2 - 62 FRONT SUSPENSION •
b l e c a u s e s c o u l d b e t h a t t h e ring g e a r i s n o t
tightly a t t a c h e d t o t h e d i f f e r e n t i a l case f l a n g e o r
t h e d i f f e r e n t i a l case i s d a m a g e d .
(10) D e t e r m i n e i f the clearance between t h e differ-
e n t i a l b e a r i n g caps a n d bearing cups is excessive b y
a t t e m p t i n g t o insert a 0.003- i n c h (0.076-mm) t h i c k
feeler gauge blade between t h e m . N o r m a l l y , a 0.003-
i n c h (0.076-mm) t h i c k feeler gauge blade should be
too t h i c k t o be inserted between a bearing cap a n d
cup.
I f t h e c l e a r a n c e i s m o r e t h a n 0.003 i n c h (0.076
mm), t h e cause c o u l d b e t h a t t h e applicable
bearing c u p rotated i n the differential housing
" s e a t " a n d caused excessive w e a r .
(11) N o t e t h e i n s t a l l a t i o n reference letters stamped
i n t o t h e differential bearing caps a n d i n t o t h e differ-
e n t i a l h o u s i n g machined sealing surface (Fig. 21).
Fig. 22 Differential Housing Separation
The letters are stamped horizontally on t h e r i g h t (15) T i g h t e n t h e spreader tool t u r n b u c k l e (Fig. 22)
side a n d are stamped v e r t i c a l l y on t h e left side of the and separate t h e differential housing only enough t o
differential housing. A l w a y s m a t c h t h e reference let- remove t h e differential case f r o m t h e housing. S e p a -
ters w h e n i n s t a l l i n g t h e differential bearing caps. rate t h e differential housing a m a x i m u m dis-
t a n c e o f 0.38 m m (0.015 i n ) w i t h t h e s p r e a d e r
t o o l . Measure t h e separation distance w i t h t h e d i a l
i n d i c a t o r (Fig. 22) as t h e h o u s i n g is b e i n g separated.
(16) Remove t h e d i a l indicator (Fig. 22) w h e n t h e
d i f f e r e n t i a l housing has been separated sufficiently
to remove t h e differential case f r o m t h e housing.
(17) P r y t h e differential case loose from t h e hous-
i n g . A l i g h t p r y i n g action w i t h a s m a l l p r y b a r o r
p i n c h b a r w i l l loosen t h e case sufficiently for easy r e -
m o v a l . To prevent damage, p r y t h e differential case
o u t w a r d toward t h e opening w i t h t h e p r y bar pivot-
i n g o n t h e differential housing a n d w i t h t h e e n d o f
the p r y b a r against t h e differential case.
(18) Remove t h e differential case f r o m t h e differen-
t i a l housing. I f they are reusable, r e t a i n t h e differen-
t i a l b e a r i n g cups a n d bearings together as "matched
Fig. 21 Bearing Cap Identification sets".
(19) Clamp t h e differential case i n a vise equipped
(12) Remove t h e differential bearing caps.
w i t h soft jaws a n d remove ( a n d d i s c a r d ) t h e r i n g
(13) Position Spreader Tool W-129-A on t h e differ-
gear bolts. " T a p " t h e r i n g gear w i t h a r a w h i d e m a l l e t
e n t i a l h o u s i n g w i t h t h e tool dowel pins "seated" i n
to loosen i t from t h e differential case flange. Remove
the l o c a t i n g holes ( F i g . 22). I n s t a l l t h e holddown
the r i n g gear.
clamps a n d t i g h t e n t h e tool t u r n b u c k l e "finger-
(20) I f t h e r i n g gear " r u n o u t " exceeded 0.006 i n c h
tight".
(0.15 m m ) i n Step 9 (above), t h e differential case
(14) I n s t a l l a p i l o t stud a t t h e left side o f t h e dif-
flange " r u n o u t " should be measured a t t h i s t i m e .
ferential housing. A t t a c h D i a l Indicator Tool C-3339
(21) I n s t a l l t h e differential case ( w i t h t h e o r i g i n a l
to t h e differential housing (via t h e p i l o t stud) w i t h
b e a r i n g cups), i n t h e differential housing.
the indicator plunger s l i g h t l y "loaded" against t h e
(22) Remove the holddown clamps a n d t h e spreader
opposite side o f t h e differential housing ( F i g . 22).
tool f r o m t h e differential housing (Fig. 22).
"Zero" t h e d i a l indicator pointer.
(23) I n s t a l l t h e differential bearing caps a n d
CAUTION: Do not exceed the specified separation t i g h t e n t h e bolts " f i n g e r - t i g h t " u n t i l each bolt head
distance when separating the differential housing. If is l i g h t l y "seated" on t h e bearing cap.
the housing is over-separated, it could be distorted (24) I n s t a l l a p i l o t stud a t t h e r i g h t side o f t h e dif-
or damaged, which would necessitate replacement. f e r e n t i a l housing. A t t a c h D i a l Indicator Tool C-3339
to t h e differential housing ( v i a t h e p i l o t stud) w i t h
 • FRONT SUSPENSION 2 - 63

the indicator plunger slightly "loaded" against t h e When installing t h e r i n g gear o n the differen-
i n n e r face of the flange (Fig. 23). "Zero" t h e d i a l i n - t i a l case, i t i s o f t e n p o s s i b l e t o r e d u c e e x c e s s i v e
dicator pointer. r i n g gear " r u n o u t " b y positioning the r i n g gear
w i t h i t s m a x i m u m " r u n o u t " m a r k l o c a t e d 180 d e -
FLANGE FACE DIAL INDICATOR grees o p p o s i t e t h e f l a n g e m a x i m u m " r u n o u t "
mark.
(26) Remove the drive p i n i o n gear shaft (axle) yoke
n u t and washer. Use Removal Tool C-452 and H o l d -
i n g Tool C-3281 to remove t h e drive p i n i o n gear
shaft (axle) yoke (Fig. 24).
(27) Use Removal Tool C-748 t o remove t h e drive
p i n i o n gear shaft seal (Fig. 25).

Fig. 23 Differential Case Flange "Runout"

Measurement
(25) Measure t h e differential case flange " r u n o u t "
by r o t a t i n g t h e flange several complete revolutions
and observing t h e d i a l indicator pointer. M a r k t h e
flange at t h e location of m a x i m u m " r u n o u t " . The
flange m a x i m u m " r u n o u t " should n o t exceed 0.003 J9003-59
i n c h (0.076 mm).
Fig. 24 Drive Pinion Gear Shaft (Axle) Yoke
Removal
 RH439 •

Fig. 25 Model 60 Axle Differential—Exploded View

 • FRONT SUSPENSION
(28) Remove t h e o i l slinger, t h e shaft front b e a r i n g
and the " p r e l o a d " torque shims (Fig. 25). Record t h e
thickness o f t h e shims. T h i s w i l l s a v e t i m e i f t h e y
should become misplaced.
(29) Use a n appropriate tool t o force the drive p i n -
i o n gear shaft ( w i t h t h e rear bearing) from t h e dif-
ferential h o u s i n g bore (Fig. 25).
(30) Use Removal Tool D-158 and Handle Tool C-
4171 t o remove t h e drive p i n i o n gear shaft outer
(front) b e a r i n g cup f r o m the differential housing bore
(Fig. 25).
(31) Use Removal Tool D-162 and Handle Tool C-
4171 to remove t h e d r i v e p i n i o n gear shaft i n n e r
(rear) b e a r i n g cup from the differential housing bore
(Fig. 25).
(32) Remove t h e d r i v e p i n i o n gear depth shims
from t h e differential housing bore (Fig. 25). Record
the thickness o f the depth shims.
(33) Remove t h e i n n e r (rear) bearing f r o m t h e
drive p i n i o n gear shaft w i t h Removal Tool DD-914-P,
Adapter R i n g Tools DD-914-9 a n d Plate Tools D D -
914-37 (or Tool C-293-P a n d Adapter Tools C-293-37).
(34) Clamp t h e differential case i n a vise equipped
w i t h soft jaws. Use a p i n punch t o force t h e p i n i o n
gear mate shaft lock p i n f r o m t h e differential case
bore (Fig. 26).
DIFFERENTIAL
Fig. 26 Pinion Gear Mate Shaft Lock Pin Removal
(35) Remove the d i f f e r e n t i a l p i n i o n gear mate shaft
f r o m the d i f f e r e n t i a l case bores, remove the differen-
t i a l p i n i o n gears and remove the t h r u s t washers (lo-
cated adjacent t o t h e differential case i n t e r n a l
surface) f r o m t h e d i f f e r e n t i a l case.
(36) Remove t h e d i f f e r e n t i a l side gears a n d t h e
t h r u s t washers (located adjacent t o t h e differential
case i n t e r n a l surface) f r o m the differential case.
(37) Remove the d i f f e r e n t i a l case from the vise.
(38) Remove the bearings f r o m the differential case
w i t h Removal Tool DD-914-P, Adapter R i n g Tools
DD-914-8, Plate Tools DD-914-62, Screw Extension
Tool DD-914-7, B u t t o n Tool DD-914-42 a n d a vise
(Fig. 27).
2 - 65
Use c a r e a n d e n s u r e t h a t t h e a d a p t e r r i n g s a r e
s i t u a t e d so t h a t t h e y d o n o t cause f o r c e t o b e ex-
erted o n the b e a r i n g race.
Fig. 27 Differential Bearing Removal
(39) Remove t h e differential bearing shims from
each of t h e differential case hubs a n d m a r k t h e m
( w i t h hub identity) for assembly reference. Record
the thickness o f the shims.
(40) Remove the seals from the axle shaft tubes.
CLEANING/INSPECTION
(1) Wash and clean a l l the differential components
(Fig. 25) w i t h a n appropriate cleaning solvent and,
w i t h t h e exception of t h e bearings, d r y w i t h com-
pressed air.
Do n o t steam clean the differential compo-
nents.
(2) To clean the axle shaft tubes, insert a stiff w i r e
into each tube, attach a clean cloth to the w i r e a t the
differential housing opening and w i t h d r a w t h e w i r e
(and cloth) f r o m t h e housing outward t h r o u g h t h e
tube.
(3) Inspect t h e differential bearings and t h e drive
p i n i o n gear shaft bearings, and the differential case
and housing (Fig. 25):
• the differential bearings and the drive p i n i o n gear
shaft outer (front) and inner (rear) bearings and cups
should have a smooth appearance w i t h no broken/
dented surfaces on t h e bearing rollers or t h e roller
contact surfaces;
• the bearing races m u s t not be distorted or cracked;
I f a differential bearing must be replaced, the
c u p a n d t h e b e a r i n g m u s t b e r e p l a c e d as a
"matched set" only.
• a l l t h e machined contact surfaces i n t h e differen-
t i a l housing a n d on t h e differential bearing caps
should be smooth and w i t h o u t any raised edges;
 2 - 66 FRONT SUSPENSION •
• the drive p i n i o n gear shaft outer (front) and i n n e r (6) C l a m p t h e differential case i n a vise equipped
(rear) bearing cup bores i n t h e differential housing w i t h soft j a w s and alternately t i g h t e n each r i n g gear
should be smooth; a n d bolt w i t h 110 N*m (81 ft-lbs) torque.
• i f i t exists, raised m e t a l o n t h e shoulders o f the (7) Place Master D i f f e r e n t i a l B e a r i n g Tools D-117
bearing cup bores i n c u r r e d d u r i n g removal o f t h e on the differential case hubs (Fig. 28).
cups should be removed w i t h a hand stone.
MASTER BEARING
(4) E x a m i n e t h e differential pinion gear mate
shaft, p i n i o n gears, side gears and t h r u s t washers
(Fig. 25) for wear a n d damage. Replace a l l defective
components.
I f either o f the differential p i n i o n gears is n o t MASTER BEARING
reusable, b o t h gears m u s t be replaced as a
" m a t c h e d s e t " only. D o n o t replace only one
gear.
(5) E x a m i n e t h e r i n g gear and t h e drive p i n i o n
gear shaft (Fig. 25) for excessively w o r n and chipped
teeth. E x a m i n e the r i n g gear for damaged a t t a c h i n g
bolt threads.
I f r e p l a c e m e n t o f either gear is necessary, b o t h
the r i n g gear a n d t h e drive p i n i o n gear shaft
m u s t b e r e p l a c e d b e c a u s e t h e y a r e a v a i l a b l e as
a " m a t c h e d set" only.
(6) Inspect t h e d r i v e p i n i o n gear shaft (axle) yoke
(Fig. 25) for cracks, w o r n splines, " p i t t e d " areas, and
a rough/corroded seal contact surface. Repair or r e -
place the yoke as necessary. RY652
(7) Inspect the drive p i n i o n gear shaft bearing "pre-
Fig. 28 Master Bearing Tools On Hubs
load" torque shims (Fig. 25) for cracks, damage a n d
distortion. I n s t a l l replacement shims ( i f necessary) (8) Position Spreader Tool W-129-A on t h e differen-
for the "preload" torque adjustment. t i a l housing w i t h the tool dowel pins "seated" i n the
locating holes (Fig. 29). I n s t a l l the holddown clamps
ASSEMBLY and t i g h t e n the tool t u r n b u c k l e " f i n g e r - t i g h t " .
(1) L u b r i c a t e a l l t h e differential components w i t h TOOL W-129-A*
hypoid gear l u b r i c a n t .
(2) I n s t a l l t h e differential side gears a n d t h r u s t
washers, p i n i o n gears and t h r u s t washers and p i n i o n
gear mate shaft i n t h e differential case (Fig. 25).
(3) A l i g n the lock p i n hole i n the p i n i o n gear mate
shaft w i t h the hole i n the differential case (Fig. 25).
Insert a n d "seat" t h e lock p i n i n the case and t h e
shaft.
I f replacement gears a n d thrust washers were
installed, i t i s not necessary t o measure the gear
" b a c k l a s h " . The gear meshing w i l l be correct be-
cause " c l o s e " m a c h i n i n g tolerances a r e u s e d
d u r i n g m a n u f a c t u r e o f t h e gears.
(4) Position t h e r i n g gear o n t h e differential case TOOL C-3339 RH437
flange and a l i g n t h e r i n g gear threaded holes w i t h
those i n the differential case flange (Fig. 25). Fig. 29 Differential Housing Separation
(5) Insert r e p l a c e m e n t r i n g gear bolts (Fig. 25) (9) I n s t a l l a pilot stud a t t h e left side o f t h e differ-
t h r o u g h the differential case flange and thread t h e m e n t i a l housing. A t t a c h D i a l Indicator Tool C-3339 t o
i n t o the r i n g gear. the differential housing (via the pilot stud) w i t h t h e
After a l l the bolts are initially correctly indicator plunger s l i g h t l y "loaded" against the oppo-
t h r e a d e d i n t o t h e r i n g g e a r b o l t holes, " t a p " t h e site side o f the differential housing (Fig. 29). "Zero"
r i n g gear w i t h a non-metallic mallet a n d ensure
the d i a l indicator pointer.
t h a t i t i s f l u s h against the flange.
 • FRONT SUSPENSION
CAUTION: Do not exceed the specified separation
distance when separating the differential housing. If
the housing is over-separated, it could be distorted
or damaged, which would necessitate replacement.
(10) T i g h t e n the spreader tool t u r n b u c k l e (Fig. 29)
and separate t h e differential housing only enough t o
i n s t a l l the differential case i n the housing. S e p a r a t e
the d i f f e r e n t i a l h o u s i n g a m a x i m u m distance o f
0.38 m m (0.015 i n ) w i t h t h e s p r e a d e r t o o l . Mea-
sure t h e separation distance w i t h t h e d i a l indicator
(Fig. 29) as t h e housing i s being separated.
(11) Remove t h e d i a l indicator tool and t h e pilot
stud (Fig. 29) w h e n the differential housing has been
separated sufficiently t o i n s t a l l t h e differential case
i n the housing.
(12) I n s t a l l t h e differential case i n t h e differential
housing.
(13) Remove the holddown clamps a n d the spreader
tool from the differential housing (Fig. 29).
(14) Observe the assembly reference m a r k s and po-
sition t h e b e a r i n g caps a t t h e i r o r i g i n a l locations.
T i g h t e n the bearing cap bolts " f i n g e r - t i g h t " .
(15) I n s t a l l a pilot s t u d a t the r i g h t side of the dif-
ferential housing. A t t a c h D i a l Indicator Tool C-3339
to t h e differential housing ( v i a t h e p i l o t stud) w i t h
the indicator plunger s l i g h t l y "loaded" against t h e
back o f the r i n g gear (Fig. 30).
Fig. 30 Differential Case "End Play" Measurement
(16) Insert a small p r y bar between the bearing cap
a n d the left side of the d i f f e r e n t i a l case. P r y the dif-
ferential case as far as possible t o w a r d the r i g h t side
of the differential housing (Fig. 30). "Zero" the dial
indicator pointer.
2 - 67
(17) Pry t h e d i f f e r e n t i a l case t o w a r d the left side o f
the housing w i t h t h e p r y bar and r e c o r d the t r a v e l
distance indicated b y t h e d i a l indicator pointer.
The measurement above indicates t h e shim
t h i c k n e s s n e c e s s a r y f o r d i f f e r e n t i a l case " z e r o "
" e n d - p l a y " (i.e., t o e l i m i n a t e t h e space/gap t h a t
exists b e t w e e n t h e differential bearings a n d t h e
d i f f e r e n t i a l case). T h e a c t u a l t o t a l s h i m t h i c k -
ness w i l l b e d e t e r m i n e d d u r i n g t h e r i n g g e a r
" b a c k l a s h " a d j u s t m e n t (after i n s t a l l a t i o n o f t h e
d r i v e p i n i o n gear shaft).
(18) Remove t h e d i a l indicator tool and t h e p i l o t
s t u d from t h e d i f f e r e n t i a l housing.
(19) Remove t h e differential bearing caps.
(20) Position Spreader Tool W-129-A o n the differ-
e n t i a l housing w i t h t h e tool dowel pins "seated" i n
t h e locating holes ( F i g . 29). I n s t a l l t h e holddown
clamps a n d t i g h t e n t h e tool t u r n b u c k l e "finger-
tight".
(21) I n s t a l l a p i l o t s t u d a t the left side o f the dif-
f e r e n t i a l housing. A t t a c h D i a l Indicator Tool C-3339
to t h e differential housing ( v i a t h e pilot stud) w i t h
the indicator p l u n g e r s l i g h t l y "loaded" against t h e
opposite side o f t h e differential housing ( F i g . 29).
"Zero" the d i a l indicator pointer.
CAUTION: Do not exceed the specified separation
distance when separating the differential housing. If
the housing is over-separated, it could be distorted
or damaged, which would necessitate replacement.
(22) T i g h t e n the spreader tool t u r n b u c k l e (Fig. 29)
a n d separate the differential housing only enough t o
remove the d i f f e r e n t i a l case from the housing. Sepa-
r a t e t h e d i f f e r e n t i a l h o u s i n g a m a x i m u m dis-
t a n c e o f 0.38 m m (0.015 i n ) w i t h t h e s p r e a d e r
t o o l . Measure t h e separation distance w i t h t h e d i a l
indicator (Fig. 29) as t h e housing is being separated.
(23) Remove t h e d i a l indicator tool and t h e p i l o t
stud (Fig. 29) w h e n t h e differential housing has been
separated sufficiently t o remove the differential case
f r o m the housing.
(24) Remove the differential case from the differen-
t i a l housing.
(25) Remove t h e holddown clamps and the spreader
tool from t h e differential housing (Fig. 29).
(26) I n s t a l l t h e axle shaft seals i n t h e tubes w i t h
Tool C-4026-A and H a n d l e Tool C-4171.
DRIVE PINION GEAR DEPTH INFORMATION
D r i v e p i n i o n gear shafts and r i n g gears are sup-
p l i e d as "matched sets" only. The i d e n t i f y i n g n u m -
bers for b o t h the drive p i n i o n gear and the r i n g gear
are etched i n t o t h e face o f each gear (Fig. 31). I n ad-
d i t i o n , either a plus (" + ") number, a m i n u s ("-")
n u m b e r or a zero ("0") i s also etched i n t o the face o f
the drive p i n i o n gear. T h i s number indicates t h e
a m o u n t ( i n thousandths o f a n inch) t h a t t h e drive
2 - 68 FRONT SUSPENSION
p i n i o n gear depth o f mesh varies from t h e standard
depth " s e t t i n g " o f 3.125 inches (79.37 m m ) for Model
60 axles. T h e standard depth o f mesh provides t h e
best teeth contact between t h e drive p i n i o n gear
teeth and t h e r i n g gear teeth. The depth variance of
a d r i v e p i n i o n gear can be either greater ( + ) , zero (0)
or less t h a n (-) the standard depth.
DRIVE PINION
Fig. 31 Drive Pinion Gear ID Numbers
The standard depth is t h e distance (Fig. 32) from
the centerline o f the axle shaft/ring gear t o the face
of t h e drive p i n i o n gear. F o r a Model 60 axle, t h e
standard depth/distance i s 3.125 inches (79.37 m m ) .
MODEL DEPTH
60 SETTING
Fig. 32 Drive Pinion Gear Standard Depth/Distance
Compensation for t h e depth variance is achieved by
shims placed adjacent t o t h e drive p i n i o n gear shaft
rear bearing cup (Fig. 33).
For Example:
• one complete " p a c k " o f d e p t h shims is re-
quired i f the depth variance is " 0 " ;
• i f t h e d e p t h v a r i a n c e i s " + 3 " ( m + 8), t h e d r i v e
p i n i o n g e a r w o u l d r e q u i r e 0.003 i n c h (0.08 m m )
less i n s h i m t h i c k n e s s t h a n a d e p t h v a r i a n c e o f
" 0 " (i.e., o n e c o m p l e t e s h i m " p a c k " m i n u s 0.003
i n c h o r 0.08 m m ) ;
•
DRIVE
Fig. 33 Shim Locations
• b y r e d u c i n g t h e t h i c k n e s s o f t h e s h i m s 0.003
i n c h (0.08 m m ) , t h e d e p t h p o s i t i o n o f t h e d r i v e
p i n i o n g e a r w i l l b e d e c r e a s e d f r o m 3.128 i n c h e s
(79.45 m m ) t o t h e s t a n d a r d d e p t h o f 3.125 i n c h e s
(79.37 m m ) ; o r
• i f t h e d e p t h v a r i a n c e i s " - 3 " (m-8), t h e d r i v e
p i n i o n g e a r w o u l d r e q u i r e 0.003 i n c h (0.08 m m )
more i n shim thickness than a depth variance o f
" 0 " (i.e., o n e c o m p l e t e s h i m " p a c k " p l u s 0.003
i n c h o r 0.08 m m ) ;
• b y i n c r e a s i n g t h e t h i c k n e s s o f t h e s h i m s 0.003
i n c h (0.08 m m ) , t h e d e p t h p o s i t i o n o f t h e d r i v e
p i n i o n g e a r w i l l b e i n c r e a s e d f r o m 3.122 i n c h e s
(79.34 m m ) t o t h e s t a n d a r d d e p t h o f 3.125 i n c h e s
(79.37 m m ) .
I f t h e o r i g i n a l drive p i n i o n gear shaft a n d r i n g
gear set w i l l be installed b u t the depth shims m u s t
be replaced, measure t h e thickness o f the o r i g i n a l
depth shims a n d " b u i l d " a replacement "pack" o f
depth shims w i t h the same thickness.
I f equipped, the o i l slinger located between the
r e a r b e a r i n g a n d t h e t h r u s t face o f d r i v e p i n i o n
gear must b e measured a n d t h e thickness i n -
cluded w i t h the total shim " p a c k " thickness.
I f the o r i g i n a l d r i v e pinion/ring gear set is not re-
usable, the d e p t h s h i m thickness for the replacement
drive p i n i o n gear m u s t be determined before i n s t a l l -
i n g the d i f f e r e n t i a l case i n the housing.
I f a replacement gear set is being installed, note
the depth variance etched into both the o r i g i n a l and
the replacement drive p i n i o n gear, a n d alter t h e
thickness o f t h e o r i g i n a l depth shims to compensate
for the difference i n the depth variances. Refer to the
D r i v e P i n i o n Gear D e p t h Variance chart.
 • FRONT SUSPENSION 2 - 69

For Example: original depth shims.

• i f t h e o r i g i n a l d r i v e p i n i o n gear h a s a d e p t h I n d i v i d u a l depth shims are available i n 0.003-inch,
v a r i a n c e o f " + 2" ( m + 5) a n d t h e r e p l a c e m e n t 0.005-inch, 0.010-inch, a n d 0.030-inch (0.08-mm,
drive pinion gear has a depth variance o f " - 2 " 0.13-mm, 0.25-mm, and 0.76-mm) thicknesses.
(m-5), a d d 0.004-inch (0.10-mm) t h i c k n e s s t o t h e

DRIVE PINION GEAR DEPTH VARIANCE

Original Pinion Replacement Pinion G e a r Depth V a r i a n c e

G e a r Depth
Variance -4 -3 • -2 -1 0 + 1 +2 +3 +4

+4 + 0.008 + 0.007 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0

+3 + 0.007 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001

+2 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001 -0.002

+ 1 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001 -0.002 -0.003

0 + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001 -0.002 -0.003 -0.004

-1 + 0.003 + 0.002 + 0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005

-2 + 0.002 . +0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006

-3 + 0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007

-4 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007 -0.008

J8902-46

DRIVE PINION GEAR DEPTH MEASUREMENT

AND ADJUSTMENT WITH TOOL SET D-271
The following drive p i n i o n gear depth (i.e., t h e
depth of the gear teeth mesh between t h e d r i v e p i n -
ion gear and t h e r i n g gear) measurement a n d adjust-
m e n t procedure involves u s i n g Tool Set D-271 (Fig.
34).
(1) Insert Master P i n i o n Block Tool D-120 i n t o t h e
drive p i n i o n gear shaft bore i n t h e differential hous-
i n g (Fig. 35).
(2) Place A r b o r Disc Tools D-116-2 o n A r b o r Tool
D-115-3 and position t h e tool set i n t h e differential
housing w i t h t h e disc tools located i n t h e differential
b e a r i n g cradles (Fig. 36). This is the centerline o f the
r i n g gear/axle shaft.
(3) Place P i n i o n H e i g h t Block Tool D-116-1 o n top
of t h e master p i n i o n block tool and against t h e arbor
tool (Fig. 37).
(4) Place Gauge Block Tool D-115-2 a n d D i a l I n d i -
cator Tool D-106-5 on t h e l o w e s t step o f t h e p i n i o n
h e i g h t block tool ( F i g . 38). Ensure t h a t t h e gauge
block tool is r e s t i n g f i r m l y o n t h e lowest step o f p i n -
ion h e i g h t block tool a n d "zero" t h e d i a l indicator Fig. 34 Pinion Gear Depth Gauge Tool Set D-271
pointer.
(5) W i t h t h e d i a l indicator pointer "zeroed", move t i p of t h e d i a l indicator p l u n g e r contacts t h e arbor
the gauge block tool t o w a r d t h e arbor tool u n t i l t h e tool ( F i g . 38). Slide t h e gauge block tool ( w i t h t h e
2 - 70 FRONT SUSPENSION
Fig. 35 Pinion Block Tool Inserted In Shaft Bore
Fig. 36 Arbor Disc & Arbor Tools In Housing
Fig. 37 Pinion Height Block Tool Against Arbor Tool
dial indicator) across and back and f o r t h along t h e
arbor tool w h i l e observing the d i a l indicator pointer.
Record t h e longest plunger t r a v e l distance, whether
i n w a r d ("-") or outward (" + "), indicated b y t h e
pointer.
•
Fig. 38 Drive Pinion Gear Depth Measurement
The longest plunger t r a v e l distance indicated,
plus o r minus the d e p t h variance etched into the
face o f t h e d r i v e p i n i o n gear, i s t h e r e q u i r e d
thickness f o r the drive p i n i o n gear depth shims.
(6) Measure the thickness o f each depth s h i m sep-
arately w i t h a micrometer a n d combine t h e shims
necessary t o obtain t h e t o t a l required depth s h i m
" p a c k " thickness. I f e q u i p p e d , t h e o i l s l i n g e r l o -
cated between t h e rear bearing a n d the thrust
face o f d r i v e p i n i o n gear m u s t b e measured a n d
the thickness included w i t h t h e total shim
" p a c k " thickness.
(7) Remove the measurement tools f r o m the differ-
e n t i a l housing.
(8) Place t h e depth shims i n t o the drive p i n i o n gear
shaft rear bearing bore i n t h e differential housing
and t h e n force t h e rear bearing cup i n t o t h e bore
w i t h B e a r i n g Cup I n s t a l l a t i o n Tool D - l l l and D r i v e r
H a n d l e Tool C-4171. Ensure t h a t t h e cup is correctly
"seated".
(9) Use B e a r i n g Cup I n s t a l l a t i o n Tool C-4203 a n d
D r i v e r Handle Tool C-4171 t o force the drive p i n i o n
gear shaft outer (front) b e a r i n g cup i n t o the differen-
t i a l housing bore (Fig. 39).
(10) Force t h e i n n e r (rear) b e a r i n g onto t h e drive
p i n i o n gear shaft u n t i l i t is completely "seated" w i t h
B e a r i n g I n s t a l l a t i o n Tool C-3095-A (Fig. 40).
(11) I n s t a l l t h e d r i v e p i n i o n gear shaft i n t h e dif-
f e r e n t i a l housing.
(12) I n s t a l l the drive p i n i o n gear shaft outer (front)
bearing, o i l slinger, (axle) yoke, washer and n u t . Use
I n s t a l l a t i o n Tool C-3718 a n d H o l d i n g Tool 3281 to
i n s t a l l t h e yoke (Fig. 41).
Do n o t install t h e " p r e l o a d " torque shims o r
t h e d r i v e p i n i o n g e a r s h a f t seal a t t h i s t i m e .
(13) "Seat" t h e shaft bearings b y t i g h t e n i n g t h e
(axle) yoke n u t u n t i l i t requires 1 N T H (10 in-lbs)
torque t o rotate the d r i v e p i n i o n gear shaft (Fig. 42).
Use a Newton-meter or a n inch-pound torque wrench
to measure the torque.
 • FRONT SUSPENSION
BEARING CUP DRIVER
INSTALLATION TOOL G4203 HANDLE
Fig. 39 Shaft Outer (Front) Bearing Cup Installation
Fig. 40 Shaft Inner (Rear) Bearing Installation
(14) Measure t h e drive p i n i o n gear depth o f mesh
( w i t h t h e r i n g gear). Place t h e p i n i o n h e i g h t block
tool on t h e face o f t h e drive p i n i o n gear (Fig. 35).
Place t h e arbor a n d disc tools i n t o t h e d i f f e r e n t i a l
b e a r i n g cradles i n t h e differential housing (Fig. 36).
Place t h e gauge block tool w i t h t h e d i a l indicator
tool on the lowest step of the p i n i o n h e i g h t block tool
(Fig. 38). Ensure t h a t the gauge block tool is r e s t i n g
f i r m l y on the lowest step of the p i n i o n h e i g h t block
tool and "zero" the d i a l indicator pointer.
(15) W i t h the d i a l indicator pointer "zeroed", move
the gauge block tool t o w a r d the arbor tool u n t i l t h e
t i p o f the d i a l indicator plunger contacts t h e arbor
tool ( F i g . 38). Slide t h e gauge block tool ( w i t h t h e
d i a l indicator) across and back and f o r t h along t h e
arbor tool w h i l e observing the d i a l indicator pointer.
2 - 71
Fig. 42 Rotating Drive Pinion Gear Shaft
Record t h e longest plunger t r a v e l distance (whether
i n w a r d or outward) indicated b y the pointer.
The d i a l i n d i c a t o r pointer s h o u l d indicate a n
i n w a r d ("-") o r o u t w a r d (" + ") m a x i m u m t r a v e l
distance t h a t closely a p p r o x i m a t e s t h e d e p t h
v a r i a n c e e t c h e d i n t o t h e face o f t h e d r i v e p i n i o n
gear.
(16) I f the measurement indicates t h a t t h e actual
depth variance is w i t h i n 0.002 i n c h (0.05 m m ) of the
depth variance etched into the drive p i n i o n gear face,
i t is acceptable.
(17) I f t h e drive p i n i o n gear actual depth variance
is w i t h i n t h e specified tolerance, continue w i t h t h e
differential assembly. I f the actual depth variance is
not w i t h i n t h e specified tolerance, correct t h e s h i m
thickness accordingly and t h e n re-measure the depth
variance
F i g u r e 43 d e p i c t s a n a r r o w p o i n t i n g o u t w a r d
a n d i n w a r d w i t h i n t h e d r i v e p i n i o n gear shaft.
2 - 72 FRONT SUSPENSION
The o u t w a r d direction (pointing t o w a r d the
yoke) indicates that i f the drive p i n i o n gear
shaft d e p t h s h i m thickness is decreased, the dis-
tance/depth f r o m t h e centerline o f the axle/ring
g e a r t o t h e d r i v e p i n i o n gear face w o u l d b e i n -
c r e a s e d (i.e., i t w o u l d i n c r e a s e t h e d i a l i n d i c a t o r
p l u n g e r o u t w a r d (" + ") t r a v e l d i s t a n c e ) . T h e
shaft b e a r i n g " p r e l o a d " torque s h i m thickness
does n o t affect t h e d e p t h o f m e s h adjustment.
The a r r o w o n the r i n g gear indicates the m e t h o d
of increasing o r decreasing shim thickness a t
t h e a p p l i c a b l e side o f t h e d i f f e r e n t i a l case t o i n -
crease o r decrease the r i n g gear " b a c k l a s h " a n d
the differential bearing "preload" torque.
REMOVE SHIMS
SHIM PACKS
Fig. 43 Shim Locations
(18) Remove the measurement tools f r o m the differ-
e n t i a l housing.
(19) Remove t h e d r i v e p i n i o n gear shaft n u t ,
washer, (axle) yoke, o i l slinger, a n d outer (front)
bearing.
(20) I n s t a l l the bearing "preload" torque shims t h a t
were removed d u r i n g disassembly (Fig. 43), t h e shaft
outer (front) bearing a n d the o i l slinger o n t h e d r i v e
p i n i o n gear shaft.
(21) A p p l y a l i g h t coating of hypoid gear l u b r i c a n t
on t h e l i p o f drive p i n i o n gear shaft seal, position i t
over the end o f the shaft and i n s t a l l i t i n the differ-
e n t i a l housing bore w i t h Seal I n s t a l l a t i o n Tool C-
3719-A a n d D r i v e r H a n d l e Tool C-4171 (Fig. 44).
(22) I n s t a l l the drive p i n i o n gear shaft (axle) yoke,
•
Fig. 44 Drive Pinion Gear Shaft Seal Installation
washer, and a replacement n u t on t h e shaft. T i g h t e n
the n u t w i t h 325 to 406 N * m (240 t o 300 ft-lbs)
torque.
(23) Use a Newton-meter or a n i n c h pound torque
wrench (Fig. 42) to rotate the d r i v e p i n i o n gear shaft
and observe t h e indicated b e a r i n g "preload" torque.
The torque necessary to rotate t h e drive p i n i o n gear
shaft should be between 1 to 3 N»m (10 t o 20 in-lbs).
I f t h e drive p i n i o n gear shaft bearing " p r e -
l o a d " t o r q u e is n o t w i t h i n t h e specified toler-
ance, c o r r e c t t h e s h i m t h i c k n e s s a c c o r d i n g l y . T o
increase the " p r e l o a d " torque, decrease the s h i m
t h i c k n e s s ; t o decrease t h e " p r e l o a d " t o r q u e , i n -
RY660 crease t h e s h i m thickness. S h i m s a r e a v a i l a b l e
i n t h e f o l l o w i n g t h i c k n e s s e s : 0.003, 0.005, 0.010,
a n d 0.030 i n c h (0.076, 0.127, 0.254, a n d 0.762 m m ) .
DRIVE PINION GEAR DEPTH MEASUREMENT
AND ADJUSTMENT WITH TOOLSET 0-758-06
The following drive p i n i o n gear depth (i.e., t h e
depth o f the gear teeth mesh between t h e drive p i n -
ion gear and t h e r i n g gear) alternate measurement
and adjustment procedure involves u s i n g A x l e Mea-
surement Gauge Tool Set C-758-D6. Tool Set C-758-
D6 is also used to i n s t a l l the d r i v e p i n i o n gear shaft
bearing cups.
(1) Position each drive p i n i o n gear shaft b e a r i n g
cups i n t h e applicable differential h o u s i n g bore.
(2) B e g i n assembling Tool Set C-758-D6 b y posi-
t i o n i n g D r i v e Pinion Gear Shaft Locating Spacer
Tool SP-5184 on the tool p r i m a r y screw.
 • FRONT SUSPENSION
(3) Position t h e drive p i n i o n gear shaft i n n e r (rear)
b e a r i n g o n t h e tool p r i m a r y screw a n d insert t h e
screw ( w i t h t h e bearing) i n t o and t h r o u g h t h e differ-
e n t i a l h o u s i n g bore.
(4) Position t h e drive p i n i o n gear shaft outer (front)
b e a r i n g o n t h e tool p r i m a r y screw a t t h e opposite
side o f t h e differential housing. I n s t a l l Compression
Sleeve Tool SP-535-A, C e n t r a l i z i n g Washer Tool SP-
534 a n d P r i m a r y Screw N u t Tool SP-533 o n t h e tool
p r i m a r y screw.
(5) L u b r i c a t e the drive p i n i o n gear shaft outer a n d
i n n e r (front and rear) bearings w i t h M O P A R H y p o i d
Gear L u b r i c a n t (or a n equivalent product).
(6) T i g h t e n t h e n u t tool, w h i l e r e t a i n i n g the com-
pression sleeve tool w i t h Tool C-3281, and force t h e
d r i v e p i n i o n gear shaft bearing cups into t h e differ-
e n t i a l h o u s i n g bearing cup bores. A l l o w t h e c o m -
pression t o o l t o rotate several revolutions
d u r i n g t h e tightening p r o c e s s t o p e r m i t t h e b e a r -
i n g rollers t o properly align a n d prevent " b r i n e l -
B n g " o f the bearing cups.
D o n o t remove t h e tool after installing t h e
d r i v e p i n i o n gear shaft b e a r i n g cups. T h e d r i v e
p i n i o n gear depth o f mesh must be measured
next.
(7) Loosen t h e n u t tool and t h e n re-tighten i t suf-
f i c i e n t l y t o o b t a i n 1 t o 3 N»m (10 to 30 in-lbs) o f
b e a r i n g " p r e l o a d " torque. W h i l e t i g h t e n i n g t h e n u t ,
rotate the tool t o align the bearing rollers.
(8) I n s t a l l Gauge Block Tool SP-5260 on Tool Set
C-758-D6 (Fig. 45) and t i g h t e n t h e r e t a i n i n g screw
securely w i t h a n A l l e n wrench.
(9) Position Cross Bore A r b o r Tool SP-5183 ( F i g .
45) i n t h e differential bearing cradles ( i n t h e differ-
e n t i a l housing). Center the arbor tool i n the cradles
so t h a t a n approximately equal space exists a t b o t h
ends.
(10) Observe t h e i n s t a l l a t i o n reference letters a n d
position t h e differential bearing caps on t h e arbor
tool (Fig. 45). I n s t a l l t h e cap bolts and t i g h t e n t h e m
w i t h 95 t o 122 N*m (70 to 90 ft-lbs) torque.
(11) To measure t h e drive p i n i o n gear depth o f
mesh, select a n d insert a feeler gauge blade t h a t
" s n u g l y " fits between t h e arbor tool and t h e gauge
block tool (Fig. 45). T h e " f i t " m u s t be " s n u g " b u t not
excessively t i g h t . R e c o r d t h e t h i c k n e s s o f t h e
f e e l e r g a u g e b l a d e so t h a t i t c a n b e u s e d w h e n
d e t e r m i n i n g the correct d r i v e p i n i o n gear d e p t h
shim thickness.
(12) Observe t h e depth variance etched i n t o t h e
end o f t h e drive p i n i o n gear (e.g., 0, - 1 , -2, + 1 , + 2 ,
etc.). I f the etched depth variance is a "-" (minus)
value, add i t to the thickness measured and recorded
i n step (11) above. I f the etched depth variance is a
" -f " (plus) value, subtract i t f r o m the thickness mea-
sured and recorded i n step (11) above.
2 - 73
RH1400
Fig. 45 Drive Pinion Gear Depth Measurement
(13) Remove t h e arbor tool f r o m t h e differential
housing cavity and t h e tool set ( w i t h t h e outer and
inner/front and rear bearings) f r o m t h e housing bore.
(14) Use Removal Tool D-162 and D r i v e r Handle
Tool C-4171 to remove t h e drive p i n i o n gear shaft
rear bearing cup f r o m the differential housing bore.
(15) Position t h e depth shims i n t h e differential
housing rear bearing cup bore and i n s t a l l t h e bear-
i n g cup according t o the method previously described
i n steps (1) t h r o u g h (6) above. W h e n the b e a r i n g cup
is correctly "seated" i n the housing bore, remove the
tool set and the drive p i n i o n gear shaft bearings.
(16) I f the drive p i n i o n gear depth o f mesh w i t h the
r i n g gear has been correctly established according to
the instructions and i n f o r m a t i o n provided i n t h e pro-
cedure above, good gear teeth contact should exist.
(17) Lubricate t h e drive p i n i o n gear shaft i n n e r
(rear) bearing w i t h M O P A R H y p o i d Gear L u b r i c a n t
(or a n equivalent product) and i n s t a l l t h e b e a r i n g o n
the drive p i n i o n gear shaft w i t h Tool C-3095-A. Use
an arbor press w i t h the i n s t a l l a t i o n tool (Fig. 46).
(18) I n s t a l l t h e drive p i n i o n gear shaft w i t h t h e
bearing i n the differential housing bore.
(19) I n s t a l l t h e o r i g i n a l drive p i n i o n gear shaft
bearing "preload" torque shims followed b y t h e outer
(front) bearing.
D o n o t i n s t a l l t h e shaft o i l slinger o r seal a t
t h i s time.
(20) I n s t a l l the drive p i n i o n gear shaft (axle) yoke,
washer a n d n u t . T i g h t e n t h e n u t w i t h 339 t o 366
N n n (250 to 270 ft-lbs) torque. W h i l e t i g h t e n i n g , ro-
tate drive p i n i o n gear shaft several complete revolu-
tions to "seat" the bearing rollers.
(21) Use a Newton-meter or a n inch-pound torque
wrench t o rotate t h e drive p i n i o n gear shaft a n d
measure t h e bearing "preload" torque (Fig. 47). Ro-
tate the shaft several complete revolutions before re-
2 - 74 FRONT SUSPENSION
PINION GEAR
Fig. 46 Shaft Inner (Rear) Bearing Installation
cording t h e torque. The Correct bearing "preload"
torque i s 1 to 3 N»m (10 to 20 in-lbs) torque.
Fig. 47 Rotating Drive Pinion Gear Shaft
I f t h e drive p i n i o n gear shaft b e a r i n g " p r e -
l o a d " t o r q u e is n o t w i t h i n t h e specified toler-
ance, c o r r e c t t h e s h i m t h i c k n e s s a c c o r d i n g l y . T o
i n c r e a s e t h e " p r e l o a d " t o r q u e , decrease t h e s h i m
thickness; t o decrease the " p r e l o a d " t o r q u e , i n -
crease t h e s h i m t h i c k n e s s . S h i m s a r e a v a i l a b l e
i n t h e f o l l o w i n g t h i c k n e s s e s : 0.003, 0.005, 0.010,
a n d 0.030 i n c h (0.076, 0.127, 0.254, a n d 0.762 m m ) .
(22) A f t e r the correct drive p i n i o n gear shaft bear-
i n g " p r e l o a d " torque has been established, remove
the yoke, n u t and washer.
(23) I n s t a l l the o i l slinger and the seal on the drive
pinion gear shaft w i t h Seal I n s t a l l a t i o n Tool C-3719-
A and D r i v e r Handle C-4171.
•
(24) I n s t a l l the drive p i n i o n gear shaft (axle) yoke,
washer a n d n u t . T i g h t e n t h e n u t w i t h 339 t o 366
N-m (250 t o 270 ft-lbs) torque.
RING GEAR "BACKLASH" ADJUSTMENT
(1) Position Spreader Tool W-129-A on the differen-
t i a l h o u s i n g w i t h the tool dowel pins "seated" i n the
locating holes (Fig. 48). I n s t a l l the holddown clamps
and t i g h t e n the tool t u r n b u c k l e " f i n g e r - t i g h t " .
(2) I n s t a l l a p i l o t stud a t the left side o f the differ-
e n t i a l housing. A t t a c h D i a l Indicator Tool C-3339 t o
the d i f f e r e n t i a l housing (via the p i l o t stud) w i t h the
indicator plunger s l i g h t l y "loaded" against the oppo-
site side o f the differential housing (Fig. 48). "Zero"
the d i a l indicator pointer.
Fig. 48 Differential Housing Separation
CAUTION: Do not exceed the specified separation
distance when separating the differential housing. If
the housing is over-separated, it could be distorted
or damaged, which would necessitate replacement.
(3) T i g h t e n the spreader tool t u r n b u c k l e (Fig. 48)
and separate the differential housing only enough to
i n s t a l l t h e differential case i n the housing. S e p a r a t e
the differential housing a m a x i m u m distance o f
0.38 m m (0.015 i n ) w i t h t h e s p r e a d e r t o o l . Mea-
sure the separation distance w i t h the d i a l indicator
(Fig. 48) as the housing is being separated.
(4) Remove t h e d i a l indicator tool and t h e pilot
stud (Fig. 48) when the differential housing has been
separated sufficiently t o i n s t a l l the differential case
i n the housing.
(5) I n s t a l l Master B e a r i n g Tools D-117 o n the dif-
ferential case hubs and position the case i n the dif-
ferential housing w i t h the r i n g gear teeth "meshed"
w i t h t h e drive p i n i o n gear teeth. I f necessary, " r o c k "
the r i n g gear to " m e s h " the gear teeth.
(6) I n s t a l l a p i l o t stud a t the r i g h t side of the dif-
ferential housing. A t t a c h D i a l Indicator Tool C-3339
to the differential housing ( v i a the p i l o t stud) w i t h
the i n d i c a t o r plunger s l i g h t l y "loaded" against t h e
 • FRONT SUSPENSION 2 - 75

back o f t h e r i n g gear (Fig. 49). Ensure t h a t the r i n g the indicator plunger s l i g h t l y "loaded" against t h e
gear teeth and the drive p i n i o n gear teeth are t i g h t l y opposite side of t h e differential h o u s i n g ( F i g . 48).
"meshed" and "zero" the d i a l indicator pointer. "Zero" the d i a l indicator pointer.

CAUTION: Do not exceed the specified separation

distance when separating the differential housing. If
the housing is over-separated, it could be distorted
or damaged, which would necessitate replacement.

(13) T i g h t e n the spreader tool t u r n b u c k l e (Fig. 48)

and separate the differential housing only enough to
remove t h e differential case f r o m t h e housing. Sepa-
rate t h e d i f f e r e n t i a l h o u s i n g a m a x i m u m dis-
t a n c e o f 0.38 m m (0.015 i n ) w i t h t h e s p r e a d e r
t o o l . Measure the separation distance w i t h the d i a l
indicator (Fig. 48) as the housing is b e i n g separated.
(14) Remove t h e d i a l indicator tool and t h e pilot
stud (Fig. 48) w h e n t h e differential h o u s i n g has been
separated sufficiently t o remove the differential case
from the housing.
(15) Remove the differential case f r o m the differen-
t i a l housing.
(16) Remove the holddown clamps a n d the spreader
tool f r o m the differential housing (Fig. 48).
(17) Remove the master bearing tools from the dif-
ferential case hubs.
Fig. 49 Ring Gear "Backlash" Measurement (18) Position t h e " b a c k l a s h " shims ( w i t h t h e r e -
quired thickness determined above) o n the differen-
(7) Insert a small p r y bar between the bearing cap
t i a l case h u b ( r i n g gear side). Place t h e differential
a n d the left side of the differential case. P r y t h e dif-
bearing o n t h e h u b a n d i n s t a l l i t w i t h B e a r i n g I n -
ferential case/ring gear as f a r as possible t o w a r d the
stallation Tool C-4025-A and D r i v e r Handle Tool C-
r i g h t side o f the differential housing and away f r o m 4171 (Fig. 50).
t h e drive p i n i o n gear (Fig. 49). Observe the d i a l i n -
dicator plunger t r a v e l distance indicated b y t h e
pointer.
(8) Repeat the measurement several times u n t i l the
indicated plunger t r a v e l distance is consistently the
same for each measurement a n d t h e n record t h e
t r a v e l distance.
The measurement above indicates t h e shim
thickness necessary t o eliminate t h e r i n g gear BEARING
" b a c k l a s h " . S u b t r a c t this thickness f r o m t h e dif- INSTALLER TOOL
f e r e n t i a l case " z e r o " " e n d - p l a y " s h i m t h i c k n e s s .
The r i n g gear " b a c k l a s h " shims m u s t be p l a c e d
o n the h u b a t the r i n g gear side o f the differen-
t i a l case b e t w e e n t h e d i f f e r e n t i a l case a n d t h e
differential bearing.
(9) Remove t h e d i a l indicator tool and t h e p i l o t
stud (Fig. 49) from the differential housing.
(10) Remove the differential bearing caps.
(11) Position Spreader Tool W-129-A o n the differ-
e n t i a l housing w i t h t h e tool dowel pins "seated" i n
Fig. 50 Differential Bearing Installation
the locating holes (Fig. 48). I n s t a l l t h e holddown
clamps a n d t i g h t e n t h e tool t u r n b u c k l e "finger- (19) Position the r e m a i n i n g "zero" "end-play" shims
tight". on t h e h u b a t t h e opposite side o f the differential
(12) I n s t a l l a pilot stud a t the left side of the dif- case. Include a n additional 0.015-in (0.38-mm) t h i c k
ferential housing. A t t a c h D i a l Indicator Tool C-3339 shim o n t h i s h u b to provide the r e q u i r e d differential
to t h e differential housing ( v i a t h e p i l o t stud) w i t h bearing "preload" torque.
2 - 76 FRONT SUSPENSION

(20) I n s t a l l the other differential b e a r i n g on t h e

h u b w i t h Bearing I n s t a l l a t i o n Tool C-4025-A a n d
D r i v e r Handle Tool C-4171 ( F i g . 50).
(21) M a t c h each bearing cup w i t h i t s differential
bearing (original) counterpart a n d i n s t a l l t h e cups on
the bearings.
(22) Position Spreader Tool W-129-A o n t h e differ-
e n t i a l housing w i t h t h e tool dowel pins "seated" i n
the locating holes ( F i g . 48). I n s t a l l t h e holddown
clamps a n d t i g h t e n t h e tool t u r n b u c k l e "finger-
tight".
(23) I n s t a l l a pilot s t u d a t t h e left side o f t h e dif-
ferential housing. A t t a c h D i a l Indicator Tool C-3339
to t h e differential housing ( v i a t h e p i l o t stud) w i t h
the indicator plunger s l i g h t l y "loaded" against t h e
opposite side of t h e differential housing ( F i g . 48).
"Zero" t h e d i a l indicator pointer.
Fig. 51 Differential Bearing Cap Reference Letters

CAUTION: Do not exceed the specified separation

distance when separating the differential housing. If
the housing is over-separated, it could be distorted
or damaged, which would necessitate replacement.

(24) T i g h t e n the spreader tool t u r n b u c k l e ( F i g . 48)

and separate the differential housing o n l y enough to
i n s t a l l t h e differential case i n t h e housing. S e p a r a t e
the differential h o u s i n g a m a x i m u m distance o f
0.38 m m (0.015 i n ) w i t h t h e s p r e a d e r t o o l . Mea-
sure t h e separation distance w i t h t h e d i a l indicator
(Fig. 48) as the housing is being separated.
(25) Remove t h e d i a l indicator tool a n d t h e p i l o t
stud ( F i g . 48) when t h e differential housing has been
separated sufficiently t o i n s t a l l t h e d i f f e r e n t i a l case
i n t h e housing.
(26) I n s t a l l the differential case i n t h e differential
housing.
(27) Remove the holddown clamps a n d t h e spreader
tool f r o m t h e differential housing (Fig. 48).
(28) I n s t a l l t h e differential bearing caps. Ensure
t h a t t h e i n s t a l l a t i o n reference letter stamped i n each
cap corresponds to t h e letter stamped i n t h e differen-
t i a l housing (Fig. 51). T i g h t e n t h e b e a r i n g cap bolts
w i t h 95 t o 122 N-m (70 to 90 ft-lbs) torque.
(29) Measure t h e r i n g gear " b a c k l a s h " a t four
equally spaced locations around t h e perimeter o f t h e
r i n g gear w i t h a d i a l indicator (Fig. 52).
T h e r i n g g e a r " b a c k l a s h " m u s t b e w i t h i n 0.004
- 0.009 i n c h (0.10 - 0.23 m m ) a n d i t c a n n o t v a r y
m o r e t h a n 0.002 i n c h (0.05 m m ) a t a n y o f t h e
measurement locations.
(30) Excessive "backlash" is corrected b y m o v i n g
the r i n g gear teeth closer to t h e drive p i n i o n gear
teeth. Insufficient "backlash" is corrected b y m o v i n g
the r i n g gear teeth away from t h e drive p i n i o n gear
teeth. "Backlash" correction is accomplished b y
t r a n s f e r r i n g shims f r o m one side of t h e d i f f e r e n t i a l
case t o t h e other (Fig. 53).
Fig. 52 Ring Gear "Backlash" Measurement
GEAR TEETH CONTACT PATTERNS
I f the drive p i n i o n gear depth of mesh a n d t h e r i n g
gear "backlash" have been correctly established ac-
cording to t h e instructions a n d i n f o r m a t i o n provided
i n the procedures above, good gear teeth contact pat-
terns should exist.
(1) A p p l y a t h i n coat of H y d r a t e d Ferric Oxide
(commonly referred to as Yellow Oxide o f Iron), or a n
equivalent product, t o both t h e " d r i v e " side and the
"coast" side of t h e r i n g gear teeth.
(2) Rotate t h e r i n g gear one complete revolution i n
both directions w h i l e a load is being applied w i t h a
round b a r or screwdriver inserted between t h e differ-
e n t i a l housing a n d t h e differential case flange. This
action w i l l produce a distinct contact p a t t e r n on both
the " d r i v e " side a n d t h e "coast" side of the r i n g gear
teeth.
The gear teeth contact p a t t e r n w i l l disclose
whether o r n o t t h e drive p i n i o n gear shaft rear
bearing depth s h i m has t h e correct thickness
a n d whether o r n o t t h e r i n g gear " b a c k l a s h " has
been adjusted correctly. T h e " b a c k l a s h " be-
 + FRONT SUSPENSION
BEARING
PRELOAD
SHIM PACK
PINION
LOCATING
SHIM PACK
DIFFERENTIAL BEARING
SHIM PACKS RY660
Fig. 53 Shim Locations
t w e e n the r i n g g e a r a n d t h e d r i v e p i n i o n gear
m u s t be m a i n t a i n e d w i t h i n the specified limits
u n t i l the c o r r e c t teeth c o n t a c t p a t t e r n i s ob-
tained.
(3) E x a m i n e t h e contact patterns on t h e r i n g gear
t e e t h and compare t h e m w i t h those i n Figures 54
t h r o u g h 58 t o determine i f the patterns are correct.
W i t h the drive p i n i o n gear depth of mesh correct and
t h e r i n g gear " b a c k l a s h " adjusted correctly, t h e teeth
contact patterns should closely resemble t h e patterns
i l l u s t r a t e d i n F i g . 54. Notice t h a t t h e i l l u s t r a t e d
teeth contact patterns are w e l l centered on b o t h t h e
" d r i v e " side and t h e "coast" side of the teeth.
W h e n t h e teeth c o n t a c t p a t t e r n s a r e obtained
b y the m e t h o d d e s c r i b e d above, they a r e l i k e l y
to b e r a t h e r s m a l l . W i t h a n a c t u a l operating
l o a d , h o w e v e r , the c o n t a c t a r e a i n c r e a s e s .
(4) I f , after e x a m i n i n g t h e r i n g gear contact pat-
terns, i t i s determined t h a t t h e patterns resemble
those i l l u s t r a t e d i n F i g . 55, t h e drive p i n i o n gear is
separated too m u c h f r o m t h e centerline o f t h e r i n g
gear. This condition w i l l cause t h e contact patterns
to be " h i g h " o n t h e " d r i v e " side a n d near t h e "heel"
of t h e tooth, and " h i g h " on t h e "coast" side and near
t h e " t o e " o f t h e tooth. T o correct for t h i s type teeth
contact patterns, increase t h e thickness o f t h e depth
s h i m (located between t h e drive p i n i o n gear and t h e
d r i v e p i n i o n gear shaft inner/rear bearing). T h i s w i l l
cause t h e " h i g h " contact p a t t e r n on t h e " d r i v e " side
2 - 77
PATTERNS CLOSE TO CENTER
HEEL END-DRIVE HEEL END-COAST
SIDE (CONVEX) SIDE (CONCAVE)
J9003-74
Fig. 54 Desired Teeth Contact Patterns (With Light
Load)
THICKER SHIM REQUIRED
HEEL €ND-=-DRIVE HEEL END-COAST
SIDE (CONVEX) SIDE (CONCAVE)
J9003-75
Fig. 55 Incorrect Teeth Contact Patterns—Increase
Depth Shim Thickness
to be lowered a n d to move t o w a r d t h e " t o e " o f t h e
tooth, and t h e " h i g h " contact p a t t e r n on t h e "coast"
side t o be lowered a n d t o move t o w a r d t h e "heel" of
the tooth ( F i g . 56).
(5) If, after e x a m i n i n g the contact patterns, i t is de-
t e r m i n e d t h a t t h e patterns resemble those i l l u s t r a t e d
i n F i g . 57, t h e drive p i n i o n gear is too close to t h e
centerline o f the r i n g gear. T h i s condition w i l l cause
the contact patterns t o be " l o w " on t h e " d r i v e " side
and near t h e "toe" o f the t o o t h , a n d " l o w " on "coast"
side a n d near t h e " h e e l " o f the tooth. To correct for
t h i s type o f teeth contact patterns, decrease t h e
thickness o f t h e depth s h i m (located between t h e
drive p i n i o n gear and t h e drive p i n i o n gear shaft i n -
ner/rear bearing). T h i s w i l l cause t h e " l o w " contact
p a t t e r n on t h e " d r i v e " side t o be raised and to move
toward t h e " h e e l " of the tooth, and t h e " l o w " contact
p a t t e r n on t h e "coast" side t o be raised and t o move
t o w a r d t h e " t o e " of the t o o t h (Fig. 58).
2 - 78 FRONT SUSPENSION •
PATTERNS MOVE TOWARD CENTER
AND DOWN PATTERNS MOVE INWARD AND UP

HEEL END-DRIVE HEEL END-COAST HJEj ENP-PWYE HEEL END-COAST

SIDE (CONVEX) SIDE (CONCAVE) SIDE (CONVEX) SIDE (CONCAVE)

J9003-76 J9003-78

Fig. 56 Teeth Contact Patterns After Depth Shim Fig. 58 Teeth Contact Patterns After Depth Shim
Thickness Is Increased Thickness Is Decreased
SEALANT
THINNER SHIM REQUIRED

HEEL END-DRIVE HEEL END-COAST

SIDE (CONVEX) SIDE (CONCAVE)
J9003-77

Fig. 57 Incorrect Teeth Contact Patterns—Decrease

Depth Shim Thickness
INSTALLATION
(1) I n s t a l l t h e axle shafts i n t h e axle shaft tubes. I f
necessary, refer to t h e i n s t a l l a t i o n procedures.
(2) Remove any residual R T V sealant/gasket mate-
r i a l from t h e differential housing and cover m a t i n g
surfaces, t h o r o u g h l y clean t h e surfaces w i t h m i n e r a l
spirits (or a n equivalent cleaning solution) a n d d r y
the surfaces completely.
(3) A p p l y a t h i n "bead" of M O P A R R T V Sealant (or
an equivalent sealant) around t h e bolt circle on t h e
housing and on t h e cover (Fig. 59). A l l o w t h e seal-
ant t o " c m e " f o r a f e w minutes.
I f for a n y reason t h e differential housing cover
is n o t i n s t a l l e d w i t h i n 20 m i n u t e s a f t e r a p p l y i n g
the s e a l a n t , t h e s e a l a n t m u s t b e r e m o v e d a n d
another " b e a d " o f sealant applied.
(4) I n s t a l l t h e housing cover on t h e differential
housing w i t h t h e a t t a c h i n g bolts. I n s t a l l t h e a x l e
gear r a t i o i d e n t i f i c a t i o n t a g u n d e r o n e o f t h e
c o v e r b o l t s . T i g h t e n t h e cover bolts w i t h 47 N*m (35
ft-lbs) torque.
(TYPICAL) J9003-85
Fig. 59 Sealant On Housing Cover
(5) Remove t h e supports a n d raise or lower t h e
hoist u n t i l t h e vehicle is level.
(6) Remove t h e f i l l hole p l u g a n d fill t h e differen-
t i a l h o u s i n g w i t h t h e specified q u a n t i t y of M O P A R
H y p o i d Gear L u b r i c a n t (or a n equivalent product).
I n s t a l l t h e fill hole p l u g a n d t i g h t e n w i t h 34 N*m (25
ft-lbs) torque.
(7) L o w e r t h e vehicle a n d test t h e brakes a n d t h e
axle for proper operation.
LUBRICANT
M u l t i - p u r p o s e , hypoid gear lubricant, as defined b y
M I L - L - 2 1 0 5 - B a n d by A P I G L 5 q u a l i t y specifica-
tions, should be used for Model 60 front axles. M O -
P A R H y p o i d Gear L u b r i c a n t conforms w i t h both o f
• FRONT SUSPENSION
these specifications and is h i g h l y recommended for
use w i t h both Ram T r u c k and Ramcharger vehicles.
Each t i m e a 4WD vehicle is serviced for other rea-
sons (e.g., a n engine o i l change), inspect the front
axle for evidence of l u b r i c a n t leakage. I f leakage ex-
ists, observe t h e l u b r i c a n t level i n t h e differential
housing t h r o u g h t h e f i l l hole. W h e n observing t h e
level, ensure t h a t the vehicle is level o n the hoist.
The l u b r i c a n t level should be m a i n t a i n e d a t the bot-
t o m of f i l l hole.
CAUTION: If the front axle is submerged in water,
the axle lubricant must be replaced immediately to
avoid the possibility of premature axle failure re-
sulting from water contamination of the lubricant.
DRAIN AND REFILL
(1) Drive the vehicle w i t h the f r o n t axle shafts en-
gaged (i.e., i n 4WD) u n t i l the gear l u b r i c a n t i n the
2 - 79
axle attains the n o r m a l operating temperature.
(2) Raise and support the vehicle.
(3) Remove the l u b r i c a n t f i l l hole p l u g from the dif-
ferential housing cover.
(4) Remove the differential housing cover and allow
the o r i g i n a l l u b r i c a n t to completely d r a i n from t h e
housing and the axle shaft tubes.
(5) F l u s h the differential and the housing cavity
w i t h a " f l u s h i n g " o i l (or l i g h t engine oil) to remove
residual l u b r i c a n t and foreign matter. D o n o t u s e
w a t e r , steam, kerosene o r gasoline f o r f l u s h i n g .
(6) I n s t a l l t h e differential housing cover a n d
t i g h t e n the bolts w i t h 47 N*m (35 ft-lbs) Torque.
(7) Refill the differential housing w i t h the specified
q u a n t i t y of M O P A R H y p o i d Gear L u b r i c a n t . Refer t o
the Specifications chart.
(8) I n s t a l l and t i g h t e n the f i l l hole p l u g w i t h 34
N*m (25 ft-lbs) torque.
(9) Remove the supports and lower the vehicle.
2 - 80 FRONT SUSPENSION

SPECIFICATIONS

TORQUE SPECIFICATIONS

COMPONENT SET-TO-TORQUE RECHECK TORQUE

Differential Housing Cover Bolt 2 7 N * m (20 ft-lbs)

Model 44 Axle
Ball Stud Nut
Lower
ADl50, D150 & D250 183 N*m (135 ft-lbs)
D350 237 N*m (175 ft-lbs)
Upper
D150& D250 183 N « m (135 ft-lbs)
D350 305 N*m (225 ft-lbs)

Brake Support-to-Steering Knuckle Bolt

AD 150, D150& D250 291 N « m (215 ft-lbs)
D350 305 N*m (225 ft-lbs)

Drive Pinion Gear Shaft Yoke Nut 285 N « m (210 ft-lbs)

Model 44 Axle
Differential Bearing Cap Bolt 108 N « m (80 ft-lbs)
Model 44 Axle
Lower Suspension Arm Bolt 285 N » m (210 ft-lbs)

Drive Shaft U-Joint Clamp Screw

AWl 50, W150 & W250 19 N « m (170 in-lbs)
W350 34 N » m (300 in-lbs)

Shock Absorber Lower Nut

AD150, D150, D250 & D350 23 N « m (200 in-lbs)
AWl50, W150 & W250 with Model 44 Axle 7 5 N * m (55 ft-lbs)
W250 & W350 with Model 60 Axle 75 N » m (55 ft-lbs)

Shock Absorber Upper Nut

AD 150, D150, D250 & D350 34 N*m (25 ft-lbs)
AWl50, W150 & W250 with Model 44 Axle 7 5 N « m (55 ft-lbs)
W250 & W350 with Model 60 Axle 75 N » m (55 ft-lbs)

Spring U-Bolt Nut 149 N*m (110 ft-lbs)

Steering Linkage Ball Stud Nut

AD150, D150 & D250 64 N*m (47 ft-lbs)
D350 7 5 N » m (55 ft-lbs)
AWl 50, W150, W250 & W350 81 N*m (60 ft-lbs)

Strut Nut (Front)

ADl50, D150, D250 & D350 68 N » m (50 ft-lbs)

Strut Nut (Rear)

ADl50, D150, D250 & D350 115 N » m (85 ft-lbs)

Tie-Rod Clamp Nut

AD150, D150& D250 18 N » m (160 ft-lbs)

Tie-Rod End Ball Stud Nut

2WD 54 N » m (40 ft-lbs)
4WD 81 N « m (60 ft-lbs)

Stabilizer Bar
2WD
At Frame 31 N*m (270 in-lbs)
At Link 11 N*m (100 in-lbs)

Upper Suspension Arm

Cam Bolt (2WD) 95 N » m (70 ft-lbs)

J9002-117
• FRONT SUSPENSION 2 - 81

AXLE SPECIFICATIONS

W150 (Optional Equip. W250)

W250 W330
W350 131 Inch W.B. 135 Inch W.B.
Front A x l e (4WD) and 149 Inch W.B. and 149 Inch W.B.
Type Hypoid Hypoid
Model 44-8FD 60
Differential Lubrication Capacity (Pts.) 3(1.4L) 6 (2.8L)
Axle Load Capacity (Lbs.) 3500 (1586 kg) 4500 (2039 kg)
4000 (1812 kg)
with Snow-Plow
Package
Alignment (4WD) Acceptable Range Preferred
Camber + 1/2° to 1-1/2° +1°
*Caster + 1/2° to 3-1/2° +2°
8.5° 8.5°
Toe-In (At Hub Height) . . . . . . . - 0 . 0 5 ° to +0.45° 0.20°

AD150
D150
D250
Independent Front Suspension (2WD) D350
Load Capacity (lbs.) 3000 (AD) 3300 (D150, D250)
4000 (D350, Ex. Eqt. D250)
Alignment (2WD) Acceptable Range Preferred
Camber 0tol° +1/2°
* Caster - 1 ° to + 2 ° +1/2°
0.0 to 0.50° 0.25°
Turning Angle (Base Tire) Left & Right 33° 33°
*lf vehicle wanders, caster should be increased. If steering effort is very high (especially when cornering), caster should be decreased.
J9002-116
• REAR AXLES
REAR AXLES
CONTENTS
Page
8 3/8- AND 9 1/4-INCH DIAMETER RING GEAR
AXLE SERVICE 9 REAR AXLE ALIGNMENT . . . . . . . . . . . . . . . . . . . 8
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1
MODEL 60, 60M AND 70 AXLE SERVICE . . . . 33
GENERAL INFORMATION
INDEX
Page
8 3/8- and 9 1/4-Inch Diameter Ring Gear Axies ..1
8 3/8- AND 9 1/4-INCH DIAMETER RING GEAR
AXLES
The housing for rear axles w i t h a n 8 3/8- or a 9 1/
4-inch diameter r i n g gear consists o f a n i r o n center
casting (differential housing) w i t h axle shaft tubes
extending from either side. The axle shaft tubes are
pressed i n t o and welded to the differential housing t o
f o r m a one-piece axle housing.
The removable, stamped steel cover located a t t h e
rear o f the differential housing provides a means for
inspection and for differential service w i t h o u t remov-
i n g t h e complete rear axle from t h e vehicle.
B o t h axles have a hypoid gear differential and t h e
centerline of the drive p i n i o n gear shaft i s located be-
low t h e centerline of the r i n g gear.
A 9 1/4-inch diameter r i n g gear rear axle equipped
w i t h a S u r e - G r i p differential is optionally available
for R a m T r u c k a n d Ramcharger vehicles. A S u r e -
G r i p differential has a two-piece differential case
t h a t is completely interchangeable w i t h a standard
differential case.
3 -1
Page
NOISE DIAGNOSIS 2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . S6
TIRE/WHEEL BALANCE . . . . . . . . . . . . . . . . . . . . 8
Page
Model 60, 60M and 70 Axies 1
MODEL 60, 60M AND 70 AXLES
The housing for Model 60, 6 0 M a n d 70 rear axles
consists of a n i r o n center casting (differential hous-
ing) w i t h axle shaft tubes extending f r o m either side.
The axle shaft tubes are pressed i n t o and welded to
the differential housing t o f o r m a one-piece axle
housing. B o t h axles have a hypoid gear differential
and t h e centerline o f the drive p i n i o n gear shaft is
located below the centerline o f the r i n g gear. T h e re-
movable, stamped steel cover located a t t h e rear of
the differential housing provides a means for inspec-
t i o n and for differential service w i t h o u t removing the
complete rear axle from t h e vehicle.
A s m a l l , stamped m e t a l axle gear r a t i o identifica-
t i o n t a g is attached to t h e housing cover v i a one of
the cover bolts. This t a g also identifies the number of
r i n g gear and drive p i n i o n gear teeth.
Model 60, 6 0 M a n d 70 rear axles equipped w i t h a
T r a c - L o k differential are optionally available for
R a m T r u c k vehicles. A T r a c - L o k differential has a
one-piece differential case, t h e same i n t e r n a l compo-
nents as a standard differential, plus t w o clutch disc
packs.
 NOISE DIAGNOSIS
INDEX
Page Page
Axle Shaft Bearing Noise . . 4 Front Wheel Bearing Noise 3
Backlash "Cluck" .4 Gear Noise (Drive Pinion and Ring) 3
Bearing Noise (Drive Pinion Gear Shaft and General Information 2
Differential 3 "Knock" At Low Speeds 4
Drive Shaft Vibration 4 Pre-Disassembly Inspection 4
Driveline "Snap" 4 Tire Noise . . . 3
Engine and Transmission Noise . . . . . . . . . . . . . . . 4

GENERAL INFORMATION A l l rear axles produce noise t o a c e r t a i n extent.

The most i m p o r t a n t p a r t of rear axle service is cor-
rectly i d e n t i f y i n g the cause of failures and noise com-
plaints. T h e cause o f most rear axle failures is
r e l a t i v e l y easy to identify, b u t the cause of rear axle
noise is n o r m a l l y more difficult t o identify.
I f vehicle noise becomes objectionable, or i f i t oc- 413 k m ) of vehicle operation for b o t h 8 3/8-inch and
curs at a l l vehicle speeds, a n effort should be made t o
isolate the noise to one p a r t i c u l a r area of t h e vehicle.
M a n y noises t h a t are reported as coming f r o m t h e
rear axle actually originate a t other sources (e.g.,
tires, road surfaces, wheel bearings, engine, t r a n s -
mission, exhaust, drive shaft (vibration), U - j o i n t or
vehicle body ( " d r u m m i n g " ) . A x l e noises are n o r m a l l y
divided i n t o t w o categories: gear noise or bearing
noise. A thorough and careful inspection should be
completed to determine t h e actual source of t h e noise
before axle disassembly and component inspection is
attempted.
The rear suspension rubber bushings and s p r i n g
insulators help to "dampen-out" rear axle noise w h e n
correctly installed. Inspect to confirm t h a t no m e t a l
contact exists between t h e springs and t h e s p r i n g
hangers, the shackles or the U-bolts. Metal-to-metal
contact a t a n y of these locations can r e s u l t i n a
means o f t r a n s f e r r i n g road noise and n o r m a l axle
noise t h a t w o u l d not n o r m a l l y be objectionable i f the
components were correctly i n s t a l l e d and tightened.
The complete isolation o f noise t o any one area re-
quires considerable expertise and experience. I d e n t i -
fying c e r t a i n types of vehicle noise baffles even the
most experienced mechanics. Often such practices as:
• increasing t i r e i n f l a t i o n pressure to e l i m i n a t e t i r e stop and, w i t h the clutch disengaged or w i t h the au-
noise;
• l i s t e n i n g for noise a t v a r y i n g vehicle speeds w i t h
different driveline load conditions (e.g., " d r i v e " ,
" f l o a t " a n d "coast") a n d w i t h different road/street
conditions; and
• " s w e r v i n g " the vehicle from left to r i g h t t o detect
wheel bearing noise w i l l a i d even t h e beginner i n
isolating axle shaft bearing noise w i t h axles shafts
t h a t have tapered roller bearings.
Axles can be noisy i f t h e y are not correctly adjusted
or i f they lack sufficient l u b r i c a t i o n . U s u a l l y , w h e n
incorrectly adjusted replacement gears are causing
noise, the noise can be e l i m i n a t e d b y correctly ad-
j u s t i n g the gears.
I f axle noise occurs w i t h i n t h e first 1,500 miles (2
standard or heavy d u t y 9 1/4-inch (212.72-mm a n d
234.95-mm) diameter r i n g gear axles, or w i t h i n t h e
- f i r s t 5,000 miles (8 050 k m ) for Model 60, 6 0 M a n d
70 axles, and the gears are not scored because of lack
of lubrication, t h e gear adjustment should be sus-
pected and corrected, i f necessary.
Unacceptable gear meshing (teeth contact), i n -
c o r r e c t r i n g g e a r " b a c k l a s h " a n d a loose d r i v e
p i n i o n gear shaft y o k e n u t a r e t h e p r i m a r y
c a u s e s o f gear noise w i t h r e p l a c e m e n t axles.
Regardless of w h a t has been w r i t t e n to t h e con-
t r a r y , noisy axle gears w i l l not produce less noise
w i t h additional usage. T h e y w i l l e i t h e r r e m a i n the
s a m e o r become w o r s e .
S l i g h t axle noise t h a t is noticeable only a t c e r t a i n
speeds or i n isolated situations m u s t be considered
n o r m a l . A x l e noise tends t o "peak" a t a v a r i e t y of ve-
hicle speeds and noise i s N O T A L W A Y S indicative
of a problem w i t h i n the axle.
A good diagnostic test for rear axle noise includes a
thorough road test. Select a level a n d smooth "black-
t o p " road/street. This type o f surface w i l l reduce t i r e
noise arid vehicle body " d r u m m i n g " . D r i v e f a r
enough to thoroughly w a r m up t h e axle l u b r i c a n t to
t h e n o r m a l operating temperature.
Note the vehicle speed w h e n the noise occurs. T h e n
tomatic transmission shifted to " N E U T R A L " , v a r y
the engine speed (rpm) slowly up a n d down i n a n at-
t e m p t to duplicate a n d identify t h e engine speed
w h e n t h e noise occurs. T h i s w i l l determine i f the
noise is caused b y the exhaust or another engine re-
lated component. I f a noise can not be produced, re-
peat the road test w h i l e engaging a n d disengaging
the clutch or s h i f t i n g the transmission i n t o and out
of " N E U T R A L " . I f the noise can not be isolated b y
 t h i s method, t h e noise most l i k e l y can only be iso-
lated b y r e m o v i n g the d r i v e shaft and operating t h e
engine w i t h t h e t r a n s m i s s i o n "in-gear".
TIRE NOISE
T i r e noise i s often m i s t a k e n for rear axle noise
even t h o u g h t h e noisy t i r e s are actually located o n
the front wheels. Tires t h a t are unbalanced, w o r n
unevenly or have surfaces o f non-skid type design, or
are w o r n i n a "saw-tooth" manner are usually noisy
and often produce a noise t h a t appears t o originate
i n t h e rear axle.
T i r e noise changes w i t h different road surfaces, b u t
rear axle noise does not. I n f l a t e a l l four tires w i t h
approximately 20 psi (138 kPa) more t h a n the recom-
mended i n f l a t i o n pressure (for test purposes only).
This w i l l alter noise caused b y tires, b u t w i l l not af-
fect noise caused b y t h e rear axle. Rear axle noise
usually ceases w h e n coasting a t speeds less t h a n 30
m p h (48 km/h); however, t i r e noise continues, b u t a t
a lower frequency, as t h e speed is reduced. Rear axle
noise usually w i l l change w h e n i t is compared d u r i n g
" d r i v e " and "coast" conditions, b u t t i r e noise remains
approximately t h e same.
Discern between t i r e noise and axle noise b y n o t i n g
i f t h e noise varies w i t h vehicle speed, or sudden ac-
celeration and deceleration. Exhaust and axle noise
w i l l change w i t h t h e vehicle speed w h i l e t i r e noise
w i l l r e m a i n constant a n d i s more pronounced a t
speeds o f 20 t o 30 m p h (32 t o 48 km/h). Test addi-
t i o n a l l y for t i r e noise b y d r i v i n g over smooth pave-
ments or d i r t roads (not gravel) w i t h t h e tires a t
n o r m a l i n f l a t i o n pressure. I f the noise is caused b y
the tires, i t w i l l noticeably change or disappear a n d '
reappear w i t h changes i n the road surface.
FRONT WHEEL BEARING NOISE
Loose or " r o u g h " f r o n t wheel bearings w i l l cause
noise t h a t can be confused w i t h rear axle noise; how-
ever, front wheel b e a r i n g noise (2WD or disengaged
4 W D ) does n o t change w h e n i t is compared d u r i n g
" d r i v e " and "coast" conditions.
L i g h t application o f the brake pedal w h i l e m a i n -
t a i n i n g constant speed w i l l often cause wheel bearing
noise t o d i m i n i s h because t h i s action w i l l remove
some w e i g h t f r o m the bearings. F r o n t wheel bearings
can easily be tested for noise by r a i s i n g and support-
i n g t h e vehicle and " s p i n n i n g " the front wheels (also
by " s h a k i n g " t h e wheels t o determine i f the bearings
are loose).
GEAR NOISE (DRIVE PINION AND RING)
A b n o r m a l gear noise is rare and, i f i t exists, i t i s
u s u a l l y caused b y " s c o r i n g " o n t h e r i n g a n d drive
p i n i o n gears as a r e s u l t o f insufficient or incorrect l u -
b r i c a n t i n t h e d i f f e r e n t i a l housing. The differential
side gears a n d p i n i o n gears very seldom are damaged
because t h e y are only "loaded" w h e n the rear wheels
rotate a t different speeds (e.g., w h e n t h e vehicle is
turning).
A b n o r m a l gear noise can be recognized easily be-
cause i t produces a " c y c l i n g " tone t h a t w i l l be very
pronounced w i t h i n t h e vehicle speed range t h a t i t oc-
curs. T h e noise can occur d u r i n g one or more of t h e
f o l l o w i n g d r i v i n g conditions:
• "drive",
• "road load",
• "float", or
• "coast".
A b n o r m a l gear noise usually tends t o peak w i t h i n
a n a r r o w vehicle speed range or ranges and i s more
pronounced between 30 t o 40 m p h (48 t o 64 km/h)
and 50 t o 60 m p h (80-96 km/h). W h e n objectionable
gear noise occurs, note t h e d r i v i n g conditions and t h e
speed range.
Conduct a gear teeth contact p a t t e r n test t o deter-
mine i f t h e best possible gear teeth contact patterns
exist. I f t h e patterns are n o t acceptable, adjust t h e
r i n g gear a n d the drive pinion gear " m e s h i n g " to ob-
t a i n t h e best possible t e e t h patterns. I f the noise s t i l l
exists after t h e adjustment, replace the gears w i t h a
" m a t c h e d " replacement gear set.
BEARING NOISE (DRIVE PINION GEAR SHAFT AND
DIFFERENTIAL)
Defective o r damaged bearings w i l l n o r m a l l y pro-
duce a r o u g h " g r o w l " or g r a t i n g noise t h a t is con-
stant i n p i t c h a n d varies w i t h t h e speed o f t h e
vehicle. B e i n g aware o f t h i s w i l l enable a mechanic
to discern between b e a r i n g noise and gear noise.
D r i v e p i n i o n gear shaft bearing noise t h a t results
from defective or damaged bearings can usually be
identified b y i t s constant, rough sound. D r i v e p i n i o n
gear shaft f r o n t b e a r i n g noise is usually more pro-
nounced d u r i n g a "coast" condition, where as drive
p i n i o n gear shaft rear bearing noise i s more pro-
nounced d u r i n g a " d r i v e " condition. T h e drive p i n i o n
gear shaft bearings are r o t a t i n g a t a higher rate o f
speed t h a n either the differential side bearings or the
axle shaft bearings.
D i f f e r e n t i a l side b e a r i n g noise w i l l usually produce
a constant, r o u g h sound t h a t is m u c h lower i n fre-
quency t h a n t h e noise caused by drive p i n i o n gear
shaft bearings.
B e a r i n g noise can best be detected b y road t e s t i n g
the vehicle o n a smooth road (black top). However, i t
is r e l a t i v e l y easy t o mistake t i r e noise for b e a r i n g
noise. I f a doubt exists, the tire treads should be ex-
amined f o r t h e i r r e g u l a r i t i e s t h a t often produce a
noise t h a t resembles bearing noise.
3 - 4 REAR AXLES
PRE-DISASSEMBLY INSPECTION
A close inspection o f t h e rear axle differential p r i o r
to disassembly can often reveal valuable i n f o r m a t i o n
concerning t h e extent and type o f repairs or adjust-
ments t h a t are necessary. T h i s i n f o r m a t i o n combined
w i t h t h e road test results w i l l provide a basis for de-
t e r m i n i n g t h e degree of disassembly required.
Because t h e most frequent causes of axle differen-
t i a l noise a r e incorrect r i n g gear " b a c k l a s h " and/or
differential bearing "preload" torque, a few r o u t i n e
adjustments could be a l l t h a t is necessary t o correct
the problem. Therefore, before axle differential disas-
sembly, t h e following measurements should be made:
• r i n g gear "backlash", and
• drive p i n i o n gear shaft bearing "preload" torque.
Record a n d analyze the results. The r e s u l t o f these
measurements w i l l a i d i n d e t e r m i n i n g t h e extent the
required axle differential service.
AXLE SHAFT BEARING NOISE
Defective or damaged axle shaft bearings produce a
v i b r a t i o n o r " g r o w l " noise t h a t w i l l continue after
the transmission is shifted t o " N E U T R A L " and t h e
vehicle is coasting. A " b r i n e l l e d " axle shaft bearing
causes a " w h i r r i n g " noise. "Spalled" axle shaft bear-
ings n o r m a l l y produce a noise s i m i l a r to a " g r o w l "
t h a t is caused by either flaked or p i t t e d bearing r o l l -
ers or b e a r i n g races. Unless t h e damage is severe,
axle shaft bearing noise is seldom noticed a t vehicle
speeds exceeding 30 m p h (48 km/h).
To differentiate between axle shaft bearing noise
and differential gear noise, road test the vehicle on a
smooth road (black-top) a t m e d i u m a n d l o w speed.
W i t h traffic p e r m i t t i n g , "swerve" the vehicle sharply
right-to-left. I f the noise i s caused b y axle shaft bear-
ings, i t w i l l usually increase i n loudness w h e n t h e
vehicle is "swerved" a n d i t w i l l probably be more
pronounced a t the "loaded" bearing side o f the axle
shaft ( w i t h tapered roller bearings only).
I f the source o f the noise can not be determined, a n
inspection o f the bearings w i l l be necessary.
"KNOCK" AT LOW SPEEDS
Low speed " k n o c k " is u s u a l l y caused b y either a
" b r i n e l l e d " U-joint spider or excessive differential
side gear hub-to-counterbore clearance. Inspect a n d
replace t h e U-joint or t h e differential case and side
gear, as applicable.
BACKLASH "CLUNK"
A loud " c l u n k " noise upon vehicle acceleration and
deceleration can be caused by excessive clearance i n -
v o l v i n g any of the following components (or i n com-
bination):
•
• d i f f e r e n t i a l p i n i o n mate gear shaft-to-differential
case bore,
• axle shaft splines-to-differential side gear splines,
• d i f f e r e n t i a l side gear hub-to-differential case coun-
terbore,
• d i f f e r e n t i a l side gears-to-pinion gears,
• w o r n t h r u s t washers, and
• excessive r i n g gear "backlash".
Measure t h e clearances, inspect t h e components
and replace as required (or, i f applicable, adjust t o
specifications).
DRIVELINE "SNAP"
A d r i v e l i n e "snap" noise r e s u l t i n g f r o m sudden ve-
hicle s t a r t f r o m stop, either forward or reverse, c a n
be caused b y a loose drive p i n i o n gear shaft (axle)
yoke. Remove the drive shaft and the yoke, and i n -
s t a l l t h e yoke 180 degrees f r o m its o r i g i n a l position.
The d r i v e p i n i o n gear shaft bearing "preload" torque
and t h e shaft n u t torque m u s t be adjusted t o t h e
specified values after i n s t a l l a t i o n .
ENGINE AND TRANSMISSION NOISE
Occasionally noise t h a t appears t o originate i n t h e
rear axle is actually caused b y t h e engine or t h e
transmission. To identify the t r u e source o f the noise,
note t h e approximate vehicle speed a n d t h e condi-
tions w h e n t h e noise occurs or when i t is t h e most
pronounced. Stop t h e vehicle i n a quiet place (to
avoid a n y i n t e r f e r i n g noise) and, w i t h the t r a n s m i s -
sion i n " N E U T R A L " , accelerate the engine slowly u p
t h r o u g h and t h e n decelerate down t h r o u g h t h e en-
gine speed t h a t approximately corresponds to the ve-
hicle speed noted when the noise occurred or was t h e
most pronounced. I f a s i m i l a r noise is produced b y
t h i s method, i t w i l l usually indicate t h a t the noise i s
being caused b y the engine or the transmission and
not t h e rear axle.
DRIVE SHAFT VIBRATION
Objectional v i b r a t i o n , w h i l e t r a v e l i n g o n roads/
streets w i t h a "good" surface, can be caused by t h e
wheels/tires, t h e engine or the drive shaft.
A systematic method o f i d e n t i f y i n g t h e source o f
the v i b r a t i o n w i l l a i d i n a fast and correct repair.
The order of analysis should be:
• wheels/tires,
• engine, and
• d r i v e shaft.
Tires t h a t are "out-of-round" (i.e., r a d i a l " r u n o u t " )
or wheels/tires t h a t are excessively unbalanced w i l l
cause a l o w frequency v i b r a t i o n t h a t w i l l induce
p r o m i n e n t m i r r o r a n d door "shake". Tire and/or
wheel faults m u s t be corrected before proceeding
w i t h t h e analysis.
 Engine vibration f a u l t s can be located by accelerat-
i n g the engine (transmission i n " N E U T R A L " )
through the speed range and noting the speed when
(if) the vibration occurs.
Drive shaft vibration will increase i n intensity as
the vehicle speed is increased and it is not sensitive
to engine torque. A vibration that occurs within a
specific speed range ((e.g., 55 to 65 mph or 88 to 105
km/h) and does not occur above that speed range is
not caused by drive shaft unbalance. Defective U -
joints or an incorrect drive shaft angle are usually
the cause of vibration that occurs within a specific
speed range.
3 - 6 REAR AXLES
SERVICE DIAGNOSIS
Condition Possible Cause
WHEEL NOISE (a) Wheel loose.
(b) Faulty, brinelled wheel bearing.
AXLE SHAFT NOISE (a) Misaligned axle shaft tube.
(b) Bent or sprung axle shaft.
(c) End play in drive pinion bearings.
(d) Excessive gear backlash between ring
gear and pinion gear.
(e) Improper adjustment of drive pinion
gear shaft bearings.
(t) Loose drive pinion gearshaft yoke nut.
(g) Improper wheel bearing adjustment.
(h) Scuffed gear tooth contact surfaces.
AXLE SHAFT BROKE (a) Misaligned axle shaft tube.
(b) Vehicle overloaded.
(c) Erratic clutch operation
(d) Grabbing clutch.
DIFFERENTIAL CASE (a) Improper adjustment of differential
CRACKED bearings.
(b) Excessive ring gear backlash.
(c) Vehicle overloaded.
(d) Erratic clutch operation.
DIFFERENTIAL GEARS (a) Insufficient lubrication.
SCORED
(b) Improper grade of lubricant.
(c) Excessive spinning of one wheel/tire.
LOSS OF LUBRICANT (a) Lubricant level too high.
Correction
(a) Tighten loose nuts.
(b) Faulty or brinelled bearings must be
replaced.
(a) Inspect axle shaft tube alignment.
Correct as necessary.
(b) Replace bent or sprung axle shaft.
(c) Refer to Drive Pinion Bearing Pre-Load
Adjustment.
(d) Check adjustment of ring gear
backlash and pinion gear. Correct as
necessary.
(e) Adjust drive pinion shaft bearings.
(f) Tighten drive pinion gearshaft yoke nut
with specified torque.
(g) Readjust as necessary.
(h) If necessary, replace scuffed gears.
(a) Replace broken axle shaft after
correcting axle shaft tube alignment.
(b) Replace broken axle shaft. Avoid
excessive weight on vehicle.
(c) Replace broken axle shaft after
inspecting for other possible causes.
Avoid erratic use of clutch.
(d) Replace broken axle shaft. Inspect
clutch and make necessary repairs or
adjustments.
(a) Replace cracked case; examine gears
and bearings for possible damage. At
reassembly, adjust
differential bearings properly.
(b) Replace cracked case; examine gears
and bearings for possible damage. At
reassembly, adjust ring gear backlash
properly.
(c) Replace cracked case; examine gears
and bearings for possible damage.
Avoid excessive weight on vehicle.
(d) Replace cracked case. After inspecting
for other possible causes, examine
gears and bearings for possible
damage. Avoid erratic use of clutch.
(a) Replace scored gears. Scoring marks
on the drive face of gear teeth or in
the bore are caused by instantaneous
fusing of the mating surfaces. Scored
gears should be replaced. Fill rear
differential housing to required capacity
with proper lubricant. Refer to
Specifications.
(b) Replace scored gears. Inspect all
gears and bearings for possible
damage. Clean and refill differential
housing to required capacity with
proper lubricant.
(c) Replace scored gears. Inspect all
gears, pinion bores and shaft for
damage. Service as necessary.
(a) Drain excess lubricant by removing fill
plug and allow lubricant to level at
lower edge of fill plug hole.
J9003-49

SERVICE DIAGNOSIS (CONT'D)
Condition Possible Cause
(b) Worn axle shaft seals.
(c) Cracked differential housing.
(d) Worn drive pinion gear shaft seal.
(e) Scored and worn yoke.
(f) Axle cover not properly sealed.
AXLE OVERHEATING (a) Lubricant level too low.
(b) Incorrect grade of lubricant.
(c) Bearings adjusted too tight.
(d) Excessive gear wear.
(e) Insufficient ring gear backlash,
GEAR TEETH BROKE (a) Overloading.
(RING GEAR AND
PINION)
(b) Erratic clutch operation.
(c) Ice-spotted pavements.
(d) Improper adjustments.
AXLE NOISE (a) Insufficient lubricant.
(b) Improper ring gear and drive pinion
gear adjustment.
(c) Unmatched ring gear and drive
pinion gear.
(d) Worn teeth on ring gear or drive
pinion gear.
(e) Loose drive pinion gear shaft bearings. (e) Adjust drive pinion gearshaft bearing
(f) Loose differential bearings.
(g) Misaligned or sprung ring gear.
(h) Loose differential bearing cap bolts.
REAR AXLES 3-7
Correction
(b) Replace worn seals.
(c) Repair or replace housing as
necessary.
(d) Replace worn drive pinion gear shaft
seal.
(e) Replace worn or scored yoke and seal,
(t) Remove cover and clean flange and
(a) Refill differential housing.
(b) Drain, flush and refill with correct
amount of the correct lubricant.
(c) Readjust bearings.
(d) Inspect gears for excessive wear or
scoring. Replace as necessary.
(e) Readjust ring gear backlash and
inspect gears for possible scoring.
(a) Replace gears. Examine other gears
and bearings for possible damage.
Replace parts as needed. Avoid
overloading of vehicle.
(b) Replace gears and examine the
remaining parts for possible damage.
Avoid erratic clutch operation.
(c) Replace gears. Examine the remaining
parts for possible damage. Replace
parts as required.
(d) Replace gears. Examine other parts for
possible damage. Ensure ring gear
backlash is correct.
(a) Refill axle with correct amount of the
proper lubricant. Also inspect for leaks
and correct as necessary.
(b) Check ring gear and pinion gear teeth
contact pattern.
(c) Remove unmatched ring gear and
drive pinion gear. Replace with
matched gear and drive pinion gear
set.
(d) Check teeth on ring gear and drive pi-
nion gear for correct contact.
If necessary, replace with new
matched set.
preload torque.
(f) Adjust differential bearing preload
torque.
(g) Measure ring gear runout.
(h) Tighten with specified torque.
J9003-50
3 - 8 REAR AXLES
R E A R A X L E ALIGNMENT
MEASUREMENT
The following procedure for measuring rear axle
a l i g n m e n t can be used to determine i f a complaint of
abnormal rear t i r e wear is the result of a " b e n t " or
deformed rear axle shaft.
(1) Raise both rear wheels o f f the surface w i t h a
frame contact hoist.
(2) A t t a c h a one-inch long piece o f m a s k i n g tape a t
the center of each t i r e t r e a d for use as "reference
marks".
(3) Rotate t h e rear wheels u n t i l both "reference
m a r k s " face the f r o n t o f the vehicle and measure the
distance between the outside edges of the two pieces
of tape. Record t h i s measurement as t h e " f r o n t of
t i r e " (FTR) measurement.
(4) Rotate t h e rear wheels u n t i l b o t h "reference
m a r k s " face the rear of the vehicle and measure the
distance between the outside edges o f the t w o pieces
of tape. Record t h i s measurement as t h e "rear of
t i r e " (RTR) measurement.
(5) Subtract the " r e a r o f t i r e " (RTR) measurement
from the "front o f t i r e " (FTR) measurement to obtain
TIRE/WHEEL BALANCE
Page
General Information
GENERAL INFORMATION
The "off-vehicle" (static) rear tire/wheel balancing
method is preferred for R a m R W D v a n and wagon
vehicles. I f the "on-vehicle" (dynamic) rear t i r e bal-
ancing method is employed, b o t h front wheels m u s t
be securely blocked to prevent a n y vehicle move-
ment. For vehicles equipped w i t h a standard type dif-
ferential (i.e., not equipped w i t h a S u r e - G r i p or a
T r a c - L o k differential), only t h e rear wheel/tire t h a t
is to be balanced should be l i f t e d off t h e surface.
When involved i n "on-vehicle" (dynamic) rear
w h e e l / t i r e b a l a n c i n g , b e a w a r e t h a t a 35 m p h (56
km/h) s p e e d o m e t e r i n d i c a t i o n r e p r e s e n t s a 70
m p h (113 km/h) r e a r w h e e l speed. A speed of 35
m p h (56 km/h) is t h e m a x i m u m necessary for dy-
namic wheel/tire balance.
If t h e vehicle is equipped with dual rear
•
the a m o u n t of wheel "toe". The acceptable rear wheel
"toe" position is 1/16 i n c h (1.6 mm) " t o e - i n " to 3/16
inch (4.8 mm) "toe-out".
(6) Rotate t h e rear wheels u n t i l t h e "reference
m a r k s " are facing d o w n w a r d and measure t h e dis-
tance between t h e outside edges of the two pieces of
tape. Record t h i s measurement as t h e "bottom of
t i r e " (BTR) measurement.
(7) Average t h e " f r o n t o f t i r e " (FTR) and the "rear
of t i r e " (RTR) distance measurements. Subtract t h e
"bottom of t i r e " (BTR) measurement f r o m t h i s aver-
age distance t o o b t a i n t h e camber. The acceptable
amount of camber is 1/16 i n c h to 3/32 i n c h (1.6 to 2.4
mm).
(FTR + R T R ) / 2 - B T R = C A M B E R
I f t h e " b o t t o m o f t i r e " (BTR) distance measure-
m e n t i s less t h a n t h e a v e r a g e F T R a n d R T R dis-
tance measurement, t h e camber w i l l be positive
(" + " ) . I f t h e " b o t t o m o f t i r e " ( B T R ) d i s t a n c e
measurement is greater t h a n the average F T R
and R T R distance measurement, the camber w i l l
b e n e g a t i v e ("-").
I f t h e "toe" position and/or the amount of camber
is/are not acceptable i n conjunction w i t h t h e abnor-
m a l t i r e wear, a " b e n t " or deformed rear axle shaft is
most l i k e l y the cause.
INDEX
Page
8 Sure-Grip/Trac-Loc Differentials 9
w h e e l s , i t i s a b s o l u t e l y n e c e s s a r y t h a t t h e wheel/
tire b e r e m o v e d f r o m t h e vehicle w h e n balanc-
i n g i s necessary.
B a l a n c i n g a wheel/tire w i t h t h e "on-vehicle" (dy-
namic) method essentially balances t h e t i r e , t h e
wheel and the b r a k e d r u m . The "balanced" condition
is lost w h e n the wheels/tires are rotated to equalize
t i r e t r e a d wear, or w h e n t h e wheels/tires are re-
moved f r o m the vehicle for any reason and then not
installed a t the o r i g i n a l location on t h e brake drum/
hub (i.e., before removal, t h e wheel and a stud are
indexed/marked for i n s t a l l a t i o n reference and t h e n
the wheel/tire are i n s t a l l e d a t the o r i g i n a l location).
WARNING: WITH NO LOAD ON THE ENGINE, IT IS
POSSIBLE TO ATTAIN A TIRE ROTATIONAL SPEED
(ANGULAR VELOCITY) THAT IS SUFFICIENT TO
CAUSE VIOLENT TIRE FAILURE AND CREATE A
HAZARDOUS SITUATION.
SURE-GRIP/TRAC-LOK DIFFERENTIALS
W h e n the " o n - v e h i c l e " ( d y n a m i c ) r e a r wheel/
tire b a l a n c e m e t h o d i s e m p l o y e d for v e h i c l e s
e q u i p p e d w i t h a S u r e - G r i p o r T r a c - L o k differen-
tial, r a i s e b o t h r e a r wheels/tires off the s u r f a c e
a n d remove the wheel/tire t h a t i s not b e i n g b a l -
anced.
B o t h front wheels/tires m u s t be securely blocked t o
prevent any vehicle movement.
CAUTION: Do not exceed 35 mph (56 km/h) for
Sure-Grip or Trac-Lok differentials.
8 3/8- AND 9 1/4-INCH DIAMETER RING G E A R A X L E S E R V I C E
INDEX
Page
Axle Shaft, Seal and Bearing Service 12
Complete Axle Removal/Installation 16
Drive Pinion Gear Shaft Seal Replacement 14
Lubricants 32
SERVICE INFORMATION
The rear axle housings for axles w i t h an 8 3/8- or a
9 1/4-inch diameter r i n g gear (Fig. 1, F i g . 2) consist
of a n iron center casting (differential housing) w i t h
axle shaft tubes extending f r o m either side. The axle
shaft tubes are pressed i n t o a n d welded to t h e differ-
e n t i a l housing to f o r m a one-piece axle housing. B o t h
axles have a h y p o i d gear d i f f e r e n t i a l and the center-
l i n e of the d r i v e p i n i o n gear shaft is located below
t h e centerline o f t h e r i n g gear. The removable,
stamped steel cover located a t t h e rear o f the differ-
e n t i a l housing provides a means for inspection and
for differential service w i t h o u t removing t h e com-
plete rear axle f r o m t h e vehicle.
A small, stamped m e t a l axle gear ratio identifica-
t i o n t a g is attached t o t h e h o u s i n g cover v i a one of
t h e cover bolts.
The drive p i n i o n gear shaft rotates w i t h i n two t a -
pered roller bearings (Fig. 1, F i g . 2). The drive p i n -
i o n gear shaft front a n d rear bearings are "press-
f i t t e d " on t h e drive p i n i o n gear shaft. T h e drive
p i n i o n gear shaft f r o n t and r e a r bearing cups are
"press-fitted" i n t h e d i f f e r e n t i a l housing bore a n d
against a recessed shoulder. T h e drive p i n i o n gear
shaft depth o f mesh adjustment is controlled b y the
W h e n employing rear wheel/tire balance o f t h i s
type ( w i t h the rear wheels/tires off the surface), a 35
m p h (56 km/h) speedometer i n d i c a t i o n represents a
70 m p h (113 km/h) rear wheel r o t a t i o n a l speed. A
speed o f 35 m p h (56 km/h) (speedometer indication)
is t h e m a x i m u m necessary for dynamic wheel/tire
balance.
W h e n the wheel/tire is satisfactorily balanced, i n -
s t a l l t h e unbalanced wheel/tire (tighten t h e wheel
l u g n u t s w i t h t h e specified torque) and balance i t
w i t h t h e same "on-vehicle" method. I t is not neces-
sary t o remove the balanced wheel/tire.
For a d d i t i o n a l i n f o r m a t i o n , refer t o Group
2 2 — T i r e s A n d Wheels, and the instructions supplied
b y the manufacturer o f the balancing equipment be-
i n g used.
Page
Service Information 9
Standard Differential Service 16
Sure-Grip Differential Service . 30
use o f m e t a l depth shims t h a t are installed between
t h e d r i v e p i n i o n gear shaft rear bearing a n d t h e
d r i v e p i n i o n gear.
The drive p i n i o n gear shaft bearing " p r e l o a d "
torque is provided v i a a metal, collapsible spacer t h a t
is located between t h e drive p i n i o n gear shaft f r o n t
a n d rear bearings (Fig. 1, Fig. 2). The spacer i s com-
pressed (i.e., collapsed) by t i g h t e n i n g the drive p i n i o n
gear shaft (axle) yoke n u t u n t i l the specified "pre-
l o a d " torque i s obtained.
The one-piece differential case contains t w o side
gears, t w o p i n i o n gears and two pairs of t h r u s t wash-
ers (Fig. 1, F i g . 2). The side gears rotate i n machined
counterbores i n the differential case and have i n t e r -
n a l splines t h a t " m e s h " w i t h (and drive) t h e axle
shafts. The p i n i o n gears have a smooth surface a n d
are h e l d i n place b y a solid p i n i o n mate gear shaft
t h a t is inserted i n t o a n d then "locked" i n the differ-
e n t i a l case b y means o f a lock screw. A l l four gears
are "meshed" w i t h each other and, because t h e y ro-
t a t e freely on the p i n i o n mate gear shaft, t h e p i n i o n
gears f u n c t i o n as i d l e r gears when the rear wheels
are r o t a t i n g at different speeds (e.g., d u r i n g a vehicle
turn).
The differential case hubs rotate i n the differential
h o u s i n g v i a t w o tapered roller bearings t h a t are
 AXLE SHAFT

VENT FITTING BEARING

BEARING
CUP

NUT
SEAL AXLE
SHAFT WASHER
BEARING

DIFFERENTIAL SEAL
HOUSING

AXLE SHAFT

AXLE SHAFT
WASHER BEARING SEAL

STUD

THREADED
ADJUSTER
LOCK

BOLT WASHER
FILL HOLE PLUG

BOLT J9003-52

Fig. 1 Rear Axle With 8 3/8-Inch Ring Gear

 AXLE
SHAFT

WASHER

AXLE SHAFT

WASHER
(ADJUSTER
LOCK
CAP

STUD

COLLAPSIBLE
SPACER
BOLT

CUP

THREADED
ADJUSTER
LOCK

SCREW

-FILL HOLE
PLUG

BOLT J9003-53

Fig. 2 Rear Axle With 9 1/4-Inch Ring Gear

 "press-fitted" o n the case hubs (Fig. 1, F i g . 2). A (3) Remove the brake d r u m .
threaded differential bearing adjuster ( w i t h a hex- (4) Clean a l l the foreign m a t e r i a l f r o m t h e area
shaped d r i v e hole) is located i n each b e a r i n g cap t o where t h e differential housing cover mates w i t h the
provide two functions: differential housing.
• to adjust and m a i n t a i n the " b a c k l a s h " between t h e (5) Loosen the housing cover bolts a n d d r a i n t h e l u -
r i n g gear a n d the drive p i n i o n gear; and b r i c a n t f r o m the housing and the axle shaft tubes.
• to establish a means for o b t a i n i n g and t h e n r e t a i n - Remove t h e housing cover.
i n g the differential bearing "preload" torque. (6) Rotate the differential case so t h a t t h e differen-
The rear axle shaft bearings are the s t r a i g h t - r o l l e r t i a l p i n i o n mate gear shaft lock screw is accessible.
bearing type and " r o l l " directly o n t h e axle shaft Remove t h e lock screw and t h e p i n i o n mate gear
(Fig. 1, F i g . 2). Each bearing consists o f a n outer shaft f r o m the differential case (Fig. 3).
race, a b e a r i n g cage and the rollers. The b e a r i n g is
"press-fitted" i n the axle shaft tube. Each axle shaft
is mated w i t h the differential side gear b y s l i d i n g i t
t h r o u g h t h e tube seal and the b e a r i n g bore. B o t h t h e
seal and t h e bearing rollers are i n contact w i t h the
axle shaft. T h e axle shaft splines " m e s h " w i t h t h e
differential side gear splines w i t h a semi-loose f i t .
Each axle shaft has a machined c i r c u l a r groove near
i t s end and they are retained i n the side gears v i a
C-clip "lock"s t h a t are inserted i n the grooves. W h e n
the axle shafts and t h e C-clip "locks" a r e correctly
positioned, t h e C-clip "locks" w i l l be located i n t h e
side gear machined counterbores and, w h e n t h e p i n -
ion gear mate shaft is inserted i n t h e d i f f e r e n t i a l
case (and retained by t h e lock screw), the axle shafts
are "locked" i n place. Therefore, w i t h axle shaft lat-
eral movement prevented, axle shaft b e a r i n g "end Fig. 3 Pinion Gear Mate Shaft Lock Screw
p l a y " adjustment is not required. (7) Force the applicable axle shaft t o w a r d the cen-
The axle shaft bearings are lubricated v i a t h e dif- ter o f t h e vehicle and remove the axle shaft C-clip
ferential housing gear l u b r i c a n t t h a t i s always " l o c k " f r o m t h e recessed groove i n t h e axle shaft
present i n t h e axle shaft tubes. (Fig. 4) w i t h two screwdrivers or another appropriate
B o t h axle types are equipped w i t h a remote vent tool.
f i t t i n g . For a n 8 3/8-inch diameter r i n g gear axle, the
f i t t i n g is located on the r i g h t axle shaft tube. For a 9
1/4-inch diameter r i n g gear axle, t h e fitting i s lo-
cated on t h e left axle shaft tube.
I f t h e r e a r axle i s s u b m e r g e d i n w a t e r , t h e l u -
b r i c a n t m u s t be replaced immediately t o a v o i d
the possibility o f premature axle failure result-
i n g f r o m w a t e r contamination o f the l u b r i c a n t .
" S u r e - G r i p " differentials are optionally available
for both axle types. Refer to the S u r e - G r i p D i f f e r -
e n t i a l section w i t h i n t h i s Group for service proce-
dures.

AXLE SHAFT, SEAL AND BEARING SERVICE

CAUTION: When rear axle service is necessary, or
when the axle is being rotated either via the engine
or by other means, both rear wheels must be raised
off the surface so that they are free to rotate.
AXLE SHAFT REMOVAL
(1) Raise and support the vehicle.
(2) Remove the wheel/tire.
Fig. 4 Axle Shaft C-Clip Lock
(8) Remove the axle shaft from t h e differential side
gear a n d t h e axle shaft tube. Use care t o prevent
damage t o the axle shaft bearing, w h i c h w i l l r e m a i n
i n the axle tube.
(9) Inspect the roller bearing contact surface on the
axle shaft for evidence of " b r i n e l l i n g " , " s p a l l i n g " and
"pitting".
• REAR AXLES
(10) I f any of these conditions exist, both the axle
shaft a n d the bearing m u s t be replaced.
The n o r m a l appearance (from roller bearing
contact) o f the shaft w i l l b e a d u l l gray surface
area t h a t c o u l d appear slightly dented.
AXLE SHAFT SEAL AND BEARING REMOVAL
(1) W i t h the axle shaft removed f r o m the axle shaft
tube, remove the axle shaft seal f r o m the end of t h e
axle shaft tube w i t h a s m a l l p r y bar.
(2) Remove the b e a r i n g i f i t appears damaged or i f
the axle shaft exhibits a n y o f t h e conditions de-
scribed i n the axle shaft removal procedure (above).
(3) T o remove the axle shaft b e a r i n g f r o m a n 8 3/
8-inch diameter r i n g gear axle tube (Fig. 5), use Re-
moval Tool C-4167.
A t t a c h Slide H a m m e r Tool C-637 to the end of t h e
removal tool. Use a slide h a m m e r m o t i o n t o remove
the b e a r i n g .
(4) F o r a 9 1/4-inch diameter r i n g gear axle tube,
use Removal Tool C-4828 t o remove the b e a r i n g (Fig.
6).
Fig. 6 Axle Shaft Bearing Removal (9 1/4-Inch Ring
Gear)
3-13
AXLE SHAFT BEARING AND SEAL
INSTALLATION
D o n o t i n s t a l l t h e o r i g i n a l axle shaft seal o r
b e a r i n g . A l w a y s i n s t a l l a r e p l a c e m e n t seal a n d
bearing.
(1) Wipe the bearing bore i n the axle shaft tube
clean.
(2) I n s e r t a replacement axle shaft bearing onto the
pilot o f the appropriate bearing i n s t a l l a t i o n (Tool C-
4198 for a n 8 3/8-inch diameter r i n g gear axle tube
or Tool C-4826 w i t h Handle C-4171 for a 9 1/4-inch
diameter r i n g gear axle tube).
CAUTION: DO NOT use the replacement axle shaft
seal to position or "seat" the bearing in the axle
shaft bore because this will damage the seal and
c a u s e lubricant leakage from the axle shaft tube.
(3) I n s e r t the axle shaft bearing i n t o the axle shaft
tube bore. Ensure t h a t the bearing is not "cocked" i n
the bore and t h a t i t is "seated" f i r m l y against t h e
"shoulder" i n the axle tube.
(4) I n s t a l l the replacement axle shaft seal (Fig. 7)
i n a n 8 3/8-inch diameter r i n g gear axle shaft tube
w i t h I n s t a l l a t i o n Tool C-4203 and Handle Tool C-
4171. Use I n s t a l l a t i o n Tool C-4826 t o i n s t a l l the seal
i n a 9 1/4-inch diameter r i n g gear axle shaft tube.
T h e f l a t side o f t h e i n s t a l l a t i o n t o o l m u s t f a c e
t h e seal.
INSTALLATION
SHAFT
Fig. 7 Axle Shaft Seal Installation
(5) W h e n t h e i n s t a l l a t i o n tool contacts t h e axle
tube "face", the seal w i l l be positioned at the correct
depth i n the bore.
AXLE SHAFT INSTALLATION
(1) L u b r i c a t e the bearing bore and the seal l i p , i n -
sert the axle shaft into the axle shaft tube a n d en-
gage i t s splines w i t h t h e differential side gear
splines. U s e c a r e t o p r e v e n t t h e s h a f t s p l i n e s
f r o m d a m a g i n g t h e a x l e s h a f t seal l i p .
 (2) W i t h the axle shaft i n place, insert the C-clip
" l o c k " i n t h e recessed groove a t the end o f the axle
shaft. Force the axle shaft o u t w a r d to "seat" t h e C-
clip " l o c k " i n the differential side gear counterbore.
(3) I n s e r t t h e differential p i n i o n gear mate shaft
i n t o t h e case a n d t h r o u g h the t h r u s t washers a n d the
p i n i o n gears. A l i g n t h e hole i n the shaft w i t h t h e
lock screw hole i n the differential case and i n s t a l l
t h e lock screw. T i g h t e n the screw w i t h 19 N»m (14
ft-lbs) torque.
(4) Remove the residual gasket m a t e r i a l from t h e
d i f f e r e n t i a l housing and the cover, thoroughly clean
t h e contact surfaces w i t h m i n e r a l spirits (or a n
equivalent solution) and d r y the surfaces completely.
(5) A p p l y a 1/16-inch t o 3/32-inch (1.6-mm t o 2.4-
m m ) t h i c k "bead" of M O P A R Silicone Rubber Seal-
a n t (or a n equivalent sealant) around the bolt circle
o n t h e housing cover (Fig. 8).
SEALANT
1/16-TO
3/32-INCH
(1.59-TO
38-AAM)
THICK BEAD
DIFFERENTIAL
HOUSING
COVER
(TYPICAL) J9003-85
Fig. 8 Sealant On Housing Cover
A l l o w t h e sealant t o " c u r e " for f e w m i n u t e s .
I f f o r any reason the housing cover is n o t i n -
s t a l l e d w i t h i n 20 m i n u t e s a f t e r a p p l y i n g t h e seal-
ant, t h e sealant m u s t be r e m o v e d a n d another
" b e a d " o f sealant applied.
(6) I n s t a l l t h e housing cover on t h e differential
housing w i t h t h e attaching bolts. I n s t a l l t h e axle
gear r a t i o identification t a g w i t h one of the cover
bolts. T i g h t e n the cover bolts w i t h 47 N*m (35 ft-lbs)
torque.
(7) I n s t a l l t h e brake d r u m a n d t h e wheel/tire.
T i g h t e n t h e wheel l u g nuts i n the correct sequence
(Fig. 9) w i t h the specified torque for the vehicle (Re-
fer t o Group 2 2 - T i r e s A n d Wheels).
Fig. 9 Wheel Lug Nut Tightening Sequence
(8) Remove t h e supports and raise o r lower t h e
hoist u n t i l the vehicle is level.
(9) Remove the fill hole p l u g a n d fill the differen-
t i a l housing and the axle tubes w i t h l u b r i c a n t (refer
to the Specifications chart for the type and t h e quan-
t i t y ) . I n s t a l l the fill hole plug.
(10) Lower the vehicle and test t h e brakes a n d the
axle for correct operation.
DRIVE PINION GEAR SHAFT SEAL REPLACEMENT
CAUTION; The following procedures for replace-
ment of the drive pinion gear shaft seal must be
used without exception to ensure that the correct
bearing "preload" torque is retained for the drive
pinion gear shaft bearings. If this procedure is not
completely followed, the result can be premature
failure of the rear axle.
REMOVAL
(1) Raise and support the vehicle.
(2) Score i n s t a l l a t i o n alignment reference m a r k s on
the drive shaft, t h e drive shaft f r o n t U-joint, t h e
drive p i n i o n gear shaft (axle) yoke a n d the end of the
drive p i n i o n gear shaft.
(3) Disconnect the drive shaft f r o m t h e drive p i n i o n
gear shaft (axle) yoke and secure i n a n u p r i g h t posi-
t i o n to prevent damage to the f r o n t U-joint.
(4) Remove t h e rear wheels/tires a n d t h e brake
drums t o prevent any " d r a g " from causing a possible
false bearing "preload" torque measurement.
(5) Use a Newton-meter or a n inch-pound torque
wrench (e.g., C-685-A) to measure t h e drive p i n i o n
gear shaft bearing "preload" torque. Rotate the drive
p i n i o n gear shaft w i t h the torque w r e n c h and note
(and record) t h e torque indication as t h e wrench
moves t h r o u g h several complete revolutions. T h i s
measurement is very i m p o r t a n t because t h e
 • REAR AXLES 3-15

bearing " p r e l o a d " torque must be carefully re-
a d j u s t e d a f t e r t h e r e p l a c e m e n t seal i s i n s t a l l e d .
(6) R e t a i n (axle) yoke w i t h H o l d i n g Tool C-3281
and remove drive p i n i o n gear shaft n u t a n d t h e
" B e l l e v i l l e " washer.
(7) Remove t h e yoke w i t h Yoke Removal Tool C-
452.
(8) Lower t h e rear of the vehicle t o prevent l u b r i -
cation leakage.
(9) Remove t h e drive p i n i o n gear shaft seal f r o m
the differential housing w i t h a s m a l l p r y b a r a n d a
hammer. Clean t h e seal contact surface i n t h e hous-
ing.
(7) Remove t h e tools a n d i n s t a l l t h e " B e l l e v i l l e "
washer (the convex side of t h e washer m u s t face out-
ward) and t h e drive p i n i o n gear shaft n u t .
(8) R e t a i n t h e drive p i n i o n gear shaft (axle) yoke
w i t h H o l d i n g Tool C-3281 and t i g h t e n t h e shaft n u t
w i t h 285 N*m (210 ft-lbs) torque (Fig. 11). Rotate t h e
drive p i n i o n gear shaft several complete revolutions
to ensure t h a t t h e b e a r i n g rollers are "seated".

INSTALLATION
(1) E x a m i n e t h e splines a t the end of the drive p i n -
ion gear shaft t o ensure t h a t they are w i t h o u t burrs
and are n o t w o r n excessively.
(2) I f b u r r s do exist, remove t h e m w i t h crocus cloth
by m o v i n g i t w i t h a r o t a t i o n a l motion. Clean t h e
drive p i n i o n gear shaft w i t h a clean shop cloth.
(3) Inspect t h e drive p i n i o n gear shaft (axle) yoke
for cracks, w o r n splines and w o r n seal contact sur-
face. Repair or replace t h e (axle) yoke as necessary.
T h e o u t e r p e r i m e t e r o f t h e seal i s p r e - c o a t e d
w i t h a special sealant, therefore a n a p p l i c a t i o n
o f sealant i s n o t r e q u i r e d .
(4) I n s t a l l t h e replacement drive p i n i o n gear shaft
seal (Fig. 10).
Use S e a l I n s t a l l a t i o n T o o l C-4076 f o r 8 3/8-inch
d i a m e t e r r i n g g e a r axles. U s e Seal I n s t a l l a t i o n
T o o l C-3980 o r C-4109 f o r 9 1/4-inch d i a m e t e r Fig. 11 Tightening Drive Pinion Gear Shaft Nut
r i n g g e a r a x l e s . T h e seal i s c o r r e c t l y i n s t a l l e d Use a N e w t o n - m e t e r o r a n i n c h - p o u n d t o r q u e
w h e n t h e seal f l a n g e c o n t a c t s t h e face o f t h e d i f - w r e n c h (e.g., C-685-A) t o m e a s u r e t h e d r i v e p i n -
ferential h o u s i n g flange. i o n gear shaft b e a r i n g " p r e l o a d " torque.

CAUTION: Never loosen the drive pinion gear shaft

nut to decrease the drive pinion gear shaft bearing
"preload" torque. If the specified "preload" torque
is exceeded, a replacement collapsible spacer must
be installed and the nut re-tightened until the spec-
ified bearing "preload" torque is obtained.

(9) Continue a l t e r n a t e l y t i g h t e n i n g t h e drive p i n -

Fig. 10 Drive Pinion Gear Shaft Seal Installation
(5) Position t h e drive p i n i o n gear shaft (axle) yoke
on t h e e n d o f t h e shaft w i t h t h e i n s t a l l a t i o n refer-
ence m a r k s aligned.
(6) "Seat" t h e (axle) yoke on t h e drive p i n i o n gear
shaft w i t h Tool C-3718 and H o l d i n g Tool C-3281.
ion gear shaft n u t a n d measuring the bearing "pre-
load" torque u n t i l t h e torque is t h e same as t h a t
measured a n d recorded p r i o r to yoke a n d seal r e -
moval. T h e b e a r i n g " p r e l o a d " t o r q u e s h o u l d
n e v e r b e g r e a t e r t h a n 1 N * m (10 i n - l b s ) m o r e
than the recorded amount.
The bearing " p r e l o a d " torque should be con-
stant d u r i n g a complete revolution o f the drive
p i n i o n g e a r shaft. I f t h e " p r e l o a d " t o r q u e v a r i e s
d u r i n g r o t a t i o n o f t h e shaft, this indicates a n i n -
t e r n a l " b i n d i n g " c o n d i t i o n a n d i t m u s t b e cor-
rected before c o n t i n u i n g w i t h the installation o f
the d r i v e shaft.
3-16 REAR AXLES
(10) I f t h e specified bearing "preload" torque is n o t
obtained after t i g h t e n i n g the drive p i n i o n gear shaft
n u t w i t h 285 N*m (210 ft-lbs) torque, continue t i g h t -
ening the n u t i n s m a l l increments u n t i l the recorded
bearing " p r e l o a d " torque is obtained.
(11) The seal replacement is unacceptable i f the f i -
nal d r i v e p i n i o n gear shaft n u t torque is less t h a n
285 N«m (210 ft-lbs) o r i f the drive p i n i o n gear shaft
bearing " p r e l o a d " torque is not correct.
(12) I n s t a l l t h e drive shaft w i t h t h e i n s t a l l a t i o n
reference m a r k s aligned. T i g h t e n the clamp screws
w i t h 19 N n n (170 in-lbs) torque.
(13) I n s t a l l t h e brake drums and the wheels/tires.
T i g h t e n the n u t s i n the correct t i g h t e n i n g sequence
(Fig. 12) w i t h t h e specified torque (Refer to Group
22—Tires a n d Wheels for the torque specification).
•
(4) Disconnect t h e brake f l u i d tube f i t t i n g s f r o m
t h e wheel cylinders and cap t h e fittings t o prevent
loss o f b r a k e f l u i d .
(5) Disconnect the p a r k i n g brake cables.
T o e n s u r e the c o r r e c t d r i v e l i n e b a l a n c e , s c r i b e
a l i g n m e n t m a r k s into t h e drive shaft U-joint
y o k e a n d the d r i v e p i n i o n gear shaft (axle) y o k e
before r e m o v a l o f the d r i v e shaft for i n s t a l l a t i o n
reference.
(6) Disconnect the drive shaft yoke f r o m t h e drive
p i n i o n gear shaft (axle) yoke and secure t h e drive
shaft i n a n u p r i g h t position t o prevent damage to the
front U - j o i n t .
(7) Remove t h e shock absorber lower a t t a c h i n g
bolts a n d t h e rear s p r i n g U-bolt nuts and t h e U -
bolts.
(8) Remove the complete axle from the vehicle.
(9) W a s h and clean t h e outer surface o f the axle
w i t h a n appropriate cleaning solution and d r y t h e
surface w i t h compressed air.

(14) Adjust t h e hoist so t h a t t h e vehicle is i n a
level position and check the differential housing l u -
bricant level. I f necessary, add a sufficient amount o f
M O P A R H y p o i d Gear L u b r i c a n t (or a n equivalent
product t h a t conforms to MIL-L-2105-B and A P I G L
5 q u a l i t y specifications) to increase the lubricant t o
the correct level.
COMPLETE AXLE REMOVAL/INSTALLATION
I t is n o t necessary to remove t h e complete axle
from the vehicle for routine service. However, i f t h e
differential housing or the axle shaft tubes are dam-
aged, t h e complete axle can be removed and i n s t a l l e d
d a t h e f o l l o w i n g procedures.
REMOVAL
(1) Raise t h e vehicle to a comfortable w o r k i n g
leight t h a t w i l l also enable support stands to be i n -
stalled a t the f r o n t o f the rear springs.
(2) Block t h e brake pedal i n t h e " u p " (non- springs a n d t h e n lower the rear of the hoist.
lepressed) position w i t h a wooden block.
(3) Remove t h e rear wheels/tires.
INSTALLATION
(1) W i t h the vehicle supported a t the f r o n t o f the
rear springs, position the rear axle spring pads over
the s p r i n g center bolts.
(2) I n s t a l l t h e s p r i n g U-bolts and nuts, and t h e
shock absorber lower bolts. T i g h t e n the nuts w i t h the
specified torque (Refer to Group 17—Springs a n d
Shock Absorbers).
(3) Connect the p a r k i n g b r a k e cables.
(4) Connect t h e brake f l u i d tube f i t t i n g s to t h e
wheel cylinders, and "bleed" and adjust the brakes.
(5) A l i g n the i n s t a l l a t i o n reference m a r k s and a t -
tach t h e drive shaft yoke t o t h e drive p i n i o n gear
shaft (axle) yoke. T i g h t e n t h e U-joint clamp bolts
w i t h 19 t o 23 N-m (170 to 200 in-lbs) torque.
(6) I n s t a l l t h e rear wheels/tires and t i g h t e n t h e
nuts i n t h e correct t i g h t e n i n g sequence (Fig. 12) w i t h
the specified torque (Refer to Group 22—Tires A n d
Wheels f o r the specification).
STANDARD DIFFERENTIAL SERVICE
CAUTION: When rear axle service is necessary, or
when the axle is being rotated either via the engine
or by other means, both rear wheels must be raised
off the surface so that they are free to rotate.
REMOVAUDISASSEMBL Y
I t is not n e c e s s a r y to r e m o v e the complete axle
to s e r v i c e a s t a n d a r d differential.
(1) Raise the vehicle on a hoist, position supports
under t h e vehicle frame a t t h e front of t h e rear
(2) Remove t h e rear wheels/tires and t h e brake
drums.
 (3) To ensure the correct driveline balance, scribe R e c o r d t h e d i f f e r e n t i a l case " s i d e p l a y " a n d
alignment m a r k s i n t o t h e drive shaft U-joint yoke the r i n g gear " r u n o u t " measurements, they w i l l
and the drive p i n i o n gear shaft (axle) yoke before re- be v e r y useful d u r i n g assembly.
moval of t h e drive shaft for i n s t a l l a t i o n reference. (9) Test for differential case "side p l a y " w i t h a
(4) Disconnect the drive shaft yoke from the drive s m a l l p r y bar or pinch bar (Fig. 15) placed between
pinion gear shaft (axle) yoke and secure i n a n up- the left side o f the differential housing and the dif-
r i g h t position t o prevent damage to t h e front U-joint. ferential case flange. Use a p r y i n g motion to deter-
(5) Remove t h e differential housing cover bolts, m i n e i f a n y "side p l a y " exists. Ideally, there should
d r a i n the l u b r i c a n t and remove the cover. be no "side play".
(6) Wash a n d clean t h e inside o f the differential RING GEAR
housing and t h e differential case w i t h an appropriate
cleaning solution.
(7) T u r n t h e differential case so t h a t p i n i o n gear
mate shaft lock screw is accessible (Fig. 13). Remove
the lock screw and p i n i o n gear mate shaft. Force
both axle shafts t o w a r d t h e center o f the vehicle and
remove the C-clip "locks" f r o m the recessed grooves
at the ends o f the axle shafts (Fig. 14).

J9003-55

Fig. 15 Differential "Side Play" Test

Fig. 13 Pinion Gear Mate Shaft Lock Screw D i f f e r e n t i a l case " s i d e p l a y " t h a t i s t h e r e s u l t
o f t h e b e a r i n g ( s ) b e c o m i n g loose from t h e d i f f e r -
e n t i a l case h u b s r e q u i r e s r e p l a c e m e n t o f t h e dif-
f e r e n t i a l case. O t h e r w i s e , u s e t h e t h r e a d e d
differential bearing adjuster t o remove the "side
p l a y " before measuring the r i n g gear " r u n o u t " .
(10) I n preparation for measuring t h e r i n g gear
" r u n o u t " (after a n y existing differential case "side
p l a y " has been eliminated), attach D i a l Indicator
Tool C-3339 t o P i l o t Stud Tool C-3288-B w i t h the i n -
dicator plunger a t a r i g h t angle (90°) to back face of
t h e r i n g gear (Fig. 16). The plunger should exert a
s l i g h t force against the r i n g gear back face.
(11) Measure the r i n g gear " r u n o u t " by t u r n i n g the
r i n g gear several complete revolutions and observing
the d i a l indicator pointer. M a r k the r i n g gear and
t h e d i f f e r e n t i a l case a t t h e location of m a x i m u m
Fig. 14 Axle Shaft C-Clip Lock " r u n o u t " . The r i n g gear " r u n o u t " should be no more
t h a n 0.005 i n c h (0.13 m m ) . I f the " r u n o u t " exceeds
(8) Remove t h e axle shafts f r o m t h e differential
0.005 i n c h (0.13 mm), a damaged differential case
housing. U s e c a r e t o p r e v e n t d a m a g i n g t h e a x l e
could be t h e cause. A procedure for measuring the
shaft b e a r i n g , w h i c h w i l l r e m a i n i n t h e axle
d i f f e r e n t i a l case flange " r u n o u t " is explained below.
shaft tube.
3-18 REAR AXLES
Fig. 16 Ring Gear "Runout" Measurement
The m a x i m u m " r u n o u t " m a r k o n the differen-
t i a l case w i l l b e v e r y u s e f u l l a t e r d u r i n g t h e dif-
f e r e n t i a l case flange "runout" measurement
(below).
(12) M a r k the differential housing and the differen-
t i a l bearing caps for i n s t a l l a t i o n reference (Fig. 17).
Fig. 17 Housing & Caps Marked For Installation
Reference
(13) Remove t h e differential bearing threaded ad-
juster " l o c k " from each bearing cap. Loosen, b u t do
not remove the bearing caps.
(14) Insert Tool C-4164 t h r o u g h each axle shaft
tube and i n t o the threaded adjuster hex-shaped drive
hole (Fig. 18). Loosen t h e threaded adjusters w i t h the
tool.
(15) R e t a i n the differential case i n place and, w i t h
e x t r e m e c a u t i o n , remove t h e differential bearing
caps (Fig. 19), the threaded adjusters and the differ-
ential case.
The differential bearing cup a n d the threaded
adjuster m u s t be retained w i t h their respective
b e a r i n g as a " m a t c h e d s e t " .
•
Fig. 18 Tool C-4164 In Axle Shaft Tube
BEARING
CUP
BEARING DIFFERENTIAL
CAP CASE J9003-86
Fig. 19 Differential Bearing Cap Removed
(16) Use a Newton-meter or a n inch-pound torque
wrench t o measure the drive p i n i o n gear shaft bear-
i n g " p r e l o a d " torque. Rotate t h e drive p i n i o n gear
shaft (axle) yoke n u t slowly w i t h the torque w r e n c h
and record t h e m a x i m u m torque. Remove t h e d r i v e
p i n i o n gear shaft n u t and washer. Use Tool C-452
and H o l d i n g Tool C-3281 to remove the drive p i n i o n
gear shaft (axle) yoke (Fig. 20).
(17) Use a s m a l l pry bar and a h a m m e r to remove
t h e drive p i n i o n gear shaft seal from the differential
housing bore and discard i t .
(18) Force the drive p i n i o n gear shaft r e a r w a r d and
out of t h e f r o n t bearing t o remove the shaft a n d t h e
front b e a r i n g f r o m the differential housing. T h i s w i l l
result i n damage t o the front bearing rollers a n d
the b e a r i n g cup, therefore, b o t h t h e f r o n t bear-
i n g a n d t h e c u p m u s t b e r e p l a c e d . Discard t h e
bearing " p r e l o a d " torque collapsible spacer.

J9003-59
Fig. 20 Drive Pinion Gear Shaft (Axle) Yoke
Removal
(19) Use t h e removal tools f r o m Tool Set C-4306
and Handle Tool C-4171 t o remove the front a n d rear
bearing cups from the differential housing.
(20) Remove the rear bearing f r o m the drive p i n i o n
gear shaft. For 8 3/8-inch diameter r i n g gear axles,
use Tool C-293-PA and Adapter Tools C-293-42. F o r
9 1/4-inch diameter r i n g gear axles, use Tool C-293-
P A and Adapter Tools C-293-37. Care m u s t be t a k e n
to ensure t h a t t h e adapter tools a r e positioned so
t h a t they w i l l not exert excessive force on t h e bear-
i n g cage (Fig. 21).
BEARING
REMOVAL
J9003-87
Fig. 21 Drive Pinion Gear Shaft Rear Bearing
Removal
D o not remove the r i n g gear f r o m the differen-
t i a l case u n l e s s e i t h e r t h e d i f f e r e n t i a l case o r t h e
r i n g gear/drive p i n i o n g e a r s h a f t s e t m u s t b e r e -
placed, o r unless t h e r i n g gear " r u n o u t " mea-
s u r e d i n i t e m 10 ( a b o v e ) e x c e e d s 0.005 i n c h (0.13
mm).
(21) Clamp t h e differential case ( w i t h t h e r i n g
gear) i n a vise equipped w i t h soft jaws (i.e., brass).
(22) Remove and discard t h e r i n g gear bolts. T h e
b o l t s h a v e l e f t - h a n d t h r e a d s . Use a non-metallic
hammer or a brass d r i f t t o " t a p " the r i n g gear loose
f r o m the differential case flange and remove i t .
(23) I f the r i n g gear " r u n o u t " exceeded 0.005 inch
(0.13 m m ) i n i t e m 10 (above), t h e differential case
flange " r u n o u t " should be measured. I n s t a l l t h e dif-
ferential case w i t h t h e o r i g i n a l bearing cups a n d
threaded adjusters i n housing.
(24) I n s t a l l t h e differential bearing caps and t h e
bearing cap bolts. T i g h t e n t h e bearing cap bolts
" l i g h t l y " and, w i t h Tool C-4164, thread both of the
threaded adjusters i n w a r d u n t i l a l l the bearing "side
p l a y " has been e l i m i n a t e d .
(25) A t t a c h D i a l Indicator Tool C-3339 t o t h e dif-
ferential housing w i t h t h e indicator plunger "square-
l y " (i.e., perpendicular) contacting t h e r i n g gear
m a t i n g surface (on t h e differential case flange) be-
tween the outer edge of the flange and the r i n g gear
a t t a c h i n g bolt holes.
(26) Rotate t h e differential case several complete
revolutions w h i l e observing t h e d i a l indicator
pointer. M a r k t h e location of m a x i m u m flange
" r u n o u t " . The differential case flange " r u n o u t " must
not exceed 0.003 i n c h (0.08 m m ) . I f the " r u n o u t " ex-
ceeds 0.003 i n c h (0.08 m m ) , t h e differential case
m u s t be replaced.
I n a s i t u a t i o n w h e r e t h e flange " r u n o u t " i s
c o n s i d e r e d e x c e s s i v e b u t does n o t e x c e e d 0.003
i n c h (0.08 m m ) , i t i s o f t e n p o s s i b l e t o r e d u c e t h e
combined r i n g gear " r u n o u t " b y positioning the
(marked) location o f t h e m a x i m u m r i n g gear
" r u n o u t " 180 d e g r e e s o p p o s i t e t h e ( m a r k e d ) l o -
c a t i o n o f m a x i m u m flange " r u n o u t " w h e n i n -
s t a l l i n g t h e r i n g g e a r o n t h e d i f f e r e n t i a l case
flange ( F i g . 22).
Fig. 22 Differential Case Flange "Runout"
Measurement
 (27) Remove the b e a r i n g cap bolts and remove the
differential case f r o m t h e differential housing.
(28) Rotate the differential side gears u n t i l the dif-
ferential p i n i o n gears are located at the differential
case opening and remove t h e m .
(29) Remove t h e differential side gears a n d the
t h r u s t washers.
(30) Remove the differential bearings from t h e case
hubs. For differential cases w i t h 8 3/8-inch diameter
r i n g gears, use Tool C-293-PA w i t h Adapter Tools C-
293-48 a n d P l u g Tool SP-3289. For differential cases
w i t h 9 1/4-inch diameter r i n g gears, use Tool C-293-
PA w i t h Adapter Tools C-293-47 and P l u g Tool C-
293-3 (Fig. 23).
Fig. 23 Differential Bearing Removal
CLEANING/INSPECTION
(1) Wash and clean a l l the differential components
w i t h a n appropriate; cleaning solvent and, w i t h t h e
e x c e p t i o n o f t h e b e a r i n g s , d r y t h e m w i t h com-
pressed a i r . To clean the axle shaft tubes, insert a
stiff w i r e i n t o each tube, attach a clean c l o t h to the
wire a t the differential housing opening a n d w i t h -
draw t h e w i r e w i t h t h e cloth f r o m housing o u t w a r d
to the end of the tube.
(2) A l l the machined contact surfaces i n t h e differ-
ential housing and t h e differential b e a r i n g caps
should be smooth and w i t h o u t any raised edges. The
drive p i n i o n gear shaft front and rear b e a r i n g cup
bores (machined surfaces) should also be smooth. I f
applicable, the raised m e t a l on the bore shoulders
caused b y removal of t h e bearing cups should be flat-
tened w i t h a " f l a t nose" punch.
(3) The axle shaft seal contact surfaces located at
each outer end of the axle shaft tubes should be
smooth and w i t h o u t any r u s t and corrosion. T h i s also
applies to the brake support plate and the axle tube
flange m a t i n g surface.
(4) The bearing contact surfaces on t h e axle shafts
and the axle shaft bearing rollers should be cleaned
and inspected for " p i t t i n g " , " s p a l l i n g " and other vis-
ible damage. I f either the shaft or t h e bearing is
damaged, discard both of t h e m and o b t a i n replace-
ment components.
Never reuse a n axle shaft b e a r i n g after i t has
b e e n r e m o v e d from a n a x l e s h a f t t u b e .
(5) The axle shaft splines should be smooth and
w i t h o u t any excessive wear. The seal contact sur-
faces on t h e axle shaft should be smooth and w i t h o u t
any nicks, scratches or blemishes.
P o l i s h t h e a x l e s h a f t w i t h N o . 600 c r o c u s c l o t h
to remove slight surface damage w i t h o u t reduc-
i n g t h e d i a m e t e r o f t h e a x l e s h a f t seal c o n t a c t
surface.
(6) The differential bearings and the drive p i n i o n
gear shaft front and rear bearings and cups should
have smooth surfaces w i t h no broken or dented areas
on the rollers or the roller contact surfaces. The bear-
i n g cages m u s t not be distorted or cracked.
When replacing a drive p i n i o n gear bearing,
a l w a y s r e p l a c e t h e b e a r i n g a n d t h e c u p as a
"matched set" only.
(7) Inspect the r i n g gear and the drive p i n i o n gear
shaft gear for w o r n and chipped teeth, and damaged
a t t a c h i n g bolt threads. I f r e p l a c e m e n t is neces-
sary, r e p l a c e b o t h t h e r i n g gear a n d the d r i v e
p i n i o n g e a r s h a f t as a " m a t c h e d s e t " o n l y .
(8) Inspect the drive p i n i o n gear shaft (axle) yoke
for cracks, w o r n splines, and w o r n seal contact sur-
face. Repair or replace the drive p i n i o n gear shaft
(axle) yoke as necessary.
(9) Inspect the drive p i n i o n gear shaft bearing "pre-
load" torque s h i m for damage and d i s t o r t i o n . Replace
i t i f necessary.
(10) The differential side gears and p i n i o n gears
should have smooth teeth and a u n i f o r m contact pat-
t e r n w i t h o u t excessive wear or broken surfaces. The
differential side gear h u b surfaces and t h r u s t washer
contact surfaces should be smooth and w i t h o u t any
scoring or m e t a l deposits.
(11) The machined t h r u s t washer contact surfaces
inside t h e differential case should be polished and
w i t h o u t any surface i r r e g u l a r i t i e s . The p i n i o n gear
mate shaft bore i n the differential case should be
round a n d w i t h o u t excessive wear f r o m t h e shaft con-
tact surfaces. The differential p i n i o n gear bores
should also be r o u n d and w i t h o u t excessive wear
from t h e shaft contact surfaces.
(12) Inspect the axle shaft C-clip "locks" for cracks
and wear. Replace t h e m i f necessary.
(13) Test each threaded adjuster to determine i f i t
rotates freely. I f an adjuster binds, either repair the
damaged threads or replace the adjuster, as neces-
sary, to ensure t h a t the threaded w i l l adjusters ro-
tate freely.
ASSEMBLY/INSTALLATION PILOT STUD FLANGE PILOT STUDS
(1) L i b e r a l l y lubricate a l l t h e components w i t h
gear l u b r i c a n t .
(2) Place the t h r u s t washers on the differential side
gears and position the gears i n the differential case
counterbores.
I f replacement differential side gears o r t h r u s t
w a s h e r s a r e being used, refer t o D i f f e r e n t i a l
Side Gear Clearance Measurement A n d Adjust-
ment.
(3) Position the t h r u s t washers o n the differential
p i n i o n gears and mesh the p i n i o n gears w i t h 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 the differential side gears t o a l i g n t h e
p i n i o n gears and the t h r u s t washers w i t h the differ-
e n t i a l p i n i o n gear mate shaft bores i n the differential
Fig. 25 Differential Case-To-Heated Ring Gear
case. Alignment
(5) T h e contact surfaces on the r i n g gear and on
t h e differential case flange m u s t be clean and w i t h - heated r i n g gear w i t h the differential case (Fig. 25).
o u t any b u r r s . (9) Insert replacement r i n g gear bolts ( w i t h left
(6) Use a n " A r k a n s a s " stone to remove any sharp h a n d threads) t h r o u g h t h e differential case flange
areas from the chamfered edge on the inside diame- and thread t h e m into t h e r i n g gear. A l t e r n a t e l y
t e r o f the r i n g gear (Fig. 24). t i g h t e n each bolt w i t h 95 N*m (70 ft-lbs) torque.

CAUTION: When installing a differential bearing,

never apply force to the bearing cage because bear-
ing damage will result.

(10) Place a differential bearing on each differen-

Fig. 24 Sharp Edge Removal
T h i s p r e c a u t i o n (above) i s v e r y i m p o r t a n t , b e -
cause otherwise, d u r i n g t h e installation o f t h e
r i n g g e a r o n t h e d i f f e r e n t i a l case flange, a s h a r p
e d g e c o u l d " s h a v e " m e t a l f r o m t h e flange a n d , i f
t h e metal becomes imbedded b e t w e e n the differ-
e n t i a l case flange a n d t h e r i n g g e a r , c a u s e t h e
r i n g gear n o t t o "seat" correctly o n the flange.
(7) Heat the r i n g gear w i t h a heat lamp or b y i m -
m e r s i n g i t i n a hot fluid (water or oil). The r i n g gear
t e m p e r a t u r e should not exceed 300°F (149°C). D o n o t
use a t o r c h .
(8) Position the differential case and the r i n g gear
between the brass jaws of a vise and use pilot studs
(equally spaced at three locations) to a l i g n t h e
t i a l case hub (bearing taper facing away f r o m t h e
r i n g gear) and carefully "seat" the bearings o n t h e
hubs. For differential cases w i t h 8 3/8-inch diameter
r i n g gears, use Bearing I n s t a l l a t i o n Tool C-4340 and
D r i v e r Handle Tool C-4171. F o r differential cases
w i t h 9 1/4-inch diameter r i n g gears, use B e a r i n g I n -
stallation Tool C-4213 and D r i v e r Handle Tool C-
4171. A n arbor press should be used w i t h t h e
installation Tools (Fig. 26).
(11) Select the correct drive p i n i o n gear shaft gear
adjustment gauge set (Figs. 27 and 28) and continue
the assembly according to the following instructions:
• insert both drive p i n i o n gear shaft bearing cups
i n t o the differential housing bores (ensure t h a t they
are not cocked);
• for 8 3/8-inch diameter r i n g gear axles, position
Locating Spacer Tool SP-6030 over the shaft o f Tool
SP-5385 and follow i t w i t h t h e drive p i n i o n gear
shaft rear bearing; and
• position the tools ( w i t h the bearing) i n the differ-
e n t i a l housing, i n s t a l l Shaft Locating Sleeve Tool SP-
5382, i n s t a l l t h e drive p i n i o n gear shaft front
bearing, i n s t a l l Washer Tool SP-6022 followed b y
Compression Sleeve Tool SP-3194-B, and i n s t a l l Cen-
t r a l i z i n g - Washer Tool SP-534 followed b y Compres-
sion N u t Tool SP-3193.

Fig. 26 Differential Bearing Installation
• for 9 1/4-inch diameter r i n g gear axles, position
L o c a t i n g Spacer Tool SP-6017 over the shaft o f Tool
SP-526 and follow i t w i t h the drive p i n i o n gear shaft
r e a r bearing; and
• position the tools ( w i t h the bearing) i n the differ-
e n t i a l housing, i n s t a l l Shaft Locating Sleeve Tool SP-
1730, i n s t a l l the drive p i n i o n gear shaft front
bearing, i n s t a l l Washer Tool SP-6022 followed b y
Compression Sleeve Tool SP-535-A, and i n s t a l l Cen-
t r a l i z i n g Washer Tool SP-534 followed b y Compres-
sion N u t Tool SP-533.
DRIVE PINION GEAR SHAFT
Fig. 27 8 3/8-Inch Ring Gear/Pinion Gear Adjustment
Tools
(12) W h i l e preventing the compression sleeve tool
f r o m r o t a t i n g w i t h Tool C-3281, t i g h t e n t h e n u t to
force and "seat" the drive p i n i o n gear shaft bearing
cups i n the differential housing bores (Fig. 29). Per-
SP-533
Fig. 28 9 1/4-Inch Ring Gear/Pinion Gear Adjustment
Tools
Fig. 29 Bearing Cup Installation
m i t the sleeve tool t o rotate several revolutions dur-
i n g the t i g h t e n i n g operation t o prevent " b r i n e l l i n g "
the bearing cups or the bearings.
The position o f the drive p i n i o n gear i n rela-
t i o n t o t h e r i n g g e a r ( d e p t h o f g e a r m e s h ) i s de-
termined b y the location o f the bearing cup
shoulders i n t h e differential h o u s i n g bores a n d
b y the drive p i n i o n gear shaft l e n g t h t h a t is lo-
cated f o r w a r d o f the rear bearing. A d e p t h shim
is positioned b e t w e e n the d r i v e p i n i o n gear shaft
r e a r b e a r i n g a n d t h e d r i v e p i n i o n gear. T h e re-
q u i r e d t h i c k n e s s o f t h i s d e p t h s h i m i s deter-
m i n e d according t o the f o l l o w i n g i n f o r m a t i o n .
(13) Loosen the compression n u t tool (Figs. 22 and
23). Lubricate t h e drive p i n i o n gear shaft f r o n t and
rear bearings w i t h gear l u b r i c a n t . Re-tighten t h e
compression n u t tool u n t i l 1 to 3 N*m (15 t o 25 i n -
lbs) torque is indicated. Rotate t h e d r i v e p i n i o n gear
shaft several complete revolutions to a l i g n the bear-
i n g rollers.
(14) For 8 3/8-inch diameter r i n g gear axles:
• i n s t a l l Gauge Block Tool SP-5383 a t the end of
Tool SP-5385;
• i n s t a l l Cap Screw Tool SP-536; a n d
• t i g h t e n i t securely w i t h W r e n c h Tool SP-531.
(15) For 9 1/4-inch diameter r i n g gear axles:
• i n s t a l l Gauge Block Tool SP-6020 at t h e end of
Tool SP-526;
• i n s t a l l Cap Screw SP-536; a n d
• t i g h t e n i t securely w i t h W r e n c h Tool SP-531.
(16) For 8 3/8-inch diameter r i n g gear axles, posi-
t i o n Crossbore A r b o r Tool SP-6029 i n t h e differential
bearing bores i n the differential h o u s i n g (Fig. 30).
(17) For 9 1/4-inch diameter r i n g gear axles, posi-
t i o n Crossbore A r b o r Tool SP-6018 i n t h e differential
bearing bores i n the differential housing (Fig. 30).
Center the crossbore a r b o r t o o l t o p r o v i d e a n
a p p r o x i m a t e l y equal open space at each bore.
P l a c e a p i e c e o f 0.002 i n c h s h i m s t o c k a t e a c h
e n d of the a r b o r tool, p o s i t i o n the b e a r i n g caps
o n the a r b o r tool a n d install the attaching bolts.
T i g h t e n t h e c a p b o l t s w i t h 14 N n n (10 f t - l b s )
torque.
(18) Select ( t r i a l f i t ) a drive p i n i o n gear shaft rear
bearing depth s h i m t h a t w i l l " f i t " between the cross-
bore arbor tool and the gauge block tool (Fig. 30).
T h e d e p t h s h i m " f i t " m u s t b e " s n u g " b u t n o t ex-
c e s s i v e l y t i g h t (e.g., s i m i l a r t o t h e " d r a g " f r i c t i o n
o f a feeler gauge blade).
Fig. 30 Drive Pinion Gear Shaft Bearing Depth
Selection
D e p t h s h i m s a r e a v a i l a b l e i n 0.001-inch i n c r e -
m e n t s f r o m 0.020 i n c h t o 0.038 i n c h .
(19) Note the etched n u m b e r on the face of the
drive p i n i o n gear (e.g., -0, - 1 , -2, + 1 , 4 - 2 , etc.). The
etched numbers represent 0.001 of-an-inch deviation
f r o m the standard. I f the n u m b e r is "-" (negative),
add t h a t value to the thickness of the depth s h i m se-
lected i n i t e m 20 (above). I f the n u m b e r is " + " (pos-
itive), subtract t h a t value f r o m t h e thickness of the
depth s h i m selected i n i t e m 20 (above). I f the number
is " 0 " , no change is required. E v a l u a t e other drive
p i n i o n gear etched numbers i n a s i m i l a r manner.
(20) Remove the tools from the differential housing.
(21) Position the depth s h i m selected above on the
drive p i n i o n gear shaft followed by the rear bearing
(ensure t h a t the d r i v e p i n i o n gear contact surface,
the bearing and the depth s h i m are clean and w i t h -
out foreign particles). Use B e a r i n g I n s t a l l a t i o n Tool
C-4040 for 8 3/8-inch diameter r i n g gear axles or
Tool C-3095-A for 9 1/4-inch diameter r i n g gear axles
and force the rear b e a r i n g onto the drive p i n i o n gear
shaft. A n arbor press can be used w i t h the i n s t a l l a -
t i o n tool (Fig. 31).
PINION GEAR
Fig. 31 Shaft Rear Bearing Installation
(22) Lubricate the drive p i n i o n gear shaft front and
rear bearings w i t h gear l u b r i c a n t .
(23) Insert the d r i v e p i n i o n gear shaft w i t h the
rear bearing into and t h r o u g h the differential hous-
i n g bore. Position t h e bearing "preload" torque "re-
placement" collapsible spacer at t h e end of the drive
Shim p i n i o n gear shaft. Position drive p i n i o n gear shaft
front bearing at t h e end of t h e drive p i n i o n gear
shaft.
(24) I n s t a l l the (axle) yoke on 8 3/8-inch diameter
r i n g gear axles w i t h Removal/Installation Tool C-
3718 and H o l d i n g Tool C-3281. For 9 1/4-inch diam-
eter r i n g gear axles, use Removal/Installation Tool
C-496 and H o l d i n g Tool C-3281.
Because of the f r o n t b e a r i n g "interference f i t "
o n t h e d r i v e p i n i o n g e a r s h a f t , i t is n e c e s s a r y t o
use t h e t o o l s ( a b o v e ) t o c o r r e c t l y " s e a t " t h e f r o n t
b e a r i n g o n t h e d r i v e p i n i o n g e a r s h a f t ( F i g . 32).
3 - 24 REAR AXLES
Fig. 32 Drive Pinion Gear Shaft (Axle) Yoke
Installation
JAUTION: During installation of the drive pinion
[ear shaft (axle) yoke and "seating" the front bear-
rig, use care to prevent collapsing the "preload"
orque spacer.
(25) Remove t h e (axle) yoke a n d t h e tools f r o m t h e
rive p i n i o n gear shaft.
(26) I n s t a l l t h e drive p i n i o n gear shaft seal:
for 8 3/8-inch diameter r i n g gear axles, use I n s t a l -
i t i o n Tool C-4076; a n d
for 9 1/4-inch diameter r i n g gear axles, use I n s t a l -
i t i o n Tool C-3980 or C-4109.
(27) T h e seal is correctly i n s t a l l e d w h e n t h e seal
ange contacts t h e face o f t h e differential housing
ange ( F i g . 33).
Fig. 33 Drive Pinion Gear Shaft Seal Installation
The o u t e r perimeter o f t h e seal i s pre-coated
i t h a s p e c i a l sealant, t h e r e f o r e a n a p p l i c a t i o n
' sealant is n o t r e q u i r e d .
(28) I n s t a l l t h e (axle) yoke on 8 3/8-inch diameter
i g gear axles w i t h Removal/Installation Tool C-
1 8 a n d H o l d i n g Tool C-3281. F o r 9 1/4-inch diam-
•
eter r i n g gear axles, use Removal/Installation Tool
C-496 and Holding Tool C-3281.
(29) Remove the tools a n d i n s t a l l a " B e l l e v i l l e "
washer w i t h t h e convex side o f t h e washer facing
outward a n d the r e t a i n i n g n u t o n t h e end o f t h e
drive p i n i o n gear shaft.
(30) Retain drive p i n i o n gear shaft (axle) yoke w i t h
H o l d i n g Tool C-3281 a n d i n i t i a l l y t i g h t e n t h e drive
p i n i o n gear shaft n u t enough to remove t h e bearing
"end play". W h i l e i n i t i a l l y t i g h t e n i n g t h e n u t , rotate
the drive p i n i o n gear shaft t o ensure t h a t t h e bear-
i n g rollers are correctly "seated" (Fig. 34).
(31) T i g h t e n the d r i v e p i n i o n gear shaft n u t w i t h
285 N«m (210 ft-lbs) torque ( m i n i m u m ) .
Fig. 34 Tightening Drive Pinion Gear Shaft Nut
(32) Remove the tools a n d rotate t h e drive p i n i o n
gear shaft several complete revolutions i n b o t h direc-
tions to additionally "seat" t h e b e a r i n g rollers.
CAUTION: Never loosen the drive pinion gear shaft
nut to decrease the drive pinion gear shaft bearing
"preload" torque. If the specified "preload" torque
is exceeded, a replacement collapsible spacer must
be installed and the nut re-tightened until the spec-
ified bearing "preload" torque is obtained.
(33) Measure the drive p i n i o n gear shaft b e a r i n g
"preload" torque by r o t a t i n g drive p i n i o n gear shaft
w i t h a Newton-meter or a n inch-pound torque
wrench. The correct b e a r i n g "preload" torque i s 2 to
4 N-m (20 to 35 in-lbs) for both 8 3/8-inch a n d 9 1/
4-inch diameter r i n g gear axles w i t h replacement
bearings a n d the drive p i n i o n gear shaft n u t t i g h t -
ened w i t h a m i n i m u m o f 285 N * m (210 ft-lbs) torque
(Fig. 35).
 I f the o r i g i n a l the d r i v e p i n i o n gear shaft r e a r
b e a r i n g a n d a r e p l a c e m e n t front b e a r i n g a r e
u s e d , w i t h a m i n i m u m o f 285 N*m (210 ft-lbs)
t o r q u e , the correct b e a r i n g " p r e l o a d " torque is 1
N»m (10 i n - l b s ) t o r q u e i n a d d i t i o n t o t h e t o r q u e
recorded d u r i n g disassembly.
Fig. 35 Drive Pinion Gear Shaft Bearing "Preload"
Torque Measurement
T h e b e a r i n g " p r e l o a d " t o r q u e s h o u l d be c o n -
stant d u r i n g a complete r e v o l u t i o n of the drive
p i n i o n gear shaft. I f the " p r e l o a d " t o r q u e varies
d u r i n g r o t a t i o n of the shaft, this indicates a n i n -
t e r n a l " b i n d i n g " c o n d i t i o n a n d i t m u s t be cor-
rected before c o n t i n u i n g w i t h the assembly o f
the differential.
(34) I f the specified b e a r i n g "preload" torque is not
obtained w i t h 285 N m (210 ft-lbs) torque, continue
#
t i g h t e n i n g the drive p i n i o n gear shaft n u t i n s m a l l
increments u n t i l the correct bearing "preload" torque
is obtained.
T h e a s s e m b l y o f t h e d i f f e r e n t i a l is u n a c c e p t -
able i f the f i n a l d r i v e p i n i o n gear shaft n u t
t o r q u e i s less t h a n 285 N * m (210 ft-lbs) t o r q u e o r
i f the drive p i n i o n gear shaft bearing " p r e l o a d "
t o r q u e is n o t c o r r e c t .
(35) A p p l y a coating of gear l u b r i c a n t to the differ-
e n t i a l bearings, the b e a r i n g cups and the threaded
adjusters. Carefully position the assembled differen-
t i a l case i n the housing.
(36) Note the i n s t a l l a t i o n reference m a r k s and i n -
s t a l l t h e differential b e a r i n g caps at their, original lo-
cations.
(37) I n s t a l l the b e a r i n g cap bolts. T i g h t e n the up-
per bolts w i t h 14 N«m (10 ft-lbs) torque. Tighten t h e
lower bolts " f i n g e r - t i g h t " u n t i l the bolt head is
l i g h t l y "seated" on the bearing cap.
DIFFERENTIAL BEARING "PRELOAD"
TORQUE AND RING GEAR "BACKLASH"
ADJUSTMENT
There are precautions t h a t m u s t be observed w h e n
adjusting the differential bearing "preload" torque
and the r i n g gear "backlash":
• the m a x i m u m permissible r i n g gear " b a c k l a s h "
v a r i a t i o n is 0.003 i n c h ;
• for example, i f t h e m i n i m u m " b a c k l a s h " is 0.006
inch a t one location, the m a x i m u m can be no more
t h a n 0.009 i n c h a t another location;
• t h i s v a r i a t i o n represents the m a x i m u m permissi-
ble " r u n o u t " and i t is i m p o r t a n t to index t h e gears so
t h a t the same teeth are engaged d u r i n g a l l "back-
l a s h " measurements;
• i t is also i m p o r t a n t to m a i n t a i n the specified
threaded adjuster torque w h i l e adjusting t h e differ-
e n t i a l bearing "preload" torque and the r i n g gear
"backlash";
• excessive torque w i l l introduce a h i g h bearing
" l o a d " and cause premature bearing failure, w h i l e i n -
sufficient torque w i l l not support the r i n g gear cor-
rectly and t h i s can result i n excessive differential
case "free-play" and r i n g gear noise.
The differential bearing cups w i l l n o t always
respond directly to adjustment of the threaded
adjusters, therefore to ensure accurate adjust-
m e n t responses a n d to m a i n t a i n the gear mesh
index, the bearings m u s t be " s e a t e d " b y r o t a t i n g
the d r i v e p i n i o n gear shaft a h a l f t u r n i n each
d i r e c t i o n five to ten times each t i m e the
t h r e a d e d adjusters are adjusted.
(1) Use Tool C-4164 to adjust each threaded ad-
j u s t e r i n w a r d (Fig. 36) u n t i l the excessive differential
bearing "free-play" is eliminated, b u t w i t h some r i n g
gear "backlash" (approximately 0.010 inch) r e m a i n -
i n g between the r i n g gear and drive p i n i o n gear.
"Seat" the bearing rollers as described above.
(2) I n s t a l l D i a l Indicator Tool C-3339 (Fig. 37) and
position the plunger against the drive side of a r i n g
gear tooth. Measure the " b a c k l a s h " at 4 positions
around the perimeter of the r i n g gear ( w i t h a n arc
i n t e r v a l of approximately 90 degrees between each
position) to locate t h e area of m i n i m u m "backlash".
(3) After the measurement is completed, rotate t h e
r i n g gear to the position of least " b a c k l a s h " (as i n d i -
cated by the d i a l indicator pointer) and m a r k the
gear so t h a t a l l f u t u r e "backlash" measurements w i l l
be t a k e n w i t h the same teeth meshed.
(4) Loosen the right-side threaded adjuster and
t i g h t e n the left-side threaded adjuster u n t i l the r i n g
gear "backlash" is 0.003 to 0.004 i n c h (0.08 to 0.10
m m ) after each adjuster has been tightened w i t h 14
N»m (10 ft-lbs) torque. "Seat" the bearing rollers as
described above.
 AXLE (8) T i g h t e n t h e left-side threaded adjuster w i t h 102
SHAFT TUBE N«m (75 ft-lbs) torque (and "seat" t h e b e a r i n g rollers
as described above) u n t i l torque remains constant.
(9) A f t e r t h e adjustments are completed, i n s t a l l t h e
threaded adjuster "locks". Ensure t h a t t h e "lock
t e e t h " f o r 9 1/4-inch diameter r i n g gear axles are en-
gaged w i t h t h e adjuster threads a n d t h a t t h e "lock
finger" i s engaged w i t h adjuster hole for 8 3/8-inch
diameter r i n g gear axles. T i g h t e n t h e " l o c k " screws
w i t h 10 N * m (90 in-lbs) torque.

DIFFERENTIAL SIDE GEAR CLEARANCE

MEASUREMENT/ADJUSTMENT
THREADED The correct differential side gear clearance is ob-
ADJUSTER TOOL C-4164 J9003-58
tained b y selection o f a side gear t h r u s t washer t h a t
Fig. 36 Threaded Adjuster Tool C-4164 has t h e correct thickness. Refer to t h e replacement
parts catalog for t h e required side gear t h r u s t
RING washer package.
GEAR
W h e n m e a s u r i n g side gear clearance, evaluate
each gear independently. I t is possible for one side
gear t o have a n acceptable clearance a n d for t h e
other side gear t o have a n unacceptable clearance. I f
i t necessary t o replace a side gear, replace b o t h gears
as a " m a t c h e d set".
(1) I n s t a l l t h e axle shafts and the C-clip "locks". I n
necessary, refer t o t h e i n s t a l l a t i o n located w i t h i n
t h i s group.
(2) W i t h t h e axle shafts a n d t h e C-clip " l o c k s " i n
place, measure each side gear clearance b y selec-
INDICATOR t i v e l y i n s e r t i n g a "matched p a i r " o f feeler gauge
TOOL blades between t h e gear and the d i f f e r e n t i a l housing
J9003-72
C-3339
on opposite sides of the hub (Fig. 38).
Fig. 37 Ring Gear "Backlash" Measurement (3) I f e i t h e r o f the side gear clearances is no more

(5) T i g h t e n t h e differential bearing cap bolts w i t h

95 N-m (70 ft-lbs) torque for 8 3/8-inch diameter r i n g
gear axles a n d w i t h 136 N«m (100 ft-lbs) torque for 9
1/4-inch diameter r i n g gear axles.
(6) Use Tool C-4164 t o t i g h t e n t h e right-side
threaded adjuster w i t h 102 N»m (75 ft-lbs) torque.
"Seat" t h e bearing rollers as described above. Con-
tinue t o t i g h t e n t h e right-side adjuster a n d "seat"
bearing rollers u n t i l t h e torque remains constant a t
102 N*m. (75 ft-lbs).
(7) Measure t h e r i n g gear "backlash". I f the "back-
l a s h " is n o t 0.006 to 0.008 inch (0.15 to 0.20 m m ) ,
continue increasing t h e torque at t h e right-side
threaded adjuster (and "seat" t h e bearing rollers as
J9003-73
described above) u n t i l t h e specified "backlash" is ob-
tained. Fig. 38 Side Gear Clearance Measurement
I f a l l t h e p r e v i o u s i n s t r u c t i o n s have been cor-
t h a n 0.005 i n c h , inspect the end o f the axle shaft o n
rectly completed, the initial torque indication f o r
the same side o f t h e differential housing t o deter-
the left-side t h r e a d e d adjuster s h o u l d b e a p p r o x - m i n e i f i t i s contacting the p i n i o n gear mate shaft.
i m a t e l y 102 N * m (75 f t - l b s ) . I f t h e t o r q u e i s s u b - D o n o t r e m o v e t h e feeler g a u g e s , i n s p e c t t h e
s t a n t i a l l y less, t h e c o m p l e t e p r o c e d u r e m u s t b e a x l e s h a f t w i t h t h e feeler g a u g e b l a d e s i n s e r t e d
repeated. b e h i n d t h e s i d e g e a r . I f the end o f the axle shaft is
 not contacting the p i n i o n gear m a t e shaft, the side
gear clearance is acceptable.
(4) I f a side gear clearance is more t h a n 0.005 i n c h
(and the axle shaft is not contacting the differential
pinion gear m a t e shaft), record t h e side gear clear-
ance. Remove the t h r u s t washer and measure i t s
thickness w i t h a micrometer. A d d the washer t h i c k -
ness to the recorded side gear clearance. The sum of
the gear clearance and t h e washer thickness w i l l de-
termine the r e q u i r e d thickness of the replacement
t h r u s t washer.
F o r e x a m p l e , i f t h e s i d e g e a r c l e a r a n c e is 0.007
i n c h a n d t h e t h r u s t w a s h e r t h i c k n e s s i s 0.033
i n c h , t h e s u m i s 0.04 i n c h . I n s t a l l t h e " t h i c k e s t "
thrust washer f r o m the service package t h a t
does n o t e x c e e d t h e s u m c a l c u l a t e d a b o v e . I n
t h e example s i t u a t i o n , a 0.037-inch t h i c k w a s h e r
f r o m t h e s e r v i c e p a c k a g e s h o u l d b e i n s t a l l e d be-
cause t h e n e x t l a r g e r w a s h e r size i s 0.042-inch
thick, w h i c h w o u l d be too t h i c k . W h e n the re-
p l a c e m e n t t h r u s t w a s h e r i s i n s t a l l e d , t h e side
g e a r c l e a r a n c e s h o u l d b e 0.003 i n c h .
(5) I n some instances, the end of the axle shaft w i l l
move and contact the p i n i o n gear mate shaft w h e n
the feeler gauge blades are inserted behind the side
gear. W h e n t h i s occurs, the C-clip " l o c k " on the axle
shaft is p r e v e n t i n g the side gear f r o m s l i d i n g on the
axle shaft a n d m o v i n g independently i n w a r d .
To d e t e r m i n e t h e t o t a l side gear clearance
w i t h t h i s s i t u a t i o n (above), r e - m e a s u r e t h e c l e a r -
ance wdth t h e C-clip " l o c k " r e m o v e d . Compare
this measurement w i t h the measurement w h e n
t h e C-clip " l o c k " w a s i n s t a l l e d .
(6) Remove the C-clip " l o c k " f r o m the axle shaft(s)
t h a t have no "end play". W i t h t h e differential case
disassembled, use a micrometer to measure the
t h r u s t washer thickness. Record the thickness and
r e t u r n the t h r u s t washer behind the side gear. As-
semble the differential case w i t h o u t the C-clip " l o c k "
installed and re-measure the side gear clearance.
(7) Compare the clearances. I f t h e clearance differ-
ence is less t h a n 0.012 inch, add the side gear clear-
ance recorded w h e n the C-clip " l o c k " was installed to
the t h r u s t washer thickness measured w i t h the m i -
crometer. The s u m w i l l determine the required thick-
ness of the replacement t h r u s t washer.
F o r e x a m p l e , i f t h e s i d e g e a r c l e a r a n c e i s 0.006
i n c h w i t h t h e axle shaft C-clip " l o c k " i n s t a l l e d
a n d 0.015 i n c h w i t h t h e C - c l i p " l o c k " r e m o v e d ,
t h e d i f f e r e n c e i s 0.009 i n c h , w h i c h is less t h a n
0.012 i n c h . A d d 0.006 i n c h ( t h e c l e a r a n c e w i t h
the C-clip " l o c k " installed) to the thrust washer
t h i c k n e s s (e.g., 0.032 i n c h ) . T h e s u m is 0.038 i n c h .
T h e c l o s e s t t h r u s t w a s h e r t h i c k n e s s t h a t does
n o t e x c e e d 0.038 i n c h i s 0.037 i n c h .
(8) I f the clearance difference is 0.012 inch or
greater, both side gears must be replaced ("matched
set") a n d t h e clearance measurements repeated.
(9) I f t h e side gear clearance difference (above) con-
tinues to be 0.012 i n c h or greater w i t h replacement
side gears and the " t h i c k e s t " t h r u s t washers from the
service package installed, the differential case m u s t
be replaced.
RING GEAR TEETH CONTACT PATTERNS
(1) A p p l y a t h i n coat of H y d r a t e d Ferric Oxide
(commonly referred to as Yellow Oxide of Iron), or an
equivalent product, to both the " d r i v e " side and the
"coast" side of the r i n g gear teeth.
(2) Rotate t h e r i n g gear one complete r e v o l u t i o n i n
both directions w h i l e a load is being applied w i t h a
r o u n d bar or screwdriver inserted between the differ-
e n t i a l h o u s i n g and t h e differential case flange. This
action w i l l produce a distinct contact pattern on both
the " d r i v e " side and t h e "coast" side of the r i n g gear
teeth.
T h e gear t e e t h c o n t a c t p a t t e r n w i l l disclose
w h e t h e r o r n o t t h e d r i v e p i n i o n gear s h a f t r e a r
bearing d e p t h shim has the correct thickness
a n d w h e t h e r o r n o t t h e r i n g gear " b a c k l a s h " has
b e e n a d j u s t e d c o r r e c t l y . T h e " b a c k l a s h " be-
t w e e n t h e r i n g gear a n d the drive p i n i o n gear
m u s t be m a i n t a i n e d w i t h i n the specified limits
u n t i l t h e c o r r e c t t e e t h c o n t a c t p a t t e r n is o b -
tained.
(3) E x a m i n e the contact patterns on the r i n g gear
teeth and compare t h e m w i t h those i n Figs. 39
t h r o u g h 43 to determine i f the patterns are correct.
W i t h the d r i v e p i n i o n gear depth of mesh correct and
the r i n g gear " b a c k l a s h " adjusted correctly, the teeth
contact patterns should closely resemble the patterns
i l l u s t r a t e d i n F i g . 39. Notice t h a t the i l l u s t r a t e d
teeth contact patterns are w e l l centered on both the
" d r i v e " side and the "coast" side of the teeth.
3 - 28 REAR AXLES •
When t h e teeth contact patterns are obtained
PATTERNS MOVE TOWARD CENTER
by t h e m e t h o d described above, they are l i k e l y AND DOWN
to be rather small. W i t h a n actual operating
load, h o w e v e r , t h e c o n t a c t area increases.

PATTERNS CLOSE TO CENTER

HEEL END-DRIVE HEEL END-COAST

SIDE (CONVEX) SIDE (CONCAVE)

J9003-76

Fig. 41 Teeth Contact Patterns After Depth Shim

HEEL END-DRIVE HEEL END-COAST
SIDE (CONVEX) SIDE (CONCAVE)
J9003-74
Fig. 39 Desired Teeth Contact Patterns (With Light
Load)
(4) I f , after e x a m i n i n g t h e r i n g gear contact pat-
terns, i t is determined t h a t t h e patterns resemble
those i l l u s t r a t e d i n F i g . 40, t h e drive p i n i o n gear is
separated too much f r o m t h e centerline o f t h e r i n g
gear. This condition w i l l cause t h e contact patterns
to be " h i g h " on the " d r i v e " side a n d near t h e " h e e l "
of the tooth, and " h i g h " on t h e "coast" side and near
the " t o e " o f t h e tooth. To correct for this type t e e t h
contact patterns, increase t h e thickness o f the depth
shim (located between t h e drive p i n i o n gear a n d t h e
drive p i n i o n gear shaft rear bearing). This w i l l cause
the " h i g h " contact p a t t e r n on the " d r i v e " side t o be
lowered a n d t o move t o w a r d t h e " t o e " of t h e t o o t h ,
Thickness Is Increased
(5) I f , after e x a m i n i n g the contact patterns, i t is de-
t e r m i n e d t h a t t h e patterns resemble those i l l u s t r a t e d
i n F i g . 42, t h e drive p i n i o n gear is too close t o t h e
centerline of the r i n g gear. This condition w i l l cause
the contact patterns to be " l o w " on t h e " d r i v e " side
and near t h e " t o e " of the tooth, and " l o w " on "coast"
side a n d near t h e "heel" o f the tooth. To correct for
t h i s type o f teeth contact patterns, decrease t h e
thickness o f t h e depth s h i m (located between t h e
drive p i n i o n gear and t h e drive p i n i o n gear shaft
rear bearing). T h i s w i l l cause the " l o w " contact pat-
t e r n on t h e " d r i v e " side to be raised and t o move t o -
w a r d t h e " h e e l " o f t h e tooth, and t h e " l o w " contact
p a t t e r n on t h e "coast" side to be raised and to move
t o w a r d t h e " t o e " o f the tooth (Fig. 43).
THINNER SHIM REQUIRED

and t h e " h i g h " contact p a t t e r n on t h e "coast" side t o

be lowered a n d to move t o w a r d t h e "heel" o f t h e
tooth (Fig. 41).

THICKER SHIM REQUIRED

HEEL END-DRIVE HEEL END-COAST

SIDE (CONVEX) SIDE (CONCAVE)
J9003-77

Fig. 42 Incorrect Teeth Contact Patterns—Decrease

Depth Shim Thickness
HEEL END-DRIVE HEEL END-COAST (6) W h e n t h e correct teeth contact patterns are ob-
SIDE (CONVEX) SIDE (CONCAVE) tained, i n s t a l l t h e drive shaft w i t h t h e i n s t a l l a t i o n
J9003-75 reference m a r k s aligned. T i g h t e n the clamp screws
w i t h 19 N-m (170 in-lbs) torque.
Fig. 40 incorrect Teeth Contact Patterns—Increase (7) For 8 3/8-inch diameter r i n g gear axles, i n s t a l l
Depth Shim Thickness the replacement axle shaft seals w i t h Seal I n s t a l l a -
 SEALANT

PATTERNS MOVE INWARD AND UP

HEEL END-DRIVE HEEL END-COAST

SIDE (CONVEX) SIDE (CONCAVE)

J9003-78

Fig. 43 Teeth Contact Patterns After Depth Shim

Thickness Is Decreased
Hon Tool C-4203 a n d D r i v e r H a n d l e Tool C-4171.
The flat side of t h e i n s t a l l a t i o n tool must face the
seal (Fig. 44). Use Seal I n s t a l l a t i o n Tool C-4826 for 9 (TYPICAL) J9003-85
1/4-inch diameter r i n g gear axles.
Fig. 45 Sealant On Housing Cover
" b e a d " o f sealant applied.
29
(12) I n s t a l l t h e cover on t h e differential housing
and t i g h t e n cover bolts w i t h 47 N»m (35 ft-lbs)
torque. I n s t a l l t h e axle gear r a t i o identification t a g
under one o f the cover bolts.
(13) I n s t a l l the brake d r u m s a n d t h e wheels/tires.
Tighten t h e wheel l u g n u t s i n t h e correct sequence
(Fig. 46) w i t h t h e specified torque (Refer to Group
22—Tires and Wheels for t h e torque specification).

Fig. 44 Axle Shaft Seal Installation

(8) Carefully slide t h e axle shafts t h r o u g h t h e seals
and engage t h e m w i t h t h e side gears, insert t h e C-
clip "lock"s i n t h e axle shaft recessed grooves, and
p u l l o u t w a r d on each shaft to "seat" t h e C-clip
"locks" i n t h e side gear counterbores.
(9) Insert the differential p i n i o n gear mate shaft
into and t h r o u g h t h e differential case and t h e pinion
gears, a l i g n t h e hole i n t h e shaft w i t h t h e lock screw
hole, a n d i n s t a l l t h e lock screw. T i g h t e n t h e lock
screw w i t h 11 N m (100 in-lbs) torque.
w

(10) Remove any residue gasket m a t e r i a l and/or

sealant from t h e differential h o u s i n g and cover, thor-
oughly clean t h e m a t i n g surfaces w i t h m i n e r a l spir-
its (or a n equivalent product) a n d d r y t h e surfaces
completely. Fig. 46 Wheel Lug Nut Tightening Sequence
(11) A p p l y a 1/16-inch to 3/32-inch t h i c k "bead" of
(14) Remove t h e block f r o m t h e brake pedal.
M O P A R Silicone Rubber Sealant, or a n equivalent
(15) Adjust the hoist so t h a t t h e vehicle is i n a
product, along t h e bolt circle o f t h e cover (Fig. 45).
level position.
A l l o w t h e sealant t o " c u r e " f o r a f e w minutes.
(16) Remove t h e f i l l hole p l u g and f i l l the differen-
I f f o r a n y reason t h e h o u s i n g cover is n o t i n -
t i a l housing w i t h l u b r i c a n t (refer to the Specifica-
s t a l l e d w d t h i n 20 m i n u t e s a f t e r a p p l y i n g t h e seal-
tions chart for the capacity). I n s t a l l t h e f i l l hole plug.
ant, t h e sealant m u s t be r e m o v e d a n d another
 (17) Lower the vehicle and test the brakes and the t i m e , divide the engine torque equally between t h e m .
axle for proper operation. This i s o r d i n a r i l y a desirable and n o r m a l function of
a differential. However, w h e n t h e surface t r a c t i o n
SURE-GRIP DIFFERENTIAL SERVICE condition (e.g., m u d or snow) is not the same a t both
rear wheels/tires, p a r t o f the available engine torque
cannot be u t i l i z e d because o f t h i s same "differential
GENERAL INFORMATION
action". A Sure-Grip differential transfers additional
Rear axles equipped w i t h a Sure-Grip differential
engine torque t o t h e rear wheel/tire t h a t has the bet-
are optionally available for R a m T r u c k a n d Ram-
ter t r a c t i o n surface a n d decreases the torque applied
charger vehicles (Fig. 47).
to t h e other wheel/tire. Therefore, t h e t o t a l utilized
EXCITER RING engine torque i s significantly greater t h a n i t would
RING GEAR be w i t h a standard differential.
DIFFERENTIAL Sure-Grip differentials are engineered t o function
CASE ( w i t h t h e benefit o f increased traction) w i t h a m i n i -
m a l effect o n n o r m a l vehicle d r i v i n g operation. A
S u r e - G r i p differential i s n o t a positive " l o c k i n g "
type o f differential. D u r i n g n o r m a l d r i v i n g condi-
tions, t h e "controlled" i n t e r n a l f r i c t i o n is easily over-
come d u r i n g vehicle t u r n s so t h a t standard
"differential a c t i o n " allows the rear wheels t o rotate
at different speeds. Also, a n e x t r e m e difference be-
BEARING tween t h e surface t r a c t i o n conditions a t t h e rear
wheels/tires w i l l cause one wheel to " s p i n " s i m i l a r l y
to the action of a standard differential.
J9003-119
BEARING
S u r e - G r i p differentials are s i m i l a r to standard dif-
Fig. 47 Sure-Grip Differential ferentials except for t h e inclusion of t h e helix-
grooved clutches t h a t "semi-control" t h e r o t a t i o n o f
A Sure-Grip differential has a two-piece differen- the differential side gears. T h e helix-grooves provide
t i a l case t h a t is completely interchangeable w i t h a m a x i m u m l u b r i c a t i o n o f t h e clutch surface d u r i n g
standard differential case (Fig. 48). axle operation. T h e clutches and t h e side gears are
DIFFERENTIAL statically "spring-load" t o provide a n i n t e r n a l resis-
CASE tance t h a t p a r t i a l l y averts standard "differential ac-
SIDE GEAR
t i o n " . W h e n a l o w t r a c t i o n surface is encountered
(e.g., m u d or snow), t h i s i n t e r n a l resistance is t h e
PINION means for t r a n s f e r r i n g more of the engine torque t o
GEAR
the rear wheel/tire t h a t has t h e better t r a c t i o n sur-
face and less torque t o the wheel/tire w i t h the lower
traction surface.
W h e n engine torque is applied to the r i n g gear, the
i n i t i a l s p r i n g " l o a d i n g " o f t h e clutches is supple-
mented b y t h e gear-separating friction between t h e
differential side gears and the p i n i o n gears and t h i s
progressively increases the t o t a l friction i n the differ-
COIL SPRING ential. Because a S u r e - G r i p differential is not a pos-
CLUTCH itive " l o c k i n g " type o f differential, t h e f r i c t i o n w i l l
decrease and the clutches w i l l release the side gears
before excessive engine torque is applied t o either
LUBRICATION one of the wheels/tires.
GROOVES
IDENTIFICATION
LUBRICATION Positive identification o f a S u r e - G r i p differential
WELL J9003-120
can be accomplished b y r a i s i n g both rear wheels off
Fig. 48 Sure-Grip Differential Components the surface and r o t a t i n g t h e m . I f both rear wheels ro-
tate i n t h e same direction simultaneously, the vehi-
The "differential action" o f a standard differential cle is equipped w i t h a S u r e - G r i p differential.
w i l l allow the rear wheels/tires to rotate a t different Another method o f identification is b y removing t h e
speeds (when the vehicle is t u r n i n g ) and, a t the same differential housing cover f i l l hole p l u g and examin-
i n g ( w i t h a flashlight) t h e differential case compo-
nents v i a t h e fill hole p l u g hole.
SERVICE INFORMATION
The service procedures for a S u r e - G r i p differential
are essentially t h e same as those used for a standard
differential, therefore, only information/procedures
i n v o l v i n g t h e differences t h a t exist between t h e t w o
differential types w i l l be provided i n t h i s section.
CAUTION: Whenever a rear axle is being serviced
or anytime it is to be rotated via the engine (or by
another means), RAISE BOTH REAR WHEELS off
the surface.
DIFFERENTIAL TEST
A Sure-Grip differential can be tested t o deter-
m i n e i f i t is functioning n o r m a l l y w i t h o u t r e m o v i n g
the differential case from t h e housing.
(1) Position t h e vehicle on a hoist w i t h t h e i g n i t i o n
O F F and t h e transmission selector lever i n " P A R K "
(automatic transmission) or i n first gear ( m a n u a l
transmission).
(2) A t t e m p t to m a n u a l l y rotate each rear wheel b y
g r i p p i n g t h e t i r e tread area a n d a p p l y i n g a r o t a t i n g
force w i t h your hands.
(3) I f i t is extremely difficult (or impossible) t o
m a n u a l l y rotate either wheel, consider t h a t t h e
Sure-Grip differential is functioning n o r m a l l y . I f i t
is relatively easy t o m a n u a l l y rotate either wheel
continuously, t h e differential is n o t f u n c t i o n i n g nor-
m a l l y and should be replaced.
A Sure-Grip differential case is n o t repairable
and, i f defective, must be replaced as a complete u n i t
only. Do n o t attempt t o disassemble a n d repair/
replace the differential case components.
DIFFERENTIAL NOISE
Noise complaints i n v o l v i n g rear axles equipped
w i t h a Sure-Grip differential should be evaluated t o
determine t h e source of t h e noise. I f , d u r i n g a test
ride, a s i m i l a r noise occurs w h i l e t h e vehicle is
" t u r n i n g " b u t n o t d u r i n g straight-ahead m o t i o n , t h e
probable cause is incorrect or insufficient gear l u b r i -
cant. The following d r a i n and clean procedure should
be used for possible e l i m i n a t i o n o f t h e noise before
replacing the differential.
WARNING: WHEN SERVICING VEHICLES WITH AN
AXLE EQUIPPED WITH A SURE-GRIP DIFFEREN-
TIAL, DO NOT USE THE ENGINE TO ROTATE THE
AXLE AND WHEELS UNLESS BOTH REAR WHEELS
ARE RAISED FROM THE SURFACE AND THE VEHI-
C L E SUPPORTED. A SURE-GRIP DIFFERENTIAL
EQUIPPED AXLE CAN EXERT ENOUGH DRIVING
FORCE (IF ONE WHEEL IS IN CONTACT WITH THE
SURFACE) TO CAUSE THE VEHICLE TO MOVE.
(1) W i t h t h e rear axle l u b r i c a n t a t n o r m a l operat-
i n g temperature, raise a n d support t h e vehicle (rear
wheels free t o rotate).
(2) Remove t h e differential housing cover and d r a i n
(and discard) t h e l u b r i c a n t . Rotate t h e differential
u n t i l t h e opening i n t h e differential case is facing
downward. Wipe a n d remove t h e l u b r i c a n t from a l l
accessible surface areas i n t h e differential housing.
The purpose o f d r a i n i n g a n d discarding the l u -
b r i c a n t is t o eliminate a n y solid particles o r liq-
u i d contaminants that c o u l d be causing t h e
noise.
(3) Scrape t h e residual gasket and/or sealant from
the housing a n d cover m a t i n g surfaces, thoroughly
clean t h e m a t i n g surfaces w i t h m i n e r a l spirits (or a n
equivalent product) a n d d r y t h e surfaces completely.
A p p l y a 1/16-inch t o 3/32-inch (1.6-mm t o 2.4-mm)
t h i c k "bead" of M O P A R Silicone Rubber Sealant (or
an equivalent sealant) around t h e bolt circle on t h e
housing cover ( F i g . 49). A l l o w t h e s e a l a n t t o
" c u r e " for a few minutes.
SEALANT
1/16-TO
3/32-INCH
(1.59-TO
.38-AAAA)
THICK BEAD
DIFFERENTIAL
HOUSING
COVER
(TYPICAL) J9003-85
Fig. 49 Sealant On Housing Cover
I f f o r a n y reason t h e housing cover is n o t i n -
s t a l l e d w i t h i n 20 m i n u t e s a f t e r a p p l y i n g t h e seal-
ant, t h e sealant m u s t be r e m o v e d a n d another
" b e a d " o f sealant applied.
(4) I n s t a l l t h e housing cover on t h e differential
housing w i t h t h e attaching bolts. I n s t a l l t h e axle
gear r a t i o identification t a g w i t h one of t h e cover
bolts. T i g h t e n t h e cover bolts w i t h 47 N-m (35 ft-lbs)
torque.
(5) Remove t h e supports. Raise or lower t h e hoist
u n t i l t h e vehicle is level a n d t h e n support t h e vehi-
cle.
(6) Remove t h e f i l l hole p l u g from the differential
3 - 32 REAR AXLES
housing cover. Add 4 ounces of M O P A R H y p o i d Gear
L u b r i c a n t A d d i t i v e (a f r i c t i o n modifier), or a n equiv-
alent product, to the differential housing. F i l l the dif-
ferential housing to t h e correct level w i t h M O P A R
Hypoid Gear L u b r i c a n t , or a n e q u i v a l e n t product.
(7) I n s t a l l t h e fill hole plug. Remove t h e supports
and lower t h e vehicle.
DIFFERENTIAL CASE SERVICE
CAUTION: During removal and installation of the
axle shafts, do not rotate either axle shaft unless
both are properly in-place. Rotation of one axle
shaft without the other being installed can result in
misalignment of the side gears/splines; and, for
correct axle shaft-to-side gear spline engagement,
this will necessitate side gear re-alignment before
the axle shaft can be installed.
REMOVAL
Refer to the differential case r e m o v a l procedure for
a standard differential.
CLEANING/INSPECTION
(1) Clean S u r e - G r i p differential components a n d
case (Fig. 48) w i t h fast evaporating m i n e r a l spirits or
a dry cleaning solvent. W i t h the exception o f the dif-
ferential bearings, d r y t h e case a n d t h e components
w i t h compressed a i r .
(2) Inspect the differential b e a r i n g rollers and cups
for " p i t t i n g " , " s p a l l i n g " and other visible damage. I f
differential bearing replacement i s necessary, remove
the bearings from t h e differential case according t o
the procedure for a standard d i f f e r e n t i a l bearing.
(3) Inspect the differential case for cracks and other
visible damage t h a t could cause i t to be unusable.
INSTALLATION
Refer to t h e differential case i n s t a l l a t i o n procedure
for provided for a standard d i f f e r e n t i a l .
LUBRICANTS
Multi-purpose, hypoid gear l u b r i c a n t , as defined by
MIL-L-2105-B and b y A P I G L 5 q u a l i t y specifica-
•
tions, should be used for rear axles w i t h a standard
or a S u r e - G r i p differential. M O P A R Hypoid Gear
L u b r i c a n t conforms t o b o t h o f these specifications
and i s h i g h l y recommended for use w i t h Ram T r u c k
and Ramcharger vehicles. I n addition, 4 ounces o f
M O P A R Hypoid Gear L u b r i c a n t A d d i t i v e (a f r i c t i o n
modifier), or a n equivalent product, must be included
w i t h a r e - f i l l for a S u r e - G r i p differential.
CAUTION: If a rear axle is submerged in water, the
axle lubricant must be replaced immediately to
avoid the possibility of premature axle failure re-
sulting from water contamination of the lubricant.
DRAIN/REFILL
(1) D r i v e the vehicle u n t i l the gear l u b r i c a n t i n the
axle attains t h e n o r m a l operating temperature.
(2) Raise and support t h e vehicle.
(3) Remove the l u b r i c a n t fill hole p l u g from the dif-
ferential housing cover.
(4) Remove the differential housing cover and allow
the o r i g i n a l l u b r i c a n t t o completely d r a i n from t h e
housing and t h e axle shaft tubes.
CAUTION: DO NOT FLUSH Sure-Grip differentials.
Sure-Grip differentials may be cleaned only by dis-
assembling the unit and wiping with clean, lint-free
cloths.
(5) F o r standard differentials, flush the differential
and the housing cavity w i t h a " f l u s h i n g " o i l (or l i g h t
engine oil) to remove residual l u b r i c a n t a n d 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 o r
gasoline f o r flushing.
(6) I n s t a l l t h e differential housing cover a n d
t i g h t e n t h e bolts w i t h 47 N * m (35 ft-lbs) Torque.
(7) Refill the differential housing w i t h the specified
q u a n t i t y o f M O P A R H y p o i d Gear Lubricant. F o r
S u r e - G r i p differentials, a container of M O P A R H y -
poid Gear L u b r i c a n t A d d i t i v e (a friction modifier)
must also be added.
(8) I n s t a l l a n d t i g h t e n t h e fill hole p l u g w i t h 34
N u n (25 ft-lbs) torque.
(9) Remove t h e supports and lower the vehicle.
 MODEL 6 0 , 6 0 M AND 70 A X L E S S E R V I C E
INDEX
Page Page
Axle Shaft— Removal/Installation . . . . 34 Standard Differential Service 36
Complete Axle Removal/Installation . . . . . . . . . . . . 35 Trac-Loc Differential Service 52
General Information . . . . . 33 Wheel Bearing Service 35
Lubricants 55

GENERAL INFORMATION A small, stamped m e t a l axle gear r a t i o identifica-

The axle housing for Model 60, 6 0 M a n d 70 rear
axles (Figs. 1 and 2) consists of an i r o n center cast-
i n g (differential housing) w i t h axle shaft tubes ex-
t e n d i n g from either side. T h e axle shaft tubes are
pressed into and welded to the differential housing t o
f o r m a one-piece axle housing. A l l three axles have a
hypoid gear differential and t h e centerline o f t h e
drive p i n i o n gear shaft i s located below t h e center-
l i n e o f the r i n g gear. T h e removable, stamped steel
cover located a t the rear o f the differential housing
provides a means for inspection and for d i f f e r e n t i a l
service w i t h o u t r e m o v i n g t h e complete rear axle
f r o m the vehicle.
t i o n t a g is attached t o t h e housing cover v i a one o f
the cover bolts. This t a g also identifies the number of
r i n g gear and drive p i n i o n gear teeth.
The drive p i n i o n gear shaft rotates w i t h i n two t a -
pered r o l l e r bearings (Figs. 1 and 2). The drive p i n -
ion gear shaft rear bearing is t i g h t l y "press-fitted" on
the drive p i n i o n gear shaft. The d r i v e p i n i o n gear
shaft f r o n t bearing is very l i g h t l y "press-fitted"
(which is s i m i l a r to a "close, s l i d i n g f i t " ) on the drive
pinion gear shaft. The drive p i n i o n gear shaft front
and rear bearing cups are "press-fitted" i n the differ-
ential housing bore and against a recessed shoulder.
The drive p i n i o n gear shaft depth o f mesh adjust-
ment is controlled b y the use of m e t a l depth shims

DIFFERENTIAL COVER

CONE

CUP

SHAFT YOKE

/ V , rw
SLINGER /
NUT LOCK
(TAP IN PLACE) OIL SEAL
WASHER
XT NUT

8903-19

Fig. 1 Model 60 & 60M Axle—Exploded View

3 - 34 REAR AXLES •
COVER GASKET RING GEAR CASE HALF CUP

PINION / S | D E G E A R

BEARING CONE
BOLT
BEARING CONE
DIFFERENTIAL ADJUSTING SHIMS

PINION PINION SHAFTS ^ - ^ p VENT

BEARING CONE
CAP
DIFFERENTIAL
CUP ADJUSTING SHIMS ^»*^V §
SHIMS

GASKET ADJUSTING
NUT
SLINGER
SHAFT

NUT LOCK
BOLT {TAP IN PLACE) SEAL YOKE 8903-20

Fig. 2 Model 70 Axle—Exploded View

t h a t are installed between t h e drive p i n i o n gear
shaft rear bearing and the differential housing (Figs.
1 and 2).
The drive p i n i o n gear shaft bearing "preload"
torque is provided v i a metal shims t h a t are located
between the drive p i n i o n gear shaft front and the dif-
ferential housing (Figs. 1 and 2).
The differential case hubs rotate i n the differential
housing v i a t w o tapered roller bearings t h a t are
"press-fitted" on t h e case hubs (Figs. 1 and 2). The
shims t h a t are installed between t h e bearings a n d
the hub shoulder (Figs. 1 a n d 2) have three func-
tions:
• to adjust and m a i n t a i n the "backlash" between the
r i n g gear and the drive pinion gear;
• to establish a means for obtaining and t h e n r e t a i n -
i n g the differential bearing "preload" torque; and
• to eliminate the differential "side play".
AXLE SHAFT—REMOVAL/INSTALLATION
CAUTION: Whenever a rear axle is being serviced
or anytime it is to be rotated via the engine (or by
another means), RAISE BOTH REAR WHEELS off
the surface.
REMOVAL
(1) Remove the axle shaft flange bolts.
(2) Remove the axle shaft (Figs. 1 a n d 2).
INSTALLATION
(1) Clean t h e gasket contact surface area on t h e
flange w i t h a n appropriate solvent. I n s t a l l a replace-
m e n t flange gasket and slide the axle shaft into t h e
axle shaft tube (Figs. 1 and 2).
(2) I n s t a l l t h e Durlock bolts and t i g h t e n w i t h 95
N u n (70 ft-lbs) torque.
WHEEL BEARING SERVICE
CAUTION: Whenever a rear axle is being serviced
or anytime it is to be rotated via the engine (or by
another means), RAISE BOTH REAR WHEELS off
the surface.
(1) Raise a n d support t h e vehicle.
(2) Remove the axle shaft. I f necessary, refer to the
removal procedure.
(3) Remove the n u t lock a n d loosen t h e adjustment
nut.
(4) T i g h t e n t h e adjustment n u t w i t h 163 t o 190
N»m (120 t o 140 ft-lbs) torque w h i l e r o t a t i n g t h e
wheel.
(5) Loosen t h e adjustment n u t 1/3 of-a-turn (120
degrees) t o provide 0.001-inch to 0.008-inch wheel
bearing "end play".
(6) " T a p " t h e n u t lock i n t o t h e spindle keyway.
(7) I n s t a l l a replacement flange gasket a n d t h e
axle shaft. I f necessary, refer t o the i n s t a l l a t i o n pro- fluid flexible hose fittings. I n s t a l l the hubs and b r a k e
cedure.
(8) Remove the supports a n d lower t h e vehicle.
COMPLETE AXLE REMOVAL/INSTALLATION
REMOVAL
I f i t i s necessary t o remove the complete rear axle
from t h e vehicle, use t h e f o l l o w i n g procedure.
(1) Raise t h e rear o f t h e vehicle u n t i l t h e rear
wheels/tires are not contacting the surface. Support
the vehicle body a t the f r o n t o f the rear springs.
(2) Use a wooden block to r e t a i n the brake pedal i n
the " u p " position (i.e., t h e disengaged position).
(3) Remove t h e axle shafts, t h e wheels/tires, t h e
hubs and t h e brake d r u m s . I f necessary, refer t o the
applicable removal procedures.
(4) Disconnect t h e b r a k e fluid t u b i n g from t h e
brake fluid flexible hose fittings and "cap" t h e fit-
tings t o prevent loss of b r a k e fluid.
(5) Disconnect the p a r k i n g brake cables.
To ensure that t h e driveline balance is re-
tained w h e n t h e drive shaft is installed, scribe
installation alignment reference m a r k s o n t h e
drive shaft U-joint a n d o n the drive p i n i o n gear
s h a f t (axle) y o k e b e f o r e r e m o v a l .
(6) Disconnect t h e d r i v e shaft U-joint from t h e
drive p i n i o n gear shaft (axle) yoke and secure i t i n
an u p r i g h t position to prevent damage t o the U-joint.
(7) Remove the rear shock absorbers and the rear
spring U-bolts f r o m the axle.
(8) Remove the rear axle f r o m the vehicle.
INSTALLATION
(1) I f the differential h o u s i n g cover was removed,
ensure t h a t the differential housing a n d cover m a t -
i n g surfaces are clean.
(2) I f the differential housing cover was removed,
apply a "bead" of M O P A R Silicone Rubber Sealant
(or a n equivalent sealant) around the cover bolt cir-
cle. I n s t a l l t h e differential housing cover. T i g h t e n
t h e cover bolts w i t h 47 N*m (35 ft-lbs) torque. I n s t a l l
the axle gear r a t i o identification t a g u n d e r o n e
of the cover bolts.
(3) W i t h the vehicle body supported a t the f r o n t o f
the rear springs, position t h e axle under t h e rear
springs.
(4) I n s t a l l the spring U-bolts and t i g h t e n the n u t s
w i t h t h e specified torque (refer to Group 17—Springs
A n d Shock Absorbers).
(5) I n s t a l l the shock absorbers. T i g h t e n the r e t a i n -
i n g n u t s w i t h t h e specified torque (refer to Group
17—Springs A n d Shock Absorbers).
(6) Connect the p a r k i n g brake cables.
(7) Connect t h e brake fluid t u b i n g t o t h e b r a k e
drums. Adjust t h e wheel bearings (refer to Wheel
B e a r i n g Adjustment).
(8) Remove the block from the brake pedal. " B l e e d "
and adjust the brakes.
(9) Connect the drive shaft to the drive p i n i o n gear
shaft (axle) yoke w i t h t h e i n s t a l l a t i o n reference
m a r k s aligned. T i g h t e n the U-joint clamp bolts w i t h
2 1 N-m (16 ft-lbs/186 in-lbs) torque.
(10) I n s t a l l t h e rear wheels/tires and t i g h t e n t h e
l u g n u t s w i t h t h e specified torque (refer to Group
2 2 - W h e e l s A n d Tires).
(11) Clean the axle shaft flange gasket contact sur-
face areas w i t h a a n appropriate cleaning solvent, i n -
s t a l l replacement flange gaskets and slide the axle
shafts i n t o the axle shaft tubes.
(12) I n s t a l l t h e Durlock bolts. T i g h t e n t h e bolts
w i t h 95 N-m (70 ft-lbs) torque.
(13) Raise the rear of the vehicle, remove the sup-
ports, level the vehicle and position the supports.
(14) Remove the fill hole p l u g from t h e d i f f e r e n t i a l
housing cover. F i l l t h e differential housing t o t h e
correct level w i t h M O P A R Hypoid Gear L u b r i c a n t , or
a n equivalent product.
I n a d d i t i o n , for Trac-Lok differential equipped
a x l e s , 4 o u n c e s o f M O P A R H y p o i d Gear L u b r i -
c a n t A d d i t i v e (a friction modifier), o r a n equiva-
l e n t p r o d u c t , m u s t be i n c l u d e d i f the differential
h o u s i n g i s b e i n g r e-filled.
(15) I n s t a l l the fill hole plug. Remove the supports
and lower the vehicle.
(16) Road test the vehicle to evaluate t h e results o f
t h e repair.
3 - 36 REAR AXLES •
STANDARD DIFFERENTIAL SERVICE IDENTIFICATION MARKS

CAUTION: Whenever a rear axle is being serviced

or anytime it is to be rotated via the engine (or by
another means), RAISE BOTH REAR WHEELS off
the surface.
It is not necessary to remove the complete axle
from the vehicle to service a standard differential.
To replace the differential side gears, it is neces-
sary to remove only the axle shafts, the differential
housing cover, the lubricant and the differential
case. To replace the differential bearings, it is nec-
essary to remove only the axle shafts, the differen-
tial housing cover, the lubricant, the differential
case and to adjust the ring gear "backlash".

REMOVAL/DISASSEMBLY
(1) T h o r o u g h l y clean the outside surface area o f the
d i f f e r e n t i a l housing and the axle shaft tubes w i t h a
a n appropriate cleaning solvent a n d t h e n d r y t h e
surface w i t h compressed air.
(2) Remove the differential housing cover screws
and t h e cover, and d r a i n t h e lubricant i n t o a con-
tainer.
(3) Remove the R W A L brake sensor hold-down bolt
and p u l l t h e sensor f r o m t h e differential housing.
The sensor must be removed t o prevent damage
w h e n disassembling o r assembling t h e differential
components.
(4) W a s h and clean t h e differential case, the bear-
ings, t h e r i n g gear, the drive p i n i o n gear and the i n -
t e r n a l surface of the housing w i t h a a n appropriate
cleaning solvent. D r y w i t h compressed air.
(5) D e t e r m i n e i f the clearance between t h e differ-
e n t i a l b e a r i n g caps and bearing cups is excessive by
a t t e m p t i n g t o insert a 0.003- inch (0.076-mm) t h i c k
feeler gauge blade between them. N o r m a l l y , a 0.003-
i n c h (0.076-mm) t h i c k feeler gauge blade should be
too t h i c k t o be inserted between a bearing cap and
cup.
I f t h e c l e a r a n c e i s m o r e t h a n 0.003 i n c h (0.076
Fig. 4 Differential Housing Separation
m m ) , t h e cause c o u l d b e t h a t t h e applicable
bearing c u p rotated i n the differential housing (9) I n s t a l l a pilot stud a t the left side o f t h e differ-
" s e a t " a n d caused excessive wear. e n t i a l housing. A t t a c h D i a l Indicator Tool C-3339 t o
(6) N o t e t h e i n s t a l l a t i o n reference letters stamped the differential housing ( v i a the p i l o t stud) w i t h t h e
into the differential bearing caps and i n t o t h e differ- indicator plunger s l i g h t l y "loaded" against the oppo-
e n t i a l h o u s i n g machined sealing surface (Fig. 3). The site side of the differential housing (Fig. 4). "Zero"
letters a r e stamped horizontally o n the left side and the d i a l indicator pointer.
are stamped vertically o n the r i g h t side of t h e differ-
e n t i a l housing. A l w a y s match t h e reference letters CAUTION: Do not exceed the specified separation
w h e n i n s t a l l i n g the differential bearing caps. distance when separating the differential housing. If
(7) Remove the differential bearing caps. the housing is over-separated, it could be distorted
Position Spreader Tool D-167 on the differential or damaged, which would necessitate replacement.
housing w i t h the tool dowel pins "seated" i n t h e lo-
cating holes (Fig. 4). I n s t a l l t h e holddown clamps (10) T i g h t e n t h e spreader tool t u r n b u c k l e (Fig. 4)
and t i g h t e n the tool t u r n b u c k l e " f i n g e r - t i g h t " . and separate the differential housing only enough t o
remove the differential case from the housing. Sepa-
r a t e t h e d i f f e r e n t i a l h o u s i n g a m a x i m u m dis-
t a n c e o f 0.38 m m ( 0 . 0 1 5 i n ) w i t h t h e s p r e a d e r
t o o l . Measure the separation distance w i t h the d i a l
indicator (Fig. 4) as the housing is being separated.
(11) Remove the d i a l indicator (Fig. 4) when the
differential housing has been separated sufficiently
to remove t h e differential case from the housing.
(12) Pry the differential case loose f r o m the hous-
ing. A l i g h t p r y i n g action w i t h a s m a l l p r y bar or
pinch bar w i l l loosen the case sufficiently for easy re-
moval. To prevent damage, p r y the differential case
outward t o w a r d the opening w i t h the p r y bar pivot-
i n g on the differential housing and w i t h the end of
the pry bar against the differential case.
(13) Remove the differential case from the differen-
t i a l housing. I f t h e y are reusable, r e t a i n the differen-
t i a l bearing cups and bearings together as "matched
sets".
(14) C l a m p the differential case i n a vise equipped Fig. 6 Excitor Ring Removal
w i t h soft j a w s and remove ( a n d d i s c a r d ) the r i n g (18) I n s t a l l the differential bearing caps and
gear bolts. Use a punch to loosen and remove the t i g h t e n t h e bolts " f i n g e r - t i g h t " u n t i l each bolt head
r i n g gear f r o m the differential case flange (Fig. 5). is l i g h t l y "seated" on the bearing cap.
Remove the r i n g gear. T h e r i n g g e a r c a n be re- (19) I n s t a l l a p i l o t stud a t the r i g h t side of the dif-
m o v e d w i t h o u t r e m o v i n g the R W A L b r a k e exci- ferential housing. A t t a c h D i a l Indicator Tool C-3339
tor ring. to the differential housing (via the pilot stud) w i t h
the indicator plunger s l i g h t l y "loaded" against the
i n n e r face of the flange (Fig. 7). "Zero" the d i a l i n d i -
cator pointer.

Fig. 7 Differential Case Flange "Runout"

(15) The excitor r i n g e r can be removed w i t h a soft-
faced h a m m e r (Fig. 6). Discard after removal.
(16) I n s t a l l the differential case ( w i t h the original
bearing cups) i n t h e differential housing.
(17) Remove the holddown clamps and the spreader
tool from the differential housing (Fig. 4).
Measurement
(20) Measure the differential case flange " r u n o u t "
by r o t a t i n g the case and flange several complete rev-
olutions and observing the d i a l indicator pointer.
M a r k the flange at the location of m a x i m u m
" r u n o u t " . The flange m a x i m u m " r u n o u t " should not
exceed 0.003 i n c h (0.076 m m ) .
(21) Remove the drive p i n i o n gear shaft (axle) yoke
n u t and washer. Use Removal Tool C-452 and H o l d -
i n g Tool C-3281 to remove the drive p i n i o n gear
shaft (axle) yoke (Fig. 1).
(22) Use Removal Tool C-748 to remove the drive
p i n i o n gear shaft seal (Figs. 1 and 2).
(23) Remove the oil slinger, the shaft front bearing
and the "preload" torque shims (Figs. 1 and 2).
Record the thickness of the shims. T h i s w i l l s a v e
time i f they should become misplaced.
(24) Use an appropriate tool to force the drive p i n -
i o n gear shaft ( w i t h the rear bearing) from the dif-
ferential housing bore (Figs. 1 a n d 2).
(25) Use Removal Tool D-158 and Handle Tool C-
4171 to remove the drive p i n i o n gear shaft f r o n t
bearing cup f r o m the differential housing bore (Figs.
1 and 2).
(26) For Model 60 and 6 0 M axles, use Removal
Tool D-162 and Handle Tool C-4171 to remove the
drive p i n i o n gear shaft rear bearing cup from the dif-
ferential housing bore (Fig. 1). For Model 70 axles,
use Removal Tool D-159 and Handle Tool C-4171 to
remove the drive p i n i o n gear shaft rear bearing cup
from the differential housing bore (Fig. 2). Fig. 9 Differential Case Halves—Identification
(27) Remove the drive p i n i o n gear depth shims (Model 70 Axle)
from the differential housing bore (Figs. 1 and 2). (33) Remove the bearings from the differential case
Record the thickness of the depth shims. w i t h Removal Tool DD-914-P, Adapter R i n g Tools
(28) Remove the rear bearing f r o m the drive p i n i o n DD-914-8, Plate Tools DD-914-62, Screw Extension
gear shaft w i t h Removal Tool DD-914-P, Adapter Tool DD-914-7, B u t t o n Tool DD-914-42 and a vise
R i n g Tools DD-914-9 and Plate Tools DD-914-37. Use (Fig. 10;.
Plate Tools DD-914-95 for Model 70 axles. U s e c a r e a n d e n s u r e that the adapter r i n g s a r e
(29) For Model 60 and 6 0 M axles, clamp the differ- situated so t h a t t h e y do not c a u s e force to be ex-
e n t i a l case i n a vise equipped w i t h soft jaws. Use a erted o n the b e a r i n g r a c e .
p i n punch to force the p i n i o n gear mate shaft lock
p i n from the differential case bore (Fig. 8). For Model
70 axles, m a r k the differential case halves (Fig. 9)
for assembly reference; remove the studs r e t a i n i n g
the differential case halves together; and separate
the differential case.
(30) Remove the differential p i n i o n gear mate shaft

Fig. 10 Differential Bearing Removal

Fig. 8 Pinion Gear Mate Shaft Lock Pin Removal
(Model 60 & 60M Axles)
from the differential case bores, remove the differen-
t i a l pinion gears and remove the t h r u s t washers (lo-
cated adjacent to the differential case i n t e r n a l
surface) from the differential case.
(31) Remove the differential side gears and the
t h r u s t washers (located adjacent to the differential
case i n t e r n a l surface) from the differential case.
(32) Remove the differential case from the vise.
(34) Remove the differential bearing shims from
each of the differential case hubs and m a r k t h e m
( w i t h hub i d e n t i t y ) for assembly reference. Record
the thickness of t h e shims.
CLEANING/INSPECTION
(1) Wash and clean a l l the differential components
(Figs. 11 and 12) w i t h an appropriate cleaning sol-
vent and, w i t h the exception of the bearings, d r y
w i t h compressed a i r .
 Fig. 12 Model 70 Axle
D o not steam c l e a n the differential compo-
nents.
(2) To clean the axle shaft tubes (Figs. 1 and 2), i n -
sert a stiff w i r e i n t o each tube, a t t a c h a clean cloth
to t h e w i r e at the differential housing opening and
w i t h d r a w the w i r e (and cloth) from t h e housing out-
w a r d t h r o u g h the tube.
(3) Inspect the differential bearings and the drive
p i n i o n gear shaft bearings, and the differential case
and housing (Figs. 11 and 12):
• the differential bearings and the drive p i n i o n gear
shaft front and rear bearings and cups should have a
smooth appearance w i t h no broken/dented surfaces
on the bearing rollers or the roller contact surfaces;
• the bearing races m u s t not be distorted or cracked;
I f a differential b e a r i n g m u s t be r e p l a c e d , the
c u p a n d the b e a r i n g m u s t be r e p l a c e d a s a
" m a t c h e d s e t " only.
• a l l the machined contact surfaces i n the differen-
t i a l housing and on the differential bearing caps
should be smooth and w i t h o u t any raised edges;
• the drive p i n i o n gear shaft front and rear bearing
cup bores i n the differential housing should be
smooth; and
• i f i t exists, raised m e t a l on the shoulders of the
bearing cup bores i n c u r r e d d u r i n g removal of the
cups should be removed w i t h a h a n d stone.
(4) Examine the differential p i n i o n gear mate
Differential—Exploded View
shaft, p i n i o n gears, side gears a n d t h r u s t washers
(Figs. 11 a n d 12) for wear and damage. Replace a l l
defective components.
I f e i t h e r of the differential p i n i o n g e a r s is not
r e u s a b l e , b o t h gears m u s t b e r e p l a c e d a s a
" m a t c h e d s e t " only. D o not r e p l a c e only one
gear.
(5) E x a m i n e t h e r i n g gear a n d t h e drive p i n i o n
gear shaft (Figs. 11 and 12) for w o r n and chipped
teeth. E x a m i n e t h e r i n g gear for damaged a t t a c h i n g
bolt threads.
I f r e p l a c e m e n t of either g e a r i s n e c e s s a r y , b o t h
the r i n g g e a r a n d the d r i v e p i n i o n g e a r shaft
m u s t be r e p l a c e d b e c a u s e they a r e a v a i l a b l e a s
a " m a t c h e d s e t " s only.
(6) Inspect t h e drive p i n i o n gear shaft (axle) yoke
(Figs. 11 a n d 12) for cracks, w o r n splines, " p i t t e d " ar-
eas, a n d a rough/corroded seal contact surface. Re-
pair or replace the yoke as necessary.
(7) Inspect t h e drive p i n i o n gear shaft bearing "pre-
load" torque shims (Figs. 11 and 12) for cracks, dam-
age and d i s t o r t i o n . I n s t a l l replacement shims ( i f
necessary) for t h e "preload" torque adjustment.
(8) Inspect t h e R W A L brake exciter r i n g for dam-
age a n d m i s s i n g teeth. I f i n s t a l l e d , ensure t h a t the
r i n g is f i r m l y pressed onto the differential case. Re-
place t h e r i n g i f i t is either loose or damaged.
RWAL BRAKE EXCITER RING REPLACEMENT
(1) I f replacement of the r w a l brake exciter r i n g is
necessary, a l i g n the exciter r i n g tab w i t h the slot the
i n differential case (Fig. 13).

SLOT 8^03-36

Fig. 15 Ring Gear Bolt Hole Alignment

ASSEMBLY
(1) Lubricate a l l t h e differential components w i t h
hypoid gear lubricant.
(2) I n s t a l l t h e differential side gears a n d t h r u s t
washers, p i n i o n gears a n d t h r u s t washers and, for
Model 60 a n d 6 0 M axles, i n s t a l l t h e p i n i o n gear
Fig. 13 Exciter Ring Alignment
mate shaft i n t h e differential case (Fig. 8).
(2) I n v e r t t h e differential case a n d s t a r t t w o r i n g (3) F o r Model 60 and 6 0 M axles, a l i g n the lock p i n
gear bolts t h r o u g h t h e differential case into t h e r i n g hole i n t h e p i n i o n gear mate shaft w i t h t h e hole i n
gear to provide case-to-ring gear bolt hole a l i g n m e n t the differential case (Fig. 8). Insert a n d "seat" t h e
(Fig. 14). lock p i n i n t h e case and t h e shaft. For Model 70 ax-
RING EXCITOR
les, a l i g n t h e reference m a r k s (Fig. 9), i n s t a l l t h e
studs a n d t i g h t e n t h e m evenly w i t h 9 1 N«m (67 f t -
lbs).
I f replacement gears a n d t h r u s t washers w e r e
i n s t a l l e d , i t is n o t necessary t o measure t h e gear
" b a c k l a s h " . T h e gear meshing w i l l be c o r r e c t be-
cause " c l o s e " m a c h i n i n g tolerances a r e used
d u r i n g m a n u f a c t u r e o f the gears.
(4) I f not previously positioned d u r i n g exciter r i n g
replacement, position t h e r i n g gear on t h e differen-
t i a l case flange and a l i g n t h e r i n g gear threaded
holes w i t h those i n the differential case flange.
(5) Insert r e p l a c e m e n t r i n g gear bolts t h r o u g h t h e
d i f f e r e n t i a l case flange and thread t h e m i n t o the r i n g
gear.
After a l l t h e bolts are i n i t i a l l y correctly
Fig. 14 Ring Gear Bolt Hole Alignment t h r e a d e d i n t o t h e r i n g g e a r b o l t holes, " t a p " t h e
r i n g gear w i t h a non-metallic mallet a n d ensure
(3) Press t h e exciter r i n g onto t h e differential case t h a t i t i s f l u s h against t h e flange.
using the r i n g gear as a pilot (Fig. 15). (6) C l a m p t h e differential case i n a vise equipped
(4) I n s t a l l the r i n g gear bolts and t i g h t e n w i t h t h e w i t h soft jaws and alternately t i g h t e n each r i n g gear
specified torque. bolt w i t h 110 N - m (81 ft-lbs) torque.
3 - 42 REAR AXLES
(7) Place Master D i f f e r e n t i a l B e a r i n g Tools D-117
on t h e differential case hubs (Fig. 16).
MASTER BEARING MASTER BEARING
Fig. 16 Master Bearing Tools On Hubs
Fig. 17 Differential Housing Separation
(8) Position Spreader Tool D-167 on the differential
housing w i t h t h e tool dowel pins "seated" i n t h e lo-
cating holes (Fig. 17). I n s t a l l t h e holddown clamps
and t i g h t e n t h e tool t u r n b u c k l e " f i n g e r - t i g h t " .
(9) I n s t a l l a pilot s t u d a t the left side o f the differ-
ential housing. A t t a c h D i a l Indicator Tool C-3339 to
the differential housing ( v i a t h e p i l o t stud) w i t h t h e
indicator plunger s l i g h t l y "loaded" against t h e oppo-
site side o f the differential housing (Fig. 17). "Zero"
the d i a l indicator pointer.
•
CAUTION: Do not exceed the specified separation
distance when separating the differential housing. If
the housing is over-separated, it could be distorted
or damaged, which would necessitate replacement.
(10) T i g h t e n the spreader tool t u r n b u c k l e (Fig. 17)
and separate t h e differential housing only enough t o
i n s t a l l t h e differential case i n the housing. S e p a r a t e
the differential housing a m a x i m u m distance o f
0.38 m m (0.015 i n ) w i t h t h e s p r e a d e r tool. Mea-
sure t h e separation distance w i t h t h e d i a l i n d i c a t o r
(Fig. 17) as t h e housing is being separated.
(11) Remove t h e d i a l indicator tool a n d t h e p i l o t
stud (Fig. 17) when the differential housing has been
separated sufficiently to i n s t a l l t h e differential case
i n t h e housing.
(12) I n s t a l l t h e differential case i n t h e differential
housing.
(13) Remove the holddown clamps and the spreader
tool f r o m t h e differential housing (Fig. 17).
(14) Observe the assembly reference m a r k s a n d po-
s i t i o n t h e bearing caps a t t h e i r o r i g i n a l locations.
T i g h t e n t h e bearing cap bolts "finger-tight".
(15) I n s t a l l a pilot stud a t the r i g h t side o f t h e dif-
f e r e n t i a l housing. A t t a c h D i a l Indicator Tool C-3339
to t h e differential housing (via t h e p i l o t stud) w i t h
the indicator plunger s l i g h t l y "loaded" against t h e
back o f t h e r i n g gear (Fig. 18).
Fig. 18 Differential Case "End Play" Measurement
(16) Insert a small p r y bar between the b e a r i n g cap
and t h e left side of the differential case. P r y t h e dif-
f e r e n t i a l case as far as possible toward the r i g h t side
of the differential housing (Fig. 18). "Zero" t h e d i a l
indicator pointer.
 (17) Pry t h e d i f f e r e n t i a l case t o w a r d the left side of best teeth contact between t h e drive p i n i o n gear
the housing w i t h t h e p r y bar and r e c o r d the t r a v e l teeth and the r i n g gear teeth. The depth variance o f
distance indicated b y t h e d i a l indicator pointer. a drive p i n i o n gear can be either greater ( + ) , zero (0)
The measurement above indicates t h e shim or less t h a n (-) the standard depth.
t h i c k n e s s n e c e s s a r y f o r d i f f e r e n t i a l case " z e r o "
DRIVE PINION
" e n d - p l a y " (i.e., t o e l i m i n a t e t h e space/gap t h a t
exists b e t w e e n t h e d i f f e r e n t i a l b e a r i n g s a n d t h e
d i f f e r e n t i a l case). T h e a c t u a l t o t a l s h i m t h i c k -
ness w i l l b e d e t e r m i n e d d u r i n g t h e r i n g g e a r
" b a c k l a s h " a d j u s t m e n t (after i n s t a l l a t i o n o f t h e
drive p i n i o n gear shaft).
(18) Remove t h e d i a l indicator tool a n d the p i l o t
stud from t h e d i f f e r e n t i a l housing.
(19) Remove the differential bearing caps.
(20) Position Spreader Tool D-167 o n the differen-
t i a l housing w i t h t h e tool dowel pins "seated" i n the
locating holes (Fig. 17). I n s t a l l the holddown clamps
and t i g h t e n t h e tool t u r n b u c k l e " f i n g e r - t i g h t " .
(21) I n s t a l l a p i l o t s t u d a t the left side o f the dif-
ferential housing. A t t a c h D i a l Indicator Tool C-3339
to the differential h o u s i n g (via the p i l o t stud) w i t h Fig. 19 Drive Pinion Gear ID Numbers
the indicator p l u n g e r s l i g h t l y "loaded" against t h e The standard depth is the distance (Fig. 20) f r o m
opposite side o f the differential housing (Fig. 17). the centerline o f t h e axle shaft/ring gear to the face
"Zero" the d i a l i n d i c a t o r pointer. of the drive p i n i o n gear. For a Model 60 axle, t h e
standard depth/distance is 3.125 inches (79.37 m m ) .
CAUTION: Do not exceed the specified separation
For a Model 70 axle, the standard depth/distance is
distance when separating the differential housing. If
3.5 inches (88.9 m m ) .
the housing is over-separated, it could be distorted
or damaged, which would necessitate replacement. AXLE PINION
MODEL SETTING
(22) T i g h t e n the spreader tool t u r n b u c k l e (Fig. 17)
and separate the d i f f e r e n t i a l housing only enough to
remove the d i f f e r e n t i a l case from the housing. Sepa-
rate t h e d i f f e r e n t i a l h o u s i n g a m a x i m u m dis-
t a n c e o f 0.38 m m (0.015 i n ) w i t h t h e s p r e a d e r
t o o l . Measure the separation distance w i t h the d i a l
indicator (Fig. 17) as t h e housing is being separated.
(23) Remove t h e d i a l indicator tool and the p i l o t
stud (Fig. 17) w h e n t h e differential housing has been
separated sufficiently t o remove the differential case
from the housing.
(24) Remove the differential case from the differen-
t i a l housing.
(25) Remove t h e holddown clamps and the spreader
tool from the d i f f e r e n t i a l housing (Fig. 17). Fig. 20 Drive Pinion Gear Standard Depth/Distance

DRIVE PINION GEAR DEPTH INFORMATION
Drive p i n i o n gear shafts and r i n g gears are sup-
plied as "matched sets" only. T h e i d e n t i f y i n g n u m -
bers for both the d r i v e p i n i o n gear and t h e r i n g gear
are etched i n t o the face o f each gear (Fig. 19). I n ad-
dition, either a plus (" + ") number, a m i n u s ("-")
number or a zero ("0") i s also etched i n t o the face of
the drive p i n i o n gear. T h i s number indicates t h e
amount ( i n thousandths o f a n inch) t h a t the drive
p i n i o n gear depth o f mesh varies from the standard
depth " s e t t i n g " o f 3.125 inches (79.37 m m ) for Model
60 axles. T h e standard depth o f mesh provides t h e
Compensation for the depth variance is achieved by
shims placed adjacent t o the drive p i n i o n gear shaft
rear bearing cup (Fig. 21).
For example:
• one complete " p a c k " o f d e p t h shims is r e -
q u i r e d i f the d e p t h variance is " 0 " ;
• i f t h e d e p t h v a r i a n c e i s " + 3 " ( m + 8), t h e d r i v e
p i n i o n g e a r w o u l d r e q u i r e 0.003 i n c h (0.08 m m )
less i n s h i m t h i c k n e s s t h a n a d e p t h v a r i a n c e o f
" 0 " (i.e., o n e c o m p l e t e s h i m " p a c k " m i n u s 0.003
i n c h o r 0.08 m m ) ;
• b y r e d u c i n g t h e t h i c k n e s s o f t h e s h i m s 0.003
i n c h (0.08 mm), t h e d e p t h p o s i t i o n o f t h e d r i v e
 DRIVE
Fig. 21 Shim Locations
p i n i o n g e a r w i l l b e d e c r e a s e d f r o m 3.128 i n c h e s
(79.45 m m ) t o t h e s t a n d a r d d e p t h o f 3.125 i n c h e s
(79.37 m m ) ; o r
• i f t h e d e p t h v a r i a n c e i s " - 3 " (m-8), t h e d r i v e
p i n i o n g e a r w o u l d r e q u i r e 0.003 i n c h (0.08 m m )
more i n s h i m thickness than a depth variance of
" 0 " (i.e., o n e c o m p l e t e s h i m " p a c k " p l u s 0.003
i n c h o r 0.08 m m ) ;
• b y i n c r e a s i n g t h e t h i c k n e s s o f t h e s h i m s 0.003
i n c h (0.08 m m ) , t h e d e p t h p o s i t i o n o f t h e d r i v e
p i n i o n g e a r w i l l b e i n c r e a s e d f r o m 3.122 i n c h e s
(79.34 m m ) t o t h e s t a n d a r d d e p t h o f 3.125 i n c h e s
(79.37 m m ) .
I f t h e o r i g i n a l drive p i n i o n gear shaft a n d r i n g
gear set w i l l be i n s t a l l e d b u t t h e depth shims m u s t
be replaced, measure t h e thickness of t h e o r i g i n a l
depth shims a n d " b u i l d " a replacement " p a c k " o f
depth s h i m s w i t h t h e same thickness.
I f equipped, the o i l slinger located between the
rear b e a r i n g a n d t h e t h r u s t face o f d r i v e p i n i o n
gear m u s t be measured a n d the thickness i n -
cluded w i t h the total s h i m " p a c k " thickness.
I f t h e o r i g i n a l drive pinion/ring gear set is not re-
usable, t h e depth s h i m thickness for t h e replacement
drive p i n i o n gear m u s t be determined before i n s t a l l -
i n g t h e d i f f e r e n t i a l case i n t h e housing.
I f a replacement gear set is being installed, note
the d e p t h variance etched i n t o b o t h t h e o r i g i n a l a n d
the replacement drive p i n i o n gear, and alter t h e
thickness of t h e o r i g i n a l depth shims to compensate
for t h e difference i n t h e depth variances. Refer to t h e
D r i v e P i n i o n Gear D e p t h Variance chart.
For example:
• i f t h e o r i g i n a l drive p i n i o n gear has a d e p t h
variance of " + 2 " ( m + 5 ) a n d the replacement
drive p i n i o n gear has a d e p t h variance o f " - 2 "
(m-5), a d d 0.004-inch (0.10-mm) t h i c k n e s s t o t h e
o r i g i n a l d e p t h shims.
I n d i v i d u a l depth shims are available i n 0.003-inch,
0.005-inch, 0.010-inch, a n d 0.030-inch (0.08-mm,
0.13-mm, 0.25-mm, a n d 0.76-mm) thicknesses.

DRIVE PINION GEAR DEPTH VARIANCE

Original Pinion Replacement Pinion G e a r Depth V a r i a n c e

G e a r Depth
Variance -4 -3 -2 -1 0 +1 +2 +3 +4

+4 + 0.008 + 0.007 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0

+3 + 0.007 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001

+2 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001 -0.002

+1 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001 -0.002 -0.003

0 + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001 -0.002 -0.003 -0.004

-1 + 0.003 + 0.002 + 0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005

-2 + 0.002 + 0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006

-3 + 0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007

-4 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007 -0.008

J8902-46
DRIVE PINION GEAR DEPTH MEASUREMENT
AND ADJUSTMENT WITH TOOL SET D-116
The following drive p i n i o n gear depth (i.e., the
depth of the gear teeth mesh between the drive p i n -
i o n gear and the r i n g gear) measurement and adjust-
ment procedure involves u s i n g Special Tool Set D-
116.
(1) Insert Master P i n i o n Block Tool D-120 (for
Model 60 and 6 0 M axles) or Tool D-137 (for Model 70
axles) into the drive p i n i o n gear shaft bore i n the dif-
ferential housing (Fig. 22).

Fig. 24 Pinion Height Block Tool Against Arbor Tool

block tool is r e s t i n g f i r m l y on the lowest step of p i n -
ion h e i g h t block tool a n d "zero" t h e d i a l indicator
pointer.

Fig. 22 Pinion Block Tool Inserted In Shaft Bore

(2) Place A r b o r Disc Tools D-116-2 on A r b o r Tool
D-115-3 and position t h e tool set i n the differential
housing w i t h the disc tools located i n the differential
bearing cradles (Fig. 23). T h i s is the centerline of the
r i n g gear/axle shaft.

Fig. 25 Drive Pinion Gear Depth Measurement

Fig. 23 Arbor Disc & Arbor Tools In Housing
(3) Place P i n i o n H e i g h t Block Tool D-116-1 on top
of the master p i n i o n block tool and against the arbor
tool (Fig. 24).
(4) Place Gauge Block Tool D-115-2 and D i a l I n d i -
cator Tool D-106-5 on the lowest step of the p i n i o n
height block tool (Fig. 25). Ensure t h a t the gauge
(5) W i t h t h e d i a l indicator pointer "zeroed", move
the gauge block tool t o w a r d the arbor tool u n t i l the
t i p of t h e d i a l indicator plunger contacts the arbor
tool (Fig. 25). Slide the gauge block tool ( w i t h the
d i a l indicator) across and back and f o r t h along the
arbor tool w h i l e observing the d i a l indicator pointer.
Record t h e longest plunger t r a v e l distance, whether
i n w a r d ("-") or o u t w a r d (" + "), indicated by the
pointer.
T h e longest p l u n g e r t r a v e l d i s t a n c e indicated,
plus o r m i n u s the depth v a r i a n c e e t c h e d into the
face of the d r i v e p i n i o n gear, i s the r e q u i r e d
t h i c k n e s s for the d r i v e p i n i o n g e a r depth shims.
(6) Measure t h e thickness of each depth shim sep-
arately w i t h a micrometer and combine the shims
necessary to o b t a i n the t o t a l required depth shim
"pack" thickness. I f equipped, the oil slinger lo-
cated b e t w e e n the r e a r b e a r i n g a n d the thrust
face of drive p i n i o n g e a r m u s t b e m e a s u r e d a n d
the t h i c k n e s s i n c l u d e d w i t h t h e total s h i m
" p a c k " thickness.
(7) Remove the measurement tools f r o m the differ-
e n t i a l housing.
(8) Place t h e depth shims i n t o t h e d r i v e p i n i o n gear
shaft rear bearing bore i n t h e differential housing
and t h e n force t h e rear b e a r i n g cup i n t o t h e bore
w i t h B e a r i n g Gup I n s t a l l a t i o n Tool D-111 (for Model
60 and 6 0 M axles) or Tool C-4204 (for Model 70 ax-
les) and D r i v e r Handle Tool C-4171. Ensure t h a t the
cup is correctly "seated".
(9) Use B e a r i n g Cup I n s t a l l a t i o n Tool C-4203 and
D r i v e r Handle Tool C-4171 t o force t h e drive p i n i o n
gear shaft front bearing cup i n t o t h e differential
housing bore (Fig. 26).

BEARING CUP DRIVER

INSTALLATION TOOLC^203 HANDLE

PINION GEAR

Fig. 27 Shaft Rear Bearing Installation

Fig. 26 Shaft Front Bearing Cup Installation

(10) Force t h e rear b e a r i n g onto t h e drive p i n i o n
gear shaft u n t i l i t is completely "seated" w i t h Bear-
i n g I n s t a l l a t i o n Tool C-3095-A (Fig. 27).
(11) I n s t a l l the drive p i n i o n gear shaft i n the dif-
ferential housing.
(12) I n s t a l l the drive p i n i o n gear shaft front bear-
ing, oil slinger, (axle) yoke, washer and n u t . Use I n -
stallation Tool C-3718 a n d H o l d i n g Tool 3281 t o
Fig. 28 Drive Pinion Gear Shaft (Axle) Yoke
i n s t a l l the yoke (Fig. 28). Installation
D o not i n s t a l l the b e a r i n g " p r e l o a d " torque
shims o r the d r i v e p i n i o n g e a r shaft s e a l a t t h i s tool o n t h e lowest step o f the p i n i o n height block
time. tool. E n s u r e t h a t t h e gauge block tool is resting
(13) "Seat" t h e shaft bearings b y t i g h t e n i n g t h e firmly on t h e lowest step o f the p i n i o n height block
(axle) yoke n u t u n t i l i t requires 1 N m (10 in-lbs)
# tool a n d "zero" t h e d i a l indicator pointer.
torque to rotate the drive p i n i o n gear shaft (Fig. 29). (15) W i t h t h e d i a l indicator pointer "zeroed", move
Use a Newton-meter or a n inch-pound torque wrench the gauge block tool t o w a r d the arbor tool u n t i l the
to measure the torque. t i p o f t h e d i a l indicator plunger contacts the arbor
(14) Measure the drive p i n i o n gear depth o f mesh tool (Fig. 25). Slide the gauge block tool ( w i t h t h e
( w i t h the r i n g gear). Place t h e p i n i o n height block d i a l indicator) across and back and forth along t h e
tool on t h e face of the d r i v e p i n i o n gear (Fig. 22). arbor tool w h i l e observing the d i a l indicator pointer.
Place t h e arbor and disc tools i n t o t h e differential Record t h e longest plunger t r a v e l distance (whether
bearing cradles i n the differential housing (Fig. 23). i n w a r d or o u t w a r d ) indicated by the pointer.
Place t h e gauge block tool w i t h t h e d i a l indicator
 Fig. 29 Rotating Drive Pinion Gear Shaft
T h e dial indicator pointer should indicate a n
i n w a r d ("-") or o u t w a r d (" +") m a x i m u m t r a v e l
d i s t a n c e that closely a p p r o x i m a t e s the d e p t h
v a r i a n c e etched into the face of the d r i v e p i n i o n
gear.
(16) I f the measurement indicates t h a t t h e a c t u a l
depth variance is w i t h i n 0.002 i n c h (0.05 m m ) of t h e
depth variance etched i n t o t h e drive p i n i o n gear face, Fig. 30 Shim Locations
i t is acceptable.
(21) A p p l y a l i g h t coating of hypoid gear l u b r i c a n t
(17) I f the drive p i n i o n gear actual depth variance
on the l i p of drive p i n i o n gear shaft seal, position i t
is w i t h i n the specified tolerance, continue w i t h the
over the end of t h e shaft and i n s t a l l i t i n the differ-
differential assembly. I f the actual depth variance is
e n t i a l housing bore w i t h Seal I n s t a l l a t i o n Tool C-
not w i t h i n the specified tolerance, correct t h e s h i m
3719 (for Model 60 and 6 0 M axles) or Tool C-359 (for
thickness accordingly a n d t h e n re-measure t h e depth
Model 70 axles) and D r i v e r Handle Tool C-4171 (Fig.
variance.
31).
F i g u r e 30 depicts a n a r r o w p o i n t i n g o u t w a r d
a n d i n w a r d w i t h i n the d r i v e p i n i o n g e a r shaft.
T h e o u t w a r d d i r e c t i o n (pointing t o w a r d the
yoke) indicates that i f the d r i v e p i n i o n g e a r
shaft d e p t h s h i m t h i c k n e s s i s d e c r e a s e d , the d i s -
tance/depth from the c e n t e r l i n e of the axle/ring
g e a r to the drive p i n i o n g e a r face w o u l d be i n -
c r e a s e d (i.e., it w o u l d i n c r e a s e the d i a l i n d i c a t o r
p l u n g e r o u t w a r d (" +") t r a v e l distance). T h e
shaft b e a r i n g " p r e l o a d " torque s h i m t h i c k n e s s
does not affect the d e p t h of m e s h adjustment.
T h e a r r o w on the r i n g g e a r i n d i c a t e s the m e t h o d
of i n c r e a s i n g or d e c r e a s i n g s h i m t h i c k n e s s a t
the a p p l i c a b l e side of the differential c a s e to i n -
c r e a s e or d e c r e a s e the r i n g g e a r " b a c k l a s h " a n d SEAL

the differential b e a r i n g " p r e l o a d " torque.

(18) Remove the measurement tools f r o m t h e differ-
e n t i a l housing.
(19) Remove t h e drive p i n i o n gear shaft n u t ,
washer, (axle) yoke, o i l slinger, and f r o n t bearing.
(20) I n s t a l l the b e a r i n g " p r e l o a d " torque shims
RY659A
(Fig. 30) t h a t were removed d u r i n g disassembly, t h e
shaft front bearing a n d t h e o i l slinger on the d r i v e
Fig. 31 Drive Pinion Gear Shaft Seal Installation
p i n i o n gear shaft.
 (22) I n s t a l l the drive p i n i o n gear shaft (axle) yoke, Do not remove the tool after installing the
washer, and a replacement n u t on the shaft. T i g h t e n drive p i n i o n gear shaft b e a r i n g cups. The drive
t h e n u t w i t h 339 to 366 N-m (250 to 270 ft-lbs) p i n i o n gear d e p t h of mesh m u s t be measured
torque. next.
(23) Use a Newton-meter or a n i n c h pound torque (7) Loosen t h e n u t tool a n d t h e n r e - t i g h t e n i t suf-
wrench (Fig. 29) to rotate t h e d r i v e p i n i o n gear shaft ficiently to o b t a i n 1 to 3 N n n (10 t o 30 in-lbs) of
and observe the indicated b e a r i n g "preload" torque. bearing "preload" torque. W h i l e t i g h t e n i n g t h e n u t ,
The torque necessary to rotate t h e drive p i n i o n gear rotate the tool to align the bearing rollers.
shaft should be between 2.26 to 4.53 N-m (20 to 40 (8) I n s t a l l Gauge Block Tool SP-5260 on Tool Set
in-lbs). C-758-D6 (Fig. 32) and t i g h t e n t h e r e t a i n i n g screw
I f the drive p i n i o n gear shaft bearing "pre- securely w i t h a n A l l e n wrench.
l o a d " t o r q u e is n o t w i t h i n t h e specified toler- (9) Position Cross Bore A r b o r Tool SP-5183 (Fig.
ance, c o r r e c t t h e s h i m t h i c k n e s s a c c o r d i n g l y . T o 32) i n the d i f f e r e n t i a l bearing cradles ( i n the differ-
increase t h e " p r e l o a d " t o r q u e , decrease t h e s h i m e n t i a l housing). Center the arbor t o o l i n the cradles
thickness; t o decrease t h e " p r e l o a d " t o r q u e , i n - so t h a t an approximately equal space exists a t both
crease t h e s h i m t h i c k n e s s ( F i g . 30). S h i m s a r e ends.
a v a i l a b l e i n t h e f o l l o w i n g t h i c k n e s s e s : 0.003, (10) Observe t h e i n s t a l l a t i o n reference letters and
0.005, 0.010, a n d 0.030 i n c h (0.076, 0.127, 0.254, position the differential bearing caps on the arbor
a n d 0.762 m m ) . tool (Fig. 32). I n s t a l l the cap bolts a n d t i g h t e n t h e m
w i t h 14 N*m (10 ft-lbs) torque.
DRIVE PINION GEAR DEPTH MEASUREMENT (11) To measure the d r i v e p i n i o n gear depth of
AND ADJUSTMENT WITH TOOL SET C-758-D6 mesh, select a n d insert a feeler gauge blade t h a t
The f o l l o w i n g drive p i n i o n gear depth (i.e., the " s n u g l y " fits between the arbor tool a n d the gauge
depth of the gear teeth mesh between the d r i v e p i n - block tool (Fig. 32). The " f i t " m u s t be " s n u g " b u t not
ion gear and the r i n g gear) alternate measurement excessively t i g h t . R e c o r d t h e t h i c k n e s s o f t h e
and adjustment procedure involves using A x l e Mea- f e e l e r g a u g e b l a d e so t h a t i t c a n b e u s e d w h e n
surement Gauge Tool Set C-758-D6. Tool Set C-758- determining the correct drive p i n i o n gear depth
D6 is also used to i n s t a l l t h e d r i v e p i n i o n gear shaft shim thickness.
bearing cups.
(1) Position each d r i v e p i n i o n gear shaft bearing
cups i n t h e applicable d i f f e r e n t i a l housing bore.
(2) B e g i n assembling Tool Set C-758-D6 by posi-
t i o n i n g D r i v e P i n i o n Gear Shaft Locating Spacer
Tool SP-5184 (for Model 60 and 6 0 M axles) or Tool
SP-5587 (for Model 70 axles) on the tool p r i m a r y
screw.
(3) Position the drive p i n i o n gear shaft rear bear-
i n g on the tool p r i m a r y screw and insert the screw
( w i t h the bearing) into a n d t h r o u g h the differential
housing bore.
(4) Position the drive p i n i o n gear shaft front bear-
i n g on the tool p r i m a r y screw a t the opposite side of
the differential housing. I n s t a l l Compression Sleeve
Tool SP-535-A, C e n t r a l i z i n g Washer Tool SP-534 and
P r i m a r y Screw N u t Tool SP-533 on the tool p r i m a r y
screw.
(5) Lubricate the drive p i n i o n gear shaft front and
rear bearings w i t h M O P A R H y p o i d Gear L u b r i c a n t
(or an equivalent product). Fig. 32 Drive Pinion Gear Depth Measurement
(6) T i g h t e n the n u t tool, w h i l e r e t a i n i n g the com-
(12) Observe the depth variance etched i n t o the
pression sleeve tool w i t h Tool C-3281, and force the
end of the d r i v e p i n i o n gear (e.g., 0, - 1 , -2, + 1 , + 2 ,
drive p i n i o n gear shaft b e a r i n g cups into the differ-
etc.). I f the etched depth variance is a "-" (minus)
ential housing bearing cup bores. A l l o w t h e c o m -
value, add i t to the thickness measured and recorded
pression tool to rotate several revolutions
d u r i n g t h e t i g h t e n i n g process to p e r m i t the bear- i n step (11) above. I f t h e etched d e p t h variance is a
ing rollers to properly align a n d prevent " b r i n e l - " + " (plus) value, subtract i t from t h e thickness mea-
l i n g " of the bearing cups. sured and recorded i n step (11) above.
 (13) Remove t h e arbor tool f r o m the differential
housing cavity a n d the tool set ( w i t h the front and
rear bearings) f r o m the housing bore.
(14) Use Removal Tool D-162 and D r i v e r Handle
Tool C-4171 to remove the d r i v e p i n i o n gear shaft
rear bearing cup f r o m the differential housing bore.
(15) Position t h e depth shims i n the differential
housing rear bearing cup bore and i n s t a l l the bear-
i n g cup according to the method previously described
i n steps (1) t h r o u g h (6) above. W h e n the bearing cup
is correctly "seated" i n the housing bore, remove the
tool set and the drive pinion gear shaft bearings.
(16) I f the drive p i n i o n gear depth of mesh w i t h the
r i n g gear has been correctly established according to
t h e instructions and i n f o r m a t i o n provided i n the pro-
cedure above, good gear teeth contact should exist.
(17) Lubricate the drive p i n i o n gear shaft rear
b e a r i n g w i t h M O P A R Hypoid Gear L u b r i c a n t (o»r an
equivalent product) and i n s t a l l the b e a r i n g on the
d r i v e p i n i o n gear shaft w i t h Tool C-3095-A. Use a n
arbor press w i t h the i n s t a l l a t i o n tool (Fig. 33).
PINION GEAR
Fig. 33 Shaft Rear Bearing Installation
(18) I n s t a l l the drive p i n i o n gear shaft w i t h the
b e a r i n g i n the differential housing bore.
(19) I n s t a l l the o r i g i n a l drive p i n i o n gear shaft
b e a r i n g "preload" torque shims followed by the f r o n t
bearing. D o n o t i n s t a l l t h e s h a f t o i l s l i n g e r o r seal
at this time.
(20) I n s t a l l the drive p i n i o n gear shaft (axle) yoke,
washer and n u t . Tighten t h e n u t w i t h 339 to 366
N-m (250 to 270 ft-lbs) torque. W h i l e t i g h t e n i n g , ro-
t a t e drive p i n i o n gear shaft several complete revolu-
tions to "seat" the bearing rollers.
(21) Use a Newton-meter or a n inch-pound torque
wrench to rotate t h e d r i v e p i n i o n gear shaft and
measure the bearing " p r e l o a d " torque (Fig. 34). Ro-
tate t h e shaft several complete revolutions before re-
cording the torque. The Correct bearing "preload"
torque is 1 to 3 N-m (10 to 20 in-lbs) torque.
Fig. 34 Rotating Drive Pinion Gear Shaft
I f the drive p i n i o n gear shaft b e a r i n g " p r e -
l o a d " torque is n o t w i t h i n the specified toler-
ance, c o r r e c t t h e s h i m t h i c k n e s s a c c o r d i n g l y . T o
increase the " p r e l o a d " t o r q u e , decrease t h e s h i m
thickness; to decrease the " p r e l o a d " t o r q u e , i n -
crease the s h i m t h i c k n e s s . Shims are available
i n t h e f o l l o w i n g t h i c k n e s s e s : 0.003, 0.005, 0.010,
a n d 0.030 i n c h (0.076, 0.127, 0.254, a n d 0.762 m m ) .
(22) After the correct d r i v e p i n i o n gear shaft bear-
i n g "preload" torque has been established, remove
the yoke, n u t and washer.
(23) I n s t a l l t h e o i l slinger a n d the seal on t h e drive
p i n i o n gear shaft w i t h Seal I n s t a l l a t i o n Tool C-3719-
A (for Model 60 and 6 0 M axles) or Tool C-359 (for
Model 70 axles) and D r i v e r Handle C-4171.
(24) I n s t a l l the drive p i n i o n gear shaft (axle) yoke,
washer and n u t . T i g h t e n t h e n u t w i t h 339 to 366
N-m (250 to 270 ft-lbs) torque.
RING GEAR "BACKLASH" ADJUSTMENT
(1) Position Spreader Tool D-167 on the differential
housing w i t h t h e tool dowel pins "seated" i n the lo-
cating holes (Fig. 35). I n s t a l l the holddown clamps
and t i g h t e n the tool t u r n b u c k l e " f i n g e r - t i g h t " .
(2) I n s t a l l a p i l o t s t u d at t h e left side of t h e differ-
e n t i a l housing. A t t a c h D i a l Indicator Tool C-3339 to
the differential housing (via the pilot stud) w i t h the
indicator plunger s l i g h t l y "loaded" against t h e oppo-
site side of the differential housing (Fig. 35). "Zero"
the d i a l indicator pointer.
 SPREADER
TOOLD-167

Fig. 35 Differential Housing Separation Fig. 36 Ring Gear "Backlash" Measurement

CAUTION: Do not exceed the specified separation the drive p i n i o n gear (Fig. 36). Observe t h e d i a l i n -
distance when separating the differential housing. If dicator plunger t r a v e l distance indicated b y t h e
the housing is over-separated, it could be distorted pointer.
or damaged, which would necessitate replacement. (8) Repeat the measurement several times u n t i l t h e
indicated plunger t r a v e l distance is consistently t h e
(3) T i g h t e n t h e spreader tool t u r n b u c k l e ( F i g . 35)
same for each measurement a n d t h e n record t h e
and separate t h e differential housing only enough t o travel distance.
i n s t a l l t h e differential case i n the housing. S e p a r a t e T h e m e a s u r e m e n t a b o v e indicates t h e s h i m
the differential housing a m a x i m u m distance o f t h i c k n e s s n e c e s s a r y to eliminate t h e r i n g g e a r
0.38 m m (0.015 i n ) w i t h t h e s p r e a d e r t o o l . Mea-" b a c k l a s h " . S u b t r a c t this t h i c k n e s s from t h e dif-
sure t h e separation distance w i t h t h e d i a l indicator ferential case " z e r o " " e n d - p l a y " s h i m t h i c k n e s s .
(Fig. 35) as t h e housing is being separated. T h e r i n g gear " b a c k l a s h " s h i m s m u s t b e p l a c e d
(4) Remove t h e d i a l indicator tool a n d t h e p i l o t on the h u b at the r i n g g e a r side of the differen-
stud (Fig. 35) when the differential housing has been tial c a s e b e t w e e n t h e differential c a s e a n d the
separated sufficiently t o i n s t a l l t h e differential case differential bearing.
i n t h e housing. (9) Remove t h e d i a l indicator tool a n d t h e p i l o t
(5) I n s t a l l Master Bearing Tools D-117 o n t h e dif- stud (Fig. 36) f r o m t h e differential housing.
ferential case hubs and position t h e case i n t h e dif- (10) Remove t h e differential bearing caps.
ferential housing w i t h t h e r i n g gear teeth "meshed" (11) Position Spreader Tool D-167 on t h e differen-
w i t h t h e drive p i n i o n gear teeth. I f necessary, " r o c k "
t i a l housing w i t h t h e tool dowel pins "seated" i n t h e
the r i n g gear to "mesh" the gear teeth. locating holes (Fig. 35). I n s t a l l t h e holddown clamps
(6) I n s t a l l a pilot stud a t t h e r i g h t side of the dif-
and t i g h t e n t h e tool t u r n b u c k l e " f i n g e r - t i g h t " .
ferential housing. A t t a c h D i a l Indicator Tool C-3339 (12) I n s t a l l a p i l o t stud a t t h e left side o f the dif-
to t h e differential housing ( v i a t h e p i l o t stud) w i t h
ferential housing. A t t a c h D i a l Indicator Tool C-3339
the indicator plunger s l i g h t l y "loaded" against t h e to t h e differential housing ( v i a t h e pilot stud) w i t h
back of the r i n g gear (Fig. 36). Ensure t h a t t h e r i n g the indicator plunger s l i g h t l y "loaded" against t h e
gear teeth and the drive p i n i o n gear teeth are t i g h t l y opposite side of t h e differential housing ( F i g . 25).
"meshed" and "zero" t h e d i a l indicator pointer. "Zero" t h e dial indicator pointer.
(7) Insert a small p r y bar between t h e bearing cap
and t h e left side of the differential case. P r y t h e dif- CAUTION: Do not exceed the specified separation
ferential case/ring gear as far as possible t o w a r d t h e distance when separating the differential housing. If
r i g h t side of the differential housing a n d away f r o m the housing is over-separated, it could be distorted
or damaged, which would necessitate replacement.
 (13) T i g h t e n the spreader tool t u r n b u c k l e (Fig. 35)
and separate t h e differential housing only enough to
remove the differential case from the housing. S e p a -
rate t h e d i f f e r e n t i a l h o u s i n g a m a x i m u m dis-
t a n c e of 0.38 m m (0.015 i n ) w i t h t h e s p r e a d e r
tool. Measure t h e separation distance w i t h the d i a l
indicator (Fig. 35) as the housing is being separated.
(14) Remove t h e d i a l indicator tool and t h e p i l o t
stud (Fig. 35) w h e n the differential housing has been
separated sufficiently to remove the differential case
f r o m the housing.
(15) Remove t h e differential case from the differen-
t i a l housing.
(16) Remove the holddown clamps and the spreader
tool f r o m the differential housing (Fig. 35).
(17) Remove the master bearing tools from t h e dif-
ferential case hubs.
(18) Position t h e "backlash" shims ( w i t h t h e re-
quired thickness determined above) on the differen-
t i a l case h u b ( r i n g gear side). Place the differential
bearing on the h u b and i n s t a l l i t w i t h B e a r i n g I n -
s t a l l a t i o n Tool C-4025-A and D r i v e r Handle Tool C-
4171 (Fig. 37).
BEARING
INSTALLER TOOL
Fig. 37 Differential Bearing Installation
(19) Position the r e m a i n i n g "zero" "end-play" shims
on t h e hub a t t h e opposite side o f the differential
case. Include a n additional 0.015-in (0.38-mm) t h i c k
s h i m on t h i s h u b to provide the required differential
bearing "preload" torque.
(20) I n s t a l l t h e other differential bearing o n t h e
h u b w i t h B e a r i n g I n s t a l l a t i o n Tool C-4025-A a n d
D r i v e r Handle Tool C-4171 (Fig. 37).
(21) M a t c h each bearing cup w i t h i t s differential
bearing (original) counterpart and i n s t a l l the cups on
the bearings.
(22) Position Spreader Tool D-167 on the differen-
t i a l housing w i t h the tool dowel pins "seated" i n the
locating holes (Fig. 35). I n s t a l l t h e holddown clamps
and t i g h t e n the tool t u r n b u c k l e " f i n g e r - t i g h t " .
(23) I n s t a l l a p i l o t stud a t t h e left side o f t h e dif-
ferential housing. A t t a c h D i a l Indicator Tool C-3339
to the differential housing (via t h e p i l o t stud) w i t h
the indicator plunger s l i g h t l y "loaded" against t h e
opposite side o f the differential housing (Fig. 35).
"Zero" the d i a l indicator pointer.
CAUTION: Do not exceed the specified separation
distance when separating the differential housing. If
the housing is over-separated, it could be distorted
or damaged, which would necessitate replacement.
(24) T i g h t e n the spreader tool t u r n b u c k l e (Fig. 35)
and separate the differential h o u s i n g only enough to
i n s t a l l t h e differential case i n t h e housing. S e p a r a t e
the differential housing a m a x i m u m d i s t a n c e of
0.38 m m (0.015 i n ) w i t h t h e s p r e a d e r tool. Mea-
sure the separation distance w i t h the d i a l indicator
(Fig. 35) as the housing is being separated.
(25) Remove t h e d i a l indicator tool and t h e p i l o t
stud (Fig. 35) w h e n the differential housing has been
separated sufficiently to i n s t a l l t h e differential case
i n the housing.
(26) I n s t a l l the differential case i n the differential
housing.
(27) Remove the holddown clamps and the spreader
tool from the differential housing (Fig. 35).
(28) I n s t a l l t h e differential bearing caps. Ensure
t h a t the i n s t a l l a t i o n reference l e t t e r stamped i n each
cap corresponds to the letter stamped i n t h e differen-
t i a l housing (Fig. 38). T i g h t e n t h e bearing cap bolts
w i t h 108 t o 122 N-m (80 to 90 ft-lbs) torque.
IDENTIFICATION MARKS
8903-21
Fig. 38 Differential Bearing Cap Reference Letters
3 - 52 REAR AXLES
(29) Measure the r i n g gear "backlash" a t three
equally spaced locations around t h e perimeter o f t h e
r i n g gear w i t h a d i a l indicator (Fig. 39).
Fig. 39 Ring Gear "Backlash" Measurement
T h e r i n g g e a r " b a c k l a s h " m u s t b e w i t h i n 0.004
- 0.009 i n c h (0.10 - 0.23 m m ) a n d i t c a n n o t v a r y
m o r e t h a n 0.002 i n c h (0.05 m m ) a t a n y o f t h e
measurement locations.
(30) Excessive " b a c k l a s h " is corrected b y m o v i n g
the r i n g gear teeth closer to t h e drive p i n i o n gear
teeth. Insufficient "backlash" is corrected b y m o v i n g
the r i n g gear teeth away from t h e drive p i n i o n gear
teeth. " B a c k l a s h " correction is accomplished b y
t r a n s f e r r i n g shims f r o m one side of t h e differential
case to t h e other (Fig. 30).
GEAR TEETH CONTACT PATTERNS
I f t h e d r i v e p i n i o n gear depth o f mesh a n d the r i n g
gear " b a c k l a s h " have been correctly established ac-
cording to t h e instructions and i n f o r m a t i o n provided
i n the procedures above, good gear teeth contact pat-
terns should exist.
INSTALLATION
(1) I n s t a l l t h e axle shafts i n t h e axle shaft tubes. I f
necessary, refer to t h e i n s t a l l a t i o n procedure.
(2) Remove any residual R T V sealant/gasket mate-
r i a l f r o m t h e differential housing a n d cover m a t i n g
surfaces, t h o r o u g h l y clean t h e surfaces w i t h m i n e r a l
spirits (or a n equivalent cleaning solution) a n d d r y
the surfaces completely.
(3) A p p l y a t h i n "bead" of M O P A R R T V Sealant (or
an equivalent sealant) around t h e bolt circle on t h e
housing a n d on t h e cover. A l l o w t h e s e a l a n t t o
" c u r e " f o r few minutes.
I f f o r a n y reason the differential housing cover
is n o t i n s t a l l e d w i t h i n 20 m i n u t e s a f t e r a p p l y i n g
the s e a l a n t , t h e s e a l a n t m u s t b e r e m o v e d a n d
another " b e a d " o f sealant applied.
(4) I n s t a l l t h e housing cover on t h e differential
housing w i t h t h e attaching bolts. I n s t a l l t h e a x l e
•
gear ratio identification t a g u n d e r one o f the
c o v e r b o l t s . T i g h t e n the cover bolts w i t h 47 N - m (35
ft-lbs) torque.
(5) Remove t h e supports a n d raise or lower t h e
hoist u n t i l t h e vehicle is level.
(6) Remove t h e f i l l hole p l u g a n d f i l l t h e differen-
t i a l h o u s i n g a n d t h e axle tubes w i t h t h e specified
q u a n t i t y o f M O P A R H y p o i d Gear L u b r i c a n t (or a n
equivalent product). Refer t o Rear A x l e Specifica-
tions. I n s t a l l t h e f i l l hole p l u g a n d t i g h t e n w i t h 34
N»m (25 ft-lbs) torque.
(7) Lower t h e vehicle and test t h e brakes a n d t h e
axle for proper operation.
TRAC-LOK DIFFERENTIAL SERVICE
GENERAL INFORMATION
Model 60, 6 0 M and 70 rear axles equipped w i t h a
T r a c - L o k differential are o p t i o n a l l y available for
R a m T r u c k vehicles.
A T r a c - L o k differential has a one-piece differen-
t i a l case, t h e same i n t e r n a l components as a stan-
d a r d d i f f e r e n t i a l , plus two clutch disc packs (Fig. 40).
W h e n engine torque is applied t o t h e differential
r i n g gear, t h e i n i t i a l spring " l o a d i n g " of the clutches
is supplemented by t h e gear-separating f r i c t i o n be-
tween t h e differential side gears a n d t h e p i n i o n
gears, a n d t h i s progressively increases t h e t o t a l fric-
t i o n i n t h e differential. W h e n a l o w t r a c t i o n surface
is encountered (e.g., m u d or snow), t h i s i n t e r n a l fric-
t i o n is t h e means for t r a n s f e r r i n g more of the engine
torque to t h e rear wheel/tire t h a t has the better trac-
t i o n surface a n d less torque to t h e wheel/tire w i t h
the lower t r a c t i o n surface. Because a T r a c - L o k dif-
f e r e n t i a l is n o t a positive " l o c k i n g " type of differen-
t i a l , t h e f r i c t i o n w i l l decrease a n d t h e clutches w i l l
release t h e side gears before excessive engine torque
is applied t o either one of t h e wheels/tires. T h e
wheel/tire w i t h the least t r a c t i o n w i l l " s p i n " s i m -
ilarly to t h e aption of a standard differential
w h e n e x t r e m e differences i n surface t r a c t i o n a r e
e n c o u n t e r e d . D u r i n g n o r m a l d r i v i n g conditions, t h e
controlled i n t e r n a l f r i c t i o n is easily overcome w h e n a
vehicle is t u r n i n g a corner so t h a t the d r i v i n g wheels
can rotate a t different speeds.
SERVICE INFORMATION
The service information/procedures for a T r a c - L o k
differential are essentially the same as those used for
a standard differential, therefore, only information/
procedures i n v o l v i n g t h e differences t h a t exist be-
tween t h e t w o differential types w i l l be provided
w i t h i n t h i s section.
The rear wheel anti-lock ( R W A L ) brake sensor is
attached t o t h e top, forward exterior area of t h e dif-
ferential housing. There is a seal located between t h e
sensor a n d t h e wire connector. T h i s seal m u s t b e
• REAR AXLES 3 - 53

1 PINION GEAR 10 YOKE 19 CLUTCH PACKS

2 PINION REAR BEARING
3 BEARING CUP
4 PINION DEPTH SHIMS
5 PINION PRELOAD SHIM
6 BEARING CUP
7 PINION FRONT BEARING
8 SLINGER
9 PINION SEAL
11 WASHER 20 CLUTCH PACK RETAINERS
12 PINION NUT 21 PINION THRUST WASHER
13 BEARING CUP 22 DIFFERENTIAL PINIONS
14 DIFFERENTIAL BEARING 23 PINION SHAFT SNAP RINGS
15 BACKLASH/PRELOAD SHIM 24 DIFFERENTIAL SIDE GEARS
16 RING GEAR 25 PINION SHAFT
17 DIFFERENTIAL CASE 26 PINION SHAFT LOCK PIN
18 RING GEAR BOLTS

J8903-41

Fig. 40 Trac-Lok Differential (Exploded View)

iii-place before connecting t h e w i r e connector.
The R W A L b r a k e exciter r i n g is "press f i t t e d " on the
differential case.
CAUTION: Whenever a rear axle is being serviced
or anytime it is to be rotated via the engine (or by
another means), RAISE BOTH REAR WHEELS off
the surface.
DIFFERENTIAL DIAGNOSIS
W i t h n o r m a l t i r e t r a c t i o n conditions, engine torque
is divided evenly. W i t h l o w - t r a c t i o n surfaces, engine
torque is transferred t o the wheel w i t h the most t i r e
traction. W h e n diagnosing a suspected T r a c - L o k dif-
ferential p r o b l e m condition, i t is i m p o r t a n t t o re-
member: i f t h e tire t r a c t i o n i s u n e q u a l ( o r l o w ) a t
b o t h wheels, b o t h wheels w i l l " s l i p " o r " s p i n " .
W h e n extreme differences i n wheel-to-wheel t i r e
t r a c t i o n exist, t h e wheel w i t h t h e least t i r e t r a c t i o n
w i l l continue " s p i n n i n g " regardless of the fact t h a t
m a x i m u m t o r q u e w a s transferred to t h e opposite
wheel.
Noise complaints i n v o l v i n g rear axles equipped
w i t h a T r a c - L o k differential should be t h o r o u g h l y
evaluated t o determine t h e source of the noise. Be-
fore t h e d i f f e r e n t i a l is disassembled for a n y type o f
noise complaint, the l u b r i c a n t should be replaced. A n
incorrect (or insufficient) l u b r i c a n t can cause noises
such as " c h a t t e r " a n d " m o a n " as w e l l as scoring of
the d i f f e r e n t i a l clutch plates and discs (which can re-
sult i n f a i l u r e o f the complete u n i t ) .
Generally, t h e most common T r a c - L o k differential
noise encountered is a " c h a t t e r " noise w h e n t u r n i n g
a street corner (i.e., t u r n i n g the vehicle 90 degrees).
A common cause of t h i s is incorrect or contaminated
lubricant. Replacing t h e axle gear l u b r i c a n t (and
adding M O P A R H y p o i d Gear L u b r i c a n t A d d i t i v e or
an equivalent f r i c t i o n modifier additive) w i l l correct
the condition i n most instances. However, i f t h e
"chatter" persists, c l u t c h disc damage could have oc-
curred.
The f o l l o w i n g d r a i n a n d l u b r i c a n t replacement pro-
cedure should be used for possible e l i m i n a t i o n of
noise before r e p l a c i n g the differential.
WARNING: WHEN SERVICING VEHICLES WITH AN
AXLE EQUIPPED WITH A TRAC-LOK DIFFEREN-
TIAL, DO NOT USE THE ENGINE TO ROTATE THE
AXLE AND WHEELS UNLESS BOTH REAR WHEELS
ARE RAISED FROM THE SURFACE AND THE VEHI-
CLE SUPPORTED. A TRAC-LOK DIFFERENTIAL
EQUIPPED AXLE CAN EXERT ENOUGH DRIVING
FORCE (IF ONE WHEEL IS IN CONTACT WITH THE
SURFACE) TO CAUSE THE VEHICLE TO MOVE.
(1) W i t h t h e rear axle l u b r i c a n t a t n o r m a l operat-
i n g t e m p e r a t u r e , raise and support the vehicle (rear
wheels free t o rotate).
(2) Remove t h e f i l l hole p l u g from t h e d i f f e r e n t i a l
housing cover and remove as m u c h o f t h e l u b r i c a n t
as possible w i t h a suction p u m p .
(3) F i l l t h e differential housing w i t h M O P A R H y -
poid Gear L u b r i c a n t , or a n equivalent product. I n -
s t a l l t h e f i l l hole p l u g i n t h e cover a n d t i g h t e n i t
w i t h 34 N*m (25 ft-lbs) torque.
(4) S t a r t t h e engine, shift t h e t r a n s m i s s i o n t o
D R I V E (or a f o r w a r d gear) and increase t h e speed t o
a p p r o x i m a t e l y 40 m p h (64 km/h) for 10 m i n u t e s .
T h i s w i l l t h o r o u g h l y circulate t h e l u b r i c a n t a n d
cause t h e temperature t o increase to t h e n o r m a l op-
e r a t i n g range.
(5) Stop t h e engine, remove t h e f i l l hole p l u g a n d
( w i t h a suction pump) remove as m u c h o f the l u b r i -
cant as possible.
(6) I n s t a l l 4 ounces of M O P A R H y p o i d Gear L u b r i -
cant A d d i t i v e (or a n equivalent friction modifier a d -
ditive) i n t h e differential housing. R e f i l l t h e
differential housing to the correct level w i t h M O P A R
H y p o i d Gear L u b r i c a n t (or a n equivalent product).
I n s t a l l t h e f i l l hole p l u g and t i g h t e n i t w i t h 34 N»m
(25 ft-lbs) torque.
I f sufficient time is available, after r e p l a c i n g
the l u b r i c a n t i n a T r a c - L o k d i f f e r e n t i a l , d r i v e
t h e v e h i c l e a n d m a k e 10 t o 12 s l o w , figure-eight
t u r n s . T h i s type o f maneuver ensures that t h e
replacement lubricant is pumped through t h e
c l u t c h disc packs.
(7) Lower the vehicle and r e t u r n i t t o t h e owner t o
drive a n d evaluate for approximately 100 miles (160
k m ) t o determine i f replacing t h e l u b r i c a n t corrects
the noise condition.
I f , a f t e r d r i v i n g t h e v e h i c l e a p p r o x i m a t e l y 100
m i l e s (160 k m ) , t h e d i f f e r e n t i a l n o i s e s t i l l o c c u r s ,
r e p l a c e t h e d i f f e r e n t i a l case ( w i t h i t s i n t e r n a l
components). W i t h the exception o f the r i n g gear
and t h e differential bearings, the differential
case a n d i t s i n t e r n a l c o m p o n e n t s a r e s e r v i c e d a s
a u n i t o n l y a n d should n o t be disassembled.
DIFFERENTIAL TEST
(1) D r i v e the vehicle to thoroughly w a r m up the l u -
b r i c a n t i n t h e rear axle.
(2) Place a large piece of K r a f t paper (or a n equiv-
alent product) over a smooth Formica board (or a n
equivalent product). E n s u r e t h a t t h e F o r m i c a
b o a r d is o n a flat a n d level surface.
(3) D r i v e t h e vehicle over the Formica board u n t i l
one rear wheel/tire is i n the center of t h e board a n d
the paper.
(4) Place a block of wood t h a t is 2-inches h i g h a n d
a m i n i m u m o f 3-inches wide i n front o f one o f t h e
front tires.
 (5) W i t h a " g r a d u a l " t h r o t t l e opening, attempt to
slowly d r i v e the vehicle over the block of wood.
(6) I f the K r a f t paper slips out from under the rear
wheel/tire before the f r o n t wheel/tire moves over t h e
block of wood; reposition the vehicle so t h a t the pa-
per and board are under the opposite rear wheel/tire;
and a t t e m p t t o drive over the block o f wood the sec-
ond t i m e .
(7) I f t h e front wheel/tire moves over the block o f
wood on e i t h e r the first or second attempt, the axle
can be considered to be functioning normally.
DIFFERENTIAL CASE SERVICE
REMOVAL
Refer to t h e differential case removal procedure for
a standard differential.
CLEANING/INSPECTION
(1) Clean t h e T r a c - L o k differential case and com-
ponents (Fig. 40) w i t h fast evaporating m i n e r a l spir-
its or a d r y cleaning solvent. W i t h the exception o f
t h e differential bearings, dry the case and the com-
ponents w i t h compressed air.
(2) Inspect the differential bearing rollers and cups
for " p i t t i n g " , " s p a l l i n g " and other visible damage. I f
differential bearing replacement is necessary, remove
t h e bearings from t h e differential case according to
t h e procedure provided for a standard differential
bearing.
(3) Inspect the differential case for cracks and other
visible damage t h a t could cause i t t o be unusable.
ASSEMBLY
(1) I f t h e r i n g gear was removed for a n y reason
f r o m the differential case (or i f i t is being replaced),
replacement r i n g gear bolts must be installed.
(2) Place t h e differential case i n an appropriate fix-
t u r e . I n s t a l l t h e r i n g gear w i t h replacement bolts.
T i g h t e n t h e bolts w i t h 136 to 203 N*m (100 to 120
ft-lbs) torque.
INSTALLATION
Refer to t h e differential case i n s t a l l a t i o n procedure
provided for a standard differential.
LUBRICANTS
TYPE
Multi-purpose, hypoid gear lubricant, as defined b y
M I L - L - 2 1 0 5 - B a n d b y A P I G L 5 q u a l i t y specifica-
tions, should be used for Model 60, 6 0 M and 70 rear
axles w i t h standard or Trac-Lok differentials. M O -
P A R H y p o i d Gear L u b r i c a n t conforms t o b o t h of
these specifications and i s h i g h l y recommended for
use w i t h R a m T r u c k and Ramcharger vehicles. I n ad-
d i t i o n , 4 ounces o f M O P A R Hypoid Gear L u b r i c a n t
A d d i t i v e (or a n equivalent f r i c t i o n modifier product)
can be included w i t h a r e - f i l l for T r a c - L o k differen-
tials.
CAUTION: If the rear axle is submerged in water,
the axle lubricant must be replaced immediately to
avoid the possibility of premature axle failure re-
sulting from water contamination of the lubricant.
DRAIN AND REFILL
(1) D r i v e t h e vehicle u n t i l the gear l u b r i c a n t i n the
axle a t t a i n s t h e n o r m a l operating temperature.
(2) Raise a n d support t h e vehicle.
(3) Remove the l u b r i c a n t f i l l hole p l u g f r o m the dif-
ferential h o u s i n g cover.
(4) Remove the differential housing cover and allow
t h e o r i g i n a l l u b r i c a n t t o completely d r a i n f r o m t h e
housing a n d t h e axle shaft tubes.
CAUTION: DO NOT FLUSH Trac-Lok differentials.
Trac-Lok differentials may be cleaned only by dis-
assembling the unit and wiping with clean, lint-free
cloths.
(5) F o r standard differentials (only), f l u s h t h e dif-
ferential a n d t h e housing cavity w i t h a " f l u s h i n g " o i l
(or l i g h t engine oil) t o remove residual l u b r i c a n t and
foreign m a t t e r . D o n o t use w a t e r , s t e a m , k e r o s e n e
o r gasoline f o r flushing.
(6) I n s t a l l t h e differential housing cover a n d
t i g h t e n t h e bolts w i t h 47 N*m (35 ft-lbs) Torque.
(7) Refill t h e differential housing w i t h t h e specified
q u a n t i t y o f M O P A R H y p o i d Gear L u b r i c a n t (or a n
equivalent product). Refer to Rear A x l e Specifica-
tions. A container of M O P A R Hypoid Gear L u b r i c a n t
A d d i t i v e (a f r i c t i o n modifier) can also be added for
Trac-Lok differentials.
(8) I n s t a l l and t i g h t e n t h e f i l l hole p l u g w i t h 34
N - m (25 ft-lbs) torque.
(9) Remove t h e supports and lower the vehicle, o f
M O P A R H y p o i d Gear L u b r i c a n t .
(10) I f equipped w i t h a Trac-Lok differential, drive
t h e vehicle a n d make 10 to 12 slow, figure-eight
t u r n s . T h i s type of maneuver w i l l ensure t h a t the re-
placement l u b r i c a n t is pumped t h r o u g h t h e Trac-Lok
clutch discs.
3 - 56 REAR AXLES •
SPECIFICATIONS

TORQUE SPECIFICATIONS

COMPONENT SET-TO-TORQUE RECHECK TORQUE

Differential Bearing Cap Bolt

8-3/8 Inch Axle 95 N » m (70 ft-lbs)
9- 1/4 inch Axle (Std. & HD) 136 N*m (100 ft-lbs)
Model 60 & 60M Axle 115 N » m (85 ft-lbs) 108-122 N » m (80-90 ft-lbs)
Model 70 Axle 119 N » m (88 ft-lbs) 115-122 N » m (85-90 ft-lbs)

Ring Gear-to-Differential Case Bolt (LH Thread)

8-3/8 Inch Axle 95 N » m (70 ft-lbs)
9- 1/4 Inch Axle 95N»m (70 ft-lbs)
Model 60&60M Axle 153 N*m (113 ft-lbs) 149-156 N*m (100-115 ft-lbs)
Model 70 Axle 142 N « m (105 ft-lbs) 136-149 N*m (100-110 ft-lbs)

Drive Pinion Gear Shaft Flange/Yoke N ut

8-3/8 inch Axle 285 N » m (210 ft-lbs) Min.
9- 1/4 inch Axle 285 N « m (210 ft-lbs) Min.
Model 60, 6GM & 70 Axle 352 N*m (260 ft-lbs) 339-366 (250-270 ft-lbs)

Differential Housing Cover Bolt

8-3/8 inch Axle 4 7 N * m (35 ft-lbs)
9- 1/4 Inch Axle 4 7 N * m (35 ft-lbs)
Model 60, 60M&70 Axle 4 7 N « m (35 ft-lbs) 41-54 N » m (30-40 ft-lbs)

Brake Support Plate Retainer Nut

8-3/8 Inch Axle 44 N « m (33 ft-lbs) 41-47 N » m (30-35 ft-lbs)
9- 1/4 Inch Axle 47 N » m (35 ft-lbs)
Model 60, 60M & 70 Axle 115 N*m (85 ft-lbs) 88-142 N*m (65-105 ft-lbs)

Drive Shaft U-Joint Clamp Screw 21 N*m (185 in-lbs) 19-23 N » m (170-200 in-lbs)

Spring U-Bolt Nut

8-3/8 Inch Axle 61 N*m (45 ft-lbs)
9- 1/4 Inch Axle 88 N*m (65 ft-lbs) Min.
Model 60, 60M & 70 Axle 244 N*m (180 ft-lbs) 203-285 N » m (150-210 ft-lbs)

Wheel Lug Nut

8-3/8 Inch Axle 142 N » m (105 ft-lbs)
9- 1/4 Inch Axle 142 N*m (105 ft-lbs)
Model 60, 60M & 70 Axle
Coned Nut 281 N » m (200 ft-lbs) 237-305 N « m (175-225 ft-lbs)
Flanged 5/8 x 18 Nut 441 N » m (325 ft-lbs) 407-475 N<>m (300-350 ft-lbs)
Flanged 1-1/8 x 16 Nut 644 N*m (475 ft-lbs) 610-678 N « m (450-500 ft-lbs)

Shock Absorber Stud N ut

8-3/8 Inch Axle 68 N » m (50 ft-lbs)
9- 1/4 Inch Axle 68 N*m (50 ft-lbs)
Model 60, 60M & 70 Axle 68 N » m (50 ft-lbs) 47-88 N » m (35-65 ft-lbs)

Axle Shaft Flange Bolt

Model 60, 60M & 70 Axle 99 N » m (72 ft-lbs) 75-122 N » m (55-90 ft-lbs)

Differential Case Half Bolt

Model 60, 60M & 70 Axle 9 2 N » m (68 ft-lbs) 88-95 N » m (65-70 ft-lbs)

RWAL Brake Sensor Cover Screw 24 N » m (200 in-lbs) 19-29 N « m (170-230 in-lbs)

J9003-124
• REAR AXLES 3 - 57

REAR AXLE SPECIFICATIONS

DIM
W150 D2M
DIM AD1M D2M W2M D3M
Vehicle Model AD1M AW1M W2M W350 W3M D350

Type SFH SFH SFH FFH FFH FFH

Capacity (Load) 3400 3600 5500 5500 7500 5800
Axle Designation 8-3/8 9-1/4 9-1/4 HD 60 70 60M
Number of Differential Pinion Gears 2 2 2 2 2 2
Ring Gear Pitch Diameter 8.375 9.25 9.25 9.75 10.5 9.75
Number of Teeth
Ring Gear 45 — — 41 39 41
Drive Pinion Gear 14 — — 10 8 10
Ratio to 1 3.21 — — 4.1** 4.88** 4.10**
Number of Teeth
Ring Gear 39 45 39 — 41 —
Drive Pinion Gear 11 14 11 —. 9 —
Ratio to 1 3.55 3.21* 3.55* — 4.56(1) —
Number of Teeth
Ring Gear 47 39 39 — 41 —
Drive Pinion Gear 16 11 10 — 10 —
Ratio to 1 2.94 3.55* 3.90 — 4.10(1) —
Lubricant Capacity (Pints) 4.4 4 4 6 7 6
(Liters) 2.1 1.9 1.9 2.8 3.3 3.3
(1) Not available for Model W350
SFH—Semi-Floating Hypoid.
FFH—Full-Floating Hypoid.
*Sure-Grip Differential Available.
**Trac-Loc Differential Available.

J9003-125
 • BRAKES
BRAKES
CONTENTS
Page
11- INCH DRUM BRAKE . . . . . . , 42
12- INCH DRUM BRAKE .46
BENDIX DISC BRAKE 32
CHRYSLER DISC BRAKE 22
COMPONENT SERVICE 59
GENERAL INFORMATION 1 SERVICE DIAGNOSIS
MASTER CYLINDER-COMBINATION
VALVE-BRAKE LINES 10
G E N E R A L INFORMATION
INDEX
Page
Antilock Rear Wheel Brake System (RWAL) 1 Brake Fluid/Lubricants/Cleaning Solvents
Brake Components 1 Brake Safety Precautions .
BRAKE COMPONENTS
A l l A D models are equipped w i t h front disc a n d
rear d r u m brakes. Power assist brakes a n d rear
wheel antilock brakes are also standard o n a l l mod-
els. A d u a l reservoir master cylinder and single or
d u a l diaphragm, v a c u u m operated power brake
booster is used for a l l applications.
The f r o n t disc brake u n i t s consist o f single piston,
sliding-type calipers w i t h semi metallic brakeshoe
l i n i n g . Vented disc b r a k e rotors are used on a l l mod-
els. Bendix calipers are used on four wheel drive
W250/W350 models. Chrysler disc brake calipers are
used for a l l other applications.
The rear d r u m brakes are d u a l shoe u n i t s w i t h a n
automatic adjustment mechanism. Bendix a n d
Chrysler d r u m brake assemblies are used.
A combination valve is used on a l l models. The
valve consists o f a f r o n t brake m e t e r i n g (hold-off)
valve and a front/rear pressure differential switch.
A red, brake indicator and w a r n i n g l i g h t is used t o
alert t h e driver i f a pressure differential exists be-
tween t h e f r o n t a n d rear h y d r a u l i c systems. The
l i g h t also alerts the d r i v e r w h e n the p a r k i n g brakes
are applied. The l i g h t is located a t the left side of the
i n s t r u m e n t cluster.
A n a d d i t i o n a l indicator l i g h t is used for the a n t i -
lock system. This l i g h t is amber and is located i n the
same side o f the i n s t r u m e n t cluster as t h e r e d i n d i -
cator l i g h t . The anti-lock l i g h t alerts the d r i v e r i f a n
anti-lock system f a u l t occurs.
5- 1
Page
PARKING BRAKES ....52
POWER BRAKE BOOSTER-BRAKE PEDAL . . . 20
REAR WHEEL ANTI-LOCK BRAKES (RWAL) . . 53
RWAL SERVICE DIAGNOSIS 57
SERVICE ADJUSTMENTS . . . 6
2
Page
........ 1
2
ANTILOCK REAR WHEEL BRAKE SYSTEM (RWAL)
A l l t r u c k models are equipped w i t h antilock rear
brakes. The R W A L system i s designed to r e t a r d
wheel lockup d u r i n g periods o f h i g h wheel slip w h e n
b r a k i n g . Retarding wheel lockup is accomplished b y
m o d u l a t i n g f l u i d pressure t o t h e wheel brake u n i t s .
Refer t o the Rear Wheel A n t i L o c k B r a k e section for
operation and service i n f o r m a t i o n .
BRAKE FLUID/LUBRICANTS/CLEANING SOLVENTS
Recommended fluid for a l l A D models is Mopar
brake fluid or equivalent m e e t i n g S A E J1703 a n d
D O T 3 standards.
W h e n servicing rear brakes, use Mopar m u l t i pur-
pose grease to lubricate caliper slide surfaces, d r u m
brake pivot pins and shoe contact points on the back-
i n g plates. Use GE 661 or Dow 111 silicone grease on
caliper bushings and slide pins.
Use fresh brake fluid or M o p a r brake cleaner to
clean or flush brake system components. These are
the only cleaning materials recommended.
CAUTION: Never use gasoline, kerosene, alcohol,
motor oil, transmission fluid, or any fluid containing
mineral oil to clean the system components. These
fluids damage rubber cups and seals. If system
contamination is suspected, check the fluid for dirt,
discoloration, or separation into distinct layers.
Drain and flush the system with new brake fluid if
contamination is suspected.
5 - 2 BRAKES
BRAKE SAFETY PRECAUTIONS
WARNING: DUST AND DIRT ON BRAKE PARTS
GENERATED DURING THE NORMAL USE AND
WEAR OF MOTOR VEHICLE BRAKE SYSTEMS MAY
CONTAIN ASBESTOS FIBERS. BREATHING EXCES-
SIVE CONCENTRATIONS OF ASBESTOS FIBERS
CAN CAUSE SERIOUS BODILY HARM. EXTREME
CARE SHOULD BE EXERCISED WHILE SERVICING
BRAKE ASSEMBLIES OR COMPONENTS. DO NOT
CLEAN BRAKE ASSEMBLIES OR COMPONENTS
WITH COMPRESSED AIR OR BY DRY BRUSHING.
USE A VACUUM CLEANER SPECIFICALLY RECOM-
MENDED FOR USE WITH ASBESTOS FIBERS. IF A
SUITABLE VACUUM CLEANER IS NOT AVAILABLE,
SERVICE
Page
Diagnosing Brake Problems
Diagnosis Procedures
Master Cylinder/Power Booster Test
DIAGNOSIS PROCEDURES
B r a k e diagnosis involves d e t e r m i n i n g i f t h e prob-
l e m is related to a mechanical, h y d r a u l i c or v a c u u m
operated component. A p r e l i m i n a r y check, road test-
i n g and component inspection can a l l be used to de-
t e r m i n e a problem cause.
Road testing w i l l either verify proper b r a k e opera-
t i o n or confirm the existence of a problem. Compo-
n e n t inspection w i l l , i n most cases, identify t h e
actual p a r t causing a problem.
The first diagnosis step is the p r e l i m i n a r y check.
T h i s involves inspecting fluid level, p a r k i n g brake
action, wheel and t i r e condition, checking for obvious
leaks or component damage and testing b r a k e pedal
response. A road test w i l l confirm or deny t h e exist-
ence of a problem. The f i n a l diagnosis procedure i n -
volves road test analysis and a v i s u a l inspection of
brake components.
PRELIMINARY BRAKE CHECK
(1) Check condition of tires and wheels. Damaged
wheels and w o r n , damaged, or underinflated t i r e s
can cause p u l l , shudder, t r a m p , and a condition si-
m i l i a r to grab.
(2) I f complaint was based on noise w h e n b r a k i n g ,
check suspension components. Jounce f r o n t and rear
of vehicle and listen for noise t h a t m i g h t be caused
by loose, w o r n or damaged suspension or steering
components.
•
CLEANING SHOULD BE DONE WET USING A WA-
TER DAMPENED CLOTH. DO NOT CREATE DUST
BY SANDING, GRINDING, AND/OR SHAVING
BRAKE LININGS OR PADS UNLESS SUCH OPERA-
TION IS DONE WHILE USING PROPERLY EXHAUST
VENTILATED EQUIPMENT. DISPOSE OF ALL DUST
AND DIRT SUSPECTED TO CONTAIN ANY ASBES-
TOS FIBERS IN SEALED BAGS OR CONTAINERS
TO MINIMIZE DUST EXPOSURE TO YOURSELF AND
OTHERS. FOLLOW ALL RECOMMENDED PRAC-
TICES PRESCRIBED BY THE OCCUPATIONAL
SAFETY AND HEALTH ADMINISTRATION AND THE
ENVIRONMENTAL PROTECTION AGENCY FOR THE
HANDLING, PROCESSING, AND DISPOSITION OF
DUST OR DIRT WHICH MAY CONTAIN ASBESTOS
FIBERS.
DIAGNOSIS
INDEX
Page
3 Power Booster Check Valve Vacuum Test 5
2 Power Booster Vacuum Test . . . . . . . . . . . . . . . . . 5
4
(3) Inspect brake fluid level a n d condition. Note
t h a t the f r o n t disc brake reservoir fluid level w i l l
drop i n proportion to n o r m a l l i n i n g wear.
(a) I f fluid level is a b n o r m a l l y low, look for ev-
idence of leaks at calipers, w h e e l cylinders, brake-
lines and master cylinder.
(b) I f fluid appears contaminated, d r a i n out a
sample. I f fluid is separated i n t o layers, or obvi-
ously contains o i l or a substance other t h a n brake
fluid, the system seals and cups w i l l have to be re-
placed and the h y d r a u l i c system flushed.
(4) Check p a r k i n g brake operation. Verify free
movement and f u l l release of cables and pedal. Also
note i f vehicle was being operated w i t h p a r k i n g
brake p a r t i a l l y applied.
(5) Check brake pedal operation. V e r i f y t h a t pedal
does not b i n d and has adequate free play. I f pedal
lacks free play, check pedal and power booster for be-
i n g loose or for b i n d condition. Do not road test u n t i l
condition is corrected.
(6) I f components checked appear O K , road test the
vehicle.
ROAD TESTING
(1) I f complaint involved l o w brake pedal, p u m p
the pedal and note i f the pedal comes back up to nor-
m a l height.
(2) Check brake pedal response w i t h transmission
i n N e u t r a l and engine r u n n i n g . Pedal should r e m a i n
f i r m under steady foot pressure.
 • BRAKES
(3) D u r i n g road test, make n o r m a l and f i r m b r a k e
stops i n 25-40 m p h (40-64 Km/h) range. Note f a u l t y
brake operation such as p u l l , grab, drag, noise, l o w
pedal, h a r d pedal, fade, pedal pulsation, etc.
(4) Inspect suspect brake components a n d refer t o
problem diagnosis i n f o r m a t i o n for causes o f various
brake conditions.
COMPONENT INSPECTION
F l u i d leak points and dragging brake u n i t s can
u s u a l l y be located w i t h o u t r e m o v i n g a n y compo-
nents. The area around a leak p o i n t w i l l be w e t w i t h
f l u i d . The components a t a dragging b r a k e u n i t
(wheel, t i r e , rotor) w i l l be quite w a r m or h o t to t h e
touch.
Other brake problem conditions w i l l require compo-
n e n t removal for proper inspection. Raise t h e vehicle
and remove the necessary wheels for better v i s u a l ac-
cess.
DIAGNOSING BRAKE PROBLEMS
PEDAL FALLS AWAY
A brake pedal t h a t falls away under steady foot
pressure is generally the result o f a system l e a k . T h e
leak point could be a t a brakeline, f i t t i n g , hose, or
caliper. I n t e r n a l leakage i n t h e master cylinder
caused by w o r n or damaged piston cups, m a y also be
t h e problem cause.
I f leakage is severe, fluid w i l l be evident a t or
around t h e l e a k i n g component. However i n t e r n a l
leakage i n t h e master cylinder w i l l not be physically
evident. Refer to t h e cylinder test procedure i n t h i s
section.
LOW PEDAL
I f a low pedal is experienced, p u m p t h e pedal sev-
e r a l times. I f the pedal comes back up, w o r n l i n i n g
and w o r n rotors or drums are t h e l i k e l y causes.
A decrease i n fluid level i n the master cylinder res-
ervoirs may only be the result of n o r m a l l i n i n g wear.
F l u i d level can be expected to decrease i n p r o p o r t i o n
to wear. I t is a result of t h e o u t w a r d movement o f
caliper and wheel cylinder pistons to compensate for
n o r m a l wear. Top off t h e reservor fluid level a n d
check brake operation to verify proper operation.
SPONGY PEDAL
A spongy pedal is most often caused by a i r i n t h e
system. T h i n brake drums or substandard b r a k e
lines a n d hoses can also cause a spongy pedal. T h e
proper course of action is to bleed t h e system and re-
place t h i n drums and suspect q u a l i t y brake lines a n d
hoses.
HARD PEDAL OR HIGH PEDAL EFFORT
A h a r d pedal or h i g h pedal effort m a y be due t o
l i n i n g t h a t is water soaked, contaminated, glazed, or
5 - 3
badly w o r n . The power booster or check valve could
also be faulty. Test t h e booster a n d valve as de-
scribed i n t h i s section.
BRAKE DRAG
B r a k e drag occurs w h e n t h e l i n i n g is i n constant
contact w i t h t h e rotor or d r u m . D r a g can occur a t
one wheel, a l l wheels, fronts only, or rears only. I t is
a product of incomplete brakeshoe release. D r a g can
be m i n o r or severe enough to overheat t h e l i n i n g s ,
rotors and drums.
B r a k e drag also has a direct effect o n fuel economy.
I f undetected, m i n o r brake drag can be misdiagnosed
as a n engine or transmission/torque converter prob-
lem.
M i n o r drag w i l l u s u a l l y cause s l i g h t surface char-
r i n g o f the l i n i n g . I t can also generate h a r d spots i n
rotors a n d drums from t h e overheat-cool down pro-
cess. I n most cases, t h e rotors, drums, wheels a n d
t i r e s are quite w a r m t o t h e touch after t h e vehicle is
stopped.
Severe drag can char t h e brake l i n i n g a l l t h e w a y
t h r o u g h . I t can also distort and score rotors a n d
d r u m s to t h e point of replacement. T h e wheels, tires
and brake components w i l l be extremely hot. I n se-
vere cases, the l i n i n g may generate smoke as i t chars
f r o m overheating.
Some common causes of brake drag are: seized or
i m p r o p e r l y adjusted p a r k i n g brake cables, loose/worn
wheel bearing, seized caliper or wheel cylinder pis-
t o n , caliper b i n d i n g on corroded bushings or rusted
slide surfaces, loose caliper m o u n t i n g bracket, d r u m
brakeshoes b i n d i n g on w o r n or damaged support
plates, or misassembled components.
I f brake drag occurs a t a l l wheels, the problem m a y
be related to a blocked master cylinder r e t u r n port or
f a u l t y power booster (binds-does not release).
BRAKE FADE
B r a k e fade is a product of overheating caused by
brake drag. However, brake overheating a n d subse-
quent fade can also be caused by r i d i n g t h e brake
pedal, m a k i n g repeated h i g h deceleration stops i n a
short t i m e span, or constant b r a k i n g on steep m o u n -
t a i n roads. Refer to t h e Brake D r a g i n f o r m a t i o n i n
t h i s section for additional causes.
PEDAL PULSA TION
Pedal pulsation is caused by components t h a t are
loose, or w o r n beyond tolerance l i m i t s .
Disc brake rotors w i t h excessive l a t e r a l r u n o u t or
thickness v a r i a t i o n , or out of round brake d r u m s are
t h e p r i m a r y causes of pulsation. Other causes are
loose wheel bearings or calipers and w o r n , damaged
tires.
5 - 4 BRAKES
PULL
A f r o n t p u l l condition could be t h e r e s u l t o f con-
t a m i n a t e d l i n i n g i n one caliper, seized caliper piston,
b i n d i n g caliper, loose caliper, loose or corroded slide
pins, improper brakeshoes, or a damaged rotor.
A w o r n , damaged wheel b e a r i n g or suspension
component are f u r t h e r causes of p u l l . A damaged
front t i r e (bruised, p l y separation) can also cause
pull.
A common and frequently misdiagnosed p u l l condi-
t i o n is where direction o f p u l l changes after a few
stops. T h e cause is a combination o f brake d r a g fol-
lowed b y fade a t one o f the brake u n i t s .
As the d r a g g i n g b r a k e overheats, efficency i s so re-
duced t h a t fade occurs. Since the opposite b r a k e u n i t
is s t i l l f u n c t i o n i n g n o r m a l l y , i t s b r a k i n g effect is
magnified. T h i s causes p u l l t o switch direction i n fa-
vor of t h e n o r m a l l y f u n c t i o n i n g brake u n i t .
W h e n diagnosing a change i n p u l l condition, r e -
member t h a t p u l l w i l l r e t u r n t o the o r i g i n a l d i r e c t i o n
i f the d r a g g i n g brake u n i t is allowed t o cool down
(and is not seriously damaged).
REAR BRAKE GRAB OR PULL
Rear grab or p u l l is u s u a l l y caused by a n i m p r o p -
e r l y adjusted or seized p a r k i n g brake cable, contam-
inated l i n i n g , bent or b i n d i n g shoes a n d support
plates, or i m p r o p e r l y assembled components. T h i s is
p a r t i c u l a r l y t r u e w h e n only one rear wheel i s i n -
volved. However, w h e n both rear wheels are affected,
the master cylinder or p r o p o r t i o n i n g valve could be
at f a u l t .
BRAKES DO NOT HOLD AFTER DRIVING
THROUGH DEEP WA TER PUDDLES
T h i s condition is generally caused b y water soaked
l i n i n g . I f the l i n i n g is only wet, i t can be d r i e d b y
d r i v i n g w i t h the brakes l i g h t l y applied for a m i l e or
two. However, i f the l i n i n g is both wet and d i r t y , dis-
assembly a n d cleaning w i l l be necessary.
BRAKE NOISE
Squeak/Squeal
B r a k e squeak or squeal may be due to l i n i n g s t h a t
are wet or contaminated w i t h brake fluid, grease, or
o i l . Glazed l i n i n g s a n d rotors w i t h h a r d spots can
also contribute to squeak. D i r t and foreign m a t e r i a l
embedded i n the brake l i n i n g can also cause squeak/
squeal.
A very loud squeak or squeal is frequently a sign
of severely w o r n brake l i n i n g . I f the l i n i n g has w o r n
t h r o u g h to t h e brakeshoes i n spots, metal-to-metal
contact occurs. I f the condition is allowed to continue,
rotors can become so scored t h a t replacement is nec-
essary.
•
Thump/Clunk
T h u m p i n g or c l u n k noises d u r i n g b r a k i n g are fre-
q u e n t l y n o t caused b y b r a k e components. I n m a n y
cases, such noises are caused b y loose or damaged
steering, suspension, or engine components. How-
ever, calipers t h a t b i n d o n t h e slide pins can gener-
ate a t h u m p or clunk noise. I n a d d i t i o n , w o r n out,
improperly adjusted, or i m p r o p e r l y assembled rear
brakeshoes can also produce noise a t h u m p noise.
Chatter
B r a k e chatter is usually caused b y loose or w o r n
components, or glazed/burnt l i n i n g . Rotors w i t h h a r d
spots can also contribute t o chatter. A d d i t i o n a l
causes o f chatter are out-of-tolerance rotors, brake
l i n i n g not securely attached t o the shoes, loose wheel
bearings and contaminated brake l i n i n g .
BRAKELINING CONTAMINATION
B r a k e l i n i n g contamination is u s u a l l y a product o f
l e a k i n g calipers or wheel cylinders, d r i v i n g t h r o u g h
deep water puddles, or l i n i n g t h a t has become cov-
ered w i t h grease and g r i t d u r i n g repair.
WHEEL AND TIRE PROBLEMS
Some conditions a t t r i b u t e d to b r a k e components
may actually be caused b y a wheel or t i r e problem.
A damaged wheel can cause shudder, v i b r a t i o n and
p u l l . A w o r n or damaged t i r e can also cause p u l l .
Severely w o r n tires w i t h very l i t t l e t r e a d left can
produce a grab-like condition as the t i r e loses and re-
covers t r a c t i o n .
Flat-spotted tires can cause v i b r a t i o n a n d wheel
t r a m p and generate shudder d u r i n g b r a k e operation.
A t i r e w i t h i n t e r n a l damage such as a severe
bruise or p l y separation can cause p u l l a n d v i b r a t i o n .
MASTER CYLINDER/POWER BOOSTER TEST
(1) S t a r t engine a n d check booster v a c u u m hose
connections. Hissing noise indicates v a c u u m leak.
Correct any v a c u u m leak before proceeding.
(2) Stop engine a n d shift transmission i n t o N e u -
tral.
(3) Pump brake pedal u n t i l a l l v a c u u m reserve i n
booster is depleted.
(4) Press a n d hold brake pedal under l i g h t foot
pressure.
(a) I f pedal holds firm, proceed to step (5).
(b) I f pedal does not hold firm a n d falls away,
master cylinder is f a u l t y ( i n t e r n a l leakage).
(5) S t a r t engine and note pedal action.
(a) I f pedal falls away s l i g h t l y under l i g h t foot
pressure t h e n holds firm, proceed t o step (6).
(b) I f no pedal action is discernible, power
booster or vacuum check valve is f a u l t y . I n s t a l l
k n o w n good check valve a n d repeat steps (2)
t h r o u g h (5).
 • BRAKES 5 -S

(6) R e b u i l d booster v a c u u m reserve as follows: Re- POWER BOOSTER VACUUM TEST

lease b r a k e pedal. Increase engine speed t o 1500
(1) Connect a v a c u u m gauge t o t h e booster check
r p m , close t h e t h r o t t l e and immediately t u r n off i g -
valve w i t h a short l e n g t h of hose and a T - f i t t i n g (Fig.
nition.
3).
(7) W a i t a m i n i m u m o f 90 seconds and t r y b r a k e
(2) S t a r t a n d r u n engine a t idle speed for one
action again. Booster should provide t w o or more
minute.
v a c u u m assisted pedal applications. I f v a c u u m assist
(3) C l a m p hose shut between vacuum source a n d
is not provided, perform booster and check valve vac-
check valve (Fig. 3).
u u m tests.
(4) Stop engine and observe v a c u u m gauge.
(5) I f v a c u u m drops more t h a n one i n c h H G (33
POWER BOOSTER CHECK VALVE TEST m i l l i b a r s ) w i t h i n 15 seconds, either booster dia-
(1) Disconnect the v a c u u m hose f r o m check valve. p h r a g m or check valve are faulty.
(2) Remove check valve and valve seal from booster SHORT
(Fig. 1). CONNECTING CHECK
(3) H a n d operated v a c u u m pump can be used for
test (Fig. 2).
(4) A p p l y 15-20 inches (50-67 kPa) v a c u u m a t large
end o f check valve (Fig. 1).
(5) V a c u u m should h o l d steady. I f gauge o n p u m p
indicates a n y v a c u u m loss, valve is f a u l t y and m u s t
be replaced.
BOOSTER
CHECK

VACUUM
GAUGE
J9005-81

Fig. 3 Typical Booster Vacuum Test Connections

Fig. 1 Vacuum Check Valve And Seal (Typical)

Fig. 2 Hand Operated Vacuum Pump (Typical)

5 - 6 BRAKES
SERVICE ADJUSTMENTS
Page
Brake Fluid And Level •."
Brake System Bleeding
Rear Brake Adjustment
BRAKE FLUID AND LEVEL
RECOMMENDED FLUID
The only brake fluid recommended for A D models
is M o p a r b r a k e fluid, or a n equivalent fluid meeting
SAE J1703 and DOT 3 standards.
U s e n e w b r a k e fluid only, to top off the m a s t e r
c y l i n d e r o r refill t h e system. Never, u s e re-
c l a i m e d fluid, fluid n o t meeting the S A E / D O T
s t a n d a r d s , fluid m a r k e d 70R1, o r fluid from a
c o n t a i n e r t h a t h a s been left open for a n y length
of time. U s i n g non r e c o m m e n d e d o r unspecified
fluid c a n r e s u l t i n b r a k e failure after h a r d pro-
longed b r a k i n g .
BRAKE FLUID LEVEL
A l w a y s clean t h e master cylinder cover before
checking fluid level. I f not cleaned, d i r t f r o m t h e
cover could enter the fluid. Also check the cover seal
and replace i t i f torn or distorted.
Correct fluid level is to the bottom of the r i n g i n -
dicators on models w i t h a plastic reservoir and to
w i t h i n 1/4 i n c h of the reservoir r i m on a l l others.
I f necessary, add f l u i d to b r i n g up to t h e proper
level. Note t h a t on disc brake equipped vehicles,
fluid level can be expected to fall as the brake pads
wear.
BRAKE FLUID CONTAMINATION
O i l i n t h e fluid w i l l cause brake system rubber
seals to soften and swell. The seals may also become
porous and begin to deteriorate.
I f fluid contamination is suspected, drain off a sam-
ple f r o m the master cylinder. A suction gun can or
s i m i l a r device can be used for t h i s purpose.
E m p t y t h e drained fluid i n t o a glass container.
C o n t a m i n a n t s i n the fluid w i l l cause the fluid to sep-
arate i n t o d i s t i n c t layers. I f contamination has oc-
curred, the system rubber seals, hoses and cups must
be replaced and the system thoroughly flushed w i t h
clean brake fluid.
•
INDEX
Page
6 Stop Lamp Switch Adjustment 8
7 Wheel Nut Tightening 8
6
REAR BRAKE ADJUSTMENT
The rear d r u m brakes are equipped w i t h a self ad-
j u s t i n g mechanism. U n d e r n o r m a l circumstances, t h e
only t i m e adjustment is required i s w h e n t h e brake-
shoes are replaced; removed for access t o other parts;
or w h e n one or b o t h drums are replaced.
Adjustment can be performed w i t h a standard
brake gauge or w i t h adjusting tool C-3784.
ADJUSTMENT WITH STANDARD BRAKE
GAUGE
(1) Verify t h a t the left/right automatic adjuster le-
ver and cable are properly connected a n d t h a t t h e
p a r k i n g brakes are f u l l y released. Be sure there is
slack i n the cables.
(2) Insert t h e brake gauge i n the d r u m . E x p a n d t h e
gauge u n t i l t h e gauge i n n e r legs contact t h e d r u m
b r a k i n g surface. T h e n lock t h e gauge i n position
(Fig. 1).
Fig. 1 Adjusting Gauge To Brake Drum
(3) Reverse the gauge and i n s t a l l i t o n t h e brake-
shoes (Fig. 2). Position t h e gauge legs a t t h e shoe
centers as shown. I f the gauge does not f i t (too loose/
too t i g h t ) , adjust the shoes.
(4) P u l l the shoe adjuster star wheel away from the
automatic adjuster lever.
 • BRAKES
(5) T u r n t h e adjuster star wheel (by hand) to ex-
pand or r e t r a c t the brakeshoes. Continue adjustment
u n t i l the gauge outside legs are a l i g h t drag-fit o n
t h e shoes (Fig. 2). , :
BRAKE SHOES
Fig. 2 Adjusting Brakeshoes To Gauge
(6) Repeat adjustment a t the opposite brakeshoe as-
sembly.
(7) I n s t a l l t h e brake drums and wheels a n d lower
the vehicle.
(8) Make f i n a l adjustment. D r i v e vehicle a n d make
one forward stop followed by one reverse stop. Repeat
procedure 8-10 times to actuate adjuster mechanism
and equalize adjustment. B r i n g vehicle to complete
standstill a t each stop. Incomplete, r o l l i n g stops w i l l
not activate t h e automatic adjusters.
ADJUSTMENT WITH TOOL C-3784
(1) Release p a r k i n g brakes f u l l y , i f applied. Be sure
there is slack i n t h e cables.
(2) Raise vehicle so a l l wheels are free to t u r n .
(3) Remove rubber plugs from access holes i n sup-
port plates.
(4) Insert a d j u s t i n g Tool C-3784 i n t o star wheel of
adjuster screw. T u r n star wheel counterclockwise
(move tool u p w a r d ) u n t i l a slight drag is felt w h e n
road wheel i s rotated.
(5) Insert a t h i n screwdriver or l e n g t h of w e l d i n g
rod into support plate access hole a n d push adjuster
lever out o f engagement w i t h star wheel (Fig. 3). Do
not bend t h e lever or distort the lever spring.
(6) H o l d adjuster lever away from star wheel. Then
back off star wheel t o u n t i l shoe drag on the d r u m is
eliminated.
(7) Repeat above adjustment a t the opposite wheel.
Be sure adjustment is equal.
(8) I n s t a l l access hole plugs i n support plate.
(9) Adjust t h e p a r k i n g brake after wheel brake ad-
justment.
(10) M a k e f i n a l adjustment. D r i v e vehicle a n d
make one f o r w a r d stop followed by one reverse stop.
Repeat procedure 8-10 times to actuate adjuster
5 - 7
mechanism a n d equalize adjustment. B r i n g vehicle t o
complete s t a n d s t i l l a t each stop. Incomplete, r o l l i n g
stops w i l l not activate t h e automatic adjusters.
Fig. 3 Rear Brake Adjustment With Tool C-3784
TESTING DRUM BRAKE ADJUSTER
OPERATION
Place t h e vehicle on a hoist, w i t h a helper i n t h e
d r i v e r seat t o apply the brakes.
(2) Remove t h e access plugs from t h e support
plates.
(3) Back off the adjuster screw star wheel approxi-
m a t e l y 30 notches.
(4) Observe t h e adjuster screw star wheel and spin
t h e d r u m a n d road wheel wheel rapidly i n t h e re-
verse direction. Have t h e helper apply t h e brakes
w i t h q u i c k l y and w i t h more t h a n n o r m a l force. F i r m
b r a k e application w i l l cause t h e secondary shoe to
move a n d engage t h e r o t a t i n g d r u m . The r e s u l t i n g
shoe wrap-up effect should move t h e secondary shoe
enough t o cause the adjuster cable to p u l l t h e ad-
j u s t e r lever u p and t u r n t h e star wheel.
BRAKE SYSTEM BLEEDING
The brake system can be bled m a n u a l l y or w i t h
pressure equipment. M a n u a l bleeding requires t h e
a i d o f a helper. Pressure equipment allows t h e sys-
t e m t o be bled by one person.
A l l models are equipped w i t h a front brake meter-
i n g (hold off) valve. The m e t e r i n g valve is located
w i t h i n t h e combination valve. The m e t e r i n g valve
balances brake action between t h e front disc a n d
rear d r u m brakes d u r i n g i n i t i a l brake application.
The m e t e r i n g valve is designed to hold off f l u i d
flow t o t h e f r o n t disc brakes a t pressures between 3
a n d 135 p s i (20.68 a n d 930.8 kPa). The pressures
generated b y g r a v i t y or m a n u a l type bleeding tech-
niques w i l l n o t affect t h e valve. However, pressure
bleeding equipment w i l l generate enough fluid pres-
sure (20 t o 30 psi) to close t h e valve a n d prevent
5 - 8 BRAKES •
fluid flow to t h e front brakes. A s a result, t h e valve (8) Continue bleeding operations i n t h e recom-
m u s t be h e l d open w i t h special tool C-4121 w h e n us- mended sequence a t the wheel brake u n i t s .
i n g pressure bleeding equipment. (9) Repeat the bleeding procedure i f the system i n -
dicator l i g h t s r e m a i n on or i f the pedal is spongy.
BLEEDING PROCEDURE
(1) I f a new or overhauled master cylinder w i l l be
used, be sure to bleed t h e cylinder before i n s t a l l i n g i t
i n t h e vehicle. Refer t o t h e procedure i n the Master
Cylinder section.
(2) I f master cylinder has not been serviced, clean
a l l d i r t a n d foreign m a t e r i a l from master cylinder
and cover t o prevent d i r t e n t e r i n g t h e cylinder reser-
voirs. T h e n remove the cover.
(3) I f pressure bleeding t a n k C-3496-B w i l l be used,
i n s t a l l adapter C-4578 o n t h e master cylinder and
prepare t h e t a n k for bleeding according to instruc-
tions provided b y the supplier.
(4) I f pressure bleeding equipment w i l l be used, Fig. 4 Metering Valve Tool C-4121
hold the m e t e r i n g valve open w i t h tool C-4121. T h e
WHEEL NUT TIGHTENING
tool is i n s t a l l e d on the valve stem t o h o l d i t (and the
valve) open (Fig. 4). The wheel a t t a c h i n g nuts m u s t be tightened prop-
e r l y t o ensure efficient brake operation. O v e r t i g h t e n -
CAUTION: Under no condition should a rigid clamp, i n g t h e n u t s or t i g h t e n i n g t h e m i n t h e w r o n g
wedge or block be used to press the valve stem in- sequence can cause distortion o f t h e brake rotors a n d
ward tyo hold the valve open. This practice could drums.
damage the valve resulting in valve failure and Impact wrenches are not recommended for t i g h t e n -
complete loss of front brake action. Note that the i n g wheel nuts. A torque wrench should be used for
valve stem is in its innermost position when there t h i s purpose a t a l l times.
is no pressure present. No attempt should be made The correct t i g h t e n i n g sequence is i m p o r t a n t i n
to further depress the valve stem. avoiding rotor and d r u m d i s t o r t i o n . The correct se-
quence is i n a diagonal crossing p a t t e r n (Fig. 5).
(5) Bleed t h e system i n the f o l l o w i n g sequence and
Seat t h e wheel and i n s t a l l t h e wheel nuts finger
bleed only one wheel or valve a t a t i m e :
t i g h t . T i g h t e n t h e nuts i n t h e sequence t o 1/2 re-
• R W A L h y d r a u l i c valve
q u i r e d torque. T h e n repeat the t i g h t e n i n g sequence
• r i g h t rear wheel
to final specified torque.
• left rear wheel
• r i g h t f r o n t wheel
• left f r o n t wheel
(6) Clean the bleed screw on the R W A L h y d r a u l i c
valve. Connect a bleed hose to the screw and insert
the opposite e n d of the bleed hose i n a glass con-
tainer p a r t i a l l y filled w i t h brake fluid. Be sure t h e
end o f the bleed hose is f u l l y submerged i n fluid oth-
erwise a i r w i l l be d r a w n back i n t o t h e system.
(7) Perform bleeding operations as follows:
(a) I f m a n u a l b l e e d i n g , have the helper press
the brake pedal to the floorpan. T i g h t e n the bleed
screw a t t h i s p o i n t and and have the helper release
the pedal. Open t h e bleed screw a n d have t h e
helper press the pedal down again. Continue bleed-
i n g u n t i l only clear, bubble free fluid flows i n t o the
container. Move on t o t h e r i g h t rear wheel after
valve bleeding is completed. Fig. 5 Wheel Nut Tightening Sequence
(b) I f p r e s s u r e b l e e d i n g , open t h e bleed screw STOP LAMP SWITCH ADJUSTMENT
and allow fluid to flow t h r o u g h t h e valve. Stop
bleeding w h e n only clear, bubble free fluid flows The stop l a m p (or stop lamp/speed control) s w i t c h
into the fluid container. and m o u n t i n g bracket assembly is attached t o t h e
• BRAKES
brake pedal bracket. The s w i t c h is actuated by the
brake pedal blade on a l l models and is adjusted as
follows:
WITHOUT SPEED CONTROL
(1) Loosen switch assembly to pedal bracket attach-
i n g screw and slide assembly away from pedal blade
or s t r i k e r plate.
(2) Push brake pedal down a n d allow to r e t u r n to
free position, do not p u l l brake pedal back a t any
time.
(3) Place appropriate spacer gauge on pedal brake.
(4) Slide switch assembly t o w a r d pedal blade u n t i l
switch plunger is f u l l y depressed against spacer
gauge w i t h o u t m o v i n g the pedal.
5 - 9
(5) R e t i g h t e n t h e switch bracket screw to 9 N»m
(82 in-lbs).
(6) Remove spacer. Be sure t h a t stop lamp switch
does not prevent f u l l pedal r e t u r n . Incomplete pedal
r e t u r n can cause brake d r a g and premature l i n i n g
and rotor wear.
WITH SPEED CONTROL
(1) Push s w i t c h t h r o u g h clip i n m o u n t i n g bracket
u n t i l s w i t c h is sealed against bracket. The brake
pedal w i l l move f o r w a r d s l i g h t l y .
(2) Gently p u l l back on the brake pedal as far as i t
w i l l go.
(3) The s w i t c h w i l l ratchet backwards to the correct
position a n d no f u r t h e r adjustment is required.
5-10 BRAKES •

MASTER CYLINDER—COMBINATION V A L V E - B R A K E L I N E S
INDEX
Page Page
Brake Lines And Hoses . 13 Master Cylinder Bleeding 12
Combination Valve Operation 13 Master Cylinder Installation 12
Combination Valve Removal/Installation . 13 Master Cylinder Overhaul—Integral Cylinder . . . . . 11
Combination Valve Testing . . . . . . . . . . . . . . . . . . 13 Master Cylinder Removal 11
General Information ............. 10 Master Cylinder Service—Two-Section Cylinder . . 11

GENERAL INFORMATION
Two master cylinders are used o n A D t r u c k mod-
els. A two-section master cylinder w i t h a removable
reservoir is used on D a n d W 100/150 models (Fig. 1).
A n i n t e g r a l (one-piece) master cylinder w i t h b u i l t - i n
fluid reservoirs is used on D a n d W 250/350 models
(Fig. 2).

Two-Section Master Cylinder

The two-section master cylinder consists o f the cyl-
inder body and a removable fluid reservoir. The p r i -
m a r y and secondary pistons are located i n t h e
a l u m i n u m body section. The removable reservoir is
made of n y l o n reinforced w i t h glass fiber a n d i s t h e Fig. 1 Two-Section Master Cylinder
only serviceable component. CLAMP COVER
The fluid compartments of the n y l o n reservoir are
interconnected to p e r m i t fluid level equalization.
However, t h e equalization feature does not affect cir-
cuit separation i n t h e event o f a front/rear brake
malfunction. The reservoir compartments are de-
signed t o r e t a i n t h e necessary q u a n t i t y o f fluid
needed to operate t h e f u n c t i o n i n g c i r c u i t .
Care m u s t be excercised w h e n removing/installing
the master cylinder connecting lines. T h e threads i n
the fluid ports can be damaged i f care i s n o t prac-
ticed. S t a r t a l l brake l i n e f i t t i n g s b y h a n d t o avoid
cross threading.
The a l u m i n u m b o d y section o f t h e master cyl-
inder is n o t a r e p a i r a b l e component. I f diagnosis
OUTLETS MASTER CYLINDER BODY RF494
i n d i c a t e s t h a t a n i n t e r n a l m a l f u n c t i o n h a s oc-
curred, t h e a l u m i n u m b o d y section m u s t b e re-
Fig. 2 Integral Master Cylinder
p l a c e d as a n a s s e m b l y .

Integral Master Cylinder

The cast, one-piece master cylinder is a v e n t i n g
type w i t h i n t e g r a l fluid reservoirs. T h e p r i m a r y and
secondary piston assemblies are located i n t h e cylin-
der bore. The cylinder i s a f u l l y serviceable compo-
nent and can be overhauled w h e n necessary.
 • BRAKES 5 - 11

Combination Valve
A two-way combination v a l v e is used on a l l A D RESERVOIR
models (Fig. 3). The two-way valve contains a front
b r a k e m e t e r i n g valve a n d a pressure differential
valve and switch.
FROM MASTER CYLINDER SWITCH ASSEMBLY
(FOR FRONT DISC) FROM MASTER
OUTLET TO
FRONT BRAKE CYLINDER
(FOR REAR DRUM)
SLEEVE
VALVE
SUM

Fig. 4 Removing/Installing Cylinder Reservoir

(6) Remove and discard t h e grommets t h a t secure
the reservoir i n the cylinder body.
OUTLET (7) I n s t a l l new reservoir grommets i n the cylinder
SPRING TO body.
REAR
CHECK (8) Lubricate t h e n e w reservoir grommets w i t h
OUTLET TO DIFFERENTIAL ^ ^ ™ BRAKES
VALVE J t
clean brake f l u i d .
FRONT BRAKE PISTON a W N G
RN1053

Fig. 3 Two-Way Combination Valve
MASTER CYLINDER REMOVAL
(1) Disconnect t h e p r i m a r y a n d secondary b r a k e
tubes a t the master cylinder.
(2) I n s t a l l plugs i n t h e c y l i n d e r o u t l e t ports a n d
b r a k e tubes t o prevent d i r t e n t r y .
(3) Remove t h e n u t s a t t a c h i n g master cylinder t o
t h e power brake booster.
(4) Remove t h e master c y l i n d e r f r o m thfe power
b r a k e booster m o u n t i n g studs.
MASTER CYLINDER SERVICE—TWO-SECTION
CYLINDER
T h e only s e r v i c e a b l e c o m p o n e n t o n t h e t w o -
section c y l i n d e r i s the n y l o n r e s e r v o i r . I f t h e c y l -
i n d e r body o r i n t e r n a l c o m p o n e n t s a r e w o r n o r
damaged, the c y l i n d e r b o d y m u s t b e r e p l a c e d a s
a n assembly.
RESERVOIR REPLACEMENT-TWO-SECTION
CYLINDER
(1) Clean t h e reservoir exterior a n d master c y l i n -
der body.
(2) Remove t h e reservoir caps a n d d r a i n a l l f l u i d
f r o m the reservoir.
(3) M o u n t the master cylinder i n a vise. C l a m p the
vise jaws on the a l u m i n u m body.
(4) Note position o f the reservoir before removal.
(5) Remove the reservoir b y f i r m l y r o c k i n g i t f r o m
side t o side (Fig. 4). Continue r o c k i n g u n t i l t h e res-
e r v o i r is free of the grommets.
CAUTION: The reservoir can be installed backwards
if care is not excercised. Install the reservoir so the
fluid fill information (on the reservoir side) is on the
same side as the fluid outlet ports in the cylinder
body (Fig. 4).
(9) S t a r t t h e reservoir into t h e grommets. Then
rock the reservoir side t o side u n t i l f u l l y seated. The
reservoir bottom surface should touch the grommets.
(10) Bleed t h e master cylinder before i n s t a l l i n g i t
on the vehicle. Refer t o the procedure i n t h i s section.
MASTER CYLINDER SERVICE-INTEGRAL
CYLINDER
The i n t e g r a l (one-piece) cylinder is a f u l l y service-
able component. I t can be overhauled t o restore per-
formance w h e n necessary. Overhaul procedure i s as
follows.
INTEGRAL CYLINDER DISASSEMBLY AND
INSPECTION
(1) Remove the cylinder cover (Fig. 5).
(2) D r a i n the f l u i d f r o m the cylinder reservoirs.
(3) M o u n t the cylinder i n a vise.
(4) Press t h e cylinder pistons i n w a r d w i t h a wood
dowel and remove the the piston snap r i n g (Fig. 6).
(5) Remove t h e p r i m a r y piston assembly from t h e
cylinder bore. Discard t h e piston assembly.
(6) I f cylinder is equipped w i t h piston stop screw
for secondary piston, remove the stop screw before
proceeding.
5-12 BRAKES
(7) Remove the secondary p i s t o n w i t h compressed
a i r applied t h r o u g h t h e b r a k e l i n e port o r t h e com-
pensator port a t the b o t t o m o f t h e reservoir. Discard
t h e piston assembly after removal.
COVER COVER
CLAMP RF495
Fig. 5 Removing/Installing Cylinder Cover
Fig. 6 Integral Cylinder Components
Cylinder Cleaning And Inspection
Clean the cylinder body and cover w i t h b r a k e f l u i d
or brake cleaner only. Do not use any other type of
solvents, or cleaning agent.
Inspect the cylinder body and bore. L i g h t discolor-
a t i o n of the cylinder bore is n o r m a l and is a n accept-
able condition. The bore should be smooth and free of
scores, scratches, corrosion and rust. Replace t h e cyl-
inder i f the bore is w o r n , scored, or corroded. D o n o t
h o n e t h e b o r e i n a n a t t e m p t t o restore t h e surface
f i n i s h . Replace the cylinder i f t h e bore is damaged i n
any way. Also replace t h e cylinder i f t h e body is
cracked, porous, or t h e compensator ports a t t h e bot-
t o m of each reservoir is blocked or damaged.
Inspect the cover a n d gasket. Replace t h e gasket i f
distorted, cut, or t o r n . Replace the cover a n d r e t a i n -
i n g w i r e i f either component is distorted or damaged
i n any way.
•
Do n o t reuse t h e o l d piston assemblies. Discard
these parts as soon as t h e y are removed. I n s t a l l r e -
placement p r i m a r y and secondary p i s t o n assemblies
only.
INTEGRAL CYLINDER ASSEMBLY
(1) Coat t h e cylinder bore a n d replacement piston
assemblies w i t h a l i b e r a l q u a n t i t y o f clean brake
fluid.
(2) I n s t a l l t h e secondary p i s t o n assembly i n t h e
bore w i t h a t u r n i n g m o t i o n . Do n o t use m e t a l tools o f
any k i n d t o help ease t h e p i s t o n i n t o place. Sharp
edge tools w i l l scratch t h e bore a n d c u t t h e piston.
(3) I f the c y l i n d e r i s equipped w i t h a stop screw for
the secondary piston, press t h e p i s t o n t o t h e b o t t o m
of the bore a n d i n s t a l l t h e screw.
(4) I n s t a l l t h e p r i m a r y piston i n t h e bore.
(5) Press t h e pistons i n w a r d w i t h a wood dowel and
i n s t a l l the piston snap r i n g . Be sure t h e snap r i n g is
f u l l y seated.
(6) I n s t a l l a new gasket on t h e cover i f necessary.
(7) I n s t a l l t h e cover r e t a i n i n g w i r e on the cylinder
i f removed.
(8) F i l l a n d bleed t h e master c y l i n d e r on the bench
and before i n s t a l l a t i o n o n t h e vehicle. Refer t o t h e
procedure i n t h i s section.
MASTER CYLINDER BLEEDING
Master cylinder bleeding should be performed on
the bench before i n s t a l l a t i o n i n t h e vehicle. For the
i n t e g r a l master cylinder, r e q u i r e d bleeding tools i n -
clude fabricated bleed tubes a n d a wood dowel. F o r
the two-section master cylinder, r e q u i r e d bleeding
tools include bleed tubes C-4029 a n d a wood dowel
(Fig. 7).
CYLINDER BLEEDING PROCEDURE
(1) M o u n t the master cylinder assembly i n a vise.
(2) A t t a c h t h e bleed tubes t o t h e cylinder outlet
ports and i n s e r t t h e tubes i n the reservoir f l u i d com-
partments (Fig. 7).
(3) F i l l t h e reservoir w i t h fresh brake f l u i d .
(4) Press t h e cylinder pistons i n w a r d w i t h a wood
dowel. T h e n release t h e pistons a n d allow t h e m to re-
t u r n under s p r i n g pressure. Continue bleeding oper-
ations u n t i l a i r bubbles are no longer visible i n the
fluid.
MASTER CYLINDER INSTALLATION
(1) Bleed master cylinder on bench before i n s t a l l a -
tion.
(2) Position master cylinder o n studs o f power
brake u n i t .
(3) A l i g n power brake push r o d w i t h master c y l i n -
der piston.
(4) I n s t a l l and t i g h t e n cylinder a t t a c h i n g nuts to
23 N*m (200 in-lbs).
 • BRAKES
Fig. 7 Master Cylinder Bleeding—Two-Section
Cylinder Shown
(5) Connect front and rear b r a k e l i n e s t o cylinder.
S t a r t brakeline fittings b y h a n d .
(6) T i g h t e n brakeline f i t t i n g s t o 19 N - m (170 i n -
lbs).
(7) Bleed brakes.
COMBINATION VALVE OPERATION
METERING (HOLD-OFF) VALVE
The m e t e r i n g valve is used t o balance brake action
between t h e front disc a n d r e a r d r u m brakes. T h e
valve meters (holds-off) f u l l apply pressure t o t h e
front disc brakes u n t i l the rear brakeshoes are i n f u l l
contact w i t h t h e drums. T h e valve is designed t o
m a i n t a i n f r o n t brake f l u i d pressure a t 3-30 psi u n t i l
t h e hold-off l i m i t of 117 psi is reached. A t t h i s p o i n t ,
t h e m e t e r i n g valve opens completly p e r m i t t i n g f u l l
f l u i d apply pressure t o the f r o n t disc brakes.
PRESSURE DIFFERENTIAL SWITCH AND VALVE
The pressure differential s w i t c h is connected t o t h e
brake w a r n i n g l i g h t . The s w i t c h i s triggered b y
movement o f t h e switch valve. T h e purpose o f t h e
switch is t o monitor fluid pressure i n t h e separate
front/rear brake h y d r a u l i c circuits.
A decrease or loss o f f l u i d pressure i n either h y -
draulic circuit w i l l cause the s w i t c h valve to s h u t t l e
forward or r e a r w a r d i n response t o a pressure differ-
e n t i a l . Movement of the s w i t c h valve w i l l push t h e
switch plunger upward. This closes t h e switch i n t e r -
n a l contacts completing the electrical circuit t o t h e
w a r n i n g l i g h t . The switch valve w i l l r e m a i n i n a n
actuated position u n t i l repair restores system pres-
sures t o n o r m a l levels.
COMBINATION VALVE TESTING
TESTING METERING VALVE
M e t e r i n g valve operation can be checked v i s u a l l y
and w i t h t h e a i d of a helper. Observe t h e m e t e r i n g
5-13
valve stem w h i l e a helper applys a n d releases t h e
brakes. I f t h e valve i s operating correctly, t h e stem
w i l l extend s l i g h t l y w h e n the brakes are applied and
retract w h e n the brakes are released. I f the valve is
faulty, replace the e n t i r e combination valve as a n as-
sembly.
TESTING PRESSURE DIFFERENTIAL SWITCH
(1) Have a helper s i t i n the drivers seat to observe
the brake w a r n i n g l i g h t a n d apply the brake pedal.
(2) Raise the vehicle o n a hoist.
(3) Connect a bleed hose t o one o f the rear wheel
cylinders a n d immerse t h e hose end i n a container
partially filled w i t h brake fluid.
(4) Have the helper press and hold the brake pedal
a l l the w a y down a n d observe the w a r n i n g l i g h t .
(a) I f the w a r n i n g l i g h t i l l u m i n a t e s , the switch
is operating correctly.
(b) I f the l i g h t fails to i l l u m i n a t e , check the cir-
cuit fuse, b u l b and w i r i n g . Repair as necessary and
repeat test steps (3) a n d (4).
(5) I f t h e w a r n i n g l i g h t s t i l l fails to i l l u m i n a t e ,
check the b r a k e l i g h t a n d p a r k i n g brake switches and
w i r i n g w i t h a test l a m p . Repair or replace parts as
necessary and test d i f f e r e n t i a l pressure switch oper-
ation again.
(6) I f t h e w a r n i n g l i g h t s t i l l does not i l l u m i n a t e ,
the switch i s f a u l t y . Replace t h e combination valve
assembly, bleed t h e b r a k e system and verify proper
switch and valve operation.
COMBINATION VALVE REMOVAL/INSTALLATION
VALVE REMOVAL
(1) Raise t h e vehicle o n a hoist.
(2) M a r k or t a g t h e brake lines connected t o t h e
valve for assembly reference.
(3) Disconnect the lines a t the valve (Fig. 8).
(4) Disconnect the wires f r o m the differential pres-
sure switch.
(5) Remove t h e bolts a t t a c h i n g the valve to frame
bracket and remove t h e valve.
(6) M o u n t t h e n e w valve on t h e bracket a n d
t i g h t e n the valve a n d bracket screws/nuts securely.
(7) Connect the brakelines t o t h e valve. T i g h t e n
the f i t t i n g s t o 16 N*m (145 in-lbs)
(8) Connect t h e wires t o t h e pressure differential
switch t e r m i n a l .
(9) Bleed the brakes.
(10) Lower the vehicle and verify proper brake op-
eration.
BRAKE LINES AND HOSES
BRAKE LINE AND HOSE INSPECTION
Flexible rubber hose is used at both front brakes
and a t the rear axle j u n c t i o n block. Inspect the hoses
5 - 14 BRAKES

whenever the brake system is serviced, a t every en-
gine o i l change, o r whenever the vehicle is i n for ser-
vice.
Inspect the hoses for surface c r a c k i n g , scuffing, or
w o r n spots. Replace a n y brake hose i m m e d i a t e l y i f
t h e fabric casing of t h e hose is exposed due t o cracks
or abrasions.
Also check brake hose i n s t a l l a t i o n . F a u l t y i n s t a l l a -
t i o n can result i n k i n k e d , t w i s t e d hoses, or contact
w i t h t h e wheels and t i r e s or other chassis compo-
nents. A l l o f these condition c a n lead t o scuffing,
cracking and eventual f a i l u r e .
The steel brake lines should be inspected periodi-
cally for evidence of corrosion, t w i s t s , k i n k s , leaks, or
other damage. H e a v i l y corroded lines w i l l e v e n t u a l l y
r u s t t h r o u g h causing leaks. I n any case, corroded or
damaged brake lines should be replaced.
BRAKE LINE AND HOSE REPLACEMENT
Factory replacement brake lines and hoses are rec-
ommended to ensure q u a l i t y , correct l e n g t h and su-
perior fatigue life. Care should be t a k e n to make
sure t h a t brake l i n e a n d hose m a t i n g surfaces are
clean and free f r o m nicks a n d burrs. Also remember
t h a t r i g h t and left brake hoses are not interchange-
able.
Use new copper seal washers a t a l l caliper connec-
tions ( F i g . 9). Be sure brake l i n e connections are
properly made (not cross threaded) and tightened to
recommended torque.
B r a k e l i n e r o u t i n g , connections and t i g h t e n i n g ref-
erence i n f o r m a t i o n is o u t l i n e d i n Figures 9 t h r o u g h
12.

MASTER FRAME RAIL

PREFERRED TORQUE
CYLINDER

§ 15 Nm (145 in-lbs)
11 Nm (100 ff-lbs)
(g) 19 Nm (170 in-lbs)

J9005-142

Fig. 8 Combination Valve Mounting

 en

Fig. 10 Rear Brake Lines And RWAL Components

 TUBE ASSEMBLY AAASTER BRACKET AND SHIELD
CYLINDER TO BRAKE TORQUE
VALVE REAR (SECONDARY) LET. NEWTON
POUNDS
METRES
145 IN. 16

35 FT. 47
BRAKE HOSE AND RWAL
SENSOR WIRING 170 IN. 19
XX
100 IN. 11
XX
125 IN. 14
XX

BRAKE VALVE TUBE

TO RIGHT FRONT
BRAKE HOSE

GASKET CO

VIEW IN DIRECTION
CJ1
OF ARROW A
8905-54
Fig. 11 Brake Lines—Two-Wheel Drive Models
 CJi

TORQUE
LET. NEWTON
POUNDS
METRES
C30

<A> 145 IN. 16 30

125 IN. 14

100 IN. 11

<D> 170 IN. 19 CLIP

RIGHT FRONT BRACKET AND SHIELD

<ypS
£ > SCREW
c r w w WHEEL BRAKE
^ HOSE ^

SCREW
/^FRONT
BRAKE VALVE TUBE >v
CUP TO FRONT BRAKE HOSE <*>
LEFT FRONT WHEEL
BRAKE TUBE BRAKE HOSE AND
LEFT FRONT
RIGHT BRAKE BRAKE HOSE RWAL SENSOR WIRING
^TUBE

60 FRONT AXLE

LEFT FRONT
BRAKE HOSE

< § > RIGHT

VIEW IN DIRECTION OF ARROW C
BRAKE TUBE < £ >
BRAKE HOSE

TUBE ASSEMBLY
TO BRAKE
BRACKET
VALVE <^> <^> SCREW
SCREW
44-8FD FRONT AXLE

BRAKE VALVE TUBE

VIEW IN DIRECTION OF ARROW A
TO FRONT BRAKE HOSE V A L V E

VIEW IN DIRECTION OF ARROW B ASSEMBLY 8905-55

Fig. 12 Brake Lines—Four-Wheel Drive Models

 • BRAKES 5-19

BRAKE LINE EMERGENCY REPAIR
Mopar preformed m e t a l b r a k e l i n e is recommended
and preferred for a l l repairs. However, double-wall
steel line can be used for emergency repair w h e n fac-
tory replacement parts are not readily available.
Special, heavy d u t y tube bending a n d flaring
equipment is r e q u i r e d t o prepare double w a l l brake
line. Special bending tools are needed to avoid k i n k -
i n g or t w i s t i n g m e t a l b r a k e l i n e . I n addition, special
flaring tools are needed t o provide the inverted-type,
double flare r e q u i r e d on m e t a l brake lines.
Use tool C-4047 t o provide t h e inverted, double
flare (Fig. 8). Heavy d u t y tube bending tools are
available t h r o u g h t h e dealer tool program.
compression disc over gauge and center tapered flar-
i n g screw i n recess o f compression disc.
(9) T i g h t e n tool handle u n t i l p l u g gauge is seated
on j a w s o f flaring tool. This w i l l start the i n v e r t e d
flare (Fig. 13).
(10) Remove t h e p l u g gauge and complete t h e i n -
verted flare (Fig. 8).
(11) Remove t h e flaring tools and verify t h a t t h e
i n v e r t e d flare is correct.

Flaring Procedure
(1) C u t off damaged tube w i t h tool C-3478-A or a n
equivalent t u b i n g cutter.
(2) Ream cut edges of t u b i n g to ensure proper flare.
(3) I n s t a l l replacement tube n u t o n section of tube
to be repaired.
(4) Insert tube i n flaring tool. Center tube i n area
between v e r t i c a l posts.
(5) Place gauge f o r m A over t h e end o f the tube
(Fig. 13).
(6) Push t u b i n g t h r o u g h flaring tool jaws u n t i l tube
contacts recessed notch i n gauge t h a t matches tube
diameter.
(7) Squeeze flaring tool j a w s to lock t u b i n g i n RH222
place.
(8) Insert p l u g on gauge A i n the tube. T h e n s w i n g Fig. 13 Brakeline Flaring Tools
5 - 20 BRAKES •
POWER B R A K E B O O S T E R — B R A K E P E D A L

INDEX
Page Page
Booster Installation . . . . . . . . . . . . . . . . . . . . . . . . 21 Brake Pedal Removal/Installation . 21
Booster Removal 20 General Information 20

GENERAL INFORMATION T h e p o w e r b r a k e booster i s n o t a r e p a i r a b l e

Power brakes are s t a n d a r d o n a l l A D models. A
single or t a n d e m d i a p h r a g m , v a c u u m power brake
booster is used.
D a n d W100/150 models are equipped w i t h a 250
m m (9.84 i n ) , single d i a p h r a g m booster u n i t (Fig. 1).
D and W250/350 models are equipped w i t h a 200 m m
(7.87 i n ) , t a n d e m (dual) d i a p h r a g m booster.
The booster u n i t consists of a single housing d i -
vided i n t o separate chambers b y one or two i n t e r n a l
diaphragms. The outer edge o f the diaphragm is se-
cured t o t h e housing. T h e booster push rod, w h i c h
connects t h e booster t o t h e brake pedal and master
cylinder, i s attached t o t h e center o f the diaphragm.
A check valve is used i n the booster outlet connected
to the engine i n t a k e m a n i f o l d . Power assist is gener-
ated u t i l i z i n g a c o m b i n a t i o n o f vacuum and atmo-
spheric pressure to boost brake assist.
RESERVOIR
component. T h e booster m u s t b e r e p l a c e d a s a n
a s s e m b l y i f diagnosis i n d i c a t e s a m a l f u n c t i o n
has occurred.
A suspended-type brake pedal is used for a l l a p p l i -
cations. T h e pedal is attached to t h e pedal support
bracket w i t h a pivot shaft. The pedal, b o l t a n d bush-
ings are a l l serviceable components.
BOOSTER REMOVAL
(1) Disconnect v a c u u m hoses f r o m booster check
valve.
(2) Remove nuts a t t a c h i n g master cylinder t o
booster a n d move cylinder away f r o m booster.
(3) Inside vehicle, remove clip t h a t secures booster
push rod t o brake pedal (Fig. 1). Use screwdriver t o
p r y clip off pedal pivot p i n .
(4) Remove locknuts f r o m booster m o u n t i n g studs.
PEDAL SHAFT

MASTER CYLINDER
AND BOOSTER ASSEMBLY

TIGHTENING TORQUE
(AS 200 IN.-LBS. (23 N-m)

V> 35 IN.-LBS. (4 N-ffi)

LOCKNUT
RK721

Fig. 1 Power Brake Booster And Pedal Mounting

• BRAKES
(5) Slide booster away f r o m dash and out of engine
compartment.
(6) I f booster is t o be replaced, remove booster
check valve and seal.
BOOSTER INSTALLATION
(1) I f new booster i s being i n s t a l l e d , transfer check
valve a n d seal to n e w booster.
(2) A l i g n and position booster o n dash panel.
(3) I n s t a l l locknuts o n booster m o u n t i n g studs fin-
ger t i g h t .
(4) I n s t a l l booster push rod on brake pedal p i n and
secure t h e rod w i t h a n e w r e t a i n i n g clip.
(5) T i g h t e n the booster locknuts t o 25 N*m (220 i n -
lbs) torque.
(6) I n s t a l l master cylinder on booster. T h e n i n s t a l l
5 - 21
and t i g h t e n cylinder m o u n t i n g nuts to 19-23 N * m
(170-200 in-lbs) torque.
(7) Connect v a c u u m hose t o booster check valve.
BRAKE PEDAL REMOVAL/INSTALLATION
(1) Disconnect booster push r o d from pedal.
(2) Remove screw a t t a c h i n g pedal shaft to brake
support.
(3) Slide shaft o u t o f support a n d remove brake
pedal.
(4) L u b r i c a t e pedal shaft a n d shaft bore i n pedal
w i t h Mopar multi-purpose grease.
(5) Position pedal i n support a n d slide pedal shaft
into place.
(6) Secure pedal shaft w i t h r e t a i n i n g screw.
5 - 22 BRAKES •

C H R Y S L E R DISC B R A K E
INDEX
Page Page
Brakeshoe Installation 26 Disc Brake Inspection 24
Brakeshoe Removal . 25 General Service Information 22
Caliper Installation 29 Rotor Inspection And Service 29
Caliper Removal 27 Rotor Installation 31
Caliper Overhaul 27 Rotor Removal 29

GENERAL SERVICE INFORMATION

DISC BRAKE COMPONENTS

The Chrysler disc brake assembly is used on two-
wheel drive models and four-wheel drive models w i t h
the 3300 and 4000 l b front axle. T h e caliper is a slid-
i n g type w i t h a single, 3.1 i n c h (78.7 m m ) diameter
caliper piston (Figs. 1 a n d 2). Cast i r o n , v e n t i l a t e d
die brake rotors are used for a l l applications.
Each caliper is mounted on a n adapter attached to
the steering k n u c k l e (Fig. 2). Each caliper slide lat-
erally on surfaces machined o n t h e caliper a n d
m o u n t i n g adapter. The adapters support t h e caliper
and m a i n t a i n fore a n d aft a l i g n m e n t o f the caliper
and brakeshoes. Two retainer clips are used to m a i n -
t a i n caliper alignment b u t p e r m i t l a t e r a l movement
SHIELD RK72
needed for caliper operation.
Non-metallic caliper pistons are used for a l l a p p l i -
Fig. 2 Chrysler Disc Brake Caliper Mounting—Front
cations. The pistons are made o f a phenolic resin ma- View
terial.
V e n t i l a t e d , cast i r o n disc brake rotors are used for
a l l applications. T h e rotors are serviceable a n d can
be machined to restore surface finish w h e n neces-
sary.
The outboard brake shoe has flanges t h a t locate
and position the shoe o n t h e caliper fingers (Fig. 3).
B r a k i n g force on t h i s shoe is t a k e n by t h e caliper.
The inboard shoe is held i n position by t h e adapter
and reacts directly o n t h e adapter.
The caliper is a one-piece casting w i t h t h e inboard
side c o n t a i n i n g t h e single piston cylinder bore (Fig.
3). A square-cut piston seal is located i n a machined
groove i n t h e cylinder bore. A rubber dust boot is
used to prevent d i r t , water, road splash f r t o m enter-
i n g t h e caliper piston bore. The boot is located i n a
counterbore machined i n t o t h e outboard end of t h e
caliper piston bore.

SPLASH
SHIELD RK71

Fig. 1 Chrysler Disc Brake Caliper Mounting—Rear

View
Fig. 3 Disc Brake Components
5 - 24 BRAKES •
DISC BRAKE OPERATION PISTON CALIPER
The significant feature o f single piston caliper op-
eration is t h a t t h e caliper is free t o move l a t e r a l l y on
the slide surfaces.
A t brake application, fluid pressure i s exerted
equally against the caliper piston a n d a l l surfaces of
the caliper piston bore.
Pressure applied t o t h e piston i s t r a n s m i t t e d d i -
rectly to the inboard brakeshoe pressing t h e shoe l i n -
i n g against t h e rotor. A t t h e same t i m e , pressure DUST BOOT RN102
applied to t h e caliper bore surfaces, causes t h e cali-
per t o slide i n w a r d l a t e r a l l y . T h e i n w a r d movement Fig. 4 Caliper Piston Seal Operation
presses t h e l i n i n g o f t h e outboard shoe against t h e
Check condition o f the rotor, brakeshoe l i n i n g , cal-
opposite side o f the rotor to complete b r a k i n g action.
iper a n d brake hoses. F r o n t wheel bearing adjust-
The application or release of fluid pressure causes
m e n t and condition can also be checked a t t h i s t i m e .
only a very s l i g h t movement o f t h e caliper and pis-
The bearings should be repacked and adjusted i f nec-
ton. A t brake release, t h e piston a n d caliper r e t u r n
essary.
to the non-appled position. The brakeshoes do not re-
t r a c t a n appreciable distance f r o m t h e rotor. The Brakeshoes
m i n i m a l r u n n i n g clearance between t h e l i n i n g and
W i t h t h e caliper a n d brakeshoes on t h e vehicle,
rotor provides improved response a n d reduced pedal
check r u n n i n g clearance between t h e rotor a n d
t r a v e l ; I t also helps i n p r e v e n t i n g d i r t and foreign
brakeshoes. T h e shoe l i n i n g should either be i n very
m a t e r i a l f r o m lodging between t h e shoe a n d rotor
l i g h t contact w i t h t h e rotor or have a m a x i m u m o f
surfaces.
.127 m m (.005 inch) r u n n i n g clearance. I f clearance
DISC BRAKE LINING WEAR COMPENSATION exceeds the stated amount, apply the brakes several
N o r m a l l i n i n g wear is compensated for b y exten- times and recheck clearance. I f clearance is s t i l l ex-
sion o f the caliper piston and by l a t e r a l movement of cessive, either t h e shoes are severely w o r n or t h e cal-
the caliper i n the adapter. Piston position is also de- iper piston could be b i n d i n g i n t h e bore.
t e r m i n e d i n p a r t by t h e square c u t piston seal (Fig.
4). Hoses And Adapter
N o r m a l disc brake l i n i n g wear w i l l cause the cali- Inspect condition o f the b r a k e lines and hoses. Re-
per piston to extend enough to m a i n t a i n proper pedal place either f r o n t hose i f cut, t o r n , or the reinforcing
h e i g h t and brake response. The caliper bore w i l l re- fabric is visible. Check condition o f the m e t a l brake-
ceive the e x t r a fluid needed to compensate for the ad- lines. Replace a n y line t h a t is badly rusted, l e a k i n g
d i t i o n a l piston extension. or damaged i n any way.
As the piston extends d u r i n g b r a k e application, the
Clean and lubricate the slide surfaces of the caliper
square-cut seal is deflected o u t w a r d (Fig. 4). W h e n
and adapter. Use Mopar h i g h temperature grease for
brake pressure is released, t h e seal straightens and
t h i s purpose. Also verify t h a t t h e caliper adapter
r e t u r n s to a n o r m a l relaxed position. A l t h o u g h t h e
bolts are secure and t i g h t e n e d t o proper torque.
amount of seal movement is quite s m a l l , i t is enough
to retract the piston to the necessary m i n i m u m r u n -
Fluid Level
n i n g clearance.
Check t h e master cylinder fluid level. M a i n t a i n
As l i n i n g wear occurs, t h e fluid level i n t h e front
fluid level t o the bottom o f t h e indicator r i n g s on t h e
brake reservoir w i l l decrease. T h i s is a n o r m a l con-
reservoir. Note t h a t f r o n t disc b r a k e fluid level can
d i t i o n and o n l y requires adding enough fluid to re-
be expected to drop s l i g h t l y as n o r m a l l i n i n g wear
store proper level. However, w h e n t h e brakeshoes are
occurs. Use Mopar brake fluid or equivalent m e e t i n g
replaced a n d t h e caliper pistons bottomed i n t h e
SAE a n d D O T standards J1703 a n d D O T 3. Use
bores, t h e added fluid must be compensated for to
clean brake fluid f r o m a sealed container only.
avoid o v e r f i l l a n d overflow. Removing a s m a l l
amount of fluid from the front b r a k e reservoir before-
Rotors
h a n d w i l l prevent this condition.
Check the rotor surfaces for excessive wear, discol-
oration, scoring, rust, scale, or cracks. Also look for
DISC BRAKE INSPECTION
damaged or severely rusted v e n t i l a t i n g segments. I f
Inspect t h e disc brake components whenever t h e pedal pulsation was experienced, check wheel bear-
caliper a n d brakeshoes are removed d u r i n g service i n g adjustment a n d condition. I f t h e bearings are
operations or routine maintenance. O K , also check rotor r u n o u t a n d thickness v a r i a t i o n .
 BRAKES 5 - 25

BRAKE SHOE REMOVAL

(1) I f f r o n t brakeshoes are to be replaced, remove
approximately 1/3 of fluid from master cylinder f r o n t
b r a k e reservoir w i t h suction gun.
(2) Raise and support vehicle.
(3) Remove front wheels.
(4) B o t t o m caliper pistons i n bore w i t h large C-
clamp. Position clamp screw on outboard brakeshoe
a n d opposite end o f clamp frame on back o f caliper.
(5) Remove bolts securing caliper r e t a i n e r clips t o
caliper. T h e n remove clips a n d a n t i - r a t t l e springs
(Fig. 5).

Fig. 6 Caliper Removal/Installation

(7) Remove outboard brakeshoe f r o m caliper (Fig.
7). Use p r y tool to remove shoe f r o m caliper i f
flanges are t i g h t .
(8) Remove inboard brakeshoe f r o m caliper mount-
i n g adapter (Fig. 8).

Fig. 5 Removing/Installing Retainer Clips and

Anti-Rattle Springs
(6) Remove caliper b y t i l t i n g i t r e a r w a r d and l i f t -
i n g u p and off rotor (Fig. 6).

Fig. 7 Removing Outboard Brakeshoe

5 - 26 BRAKES •
BRAKESHOE INSTALLATION
(1) I n s t a l l inboard brakeshoe i n adapter (Fig. 8).
(2) I f n e w brakeshoes are being i n s t a l l e d , remove
protective paper from noise suppresion gasket o n out-
board shoe.
(3) I n s t a l l and adjust outboard brakeshoe i n caliper
as follows:
(a) Check vertical movement o f outboard shoe
i n caliper. Shoe should fit t i g h t l y a n d n o t e x h i b i t
vertical movement (free play). Flange m u s t also fit
t i g h t l y o n caliper finger t o e l i m i n a t e free p l a y a n d
prevent shoe r a t t l e (Fig. 9).
(b) I f free play is evident, remove shoe f r o m cal-
iper.
(c) Bend shoe r e t a i n i n g flange a n d t r i a l fit shoe
i n caliper. Continue bending flange u n t i l shoe is
l i g h t interference fit i n caliper (Fig. 10).
(d) R e i n s t a l l outboard brakeshoe i n caliper. I f
shoe is difficult to i n s t a l l , use C-clamp t o seat shoe
(Fig. 11).

OUTBOARD SHOE AAACHINED

Fig. 8 Removing/Installing Inboard Brakeshoe
(9) Support caliper o n box, stool, or front control
a r m . D o n o t a l l o w b r a k e hose to s u p p o r t w e i g h t
of c a l i p e r . T h i s c o u l d d a m a g e the hose.
(10) Remove O - r i n g f r o m caliper adapter.

CLEANING AND INSPECTION

Replace t h e brakeshoes i f the l i n i n g is w o r n t o a
thickness o f 3.17 m m (1/8 inch) or less. I f shoe r e -
placement i s necessary, replace t h e shoes o n b o t h
sides a t t h e same t i m e . D o not replace t h e shoes o n
one side only. T h i s practice could result i n u n e q u a l
b r a k i n g effort and brake p u l l . Note t h a t i t is n o r m a l
for t h e i n b o a r d shoe l i n i n g t o e x h i b i t s l i g h t l y more
wear t h a n t h e outboard shoe l i n i n g .
Check for piston seal leaks w h i c h w i l l be evident
by brake fluid i n a n d a r o u n d t h e boot area a n d i n -
board l i n i n g . Also check condition of the caliper pis-
t o n dust boot. I f leakage i s evident or i f t h e boot is Fig. 9 Outboard Brakeshoe Positioned On Caliper
Finger
cut, t o r n , or damaged i n a n y way, i t w i l l be neces-
sary to o v e r h a u l t h e caliper.
Remove t h e O - r i n g f r o m t h e caliper adapter a n d
clean t h e slide surfaces o f the adapter a n d t h e m a -
chined ways o n t h e caliper w i t h a w i r e b r u s h a n d
sandpaper.
 • BRAKES 5 - 27

CALIPER REMOVAL
(1) Raise vehicle a n d remove front wheels.
(2) Remove caliper retainer clips a n d a n t i - r a t t l e
springs.
(3) Remove brakeshoes from caliper a n d adapter.
(4) Support caliper on box, stool or s i m i l a r device.
Place shop towels under caliper t o absorb spilled
brake fluid. Then insert s m a l l wood block between
caliper piston and caliper frame.
(5) Slowly press brake pedal to push p i s t o n o u t o f
bore. B r a k e pedal w i l l fall away w h e n p i s t o n has
passed seal and is approaching bore opening.
(6) Prop brake pedal to a n y position below f i r s t
i n c h of pedal t r a v e l to prevent excessive b r a k e fluid
spill.
(7) Repeat piston removal procedure a t opposite
caliper.
(8) Disconnect brakeline at caliper a n d remove cal-
Fig. 10 Adjusting Outboard Brakeshoe Retaining iper.
Flange
CALIPER OVERHAUL

CALIPER DISASSEMBLY
(1) Remove piston dust boot. Collapse boot w i t h
screwdriver or punch and remove boot (Fig. 12).

Fig. 11 Seating Outboard Brakeshoe

(4) L u b r i c a t e slide surfaces of caliper m o u n t i n g
adapter a n d machined ways o n caliper w i t h Mopar
h i g h temperature grease.
(5) I n s t a l l O - r i n g i n adapter, i f removed.
(6) Carefully i n s t a l l caliper over rotor a n d i n t o
adapter. D o n o t d i s p l a c e o r d a m a g e t h e p i s t o n
dust boot w h e n installing t h e caliper.
(7) A l i g n caliper i n adapter a n d i n s t a l l caliper re-
t a i n e r clips a n d a n t i - r a t t l e springs (Fig. 5). T i g h t e n
r e t a i n e r screws to 20 N»m (180 in-lbs) torque.
Fig. 12 Removing Caliper Piston Dust Boot
(8) I n s t a l l wheels and lower vehicle.
(9) Top off master cylinder fluid level.
(10) A p p l y brakes several t i m e s to seat caliper pis-
tons and brakeshoes and o b t a i n f i r m pedal.
5 - 28 BRAKES •
(2) Remove caliper piston seal w i t h wood pencil or scored. D o n o t attempt t o restore a scored p i s t o n b y
plastic tool (Fig. 13). Do not use metal tools as t h e y sanding o r polishing. The piston m u s t be replaced i f
could scratch piston bore. damaged.
Inspect t h e caliper piston bore. T h e bore c a n be
WOODEN OR
l i g h t l y polished w i t h h o n i n g tool C-4095 t o remove
PLASTIC STICK
very m i n o r surface imperfections ( F i g . 15). H o w -
e v e r , the c a l i p e r m u s t b e r e p l a c e d i f the b o r e i s
severely c o r r o d e d , r u s t e d , scored, o r i f polishing
w o u l d i n c r e a s e bore diameter m o r e t h a n .025
m m (.001 i n c h ) .

SPECIAL HONE CALIPER

PISTON BORE
PISTON SEAL

RH246
RH245

Fig. 13 Removing Caliper Piston Seal
GLEAMING AND INSPECTION
Clean t h e caliper components (Fig. 14) w i t h M o p a r
b r a k e cleaner, fresh brake f l u i d , or denatured alcohol
only. D o not use gasoline, kerosene, t h i n n e r , or a n y
s i m i l a r type o f solvent. These products may leave a
residue t h a t could damage the piston and seal.
Fig. 15 Lightly Polishing Piston Bore With Tool
C-4095
CALIPER ASSEMBLY
(1) Coat caliper piston bore, new piston seal a n d
piston w i t h b r a k e fluid.
(2) I n s t a l l n e w piston seal i n caliper bore. B e sure
seal is f u l l y seated i n groove (Fig. 16).

BLEEDER CALIPER INBOARD ANTI-RATTLE

SCREW SHOE SPRING
ASSEMBLY

ADAPTOR
ANTI-RATTLE
PISTON SPRING RH242A

Fig. 14 Caliper Components RB934

D r y t h e caliper and piston w i t h compressed a i r or
allow t h e m t o a i r dry. Do not use rags or shop tow- Fig. 16 Installing Caliper Piston Seal
els. L i n t f r o m such materials can adhere to the cali-
per a n d piston.
Inspect the caliper piston. The piston is made f r o m
a phenolic resin (plastic material) and should be
smooth a n d clean. Replace t h e piston i f cracked or
 • BRAKES 5 - 29

(3) I n s t a l l n e w dust boot on caliper piston. CALIPER INSTALLATION

(4) S t a r t caliper piston i n bore w i t h a r o t a t i n g mo-
tion. W h e n piston is started i n seal, push piston only
part way i n t o bore (Fig. 17). M a i n t a i n u n i f o r m pres-
sure o n piston to avoid cocking i t i n bore.
(5) Press caliper piston t o b o t t o m o f bore a n d seat
piston dust boot w i t h i n s t a l l e r tool C-4690 a n d tool
handle C-4171 ( F i g . 18).
(1) Clean slide surfaces of caliper m o u n t i n g adapter
w i t h w i r e brush. Then lubricate adapter slide sur-
faces w i t h Mopar h i g h temperature wheel b e a r i n g
grease.
(2) I n s t a l l inboard brakeshoe i n adapter.
(3) I n s t a l l outboard brakeshoe i n caliper. Be sure
shoe is l i g h t press f i t i n caliper. Refer to i n s t a l l a t i o n
procedure i n Brakeshoe Replacement.
(4) Lubricate machined ways o f caliper w i t h Mopar
h i g h temperature grease.
(5) I n s t a l l O-ring i n adapter, i f removed.
(6) I n s t a l l caliper over rotor and into adapter.
(7) A l i g n caliper i n adapter a n d i n s t a l l caliper r e -
t a i n e r clips a n d a n t i - r a t t l e springs. T i g h t e n r e t a i n e r
clip screws to 20 N»m (180 in-lbs) torque.
(8) Connect brake hose to caliper. T i g h t e n f i t t i n g
bolt to 47 N»m (35 ft-lbs) torque. B e s u r e hose i s
c l e a r of c h a s s i s a n d s u s p e n s i o n components a n d
u s e n e w s e a l w a s h e r s to s e c u r e hose fitting to
caliper. D o not reuse old washers*
(9) F i l l master cylinder w i t h Mopar brake f l u i d or
equivalent meeting S A E a n d D O T standards J1703
and D O T 3.
(10) Bleed brakes. Refer to procedure i n Service
A n d Adjustments section.
(11) I n s t a l l wheels and lower vehicle.
(12) A p p l y brakes several times to seat caliper pis-
tons a n d brakeshoes. Be sure firm pedal is obtained
before m o v i n g vehicle.

ROTOR REMOVAL
(1) Raise and support vehicle.
(2) Remove wheel and t i r e assembly.
(3) Remove caliper assembly b u t do n o t disconnect
brake hose. Do not allow brake hose to support c a l i -
per. Support caliper on stool, or suspend caliper w i t h
w i r e attached to nearby body or suspension compo-
nent.
(4) Remove grease cap, cotter p i n , n u t lock, n u t ,
t h r u s t washer and outer wheel bearing.
(5) Remove rotor from spindle.
BOOT (6) Remove rotor shield and seal i f either is t o be
STALLING serviced.
TOOL
ROTOR INSPECTION AND SERVICE

RB217 ROTOR CONDITION

Fig. 18 Seating Piston Dust Boot
(6) I n s t a l l caliper bleed screw i f removed.
The rotor b r a k i n g surfaces should not be refinished
unless actually necessary. L i g h t surface r u s t a n d
scale can be removed i n a lathe equipped w i t h d u a l
sanding discs. The rotor surfaces can be restored by
m a c h i n i n g i n a disc brake lathe i f surface scoring
and wear are l i g h t . The rotor should be replaced i f
severely scored, tapered, has h a r d spots, is cracked,
5 - 30 BRAKES •
too t h i n , or i f m a c h i n i n g w o u l d cause rotor thickness
to f a l l below m i n i m u m thickness requirements.
Check r o t o r l a t e r a l r u n o u t a n d thickness v a r i a t i o n
i f pedal p u l s a t i o n or a n occaisional l o w pedal condi-
t i o n w a s experienced. Measure r u n o u t w i t h a d i a l i n -
dicator. Measure thickness w i t h a micrometer a t a
m i n i m u m o f four points around t h e b r a k i n g surfaces.

CHECKING ROTOR MINIMUM THICKNESS

Measure rotor thickness a t t h e center of the brake-
shoe contact surface. Replace t h e rotor i f i t is w o r n
below m i n i m u m thickness, or i f r e f i n i s h i n g w o u l d re-
duce thickness below t h e allowable m i n i m u m . Rotor
m i n i m u m thickness is usually specified on t h e rotor
h u b ( F i g . 19).

Fig. 20 Checking Rotor Runout And Thickness

Variation
ROTOR THICKNESS VARIATION
V a r i a t i o n s i n rotor thickness w i l l cause pedal p u l -
sation, noise and shudder.
Measure rotor thickness a t 6 to 12 points a r o u n d
the rotor face (Fig. 20). Position t h e micrometer ap-
proximately 19.05 t o 25.4 m m (3/4 to one inch) f r o m
the rotor outer circumference for each measurement
as shown i n the bottom view ( F i g . 20).
Thickness should n o t vary by more t h a n .013 m m
(.0005 inch) from point-to-point o n t h e rotor. Refinish
or replace t h e rotor i f necessary.

ROTOR REFINISHING
Rotor b r a k i n g surfaces can be refinished b y sand-
i n g and/or m a c h i n i n g i n a disc brake lathe. T h e lathe
m u s t be capable of m a c h i n i n g both rotor surfaces s i -
Fig. 19 Typical Location Of Rotor Minimum multaneously w i t h d u a l cutter heads ( F i g . 21).
Thickness Limit E q u i p m e n t capable o f m a c h i n i n g only one side a t a
t i m e w i l l produce a tapered rotor. The l a t h e should
ROTOR RUNOUT also be equipped w i t h a grinder attachment or d u a l
Check rotor l a t e r a l r u n o u t w i t h d i a l indicator C-
sanding discs for f i n a l cleanup or l i g h t r e f i n i s h i n g
3339 as shown i n t h e top view (Fig. 20). Excessive
(Fig. 21).
l a t e r a l r u n o u t w i l l cause brake pedal pulsation a n d
I f t h e rotor surfaces only need m i n o r cleanup of
r a p i d , uneven wear of the brakeshoes. position t h e
r u s t , scale, or scoring, use abrasive discs to clean u p
d i a l indicator plunger approximately 25.4 m m (one
the rotor surfaces. However, w h e n a rotor is scored or
inch) i n f r o m t h e rotor edge.
w o r n , m a c h i n i n g w i t h c u t t i n g tools w i l l be required.
B e s u r e w h e e l b e a r i n g adjustment i s c o r r e c t
before c h e c k i n g rotor runout. I n c o r r e c t adjust-
m e n t c a n create a condition s i m i l a r to e x c e s s i v e
l a t e r a l runout.
M a x i m u m allowable rotor r u n o u t for a l l models is
.102 m m (.004 inch).
• BRAKES 5 - 31

CAUTION: Do not refinish a rotor if machining ROTOR INSTALLATION

would cause the rotor to fall below minimum allow-
(1) Inspect and repack wheel bearings i f necessary.
able thickness.
I n s t a l l new grease seal i f i n n e r bearing i s removed
for repacking.
(2) I n s t a l l rotor on spindle.
( 3 ) I n s t a l l outer bearing, t h r u s t washer and n u t .
(4) T i g h t e n wheel b e a r i n g adjusting n u t t o 2 7 - 3 4
N T H ( 2 4 0 - 3 0 0 in-lbs) w h i l e t u r n i n g rotor.
(5) Recheck rotor r u n o u t as described previously.
(6) Loosen wheel b e a r i n g adjusting n u t completely.
Then r e t i g h t e n n u t finger t i g h t . Wheel bearing end
play should be . 0 0 0 1 t o . 0 0 3 i n c h .
(7) I n s t a l l n u t lock on bearing adjusting n u t . A l i g n
lock slots w i t h cotter p i n hole a n d secure n u t and
lock w i t h new cotter p i n .
(8) Clean grease cap. T h e n coat i n t e r i o r of cap w i t h
wheel b e a r i n g grease.
(9) I n s t a l l caliper, wheel a n d t i r e assembly and
lower vehicle.
( 1 0 ) Check and adjust master cylinder f l u i d level.
( 1 1 ) A p p l y brakes several times t o seat brakeshoes.
Be sure t o obtain f i r m pedal before m o v i n g vehicle.

Fig. 21 Rotor Refinishing Equipment

5 - 32 BRAKES •
BENDIX DISC B R A K E
INDEX
Page Page
Brakeshoe Installation , . 36 General Service Information 32
Brakeshoe Removal . . . . . . . . . . . . . 35 Rotor Inspection And Service . 39
Caliper Overhaul . 37 Rotor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Disc Brake Inspection . 34 Rotor Removal ; . . . 40

GENERAL SERVICE INFORMATION

The Bendix disc b r a k e assembly is used o n W250/
350 models w i t h t h e D a n a 60 f r o n t axle (Fig. 1). The
assembly consists o f a single piston sliding caliper, a
m o u n t i n g adapter attached t o t h e steering k n u c k l e , a
ventilated rotor and a rotor splash shield. T h e splash
shield, w h i c h is bolted to t h e adapter, protects t h e
bearings a n d inboard surface o f the rotor from road
splash. The wheel protects t h e outboard surface o f
the rotor and brake assembly.
The caliper slides l a t e r a l l y on surfaces machined
into t h e caliper a n d m o u n t i n g adapter. T h e adapter
is bolted to t h e steering k n u c k l e (Fig. 2). T h e caliper
is positioned i n t h e adapter w i t h a support k e y and
spring (Fig. 1). A r e t a i n i n g screw is used t o secure
the support key.
The inboard brakeshoe i s mounted i n t h e caliper
adapter. The outboard brakeshoe is mounted i n t h e
caliper. The l i n i n g s are r i v e t e d t o t h e shoes, a n d t h e
inner and outer shoes are n o t interchangeable.
Fig. 2 Caliper Mounting Adapter Attachment
DISC BRAKE OPERATION
The s i g n i f i c a n t feature o f single piston caliper op-
eration i s t h a t t h e caliper is free to move l a t e r a l l y on
the adapter slide surfaces (Fig. 3).
A t b r a k e application, fluid pressure is exerted
equally against t h e caliper piston and a l l surfaces o f
the caliper piston bore.
Pressure applied t o t h e piston is t r a n s m i t t e d d i -
rectly t o t h e i n b o a r d brakeshoe pressing the shoe l i n -
i n g against t h e rotor. A t t h e same t i m e , pressure
applied t o t h e caliper bore surfaces, causes t h e cali-
per t o slide i n w a r d l a t e r a l l y . T h e i n w a r d movement
presses t h e l i n i n g o f t h e outboard shoe against t h e
opposite side o f t h e rotor t o complete b r a k i n g action
(Fig. 3).
A n y a p p l i c a t i o n or release o f brake fluid pressure
causes o n l y a very modest movement o f the caliper
and piston. A t b r a k e release, t h e piston a n d caliper
r e t u r n t o t h e non-appled position. The brakeshoes do
not r e t r a c t a n y appreciable distance f r o m t h e rotor.
The m i n i m a l r u n n i n g clearance provides t h e i m -
Fig. 1 Bendix Disc Brake Caliper
proved response a n d reduced pedal t r a v e l ; I t also
helps i n p r e v e n t i n g d i r t a n d foreign m a t e r i a l from-
lodging between t h e shoe a n d rotor surfaces.
Fig. 3 Bendix Disc Brake Caliper Operation
5 - 34 BRAKES
DISC BRAKE LINING WEAR COMPENSATION
N o r m a l l i n i n g wear i s compensated for b y exten-
sion of t h e caliper p i s t o n and b y l a t e r a l movement of
the caliper i n the adapter. Piston position is also de-
t e r m i n e d i n p a r t b y t h e square cut piston seal ( F i g .
4).
N o r m a l disc brake l i n i n g wear w i l l cause the cali-
per piston t o extend enough t o m a i n t a i n proper pedal
height a n d brake response. The caliper bore w i l l re-
ceive the e x t r a f l u i d needed t o compensate for t h e ad-
d i t i o n a l piston extension.
As the piston extends d u r i n g brake application, the
square-cut seal is deflected o u t w a r d (Fig. 4). W h e n
brake pressure is released, t h e seal straightens and
r e t u r n s t o a n o r m a l relaxed position. A l t h o u g h t h e
amount o f seal movement is q u i t e small, i t is enough
to retract t h e piston t o t h e necessary m i n i m u m r u n -
n i n g clearance.
As l i n i n g wear occurs, t h e fluid level i n t h e front
brake reservoir w i l l decrease. T h i s is a n o r m a l con-
d i t i o n a n d only requires adding enough fluid t o re-
store proper level. However, w h e n the brakeshoes are
replaced a n d the caliper pistons bottomed i n t h e
bores, t h e added fluid m u s t be compensated for to
avoid o v e r f i l l a n d overflow. Removing a s m a l l
amount o f fluid from t h e f r o n t brake reservoir before-
h a n d w i l l prevent t h i s condition.
Fig. 4 Caliper Piston Seal Operation
DISC BRAKE INSPECTION
Inspect t h e disc b r a k e components whenever t h e
caliper a n d brakeshoes are removed d u r i n g service
operations or routine maintenance.
Check condition o f the rotor, brakeshoe l i n i n g , cal-
iper a n d brake hoses. F r o n t wheel bearing adjust-
ment and condition can also be checked a t t h i s t i m e .
The bearings should be repacked and adjusted i f nec-
essary.
•
Brakeshoes
W i t h t h e caliper a n d brakeshoes o n t h e vehicle,
check r u n n i n g clearance between t h e rotor a n d
brakeshoes. T h e shoe l i n i n g should either be i n very
l i g h t contact w i t h t h e rotor or a m a x i m u m o f .127
m m (.005 inch) r u n n i n g clearance. I f clearance ex-
ceeds t h e stated amount, apply t h e brakes several
times and recheck clearance. I f clearance is s t i l l ex-
cessive, either the shoes are severely w o r n or the cal-
iper piston could be b i n d i n g i n the bore.
Hoses And Adapter
Inspect condition o f the brake lines and hoses. Re-
place either f r o n t hose i f cut, t o r n , or the reinforcing
fabric is visible. Check condition of the m e t a l brake-
lines. Replace any l i n e t h a t is badly rusted, l e a k i n g
or damaged i n any way.
Clean a n d lubricate t h e slide surfaces o f t h e
m o u n t i n g adapter. Use Mopar h i g h temperature
grease for t h i s purpose. Also verify t h a t t h e caliper
adapter bolts are secure a n d tightened to proper
torque.
Fluid Level
Check t h e master cylinder fluid level. M a i n t a i n
fluid level to the bottom o f the indicator rings on the
reservoir. Note t h a t front brake fluid level can be ex-
pected to drop s l i g h t l y as n o r m a l l i n i n g wear occurs.
Use Mopar brake fluid or equivalent meeting S A E
and D O T standards J1703 a n d D O T 3. Use clean
brake f l u i d f r o m a sealed container only.
Rotors
Check the rotor surfaces for excessive wear, discol-
oration, scoring, rust, scale, or cracks. Also look for
damaged or severely rusted v e n t i l a t i n g segments. I f
pedal pulsation was experienced, check wheel bear-
i n g adjustment a n d condition. I f t h e bearings are
OK, also check rotor r u n o u t and thickness v a r i a t i o n .
 BRAKES 5 - 35

BRAKESHOE REMOVAL BRASS ROD

(1) Remove approximately 1/4 o f t h e f l u i d f r o m t h e

master cylinder front brake reservoir.
(2) Raise a n d support t h e vehicle.
(3) Remove t h e wheel and t i r e assemblies.
(4) B o t t o m the caliper pistons w i t h a large C-clamp
(Fig. 5).
(5) Remove t h e support k e y r e t a i n i n g screw (Fig.
6).
(6) Remove t h e caliper support k e y and spring. Use
a p i n punch or d r i f t to t a p t h e k e y out of t h e caliper
(Fig. 7).

Fig. 7 Removing Caliper Support Key And Spring

(9) Secure t h e caliper t o a convenient chassis com-
ponent w i t h wire. Do n o t allow t h e brake hose to
support caliper weight.
(10) Remove the inboard shoe a n d a n t i - r a t t l e
s p r i n g f r o m t h e caliper adapter (Fig. 9). N o t e posi-
t i o n of the spring for i n s t a l l a t i o n reference.

Fig. 8 Removing/Installing Outboard Brakeshoe

Fig. 6 Removing/Installing Support Key Retaining
Screw
(7) L i f t t h e caliper out of the adapter.
(8) Remove t h e outboard shoe f r o m t h e caliper (Fig.
8).
5 - 36 BRAKES •
(2) I n s t a l l t h e outboard shoe i n t h e caliper. Free
play should n o t exist between t h e shoe r e t a i n i n g
flanges a n d machined surfaces o n t h e caliper. I f the
shoe shoe cannot be pressed i n t o place b y h a n d , a C-
Clamp may be used. I f a C-Clamp is used, protect the
shoe w i t h a wooden block ( F i g . 10).

Fig. 9 Removing/Installing Inboard Brakeshoe Fig. 10 Seating Outboard Brakeshoe In Caliper

CLEANING AND INSPECTION (3) Position t h e caliper over t h e rotor a n d i n the
E x a m i n e t h e shoe l i n i n g for wear. Replace t h e adapter (Fig. 11). Be careful t o avoid d a m a g i n g t h e
shoes i f t h e l i n i n g is w o r n t o w i t h i n 1.58 m m (1/16 piston dust boot d u r i n g i n s t a l l a t i o n .
inch) o f t h e r i v e t heads. I f the shoe l i n i n g w i l l be re-
used, do n o t i n t e r m i x t h e shoes. Keep t h e m w i t h t h e CAUTION: Verify that the brake hose is straight and
caliper t h e y were removed from. not twisted or kinked.
E x a m i n e t h e caliper piston area for evidence o f
leaks. Also check condition o f t h e piston boot. Over- CALIPER
h a u l t h e caliper i f leakage is evident or t h e boot is
cut o r t o r n .
Clean r u s t and corrosion from t h e support k e y a n d
the caliper a n d adapter slide surfaces (machined
ways) w i t h a w i r e brush. T h e n lubricate t h e slide
surfaces w i t h Mopar multi-purpose grease, o r equiv-
alent.

BRAKESHOE INSTALLATION
(1) I n s t a l l t h e a n t i - r a t t l e s p r i n g on t h e inboard
brakeshoe a n d i n s t a l l t h e shoe i n t h e adapter. Be
sure t h e s p r i n g remains i n place and is positioned as
shown (Fig. 9). The loop portion o f the s p r i n g should
face away f r o m the rotor.

Fig. 11 Caliper installation

(4) Seat t h e caliper i n t h e adapter.
(5) Place t h e support s p r i n g on t h e support key.
Then insert t h e spring a n d k e y between t h e caliper
and adapter.
 • BRAKES 5 - 37

(6) Tap t h e support k e y and spring i n t o place w i t h (7) Press brake pedal to h y d r a u l i c a l l y push caliper
a p i n punch or d r i f t (Fig. 12). pistons out o f bore. Pedal w i l l f a l l away w h e n pistons
pass cylinder bore opening. Place pistons on work-
CALIPER
SUPPORT KEY bench for inspection.
SUPPORT SPRING
(8) Prop and secure brake pedal to any position be-
l o w f i r s t inch o f t r a v e l t o prevent loss of brake f l u i d .
(9) Disconnect caliper b r a k e hoses a t frame
bracket.
(10) Cover brake lines to prevent d i r t entry.

CALIPER DISASSEMBLY.
(1) Remove dust boot from caliper.
(2) Remove caliper piston seal f r o m caliper bore
w i t h s m a l l wood or plastic tool. D o n o t u s e m e t a l
t o o l s t o r e m o v e t h e seal. M e t a l t o o l s c a n s c r a t c h /
score t h e p i s t o n bore surface.
(3) Remove t h e bleeder screw f r o m t h e caliper.

KEY CLEANING AND INSPECTION

RETAINING
SCREW
BRASS ROD RK85
Fig. 12 Installing Support Key And Spring
(7) A l i g n t h e notch i n t h e support k e y w i t h t h e
screw hole i n t h e caliper.
(8) I n s t a l l t h e support k e y r e t a i n i n g screw. T i g h t e n
t h e screw t o 20 N«m (15 ft-lbs) torque. B e s u r e t h e
b o s s o n t h e s c r e w i s f u l l y seated i n t h e s u p p o r t
key notch,
(9) I n s t a l l t h e wheel a n d t i r e assembly a n d lower
t h e vehicle.
(10) Top off the master cylinder f l u i d level.
(11) P u m p the brake pedal to seat t h e shoes a n d re-
store n o r m a l pedal height. Do not move t h e vehicle
u n t i l a f i r m pedal is obtained.
CALIPER OVERHAUL
CALIPER AND PISTON REMOVAL
(1) Raise vehicle a n d support o n hoist or jack-
stands.
(2) Remove wheel and t i r e assemblies.
(3) Clean brake hose and t u b i n g connections a t cal-
ipers and brake hoses.
(4) Remove screw r e t a i n i n g caliper support k e y and
s p r i n g a n d t a p support key and s p r i n g o u t w i t h a
d r i f t or p i n punch.
(5) Remove calipers a n d brakeshoes f r o m adapters
b u t do n o t disconnect caliper brake hoses a t t h i s
time.
(6) Support calipers on front axle. Position shop
towels under calipers to absorb spilled b r a k e f l u i d .
Clean t h e slide surfaces o f t h e caliper w i t h a w i r e
b r u s h and emery cloth. Then clean t h e caliper a n d
piston w i t h Mopar brake cleaner, fresh brake fluid,
or denatured alcohol only. Do n o t use any other type
of solvent or cleaning agent.
D r y t h e caliper and piston w i t h compressed a i r or
allow t h e m t o a i r dry. Do n o t use rags or towels to
d r y t h e caliper and piston. L i n t from such materials
can adhere to t h e piston and caliper.
Inspect t h e caliper piston, piston bore and t h e seal
a n d boot grooves. Replace t h e piston i f corroded, p i t -
ted, scored, or w o r n . Do n o t a t t e m p t to restore t h e
piston surface b y sanding. Replace t h e piston i f nec-
essary.
V e r y l i g h t scratches or corrosion i n the piston bore
can usually be cleaned u p w i t h a fiber brush, or b y
polishing w i t h a h o n i n g tool or crocus cloth. How-
ever, t h e caliper should be replaced i f the bore is se-
verely corroded, scored, or i f h o n i n g a n d polishing
w o u l d increase bore diameter b y more t h a n .002 i n c h
(.050 m m ) .
D a r k b r o w n or black stains on t h e piston are
caused by t h e piston seal a n d are a n o r m a l oc-
curence. I n addition, l i g h t discoloration of the piston
bore is also n o r m a l . This discoloration is acceptable
as long as t h e bore and piston surfaces are i n good
condition.
I f i t is necessary t o polish t h e caliper bore, coat t h e
crocus cloth or h o n i n g stones w i t h fresh brake fluid
only. Be sure to flush a n d clean t h e caliper thor-
oughly afterward. A l l residue generated b y p o l i s h i n g
m u s t be removed to avoid potential damage to t h e
piston, seal and bore after assembly.
5 - 38 BRAKES •
Inspect a n d clean t h e inboard shoe a n t i - r a t t l e groove w i t h fingers. Boot w i l l seem larger t h a n
spring, support key spring, r e t a i n i n g screw a n d cali- groove diameter a t first b u t w i l l snap i n t o place
per support k e y (Fig. 13). Replace these components w h e n properly positioned.
i f w o r n or damaged. (5) P l u g f l u i d i n l e t port a n d i n s t a l l bleeder screw.
(6) Coat caliper piston w i t h brake f l u i d .
SHOE AND SHOE AND CALIPER BLEEDER SCREW
LINING LINING (7) S t a r t piston i n t o dust boot a n d bore (Fig. 15).
(OUTER) (INNER) Spread dust boot w i t h fingers. T h e n w o r k piston
KEY t h r o u g h boot and i n t o bore. A i r trapped below piston
RETAINING w i l l force boot around i t and i n t o groove as piston is
SCREW installed.
(8) Remove p l u g f r o m i n l e t p o r t a n d loosen bleeder
screw.
(9) Carefully press piston i n t o bore u n t i l f u l l y bot-
tomed. A p p l y force u n i f o r m l y to avoid cocking piston
CALIPER (Fig. 15).
SUPPORT
KEY CALIPER
SUPPORT SPRING

SEAL BOOT ANTI-RATTLE SPRING RN1059

Fig. 13 Caliper Components

CALIPER ASSEMBLY
(1) M o u n t caliper i n vise equipped w i t h protective PISTON
jaws. Do n o t overtighten vise. Excessive pressure
could cause bore distortion a n d piston b i n d i n g .
(2) L u b r i c a t e new piston seal a n d piston bore w i t h
fresh brake f l u i d .
(3) I n s t a l l new piston seal i n t h e bore (Fig. 14). Po-
sition seal i n one area o f groove a n d gently work, i t DUST BOOT
around a n d i n t o groove u n t i l seated. Be sure seal is
not twisted or rolled over.
CALIPER

Fig. 15 Installing Caliper Piston

CALIPER INSTALLATION
(1) I n s t a l l brakeshoes i n caliper a n d adapter.
(2) Connect brake hose to brake line on frame
bracket. T i g h t e n hose f i t t i n g t o 13-20 N - m (115-175
in-lbs) torque.
(3) Connect brake hose to caliper. Use new seal
washers w h e n conncting f i t t i n g t o caliper. Do n o t
t i g h t e n hose f i t t i n g a t t h i s t i m e .
(4) Remove brake pedal prop.
(5) Lubricate caliper and adapter slide surfaces
PISTON SEAL w i t h Mopar h i g h temperature grease, or a n equiva-
lent grease.
(6) I n s t a l l and secure caliper i n adapter.
(7) F i l l master cylinder and bleed brakes.
(8) I n s t a l l wheel and t i r e assemblies and lower ve-
hicle.

Fig. 14 Installing Caliper Piston Seal

(4) Lu brica te new dust boot w i t h fresh brake f l u i d
and i n s t a l l i t i n caliper (Fig. 15). W o r k boot into the
 • BRAKES 5 - 39

ROTOR INSPECTION AND SERVICE

ROTOR CONDITION
Rotor condition and tolerances can be checked w i t h
t h e rotor mounted o n t h e axle. However, wheel bear-
i n g end play should be reduced t o zero before check-
i n g lateral runout.
The rotor b r a k i n g surfaces should not be machined
unless actually necessary. L i g h t surface r u s t a n d
scale can be removed i n a lathe equipped w i t h d u a l
sanding discs. T h e rotor surfaces can be restored b y
m a c h i n i n g i n a disc brake lathe i f surface scoring
and wear are l i g h t . T h e rotor should be replaced i f
severely scored, tapered, has h a r d spots, i s cracked,
too t h i n , or i f m a c h i n i n g w o u l d cause rotor thickness
to f a l l below m i n i m u m thickness requirements.
Check rotor l a t e r a l r u n o u t and thickness v a r i a t i o n
i f pedal p u l s a t i o n or a n occaisional low pedal condi-
t i o n was experienced. Measure r u n o u t w i t h a d i a l i n -
dicator. Measure thickness w i t h a micrometer a t a
m i n i m u m of four points around the b r a k i n g surfaces.
The rotor measurement points are shown i n F i g u r e
16.

CHECKING ROTOR MINIMUM THICKNESS

Measure rotor thickness a t t h e center o f the brake-
shoe contact surface. Replace t h e rotor i f i t is w o r n
below m i n i m u m thickness, or i f r e f i n i s h i n g w o u l d re-
duce thickness below t h e allowable m i n i m u m . Rotor
m i n i m u m thickness i s u s u a l l y specified o n t h e rotor
hub.

ROTOR THICKNESS VARIATION

V a r i a t i o n s i n rotor thickness w i l l cause pedal p u l -
sation, noise a n d shudder.
Measure rotor thickness a t 6 to 12 points a r o u n d
t h e rotor face ( F i g . 17). Position t h e micrometer ap-
p r o x i m a t e l y 25.4 m m (one inch) f r o m t h e rotor outer
circumference for each measurement (Figs. 16 a n d
17).
Thickness should n o t v a r y by more t h a n .025 m m
(.001 inch) f r o m point-to-point on t h e rotor. Refinish
or replace t h e r o t o r i f necessary.

Fig. 16 Rotor Measurement Points

5 - 40 BRAKES •
ROTOR RUNOUT (4) Remove support key r e t a i n i n g screw (Fig. 6).
Check rotor l a t e r a l r u n o u t w i t h a d i a l indicator C- (5) Remove caliper support key and s p r i n g w i t h p i n
3339 (Fig. 17). Excessive lateral r u n o u t w i l l cause p u n c h or d r i f t (Fig. 18).
brake pedal p u l s a t i o n and rapid, uneven wear o f the
brakeshoes. position t h e dial indicator plunger ap-
p r o x i m a t e l y 25.4 m m (one inch) i n from the rotor
edge. B e s u r e w h e e l b e a r i n g e n d p l a y i s 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 . M a x i m u m allow-
able r u n o u t is .127 m m (.005 inch).

Fig. 18 Removing Caliper Support Key And Spring

(6) Remove caliper a n d brakeshoes f r o m adapter.
D o n o t a l l o w b r a k e hose to s u p p o r t c a l i p e r
weight. S u p p o r t c a l i p e r o n stool, o r s e c u r e c a l i -
p e r to n e a r b y frame o r c h a s s i s c o m p o n e n t w i t h
wire.
(7) Remove h u b cap.
(8) Remove drive flange snap r i n g w i t h tool C-4020
(Fig. 19).

Fig. 17 Checking Rotor Runout And Thickness

Variation
ROTOR REFINISHING
Rotor b r a k i n g surfaces can be refinished b y sand-
i n g and/or m a c h i n i n g i n a disc brake lathe. The lathe
must be capable of m a c h i n i n g both rotor surfaces si-
multaneously w i t h d u a l cutter heads. Equipment ca-
pable o f m a c h i n i n g only one side a t a t i m e w i l l
produce a tapered rotor. The lathe should also be
equipped w i t h a grinder attachment or dual sanding
discs for f i n a l cleanup or l i g h t refinishing.
I f 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
w o r n , m a c h i n i n g w i t h c u t t i n g tools w i l l be required.

CAUTION: Do not refinish a rotor if machining
would cause the rotor to fall below minimum allow-
able thickness.
ROTOR REMOVAL
(1) Block b r a k e pedal i n released (up) position.
(2) Raise vehicle to a comfortable w o r k i n g height
and support w i t h jack stands.
(3) Remove wheel and t i r e assembly.
Fig. 19 Removing Drive Flange Snap Ring
(9) Remove flange nuts and lockwashers and r e -
move drive flange. Discard the flange gasket.
(10) S t r a i g h t e n t a n g on lockring.
(11) Loosen outer locknut and adjusting n u t w i t h
tool DD-1241-JD (Fig. 18). Then remove outer lock-
n u t , lock r i n g , inner adjusting n u t and outer bearing.
(12) Remove h u b and rotor from spindle.
(13) Remove seal and inner bearing from h u b i f
bearings or seal require service.
• BRAKES
(14) I f wheel b e a r i n g races require service, remove
t h e m w i t h suitable remover tools or w i t h brass d r i f t .
(15) Clean rotor and h u b a n d wheel bearings i n sol-
vent.
ROTOR INSTALLATION
(1) Repack t h e wheel bearings a n d coat the spindle
w i t h Mopar h i g h temperature b e a r i n g grease.
(2) I n s t a l l new b e a r i n g races, bearings and seal i n
hub i f necessary.
(3) I n s t a l l h u b o n spindle a n d i n s t a l l outer bearing
and i n n e r adjusting n u t .
(4) T i g h t e n adjusting n u t t o 68 N-m (50 ft-lbs) w i t h
tools DD-1241-JD a n d C-3952 t o seat bearings.
(5) Adjust wheel bearings as follows:
(a) Back o f f adjusting n u t .
(b) R e t i g h t e n a d j u s t i n g n u t t o 54 N*m (40 f t -
lbs) w h i l e r o t a t i n g h u b a n d rotor.
5 - 41
(c) Back off adjusting n u t approximately 135 t o
150 degrees.
(d) I n s t a l l lock r i n g and locknut.
(6) T i g h t e n lock n u t t o a m i n i m u m o f 88 N»m (65
ft-lbs). B e a r i n g e n d play should be .025 -.25 m m
(.001-.010 inch).
(7) Bend one t a n g o f lock r i n g over adjusting n u t
and another t a n g over locknut to secure t h e m .
(8) I n s t a l l n e w gasket on hub a n d i n s t a l l drive
flange, lockwashers and nuts. T i g h t e n nuts to 41 - 54
N*m (30 - 40 ft-lbs).
(9) I n s t a l l flange snap r i n g w i t h tool C-4020.
(10) I n s t a l l h u b cap.
(11) I n s t a l l caliper and brakeshoes. T i g h t e n sup-
port r e t a i n i n g screw t o 20 N»m (15 ft-lbs) torque.
(12) I n s t a l l wheel a n d t i r e assembly and lower ve-
hicle.
5 - 42 BRAKES •
11-INCH DRUM B R A K E
INDEX
Page Page
Brake Drum Inspection And Refinishing 44 Cleaning And Inspection 43
Brake Drum Installation . 45 General Information . . 42
Brake Drum Removal 42 Safety Precautions . 42
Brake Shoe Installation . . . 44 Wheel Cylinder Installation . . . . . . . . . . . . . . . . . . 46
Brake Shoe Removal 43 Wheel Cylinder Overhaul . 46
Brake Support Plate Installation 45 Wheel Cylinder Removal . . . . . . . . . . . . . . . . . . . . 45
Brake Support Plate Removal 45

GENERAL INFORMATION USE A VACUUM CLEANER SPECIFICALLY RECOM-

MENDED FOR USE WITH ASBESTOS FIBERS. IF A
Chrysler 11-inch r e a r d r u m brakes are used on D SUITABLE VACUUM CLEANER IS NOT AVAILABLE,
and W 100/150 models (Fig. 1). A l l applications are CLEANING SHOULD BE DONE WET USING A WA-
two-shoe, i n t e r n a l expanding u n i t s w i t h a self ad- TER DAMPENED CLOTH. DO NOT CREATE DUST
j u s t e r mechanism. A single wheel cylinder is used to BY SANDING, GRINDING, AND/OR SHAVING
expand t h e dual brakeshoes. T h e lower ends o f t h e BRAKE LININGS OR PADS UNLESS SUCH OPERA-
brake shoes are connected by a star wheel adjusting TION IS DONE WHILE USING PROPERLY VENTI-
screw w h i c h is part o f the self adjusting mechanism. LATED EXHAUST EQUIPMENT. DISPOSE OF DUST
AND DIRT SUSPECTED OF CONTAINING ASBES-
SAFETY PRECAUTIONS TOS FIBERS IN SEALED BAGS OR CONTAINERS
TO MINIMIZE EXPOSURE TO YOURSELF AND OTH-
SUPPORT RETURN ANCHOR RETURN CABLE ERS. FOLLOW ALL RECOMMENDED PRACTICES
PLATE SPRING PLATE SPRING GUIDE PRESCRIBED BY THE OCCUPATIONAL SAFETY
AND HEALTH ADMINISTRATION AND THE ENVI-
PARKING RONMENTAL PROTECTION AGENCY FOR THE
PARKING
BRAKE
BRAKE HANDLING, PROCESSING, AND DISPOSITION OF
STRUT AND
LEVER
DUST OR DIRT WHICH MAY CONTAIN ASBESTOS
SPRING FIBERS.

ADJUSTER BRAKE DRUM REMOVAL

CABLE
AND (1) Raise and support vehicle.
SPRING
(2) Remove wheel and t i r e .
PRIMARY SHOE (3) Remove clip nuts securing brake d r u m to wheel
SHOE AND RETAINER,
studs.
LINING SPRING
AND PIN (4) I f d r u m i s difficult t o remove, retract brake-
SHOE SPRING shoes as follows:
(a) Remove rear p l u g f r o m access hole i n sup-
SECONDARY port plate.
SHOE AND (b) I n s e r t a t h i n screwdriver i n t o access hole
ADJUSTER SCREW LINING
ASSEMBLY ADJUSTER LEVER and push self adjusting adjusting lever away f r o m
LEVER J9005-62
SPRING adjuster screw star wheel.
(c) I n s e r t tool C-3784 i n t o brake adjusting hole
Fig. 1 11-Inch Drum Brake Assembly and rotate adjuster screw star wheel t o r e t r a c t
WARNING: DUST AND DIRT ON BRAKE PARTS brakeshoes.
GENERATED DURING THE NORMAL USE AND (5) Remove brake d r u m .
WEAR OF MOTOR VEHICLE BRAKE SYSTEMS MAY (6) Inspect b r a k e l i n i n g for wear, alignment, or ev-
CONTAIN ASBESTOS FIBERS. BREATHING EXCES- idence of leakage from axle or wheel cylinder.
SIVE CONCENTRATIONS OF ASBESTOS FIBERS
CAN CAUSE SERIOUS BODILY HARM. EXTREME
CARE SHOULD BE EXERCISED WHILE SERVICING
BRAKE ASSEMBLIES OR COMPONENTS. DO NOT
CLEAN BRAKE ASSEMBLIES OR COMPONENTS
WITH COMPRESSED AIR OR BY DRY BRUSHING;
 • BRAKES
BRAKESHOE REMOVAL
(1) Remove rear wheel and d r u m .
(2) Remove shoe r e t u r n springs w i t h tool C-3785
(Fig. 2).
Fig. 2 Removing/Installing Shoe Return Springs
(3) Remove adjuster cable. Slide cable eye off an-
chor p i n and remove cable f r o m adjuster lever.
(4) Remove cable guide f r o m secondary shoe and
remove anchor plate f r o m anchor p i n .
(5) Remove adjuster lever. Disengage lever from
spring by s l i d i n g lever f o r w a r d to clear pivot and
w o r k lever out from under spring.
(6) Remove adjuster lever s p r i n g f r o m pivot.
(7) Disengage and remove shoe s p r i n g f r o m brake-
shoes.
(8) Disengage and remove adjuster screw assembly
f r o m brakeshoes.
(9) Remove brake shoe retainers, springs and pins
w i t h tool C-4070, (Fig. 3).
Fig. 3 Removing/Installing Shoe Retainers, Springs
and Pins
i - 43
(10) Remove secondary brakeshoe from support
plate.
(11) Remove s t r u t a n d a n t i r a t t l e spring (Fig. 4).
Fig. 4 Removing/Installing Strut And Spring
(12) Remove p a r k i n g brake lever from secondary
shoe.
(13) Remove p r i m a r y shoe f r o m support plate.
(14) Disengage p a r k i n g brake lever from p a r k i n g
brake cable.
CLEANING AND INSPECTION
Clean the brake components, i n c l u d i n g the support
plate a n d wheel cylinder exterior, w i t h a water
dampened cloth or w i t h Mopar brake cleaner. Do not
use any other cleaning agents.
Replace t h e brakeshoes i f w o r n t o w i t h i n .76 m m
(.030 in) of the r i v e t heads or i f bonded l i n i n g is less
t h a n 1.57 m m (1/16 i n ) t h i c k . E x a m i n e t h e l i n i n g
contact p a t t e r n to determine i f the shoes are bent or
the d r u m is tapered. T h e l i n i n g should e x h i b i t con-
tact across the e n t i r e w i d t h . Shoes e x h i b i t i n g contact
only on one side should be replaced and t h e d r u m
checked for r u n o u t or taper.
Clean and inspect t h e adjuster screw assembly. Re-
place t h e assembly i f t h e star wheel threads are
damaged, or t h e components are severely rusted or
corroded.
Discard the brake springs and retainer components
i f w o r n distorted, or collapsed. Also replace t h e
springs i f a brake d r a g condition had occurred. Over-
heating w i l l distort a n d weaken the springs.
5 - 44 BRAKES •
Inspect t h e brakeshoe contact pads o n t h e support
plate (Fig. 5). Remove l i g h t r u s t a n d scale f r o m t h e
pads w i t h fine sandpaper. However, replace t h e sup-
port plate i f any of t h e pads are w o r n or r u s t e d
t h r o u g h . Also replace t h e p l a t e i f i t is bent or dis-
torted.

Fig. 6 Brakeshoe Installation

WASHER SOCKET STAMPED LETTER

Fig. 5 Shoe Contact Surfaces

BRAKE SHOE INSTALLATION
(1) Lubricate anchor p i n a n d brakeshoe contact
pads on support plate (Fig. 5) w i t h Mopar m u l t i pur-
pose grease or L u b r i p l a t e .
(2) Lubricate adjuster screw socket, n u t , b u t t o n and
screw thread surfaces w i t h Mopar m u l t i purpose
grease or L u b r i p l a t e .
(3) A t t a c h p a r k i n g brake cable t o lever. T h e n con-
nect lever to secondary shoe.
(4) I n s t a l l p r i m a r y shoe o n support plate. Secure
shoe w i t h new spring retainers and p i n (Fig. 6).
(5) I n s t a l l spring on p a r k i n g brake s t r u t a n d en-
gage s t r u t i n p r i m a r y show ( F i g . 6).
(6) I n s t a l l secondary shoe o n support plate (Fig. 6).
Insert s t r u t i n shoe and guide shoe onto anchor p i n .
Temporarily secure shoe w i t h r e t a i n i n g p i n .
(7) I n s t a l l anchor plate and adjuster cable eyelet on
support plate anchor p i n ,
(8) I n s t a l l cable guide i n secondary shoe a n d posi-
t i o n cable i n guide.
(9) Assemble adjuster screw (Fig. 7). Then i n s t a l l
and engage adjuster screw i n brakeshoes.
CAUTION: Be sure the adjuster screws are installed
on the correct brake unit. The adjuster screws are
marked L (left) and R (right) for identification (Fig.
8).
BUTTON NUT RH227A
Fig. 7 Adjuster Screw Components
(13) Verify adjuster operation. P u l l adjuster cable
upward. Cable should l i f t lever a n d rotate s t a r t
wheel. Be sure adjuster lever properly engages s t a r t
wheel teeth.
(14) Adjust brakeshoes t o d r u m w i t h brake gauge
as described i n Service Adjustments section.
BRAKE DRUM INSPECTION AND REFINISHING
BRAKE DRUM REFINISHING
The brake d r u m s c a n be resurfaced on a d r u m
lathe w h e n necessary. I n i t i a l m a c h i n i n g cuts should
be l i m i t e d to .12 - .20 m m (.005 -.008 i n ) a t a t i m e as
heavier feed rates can produce taper a n d surface
v a r i a t i o n . F i n a l f i n i s h cuts of .025 to .038 m m (.001
to .0015 i n ) are recommended and w i l l generally pro-
vide t h e best surface f i n i s h .
Be sure t h e d r u m is securely mounted i n t h e lathe
before m a c h i n i n g operations. A damper strap should
always be used a r o u n d t h e d r u m to reduce v i b r a t i o n
and avoid chatter m a r k s .

(10) I n s t a l l adjuster lever a n d spring a n d connect BRAKE DRUM REFINISH LIMITS

adjuster cable to lever. The m a x i m u m allowable diameter of t h e d r u m
(11) I n s t a l l secondary shoe retainers and spring. b r a k i n g surface is stamped or cast i n t o t h e d r u m
(12) I n s t a l l shoe spring. Connect spring to second- outer edge (Fig. 8). Generally, a d r u m can be m a -
ary shoe first. Then to p r i m a r y shoe. chined to a m a x i m u m o f 1.52 m m (.060 i n ) oversize.
 • BRAKES
A l w a y s replace t h e d r u m i f m a c h i n i n g w o u l d cause
d r u m diameter to exceed indicated size l i m i t .
Fig. 8 Location Of Brake Drum Maximum Allowable
Diameter
BRAKE DRUM RUNOUT
Measure d r u m diameter and r u n o u t w i t h a n accu-
r a t e gauge. T h e most accurate method o f measure-
m e n t involves m o u n t i n g the d r u m i n a brake lathe
a n d checking v a r i a t i o n and r u n o u t w i t h a d i a l i n d i -
cator. V a r i a t i o n s i n d r u m diameter should not exceed
.076 m m (.003 inch). D r u m r u n o u t should not exceed
.20 m m (.008 i n ) out of r o u n d . Refinish the d r u m i f
r u n o u t or v a r i a t i o n exceed these values.
BRAKE DRUM INSTALLATION
(1) Clean d r u m w i t h Mopar brake cleaning solvent
or w i t h a soap a n d water solution only. Do not use
any other cleaning agents.
(2) Adjust brake shoes to d r u m w i t h a brake gauge.
(3) I n s t a l l a n d secure d r u m t o wheel studs w i t h
new r e t a i n i n g nuts/clips.
(4) I n s t a l l rubber access plugs i n support plate i f
removed.
(5) I n s t a l l wheel and t i r e .
BRAKE SUPPORT PLATE REMOVAL
(1) Remove wheel and t i r e a n d b r a k e d r u m .
(2) Remove axle shaft and retainer. Refer to Group
3 for procedures.
(3) Remove p r i m a r y brakeshoe for access to park-
i n g brake cable i f necessary.
5 - 45
(4) Compress p a r k i n g brake cable retainer tabs
w i t h a hose clamp (Fig. 9). T h e n push retainer a n d
cable t h r o u g h a n d out o f support plate.
Fig. 9 Removing Parking Brake Cable From Support
Plate
(5) Disconnect brake l i n e a t wheel cylinder.
(6) Remove wheel cylinder a n d brakeshoes f r o m
support plate.
(7) Remove bolts a t t a c h i n g support plate t o axle
and remove support plate.
BRAKE SUPPORT PLATE INSTALLATION
(1) I f new support plate i s being installed, apply
bead o f silicone sealer around wheel cylinder m o u n t -
i n g surface. T h e n transfer wheel cylinder to new sup-
port plate.
(2) A p p l y bead of silicone sealer around axle
m o u n t i n g surface o f support plate.
(3) I n s t a l l support plate on axle flange. T i g h t e n at-
taching bolts t o 25-60 ft-lbs.
(4) I n s t a l l p a r k i n g brake cable i n support plate.
(5) I n s t a l l axle shaft and retainer.
(6) S t a r t b r a k e l i n e i n wheel cylinder and i n s t a l l
cylinder on support plate. T i g h t e n brakeline f i t t i n g
after cylinder i n s t a l l a t i o n .
(7) Connect p a r k i n g brake cable t o lever on second-
ary shoe and i n s t a l l brakeshoes o n support plate.
(8) Adjust brakeshoes to d r u m w i t h brake gauge.
(9) I n s t a l l brake d r u m and wheel and t i r e .
(10) Bleed brake system.
WHEEL CYLINDER REMOVAL
(1) Raise vehicle a n d remove wheel a n d brake
drum.
(2) Disconnect wheel cylinder brakeline.
(3) Remove brakeshoe r e t u r n springs a n d move
shoes out of engagement w i t h cylinder push rods.
5 - 46 BRAKES •
(4) Remove cylinder a t t a c h i n g bolts and remove l i g h t l y polished b u t only w i t h crocus cloth. Replace
cylinder from support plate. the cylinder i f t h e bore i s scored, p i t t e d or h e a v i l y
corroded. H o n i n g t h e bore t o restore the surface i s
WHEEL CYLINDER OVERHAUL not recommended.
Inspect t h e cylinder pistons. The piston surfaces
WHEEL CYLINDER DISASSEMBLY should be smooth a n d free o f scratches, scoring a n d
(1) Remove the p u s h rods and boots (Fig. 10). corrosion. Replace t h e pistons i f w o r n , scored, or cor-
(2) Press the pistons, cups a n d s p r i n g a n d expander roded. Do a t t e m p t t o restore t h e surface by sanding
out of the cylinder bore. or polishing.
(3) Remove the bleed screw. Discard t h e old p i s t o n cups a n d the spring and ex-
pander. These p a r t s are not reusable. The o r i g i n a l
dust boots m a y be reused b u t o n l y i f they are i n good
condition.

ASSEMBLING WHEEL CYLINDER

Fig. 10 Wheel Cylinder Components
CLEANING AND INSPECTION
Clean the cylinder and pistons w i t h fresh brake
fluid or brake cleaner only. Do not use any other
cleaning agents. D r y the cylinder and pistons w i t h
compressed air. Do not use rags or shop towels to dry
the cylinder components. L i n t f r o m such materials
can adhere to the cylinder bores and pistons.
Inspect the cylinder bore. L i g h t discoloration and
d a r k stains i n the bore are n o r m a l and w i l l not i m -
pair cylinder operation. I f desired, the bore can be
(1) L u b r i c a t e wheel cylinder bore, pistons, piston
cups a n d s p r i n g a n d expander w i t h clean brake f l u i d .
(2) I n s t a l l f i r s t p i s t o n i n cylinder bore. Then i n s t a l l
cup i n bore a n d against piston. B e s u r e l i p o f p i s -
t o n c u p i s f a c i n g i n w a r d ( t o w a r d s p r i n g a n d ex-
pander) a n d f l a t side i s against p i s t o n .
(3) I n s t a l l s p r i n g a n d expanders followed b y r e -
m a i n i n g piston cup a n d piston.
(4) I n s t a l l boots on each end of cylinder and insert
push rods i n boots.
(5) I n s t a l l cylinder bleed screw.
WHEEL CYLINDER INSTALLATION
(1) A p p l y bead o f silicone sealer around cylinder
m o u n t i n g surface o f support plate.
(2) Connect b r a k e l i n e t o cylinder. M o u n t cylinder
on support plate a n d i n s t a l l cylinder a t t a c h i n g bolts.
(3) I n s t a l l wheel brake components.
(4) I n s t a l l b r a k e d r u m and wheel and bleed brakes.

12-INCH DRUM B R A K E
INDEX
Page Page
Brake Drum Installation 50 Cleaning And Inspection 49
Brake Drum Removal . 48 General Information 46
Brake Drum Service 50 Safety Precautions 48
Brake Shoe Installation 49 Wheel Cylinder Installation 51
Brake Shoe Removal . 48 Wheel Cylinder Overhaul 51
Brake Support Plate Installation . 51 Wheel Cylinder Removal 51
Brake Support Plate Removal 51

GENERAL INFORMATION mechanism. A single wheel cylinder is used t o ex-

pand t h e d u a l brakeshoes. The lower ends o f the
Twelve inch rear d r u m brakes are used on D and brake shoes are connected b y a star wheel-type ad-
W 250/350 models (Fig. 1). A l l applications are d u a l juster screw w h i c h is p a r t of t h e self adjusting mech-
shoe, i n t e r n a l expanding u n i t s w i t h a self adjusting anism (Fig. 1).
 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-
DOWN PIN
ANTI-RATTLE SPRING

FLAT WASHER BACKING PLATE

AUTOMATIC ADJUSTER
CABLE

ANCHOR BOLT
ADJUSTER LEVER
PIVOT PIN

ADJUSTER LEVER
RETURN SPRING

PARKING AUTOMATIC
BRAKE LEVER ADJUSTER LEVER RN326A

Fig. 1 12-Inch Drum Brake Assembly

5 - 48 BRAKES •
SAFETY PRECAUTIONS

WARNING: DUST AND DIRT ON BRAKE PARTS

GENERATED DURING. THE NORMAL USE AND
WEAR OF MOTOR VEHICLE BRAKE SYSTEMS MAY
CONTAIN ASBESTOS FIBERS. BREATHING EXCES-
SIVE CONCENTRATIONS OF ASBESTOS FIBERS
CAN CAUSE SERIOUS BODILY HARM. EXTREME
CARE SHOULD BE EXERCISED WHILE SERVICING
BRAKE ASSEMBLIES OR COMPONENTS. DO NOT
CLEAN BRAKE ASSEMBLIES OR COMPONENTS
WITH COMPRESSED AIR OR BY DRY BRUSHING.
USE A VACUUM CLEANER SPECIFICALLY RECOM-
MENDED FOR USE WITH ASBESTOS FIBERS. IF A
SUITABLE VACUUM CLEANER IS NOT AVAILABLE,
CLEANING SHOULD BE DONE WET USING A WA- Fig. 2 Retracting Brakeshoes
TER DAMPENED CLOTH. DO NOT CREATE DUST
BY SANDING, GRINDING, AND/OR SHAVING
BRAKESHOE REMOVAL
BRAKE LININGS OR PADS UNLESS SUCH OPERA- (1) U n h o o k adjuster lever r e t u r n s p r i n g f r o m lever
TION IS DONE WHILE USING PROPERLY VENTED (Fig. 1).
EXHAUST EQUIPMENT. DISPOSE OF A L L DUST (2) Remove lever a n d r e t u r n s p r i n g from lever
AND DIRT SUSPECTED OF CONTAINING ASBES- pivot p i n (Fig. 1).
TOS FIBERS IN SEALED BAGS OR CONTAINERS (3) U n h o o k adjuster lever from adjuster cable as-
TO MINIMIZE EXPOSURE TO YOURSELF AND OTH- sembly (Fig. 1).
ERS. FOLLOW ALL RECOMMENDED PRACTICES (4) Remove shoe-to-shoe upper s p r i n g (Fig. 3).
PRESCRIBED BY THE OCCUPATIONAL SAFETY (5) Remove shoe holddown springs (Fig. 4).
AND HEALTH ADMINISTRATION AND THE ENVI-
RONMENTAL PROTECTION AGENCY FOR THE
HANDLING, PROCESSING, AND DISPOSITION OF
DUST OR DIRT WHICH MAY CONTAIN ASBESTOS
FIBERS.

BRAKE DRUM REMOVAL

(1) Raise and support vehicle.
(2) Remove wheel and tire assembly.
(3) Remove axle shaft nuts, washers a n d cones.
S t r i k e axle shaft i n center w i t h copper or dead blow
hammer to loosen r e t a i n i n g cones.
(4) Remove axle shaft.
(5) Remove outer h u b n u t .
(6) S t r a i g h t e n and remove lock washer.
(7) Remove inner n u t and bearing.
(8) Remove d r u m . However, i f d r u m is difficult t o RK60A
remove, retract brakeshoes as follows:
(a) Remove rear p l u g f r o m access hole i n sup- Fig. 3 Removing/Installing Shoe-To-Shoe Upper
Spring
port plate.
(b) Insert a t h i n releasing tool (or screwdriver)
into access hole and push self adjusting a d j u s t i n g
lever away from adjuster screw star wheel (Fig. 2).
(c) Insert t h i n screwdriver, or tool C-3784 i n t o
access hole and rotate adjuster star wheel t o r e -
tract brakeshoes (Fig. 2).
(9) Remove brake d r u m .
(10) Inspect b r a k e l i n i n g for wear, a l i g n m e n t , or ev-
idence of leakage from axle or wheel cylinder.
 • BRAKES
Fig. 4 Removing/Installing Shoe Holddown Springs
(6) Disconnect p a r k i n g brake cable from p a r k i n g
brake lever.
(7) Remove b o t h brakeshoes, shoe-to-shoe lower
spring a n d adjuster n u t as assembly (Fig. 5).
(8) If-support plate or wheel cylinder are t o be ser-
viced, remove anchor bolt a n d n u t t h a t attaches
p a r k i n g b r a k e lever t o support plate. Then remove
lever, washer, spring, cam plate, anchor bolt b u s h i n g
and adjuster cable ( F i g . 1).
Fig. 5 Removing/Installing Brakeshoes
CLEANING AND INSPECTION
Clean t h e brake components, i n c l u d i n g t h e support
plate a n d wheel cylinder exterior, w i t h a w a t e r
dampened cloth or w i t h Mopar brake cleaner. D o n o t
use compressed a i r .
5 - 49
Replace t h e brakeshoes i f w o r n t o w i t h i n .76 m m
(.030 i n ) o f the r i v e t heads or i f bonded l i n i n g i s less
t h a n 1.57 m m (1/16 i n ) t h i c k . E x a m i n e t h e l i n i n g
contact p a t t e r n to determine i f the shoes are b e n t or
t h e d r u m i s tapered. T h e l i n i n g should e x h i b i t con-
tact across t h e entire w i d t h . Shoes e x h i b i t i n g contact
o n l y o n one side should be replaced a n d t h e d r u m
checked for r u n o u t or taper.
Clean a n d inspect t h e adjusting n u t a n d p i v o t
screw assembly. Replace t h e assembly i f t h e star
wheel threads on t h e n u t are damaged, or t h e screw
are severely rusted or corroded.
Discard t h e brake springs and retainer components
i f w o r n distorted, or collapsed. Also replace t h e
springs i f a brake drag condition h a d occurred. Over-
h e a t i n g w i l l distort and weaken t h e springs.
Inspect t h e brakeshoe contact pads o n t h e support
plate (Fig. 6). Remove l i g h t r u s t a n d scale from t h e
pads w i t h fine sandpaper. However, replace t h e sup-
port plate i f a n y o f t h e pads are w o r n or r u s t e d
t h r o u g h . Also replace t h e plate i f i t is bent or dis-
torted.
Fig. 6 Support Plate Brakeshoe Contact Pads
BRAKE SHOE INSTALLATION
(1) I f p a r k i n g brake lever was removed, i n s t a l l a n -
chor bolt bushing, cam plate, lever, spring, washer
and anchor bolt and n u t (Fig. 1).
(2) Coat contact pads on support plate (Fig. 6) w i t h
M o p a r h i g h temperature grease, or equivalent.
(3) I f b o t h sets of brakeshoes were removed, verify
t h a t adjusting nuts are installed o n correct side o f
vehicle. Pivot screw and adjusting n u t have left h a n d
threads o n left side brake assembly a n d r i g h t h a n d
threads on r i g h t side assembly.
(4) Lubricate and assemble adjusting n u t a n d p i v o t
screw.
(5) Assemble adjusting n u t , shoe-to-shoe lower
s p r i n g a n d both brakeshoes. Then position t h e as-
sembled components on t h e support plate.
5 - 50 BRAKES
(6) I n s t a l l brakeshoe holddown springs a n d pins
(Fig. 4). B e sure holddown pins are seated i n support
plate a n d springs are connected as shown (Fig. 7).
SHOE HOLD DOWN PIN
HOLD DOWN
SPRING
BRAKE SHOE WEB
\ heavier feed rates can produce taper a n d surface
\
BACKING PLATE RN1064
Fig. 7 Holddown Spring And Pin Attachment
(7) Connect p a r k i n g brake cable t o p a r k i n g brake
lever. B e sure cable e n d i s properly secured i n lever
(Fig. 8).
J90Q5-118
Fig. 8 Connecting Parking Brake Cable
(8) I n s t a l l shoe-to-shoe upper spring (Fig. 3).
(9) Position adjuster lever r e t u r n spring on pivot.
(10) I n s t a l l adjuster lever.
(11) A t t a c h adjuster cable to adjuster lever. Be sure
cable i s properly routed.
(12) A d j u s t brakeshoes t o d r u m w i t h brake gauge.
BRAKE DRUM INSTALLATION
(1) Position d r u m o n axle housing.
(2) I n s t a l l bearing a n d inner n u t . Adjust b e a r i n g as
described i n Group 3.
(3) I n s t a l l locking washer a n d outer n u t . Bend
l o c k i n g washer t o secure i t .
(4) Place n e w gasket o n hub and i n s t a l l axle shaft,
cones, lock washers a n d nuts.
(5) I n s t a l l wheel a n d t i r e assembly.
(6) Remove support stands and lower vehicle.
•
BRAKE DRUM SERVICE
BRAKE DRUM REFINISHING
The brake drums can be resurfaced o n a d r u m
l a t h e w h e n necessary. I n i t i a l m a c h i n i n g cuts should
be l i m i t e d to .12 - .20 m m (.005 -.008 i n ) a t a t i m e as
v a r i a t i o n . F i n a l f i n i s h cuts o f .025 t o .38 m m (.001 t o
.0015 i n ) are recommended a n d w i l l generally pro-
vide t h e best surface finish.
Be sure t h e d r u m i s securely m o u n t e d i n t h e l a t h e
before m a c h i n i n g operations. A damper strap should
always be used around t h e d r u m t o reduce v i b r a t i o n
a n d avoid chatter m p - k s .
BRAKE DRUM REFINISH LIMITS
The m a x i m u m allowable diameter o f t h e d r u m
b r a k i n g surface is stamped or cast i n t o t h e d r u m
outer edge ( F i g . 9). Generally, a n 1 1 i n c h d r u m can
be machined t o a m a x i m u m o f 11.060 i n c h . A l w a y s
replace t h e d r u m i f m a c h i n i n g w o u l d cause d r u m d i -
ameter to exceed indicated size l i m i t .
MAXIMUM ALLOWABLE
DIAMETER FOR
REFAONG
RB762A
Fig. 9 Location Of Brake Drum Maximum Allowable
Diameter
BRAKE DRUM RUNOUT
Measure d r u m diameter and r u n o u t w i t h a n accu-
rate gauge. The most accurate method o f measure-
m e n t involves m o u n t i n g t h e d r u m i n a b r a k e l a t h e
a n d checking v a r i a t i o n and r u n o u t w i t h a d i a l i n d i -
cator. V a r i a t i o n s i n d r u m diameter should n o t exceed
.076 m m (.003 i n ) . D r u m r u n o u t should n o t exceed
.20 m m (.008 i n ) o u t of round. Refinish t h e d r u m i f
r u n o u t or v a r i a t i o n exceed these values.
 • BRAKES
WHEEL CYLINDER REMOVAL
(1) Raise a n d support the vehicle.
(2) Remove t h e brake d r u m and brakeshoes as de-
scribed i n t h i s section.
(3) Remove t h e anchor bolt and n u t and remove the
washer, s p r i n g , p a r k i n g brake lever, adjuster cable,
cam plate a n d anchor p i n bushing.
(4) loosen t h e b r a k e l i n e a t the wheel cylinder.
(5) Remove t h e wheel cylinder bolts:
(6) Disconnect the b r a k e l i n e and remove the wheel
cylinder.
WHEEL CYLINDER OVERHAUL
WHEEL CYLINDER DISASSEMBLY
(1) Remove t h e push rods and boots (Fig. 10).
(2) Press t h e pistons, cups and spring and expander
out o f the cylinder bore.
(3) Remove t h e bleed screw.
Fig. 10 Wheel Cylinder Components
CLEANING AND INSPECTION
Clean t h e cylinder a n d pistons w i t h clean brake
f l u i d or b r a k e cleaner only. Do n o t use any other
cleaning agents. D r y t h e cylinder and pistons w i t h
compressed a i r . Do not use rags or shop towels to dry
the cylinder components. L i n t from such materials
can adhere t o t h e cylinder bores and pistons.
Inspect t h e cylinder bore. L i g h t discoloration a n d
dark stains i n t h e bore are n o r m a l and w i l l not i m -
pair cylinder operation. I f desired, t h e bore can be
l i g h t l y polished b u t only w i t h crocus cloth. Replace
the cylinder i f the bore is scored, p i t t e d or heavily
corroded. H o n i n g t h e bore to restore t h e surface is
not recommended.
Inspect t h e cylinder pistons. The piston sin-faces
should be smooth and free of scratches, scoring and
corrosion. Replace the pistons i f w o r n , scored, or cor-
roded. Do a t t e m p t t o restore t h e surface b y sanding
or polishing.
5 - it
Discard t h e old piston cups and the spring a n d ex-
pander. These parts are n o t reusable. T h e o r i g i n a l
dust boots may be reused b u t only i f they are i n good
condition.
ASSEMBLING WHEEL CYLINDER
(1) L u b r i c a t e wheel cylinder bore, pistons, p i s t o n
cups a n d s p r i n g and expander w i t h clean b r a k e f l u i d :
(2) I n s t a l l first piston i n cylinder bore. T h e n i n s t a l l
cup i n bore and against piston. B e sure lip o f pisr-
ton c u p i s facing i n w a r d ( t o w a r d s p r i n g a n d e x -
p a n d e r ) a n d flat s i d e i s a g a i n s t p i s t o n .
(3) I n s t a l l s p r i n g a n d expanders followed b y r e -
m a i n i n g piston cup a n d piston.
(4) I n s t a l l boots on each end of cylinder a n d i n s e r t
push rods i n boots.
(5) I n s t a l l cylinder bleed screw.
WHEEL CYLINDER INSTALLATION
(1) S t a r t the brakeline i n t h e cylinder.
(2) Position t h e cylinder o n t h e support plate a n d
i n s t a l l t h e cylinder a t t a c h i n g bolts.
(3) T i g h t e n t h e b r a k e l i n e f i t t i n g and t h e cylinder
a t t a c h i n g bolts.
(4) I n s t a l l t h e anchor p i n bushing, cam plate, ad-
j u s t e r cable, p a r k i n g b r a k e lever, spring washer a n d
the anchor bolt and n u t .
(5) I n s t a l l t h e brakeshoes and brake d r u m as de-
scribed i n t h i s section.
(6) I n s t a l l axle shaft.
(7) I n s t a l l the wheel and t i r e .
(8) Remove the supports and lower the vehicle.
SUPPORT PLATE REMOVAL
(1) Raise and support the vehicle.
(2) Remove the wheel a n d t i r e .
(3) Remove axle shaft.
(4) Remove the brake d r u m , brake shoes and wheel
cylinder as described i n t h i s section.
(5) Remove t h e bolts/nuts attaching t h e support
plate t o t h e axle and remove the support plate.
SUPPORT PLATE INSTALLATION
(1) Transfer the wheel cylinder and p a r k i n g brake
lever components to t h e replacement support plate.
(2) Position t h e support plate on t h e axle and i n -
s t a l l t h e a t t a c h i n g bolts/nuts.
(3) I n s t a l l t h e brakeshoes. Adjust t h e shoes t o t h e
d r u m w i t h a brake gauge.
(4) I n s t a l l the brake d r u m .
(5) I n s t a l l the axle shaft.
(6) I n s t a l l t h e wheel and t i r e .
(7) Remove the supports and lower the vehicle.
5 - 52 BRAKES •
PARKING B R A K E S
INDEX
Page Page
Front Cable Replacement . . . . . . . . . . . . . . . . . . . 52 Parking Brake Cable Adjustment 52
General Information 52 Rear Cable Replacement 52
Intermediate Cable Replacement . . . . . . . . . . . . . . 55

GENERAL INFORMATION ( 1 0 ) Disconnect t h e cable from t h e equalizer a n d

r a t i o lever.
The p a r k i n g brake mechanism o n A D models i s a ( 1 1 ) Remove t h e cable.
three cable system operated b y a foot pedal assembly
(Figs. 1 a n d 2). T h e foot pedal i s mounted o n t h e REAR CABLE INSTALLATION
driver side cowl panel. The front cable is attached t o ( 1 ) I n s e r t t h e cable t h r o u g h t h e support plate hole
the pedal assembly. A n i n t e r m e d i a t e cable connects and seat t h e cable.
the front cable t o t h e rear cables. A n equalizer a n d (2) Connect t h e cable t o the lever on the secondary
r a t i o lever connect t h e rear cables t o t h e i n t e r m e d i - brakeshoe.
ate cable. T h e rear cables are connected to t h e sec- (3) I n s t a l l t h e brakeshoes, p a r k i n g brake s t r u t and
ondary brakeshoes b y a lever attached to each shoe. spring, t h e shoe r e t u r n and holdown springs a n d t h e
self adjuster components.
PARKING BRAKE CABLE ADJUSTMENT (4) I n s t a l l t h e cable i n t h e cable guide a n d i n s t a l l
t h e cable r e t a i n i n g clips, i f equipped.
( 1 ) A d j u s t t h e rear d r u m brakes before adjusting (5) Connect t h e cable t o t h e r a t i o lever a n d equal-
the p a r k i n g b r a k e cables. izer.
(2) Release t h e p a r k i n g brakes fully. (6) A d j u s t t h e rear brakes a n d i n s t a l l t h e b r a k e
(3) Raise t h e vehicle. d r u m a n d wheel.
(4) Loosen t h e adjusting n u t o n t h e front cable u n - (7) A d j u s t t h e p a r k i n g brake cable.
t i l there is slack i n a l l t h e cables.
(5) Rotate t h e rear wheels a n d t i g h t e n t h e cable FRONT CABLE REPLACEMENT
adjusting n u t u n t i l a s l i g h t d r a g is created a t t h e
wheels. FRONT CABLE REMOVAL
(6) Continue r o t a t i n g t h e r e a r wheels a n d loosen ( 1 ) Remove t h e front cable adjusting n u t .
the cable adjusting n u t u n t i l a l l d r a g is e l i m i n a t e d . (2) Remove t h e clip seeming t h e cable t o t h e a n -
(7) Back off the cable adjusting n u t a n a d d i t i o n a l chor b r a c k e t and slide t h e cable out of the bracket.
two f u l l t u r n s . (3) Remove t h e r e t a i n e r a t t a c h i n g the cable t o t h e
(8) A p p l y t h e p a r k i n g brake several times. pedal assembly frame.
(9) Release t h e p a r k i n g brakes and and verify t h a t (4) Disengage the cable from t h e pedal clevis.
the rear wheel rotates freely (no drag). (5) Remove t h e cable grommet (or seal) from t h e
( 1 0 ) Lower t h e vehicle. floor pan.
(6) Remove t h e front cable.
REAR CABLE REPLACEMENT
FRONT CABLE INSTALLA TION
( 1 ) I n s e r t t h e cable t h r o u g h t h e floor pan.
REAR CABLE REMOVAL (2) Connect the cable t o the pedal clevis a n d i n s t a l l
( 1 ) Release t h e p a r k i n g brakes f u l l y . t h e cable r e t a i n e r .
(2) Raise t h e vehicle. (3) Seat t h e cable grommet (or seal) i n t h e floor-
(3) Remove t h e adjusting n u t f r o m t h e front cable. pan.
(4) Remove t h e rear wheels. (4) Route t h e cable t o t h e anchor bracket a n d i n -
(5) Remove t h e brake drums. termediate cable.
(6) Remove the brakeshoes a n d p a r k i n g brake s t r u t (5) Secure t h e cable i n the anchor bracket w i t h t h e
and spring. U-clip.
(7) Disconnect the cable f r o m t h e p a r k i n g b r a k e le- (6) Connect t h e cable t o t h e adjusting l i n k a n d i n -
ver on t h e secondary brakeshoe. s t a l l t h e cable adjusting n u t .
(8) Compress t h e cable r e t a i n e r tabs a n d remove (7) A d j u s t t h e rear brakeshoes, i f necessary.
the cable f r o m t h e support plate. (8) A d j u s t t h e p a r k i n g brake cable as described i n
(9) Remove the cable from the guides and r e t a i n i n g t h i s section.
clips.
 BRAKES 5 - 53
•
SUPPORT NUT ASSEMBLY <^> I TORQUE
ASSEMBLY
(15.8 N.m)
SEALING
INSTRUMENT PANEL
130 140FT. IN.LBS.LBS.
(40.6 N.m)
WASHER
17 IN. LBS. (1.9 N.m)
1 (10.7 N.mJ
95 IN. LBS.
[ 35 FT. LBS. {47.4 N.m)

FRONT CABLE
ANCHOR BRACKET

FRONT CABLE
NUT •ri ASSEMBLY
ASSEMBLY

DASH
PANEL

SEAL
ASSEMBLY

FRONT CABLE ASSEMBLY

LEFT REAR CABLE

ASSEMBLY

pm om wm W350

PAGE 1 OF 2 RR05E103

Fig. 1 Parking Brake Cable Routing

5 - 54 BRAKES •
CABLE INTERMEDIATE BRACKET BOLT

VIEW E

Fig. 2 Parking Brake Cable Attachment

 • BRAKES 5 - 55

INTERMEDIATE CABLE REPLACEMENT
(1) Remove the adjusting nut from the front cable.
(2) Disengage the intermediate cable from the ratio
lever or cable equalizer.
(3) Remove the cable.
(4) Connect the new cable to the ratio lever or ca-
ble equalizer.
(5) Connect the cable to the adjusting link.
(6) Instert the front cable i n the adjusting link and
and install the cable adjusting nut.
(7) Adjust the brakeshoes i f necessary.
(8) Adjust the parking brake cable as described i n
this section.

R E A R W H E E L ANTI-LOCK B R A K E S Y S T E M (RWAL)
INDEX
Page Page
General Information 55 System Operation .. 57
System Components 55

GENERAL INFORMATION electronic brake control module for processing. The

control unit determines rate of deceleration and
A rear wheel anti-lock brake system is standard wheel slip from these signals.
equipment on all A D models. I t i s a n electronically
operated system designed to retard rear wheel lockup SYSTEM COMPONENTS
during periods of high wheel slip and deceleration.
Retarding lockup i s accomplished by modulating Basic system components include a n electronic
fluid pressure to the rear brsjke units. brake control module, a hydraulic pressure control
Rear brake fluid apply pressure i s modulated ac- valve, a speed sensor and exiter ring and a n anti-
cording to wheel speed, degree of wheel slip and rate lock indicator lamp (Fig. 1).
of deceleration. A sensor located i n the rear axle
housing converts differential case rotating speed into
electronic signals. T h e signals are transmitted to the

RWAL
ELECTRONIC
L
CONTROL
MODULE

SPEED
SENSOR HYDRAULIC
AXLE VALVE
HOUSING
EXCITER
RING

J9005-96

Fig. 1 Rear Wheel Anti-Lock Brake System (RWAL)

5 - 56 BRAKES
A standard master cylinder and. vacuum power
brake booster are used for a l l applications.
ANTI-LOCK ELECTRONIC CONTROL MODULE
The electronic module controls a l l phases of a n t i -
lock mode brake operation. The module is separate
from other electrical circuits i n t h e vehicle a n d oper-
ates independently.
The module is located on the passenger side cowl
panel under the dash (Fig. 2). The system h y d r a u l i c
valve, speed sensor a n d indicator lamps are a l l i n cir-
cuit w i t h the module. The module contains a micro-
processor t h a t operates the system and performs
system diagnostic checks.
Speed sensor i n p u t s are continuiously monitored
and interpreted by t h e module. The module deter-
mines wheel speed and rate of deceleration from
these inputs and activates t h e appropriate solenoid
i n t h e hydraulic valve w h e n necessary.
The module microprocessor also contains a self test
program. The p r o g r a m is activated w h e n the i g n i t i o n
switch is t u r n e d to the O n position. I n t h i s mode, the
module checks indicator l i g h t operation, the system
electrical circuits and t h e pressure l i m i t i n g valve so-
lenoids.
The brake w a r n i n g and anti-lock indicator lamps
are i l l u m i n a t e d for approximately t w o seconds dur-
i n g the system self test cycle.
Fig. 2 Anti-Lock Electronic Control Module
•
RWAL HYDRAULIC VALVE
The h y d r a u l i c valve is a pressure c o n t r o l l i n g device
and is operated by the electronic module. The valve
controls f l u i d apply pressure to t h e r e a r brake u n i t s
d u r i n g a n t i - l o c k mode b r a k i n g (Fig. 3). The valve is
mounted on t h e d r i v e r side frame r a i l at the front of
the vehicle.
The valve contains a n accumulator, a n isolation
valve and a d u m p valve. The accumulator is operated
by f l u i d a n d s p r i n g pressure. The t w o valves are op-
erated by electrical solenoids. The solenoids are oper-
ated by t h e anti-lock control module.
The h y d r a u l i c valve components are inactive dur-
i n g periods o f n o r m a l b r a k i n g effort. The valve com-
ponents are activated only w h e n b r a k i n g effort a n d
rate of wheel slip and deceleration are h i g h ( a n t i -
lock mode).
D u r i n g n o r m a l b r a k i n g t h e valve allows free flow
of brake f l u i d to the rear b r a k e u n i t s . I n anti-lock
mode, t h e v a l v e w i l l decrease, h o l d or increase f l u i d
apply pressure as needed.
CONNECTOR J9005-99
Fig. 3 RWAL Hydraulic Valve
SPEED SENSOR AND EXITER RING
A single pole, variable reluctance speed sensor is
used to t r a n s m i t speed a n d rate of deceleration i n -
puts to the control module (Fig. 4). The sensor is ac-
tuated by a n exiter r i n g on the differential case.
The sensor is mounted a t t h e top of the rear axle
housing d i r e c t l y over the gear-type exiter r i n g (Fig.
1). The exiter r i n g is pressed onto the differential
case next to t h e r i n g gear.
 • BRAKES 5 - 57

The exiter r i n g i s t h e sensor t r i g g e r mechanism. ACCUMULATOR CLOSED DUMP ISOLATION

As t h e r i n g rotates, the teeth o n the r i n g w i l l i n t e r - VALVE VALVE
CLOSED £ OPEN
u p t the magnetic field around t h e sensor pole. T h e
r a t e o f i n t e r r u p t i o n is converted i n t o speed signals
w h i c h are t r a n s m i t t e d t o the control module.

MOUNTING FROM
FLANGE MASTER
SPRING CYLINDER

TO REAR BRAKES

J9005-93
CONNECTOR
TO CONTROL Fig. 5 Valve Position And Fluid Flow-Normal
MODULE Braking
SINGLE able l i m i t s of wheel slip/deceleration are about t o be
POLE exceeded. T h e module activates t h e h y d r a u l i c valve
SENSOR J9005-98
at t h i s point.
The control module t r a n s m i t s a signal t o t h e isola-
Fig. 4 RWAL Speed Sensor
t o r valve solenoid w h i c h closes t h e valve (Fig. 6).
ANTI-LOCK INDICATOR LAMP Closing the valve prevents f u r t h e r f l u i d flow t o t h e
The amber colored indicator l a m p is located i n the rear wheel cylinders. This action isolates t h e rear
message center. The l a m p alerts t h e d r i v e r i f an an- brakes from the master cylinder. The net effect is to
ti-lock system f a u l t occurs. decrease rear brake apply pressure t o t h e p o i n t
The anti-lock and brake w a r n i n g lamps are b o t h i n where t h e wheels w i l l continue t o rotate a n d n o t
c i r c u i t w i t h the electronic module. T h e module w i l l lock.
cause the t w o lamps t o i l l u m i n a t e or flash to a l e r t
ACCUMULATOR CLOSED ISOLATION
t h e d r i v e r t h a t system operation is either n o r m a l or VALVE
t h a t a f a u l t has occurred. CLOSED

ANTI-LOCK SYSTEM OPERATION

D u r i n g l i g h t b r a k e applications, rear wheel decel-
e r a t i o n and/or slip i s not sufficient to activate the an- MASTER
ti-lock system. B r a k e f l u i d apply pressure a t the rear CYLINDER
wheels is n o r m a l . However, w h e n b r a k i n g effort, de- DUMP
gree of wheel slip a n d rate o f deceleration approach VALVE
CLOSED
programmed l i m i t s , sensor i n p u t s w i l l cause t h e
module t o activate the system. TO REAR BRAKES

Normal Braking Mode

I n n o r m a l b r a k i n g mode, t h e h y d r a u l i c valve com-
ponents are inactive. The isolation valve is open and
t h e dump valve a n d accumulator are closed. F l u i d
flows unimpeded t h r o u g h the isolation valve directly
to t h e rear wheel cylinders (Fig. 5).
Start Of Anti-Lock Mode Braking
W h e n h i g h pedal effort b r a k i n g occurs, t h e de-
crease i n exiter wheel r o t a t i n g speed is noted and
converted i n t o a n electronic signal b y t h e sensor.
T h i s signal is t r a n s m i t t e d t o a n d processed by t h e
control module. T h e module determines t h a t accept-
J9005-94
Fig. 6 Valve Position And Fluid Flow At Start Of
Anti-Lock Mode Braking
Additional Pressure Relief During Anti-Lock Mode Braking
The dump valve and accumulator are h y d r a u l i c a l l y
connected and serve as additional pressure l i m i t i n g
devices. T h e accumulator a n d dump v a l v e r e m a i n
closed d u r i n g i n i t i a l closing o f the i s o l a t i o n valve.
However, i f pressure exerted b y f l u i d captured i n t h e
wheel cylinders and lines is h i g h enough t o lock the
wheels, t h e dump valve and accumulator are a c t i -
vated (Fig. 7).
5 - 58 BRAKES

When captured fluid pressure i s high, the control
module opens the dump valve (Fig. 7). Since the
dump valve is connected to the accumulator, a por-
tion of the captured fluid is diverted through the
valve and into the accumulator. The amount of fluid
diverted i s sufficient to reduce apply pressure to anti-
lock levels.
When rear brake pressure requirements return to
normal levels, the accumulator spring closes the ac-
cumulator. Fluid i n the accumulator is forced out
and back into the hydraulic system.
Isolation/Dump Valve Cycle Times
Activation (opening/closing) of the isolation and
dump valves is continous during anti-lock operation.
The valves cycle rapidly i n response to speed sensor
inputs and control module signal commands. Cycle
times are measured i n milliseconds.
A s the demand for anti-lock mode brake operation
is decreased, the module deactivates the hydraulic
valve components to restore normal brake operation.

ACCUMULATOR DUMP ISOLATION

OPEN VALVE VALVE
CLOSED

•mini]
• r v i i f f t i l

FROM
MASTER
CYLINDER

FROM REAR BRAKES TO ACCUMULATOR

J9005-95

Fig. 7 Dump Valve And Accumulator Position In

Pressure Relief Mode
 • BRAKES
RWAL S E R V I C E D I A G N O S I S
INDEX
Page
General Information 59
GENERAL INFORMATION
A n anti-lock system malfunction w i l l be indicated
by i l l u m i n a t i o n of the amber anti-lock w a r n i n g lamp.
I n most cases, t h e r e d brake w a r n i n g l a m p w i l l also
i l l u m i n a t e a t the same t i m e .
I f a problem occurs, system diagnosis should begin
w i t h a fluid level check followed b y a v i s u a l exami-
n a t i o n o f t h e system electrical and h y d r a u l i c connec-
tions. I f obvious defects (low fluid, leaks, loose
connections, etc.) are not evident, road test t h e vehi-
cle. A road test should help determine i f a malfunc-
t i o n is a c t u a l l y related to a n anti-lock component.
D u r i n g t h e road test, note i f other conditions are
evident such as a l o w pedal, p u l l , grab, or s i m i l a r
condition. Remember t h a t brake malfunctions such
as low fluid, system leaks, p a r k i n g brakes p a r t i a l l y
applied, w i l l also affect t h e anti-lock system. T h e
idea is t o determine i f a malfunction is a c t u a l l y re-
lated to a n anti-lock component.
I f a v i s u a l inspection and road test do not indicate
the problem cause, component inspection, f a u l t code
identification a n d t e s t i n g w i t h t h e D R B I I w i l l be
necessary.
5 - 59
Page
System Fault Codes 59
SYSTEM FAULT CODES
The microprocessor i n t h e electronic control module
has a self test feature. This feature is activated
whenever t h e i g n i t i o n s w i t c h is i n t h e O n and R u n
positions.
I f a system f a u l t i s detected, t h e control module
w i l l i l l u m i n a t e the anti-lock indicator lamp and store
t h e f a u l t code i n t h e microprocessor memory. I f a
f a u l t code is generated, t h e module w i l l r e t a i n t h e
code after t u r n i n g the i g n i t i o n switch to O f f position.
FAULT CODE CAPACITY
The microprocessor memory w i l l store and display
o n l y one f a u l t code a t a t i m e . The stored code can be
displayed b y g r o u n d i n g t h e R W A L diagnostic connec-
tor.
FAULT CODE IDENTIFICATION
To determine w h a t t h e f a u l t code is, m o m e n t a r i l y
g r o u n d t h e R W A L diagnostic connector a n d count
t h e n u m b e r of times t h e amber anti-lock indicator
l a m p flashes. F a u l t codes a n d t y p i c a l malfunctions
are o u t l i n e d i n Figure 8. Note t h a t w h e n a f a u l t code
is generated, the red brake w a r n i n g l a m p w i l l also i l -
luminate.
The i n i t i a l flash w i l l be a long flash followed b y a
n u m b e r o f short flashes. T h e long flash indicates t h e
b e g i n n i n g o f t h e f a u l t number sequence a n d t h e
short flashes are a c o n t i n u a t i o n o f t h a t sequence.
Y o u m u s t count the long flash along w i t h t h e
s h o r t flashes f o r a n accurate f a u l t code c o u n t .
5 - 60 BRAKES •
CLEARING A FAULT CODE Refer to Figures 9, 10 and 11 for module connector
To clear a fault code, disconnect the control module pin identification, diagnostic connector locations and
connector or disconnect the battery for a minimum of component locations. Refer to the wiring schematics
five seconds. During system retest, wait 30 seconds i n Group 8 for R W A L system electrical circuitry and
to be sure the fault code does not reappear. wire identification.

MODULE WASHER
FAULT CONNECTOR BOTTLE
CODE
NUMBER TYPICAL FAILURE DETECTED

1 Not used.

2 Open isolation valve wiring or bad control

module.

3 Open dump valve wiring or bad control

module.

4 Closed RWAL valve switch. BLACK

6-WAY
5 Over 16 dump pulses generated in 2WD CONNECTOR
vehicles (disabled for 4WD).
Fig. 9 Connector Locations
6 Erratic speed sensor reading while rolling.

7 Electronic control module fuse pellet open,

isolation output missing, or valve wiring
shorted to ground.

8 Dump output missing or valve wiring shorted to

ground.
ooo.oo o o
ooo o o o o
9 Speed sensor wiring/resistance (usually high
reading). 10 11 12 13 14

10 Sensor wiring/resistance (usually low reading).

11 Brake switch always on. RWAL light comes on 8905-38

when speed exceeds 40 mph.
Fig. 10 Module Connector Identification
12 Not used.
8 9 10 11 12 13 14
13 Electronic control module phase lock loop
failure.

14 Electronic control module program check

failure.

15 Electronic control module RAM failure.

J90Q5-101

Fig. 8 RWAL System Fault Codes

1 2 3 4 5 6 7 8905-39

Fig. 11 Module Connector Pin Position

 BRAKES 5 - 61

COMPONENT S E R V I C E

INDEX
Page Page

Checking Speed Sensor Air Gap . . . 61 Specifications 63

Electronic Control Module Replacement 61 Speed Sensor Replacement 61
General Service Information 61 Tightening Reference 64
Hydraulic Valve Replacement 61

GENERAL SERVICE INFORMATION (2) Position valve on frame bracket.

(3) I n s t a l l and t i g h t e n valve a t t a c h i n g n u t s t o 22-
The rear wheel anti-lock ( R W A L ) components are 34 N«m (16-25 ft-lbs) torque.
serviced as assemblies only. The module, anti-lock (4) T i g h t e n valve brake lines.
h y d r a u l i c control valve, speed sensor a n d exciter r i n g (5) Bleed t h e h y d r a u l i c v a l v e and brakes. Refer to
are n o t repairable. These components m u s t be r e - procedure i n Service Adjustments section.
placed i f diagnosis indicates a fault. (6) Lower vehicle.

HYDRAULIC VALVE REPLACEMENT CHECKING SPEED SENSOR AIR GAP

VALVE REMOVAL
(1) Raise vehicle.
(2) Disconnect valve-to-sensor harness connector.
Refer to F i g . 10, on page 5-16 for valve m o u n t i n g .
(3) Disconnect brake lines connecting h y d r a u l i c
valve to r e a r brakes and t o combination valve.
(4) Remove h y d r a u l i c valve a t t a c h i n g screws and
remove valve f r o m frame bracket.
VALVE INSTALLATION
(1) S t a r t b r a k e lines i n h y d r a u l i c valve.
(1) Remove sensor f r o m d i f f e r e n t i a l .
(2) Measure and record distance f r o m underside o f
sensor flange to end of sensor pole piece (Fig. 12).
Distance should be 27.17 t o 27.43 m m (1.07 to 1.08
in). T h i s measurement represents dimension B .
(3) Measure distance between sensor m o u n t i n g sur-
face o f differential case a n d t e e t h a t top o f exciter
r i n g (Fig. 13). distance should be 1.085 t o 1.12 i n c h .
This distance represents dimension A .
(4) Subtract dimension B f r o m dimension A t o de-
t e r m i n e sensor a i r gap w h i c h is dimension C (Fig.
12).

SENSOR MOUNTING FACE SENSOR FLANGE

DIMENSION A

DIMENSION B

DIMENSION C

DIMENSION B

SENSOR POLE
EXCITER RING PIECE 8905-34

Fig. 12 Checking Sensor Air Gap

5 - 62 BRAKES •
(5) A i r gap should be m i n i m u m of .12 m m (.005 i n ) (6) Lower vehicle.
and a m a x i m u m o f 1.27 m m (.050 i n ) .
(6) I f a i r gap is n o t w i t h i n stated l i m i t s , proceed as ELECTRONIC CONTROL MODULE REPLACEMENT
follows:
(a) Replace sensor i f dimension B is not w i t h i n The R W A L control module is a t the passenger side
of t h e vehicle. O n models w i t h A/C, the module is at-
l i m i t s specified i n step (2).
tached t o the dash panel near t h e defroster duct a n d
(b) Replace exciter wheel or r e p a i r differential
resistor board (Fig. 13).
i f dimension A is not w i t h i n l i m i t s specified i n step
(3).
(c) Replace sensor and exciter wheel i f b o t h
components are o u t of tolerance.

SPEED SENSOR REPLACEMENT

SENSOR REMOVAL
(1) Raise vehicle o n hoist.
(2) Remove bolt securing sensor to differential
housing.
(3) Remove sensor shield and sensor from differen-
t i a l housing.
(4) Disconnect sensor w i r i n g and remove sensor.

SENSOR INSTALLATION
"(1) Connect wires to sensor. B e s u r e seal i s se-
c u r e l y i n p l a c e b e t w e e n sensor a n d w i r i n g c o n - Fig. 13 Anti-Lock Control Module Mounting
nector,
To remove t h e module, remove t h e a t t a c h i n g
(2) I n s t a l l O-ring on sensor ( i f removed).
screws, disconnect the module harness connector a n d
(3) I n s e r t sensor i n differential housing.
remove t h e module. A f t e r i n s t a l l i n g the new module,
(4) I n s t a l l sensor shield.
t i g h t e n t h e module a t t a c h i n g screws to 2.3 N»m (21
(5) I n s t a l l and t i g h t e n sensor a t t a c h i n g bolt to 19-
in-lbs) torque.
29 N*m (170-230 in-lbs).
+ BRAKES 5 - 63

SPECIFICATIONS
D l 00/150 W250/350with
DISC B R A K E Wl007150 AD150 W250 D250/350 Model 6 0 Frt. A x l e
Caliper Chrysler Chrysler Chrysler Chrysler Bendix

Type Sliding Sliding Sliding Sliding Sliding

Piston Diameter 3.1 in 3.1 in 3.1 in 3.1 in 3.38 in

(78.7 m m) (78.7 m m) (78.7 mm) (78.7 mm) (85.8 mm)

Rotor Diameter 11.63 in 11.75 in 12.82 in 12.88 in 12.88 in

(295 mm) (298 mm) (325.6 mm) (327 mm) (327 mm)

Rotor Thickness 1.25 in 1.25 in 1.25 in 1.25 in 1.19 in

(31.75 m m) (31.75 m m) (31.75 mm) (31.75 mm) (30 m m )

A D l 00/150 D l 00/150 D250-D350 D 3 5 0 - W350

DRUM B R A K E W l 00/150 W250-W350 w/4000 1B o r Model 6 0 Frt. A x l e
Size (inches) 11 x 2.5 12 x 2.5 12x3

Make Chrysler Bendix Bendix

Drum Type Composite Cast Iron Cast Iron

Wheel Cyl. Bore .938' (23.8 mm) 1.00' (25.4 mm) 1.125' (28.57 mm)

MASTER CYLINDER:
Dand W 100/150/250. .Chrysler, Aluminum, Two-Section, 1.125* bore
D and W 250/350 Bendix, Integral, Cast One-Piece, 1.125* bore

POWER B O O S T E R :
D and W 100/150 250 mm (9.84 in) Single Diaphragm, Vacuum.
D and W 250/350 H.D 205 mm (8.07 in) Dual Diaphragm, Vacuum.

TOLERANCE LIMITS:
Rotor Runout (All except W250/350) .004 in (. 10 mm)
Rotor Runout (W250/350) .005 in (.127 mm)
Rotor Thickness Variation (All except W250/350) 0005 in (.013 mm)
Rotor Thickness Variation (W250/350) .001 in (.025 mm)
Brake Drum Runout (Max. allowable—all) .. .008 in (.20 mm)
Brake Drum Diameter Variation (Max. allowable—all) 003 in (.076 mm)

J9005-140
5 - 64 BRAKES

TIGHTENING REFERENCE
COMPONENT FOOT LBS. INCH LBS. (Niti)

Rear Wheel Brake Support Axle Housing Bolt/Nut 7/16 . . 75 (101)

1/20 . . . 85 (101)
95 (11)
15 (2)
Front Wheel Brake Hose Fitting B o l t . . . . . . . 35 (48)
Flexible Brake Hose To Brake Line Tubes (Ail). . 115-175 (13-20)

POWER BRAKE
Power Brake Booster Mounting Nuts 220 (25)
35 (4)
200 ± 30 (23)
Brake Line Tube Nuts, 3/8 or 7/16 . . . . . . . . 115-175 (13-20)
1/2 or 9/16 . . . . . . . 140-200 (15-23)
120 (162)

DISC BRAKE (CHRYSLER)

Adapter Mounting Bolts Dl 50-D250-AD150 . . . no (149)
W150, AWl 50, W250 150 (203)
D250 H.D., D350 160 (216)
Retainer and Anti-Rattle Spring . . . . . . . . . . 200 (25)

DISC BRAKE (BENDIX)

Adapter Mounting Bolts W350 and W250 Extra . 160 (216)
15 (20)

RWAL HYDRAULIC VALVE

16-25 (22-34)

J9005-141
 • CLUTCH
CLUTCH
CONTENTS
Page
CLUTCH COMPONENT SERVICE . . . . . . . . . . . . 11
GENERAL INFORMATION 1
G E N E R A L INFORMATION
INDEX
Page
Clutch Component Lubrication 1 Clutch Linkage Fluid
Clutch Components . . . . . . . . . . . . . . . . . . . . . . . . 1
CLUTCH COMPONENTS
MECHANICAL COMPONENTS
The clutch mechanism i n A D models w i t h m a n u a l
transmission consists o f a single, dry-type c l u t c h disc
and a d i a p h r a g m style c l u t c h cover. T h e transmis-
sion i n p u t shaft is supported i n t h e crankshaft b y a
p i l o t bushing. A sleeve type release b e a r i n g i s used
to engage and disengage the c l u t c h pressure plate.
The release b e a r i n g i s operated b y a release fork i n
the clutch housing. The fork pivots o n a b a l l s t u d at-
tached t o the housing i n t e r i o r . The release f o r k i s ac-
tuated b y a h y d r a u l i c slave cylinder mounted i n the
housing. T h e slave cylinder is operated b y a clutch
master cylinder connected t o t h e c l u t c h pedal.
The c l u t c h disc has cushion springs i n the disc hub.
The c l u t c h disc facing i s r i v e t e d t o t h e h u b . T h e fac-
i n g is made f r o m a non-asbestoes m a t e r i a l . The
clutch cover pressure plate is a d i a p h r a g m type u n i t
w i t h a one-piece d i a p h r a g m s p r i n g a n d m u l t i p l e re-
lease fingers. T h e pressure plate release fingers are
preset d u r i n g manufacture a n d are n o t adjustable.
A 265 m m (10 i n ) diameter c l u t c h disc and clutch
cover pressure plate are used i n models w i t h 3.9L en-
gine and NP2500 transmission.
A 280 m m (11 i n ) diameter c l u t c h disc a n d clutch
cover pressure plate are used i n models w i t h a 3.9L,
5.2L, or 5.9L engine a n d a n A435 or A833 transmis-
sion.
HYDRAULIC LINKAGE COMPONENTS
A h y d r a u l i c l i n k a g e mechanism i s used for clutch
actuation. The l i n k a g e consists o f a remote reservoir,
clutch master cylinder, slave cylinder, and intercon-
necting f l u i d lines.
The master cylinder is connected t o t h e clutch
pedal a n d t h e slave cylinder i s connected t o t h e
clutch release fork. T h e c l u t c h master cylinder is
mounted o n t h e drivers side o f t h e dash panel adja-
6- 1
Page
SERVICE DIAGNOSIS 2
Page
1
cent to the brake master cylinder. The cylinder i s op-
erated b y a suspended type c l u t c h pedal.
CLUTCH LINKAGE FLUID ^
The clutch f l u i d reservoir, master cylinder, slave
cylinder and fluid lines are prefilled w i t h f l u i d a t t h e
factory d u r i n g assembly operations.
The h y d r a u l i c system should not require a d d i t i o n a l
f l u i d under n o r m a l circumstances. I n fact, the r e s e r -
v o i r f l u i d l e v e l w i l l a c t u a l l y i n c r e a s e as n o r m a l
clutch wear occurs. F o r this reason, it is impor-
t a n t to a v o i d o v e r f i l l i n g , o r r e m o v i n g f l u i d from
the r e s e r v o i r .
I f inspection or diagnosis indicates additional f l u i d
m a y be needed, use Mopar brake fluid, or a n equiv-
alent meeting S A E and D O T standards J1703 a n d
D O T 3. Do not use any other type of fluid.
CLUTCH COMPONENT LUBRICATION
Proper clutch component l u b r i c a t i o n is i m p o r t a n t
to satisfactory operation. U s i n g the correct l u b r i c a n t
and avoiding overlubrication are also equally impor-
t a n t . D u r i n g service, apply recommended l u b r i c a n t
sparingly. Do not overlubricate as t h i s could r e s u l t i n
disc and pressure plate contamination.
C l u t c h components r e q u i r i n g l u b r i c a t i o n are: t h e
p i l o t bushing; release lever pivot b a l l ; release lever
contact surfaces; clutch disc h u b splines and c l u t c h
pedal pivot bore and bushings. Transmission compo-
nents r e q u i r i n g l u b r i c a t i o n are t h e : i n p u t shaft
splines and p i l o t h u b and release bearing slide sur-
face o f t h e front bearing retainer. D o not apply
grease t o any p a r t o f the c l u t c h cover, disc, or release
bearing.
Use Mopar multi-purpose grease or a silicone
grease for the c l u t c h pedal bushings and pivot shaft.
Use Mopar H i g h Temperature Wheel Bearing Grease
or equivalent for a l l other c l u t c h l u b r i c a t i o n require-
6 - 2 CLUTCH
ments. A p p l y recommended amounts only a n d do not
overlubricate. Refer t o t h e C l u t c h Service section for
specific i n f o r m a t i o n .
S E R V I C E DIAGNOSIS
INDEX
Page
Clutch Problem Causes . . . . . . . . . . . . . . . . . 2
General Diagnosis Information 2
GENERAL DIAGNOSIS INFORMATION
Unless t h e cause o f a clutch problem i s extremely
obvious, a road test followed by component inspection
w i l l be r e q u i r e d for accurate diagnosis. The test w i l l
help determine the type of f a u l t a n d component i n -
spection w i l l identify t h e problem component.
D u r i n g a road test, drive t h e vehicle a t n o r m a l
speeds. S h i f t t h e transmission t h r o u g h a l l gear
ranges a n d observe c l u t c h action. I f chatter, grab,
slip, or improper release is experienced, remove and
inspect t h e clutch components. However, i f the prob-
l e m i s noise or h a r d s h i f t i n g , f u r t h e r diagnosis may
be needed as the transmission o r another driveline
component m a y be a t f a u l t . Careful observation dur-
i n g the test w i l l help n a r r o w t h e problem area.
CLUTCH PROBLEM CAUSES
CONTAMINATION
F l u i d contamination i s one o f t h e more common
causes o f c l u t c h malfunctions. O i l , water, or clutch
fluid on t h e clutch contact surfaces w i l l result i n
f a u l t y operation. The u s u a l r e s u l t i s chatter, slip, or
grab.
D u r i n g inspection, note i f any components are con-
t a m i n a t e d w i t h oil, h y d r a u l i c fluid, or water/road
splash.
O i l contamination indicates a leak a t either t h e
rear m a i n seal or transmission i n p u t shaft. O i l leak-
age produces a residue o f o i l on t h e housing i n t e r i o r
and o n t h e clutch cover and flywheel. Heat b u i l d u p
caused b y slippage between t h e cover, disc and fly-
wheel, can sometimes bake t h e o i l residue onto the
components. The glaze-like residue ranges i n color
from amber t o black.
Road splash contamination means dirt/water i s en-
t e r i n g the clutch housing due t o loose bolts, .housing
cracks, or t h r o u g h h y d r a u l i c cylinder openings. D r i v -
i n g t h r o u g h deep water puddles can force water/road
splash i n t o the housing t h r o u g h such openings.
C l u t c h fluid leaks are from a loose or damaged
slave cylinder line or connection. However, clutch
fluid leaks w i l l usually be noted a n d corrected before
severe contamination occurs.
•
Page
Inspection And Diagnosis Charts 5
CLUTCH MISALIGNMENT
C l u t c h components m u s t be i n proper a l i g n m e n t
w i t h t h e crankshaft a n d t r a n s m i s s i o n i n p u t shaft.
M i s a l i g n m e n t caused b y excessive r u n o u t or warpage
of any c l u t c h component w i l l cause grab, chatter and
improper c l u t c h release.
Flywheel Runout
Common causes o f r u n o u t a r e heat warpage, i m -
proper m a c h i n i n g , m o u n t i n g t h e flywheel o n a d i r t y
crankshaft flange, incorrect b o l t t i g h t e n i n g , or i m -
proper seating on t h e crankshaft flange shoulder.
V e r y l i g h t scratches o r surface roughness o n t h e
flywheel face can be cleaned u p by scuff sanding w i t h
180 g r i t paper. However, i f t h e surface is warped or
severely scored, replace t h e flywheel. D o n o t m a -
c h i n e t h e flywheel. T h e flywheel face i s m a n u -
f a c t u r e d w i t h a u n i q u e s u r f a c e finish. M a c h i n i n g
w o u l d negate this feature a n d c o u l d result i n u n -
satisfactory operation.
Clean t h e crankshaft flange before m o u n t i n g t h e
flywheel. D i r t and grease o n t h e flange surface may
cock t h e flywheel causing r u n o u t . Use n e w bolts
w h e n r e m o u n t i n g a flywheel a n d secure t h e bolts
w i t h Mopar Lock A n d Seal. T i g h t e n flywheel bolts to
specified torque only. O v e r t i g h t e n i n g could distort
the flywheel h u b causing r u n o u t .
Clutch Cover And Disc Runout
Check t h e c l u t c h disc before i n s t a l l a t i o n . A x i a l
(face) r u n o u t o f a n e w disc should not exceed .5 m m
(.020 inch). Measure r u n o u t about .35 m m (1/4 inch)
from t h e outer edge o f t h e disc facing. O b t a i n an-
other disc i f r u n o u t i s excessive.
Check condition o f t h e c l u t c h before i n s t a l l a t i o n . A
warped cover or d i a p h r a g m s p r i n g w i l l cause grab
and incomplete release or engagement. Be careful
when h a n d l i n g t h e cover a n d disc. Impact can distort
the cover, d i a p h r a g m s p r i n g , release fingers a n d the
h u b of t h e clutch disc.
Use a n a l i g n m e n t tool w h e n positioning the disc on
the flywheel. T h e tool prevents accidental m i s a l i g n -
ment w h i c h could r e s u l t i n cover distortion a n d disc
damage.
A frequent cause o f c l u t c h cover distortion (and
consequent m i s a l i g n m e n t ) is improper bolt t i g h t e n -
 • CLUTCH
ing. To avoid w a r p i n g the cover, the bolts must t i g h t -
ened alternately (diagonal pattern) and evenly (2-3
threads at a time) to specified torque.
Clutch Housing Misalignment And Runout
C l u t c h housing alignment is i m p o r t a n t t o proper
operation. The housing bore m a i n t a i n s a l i g n m e n t be-
tween t h e crankshaft and transmission i n p u t shaft.
Misalignment can cause noise, incomplete clutch r e -
lease and chatter; I t can also result i n premature
wear o f the pilot bearing, cover release fingers and
clutch disc. I n severe cases, m i s a l i g n m e n t can also
cause premature wear of t h e transmission i n p u t
shaft and bearing.
Housing face m i s a l i g n m e n t is generally caused b y
incorrect seating on the engine or transmission, loose
housing bolts, missing a l i g n m e n t dowels or housing
damage. Infrequently, m i s a l i g n m e n t m a y also be
caused by housing m o u n t i n g surfaces t h a t are n o t
parallel.
I f housing m i s a l i g n m e n t is suspected, housing bore
and face r u n o u t can be checked w i t h a d i a l indicator
as described i n the following two procedures:
MEASURING CLUTCH HOUSING BORE
RUNOUT
(1) Remove the clutch housing and s t r u t .
(2) Remove the clutch cover and disc.
(3) Replace one of the flywheel bolts w i t h a 7/16-20
by t e n inch (25.4 cm) long threaded rod (Fig. 1). T h e
rod w i l l be used to m o u n t t h e d i a l indicator.
(4) Remove the release fork f r o m the clutch hous-
ing.
(5) Reinstall the clutch housing. T i g h t e n the hous-
i n g bolts nearest the alignment dowels first.
(6) M o u n t t h e d i a l indicator on t h e threaded r o d
and position the indicator plunger on t h e surface o f
the clutch housing bore (Fig. 2).
(7) Rotate t h e crankshaft u n t i l t h e indicator
plunger is a t the top center o f the- housing bore. Zero
the indicator at t h i s point.
(8) Rotate the crankshaft and record t h e indicator
readings a t eight points (45 degrees apart) around
the bore (Fig. 3). Repeat the measurement a t least
twice for accuracy.
(9) Subtract each reading f r o m the one 180 degrees
opposite to determine magnitude a n d direction o f
runout. Refer to Figure 3 and following example.
Bore r u n o u t example:
.000 -(-.007) = .007 i n c h
+ .002 - (-.010) = .012 inch
+ .004 - (-.005) = .009 i n c h
-.001 - ( + .001) = -.002 i n c h ( = .002 inch)
6-3
I n the above example, the largest difference is .012
i n c h and is called the t o t a l indicator reading (TIR).
This means t h a t the housing bore is offset from the
crankshaft centerline b y .006 i n c h (which is 1/2 of
.012 inch).
The acceptable m a x i m u m T I R for the housing bore
is .010 i n c h . However, i f the T I R is more t h a n .010
(as i n t h e example), bore r u n o u t w o u l d have t o be
corrected w i t h offset dowels. Offset dowels are avail-
able i n .007, .014 and .021 i n c h sizes for t h i s purpose
(Fig. 4).
I f housing bore r u n o u t exceeds .010 TIR, refer to
Correcting Housing Bore R u n o u t for offset dowel i n -
stallation.
CORRECTING CLUTCH HOUSING BORE
RUNOUT
The d i a l indicator reads positive w h e n the plunger
moves i n w a r d (toward indicator) and negative when
i t moves o u t w a r d (away f r o m indicator). A s a result,
the lowest or most negative reading determines t h e
direction o f housing bore offset (runout).
I n t h e sample readings shown i n F i g u r e 3 and i n
step (7) above, the bore is offset t o w a r d the .010 inch
reading. To correct t h i s , remove t h e housing and
o r i g i n a l dowels. T h e n i n s t a l l the new offset dowels i n
the direction needed to center t h e bore w i t h t h e
crankshaft centerline.
I n t h e example, T I R was .012 inch. T h e dowels
needed t o correct offset w o u l d be P/N 1736347 w i t h
an offset of .007 i n c h (Fig. 4).
I n s t a l l the dowels w i t h the slotted side facing out
so they can be t u r n e d w i t h a screwdriver. Then i n -
s t a l l t h e housing, r e m o u n t t h e d i a l indicator a n d
check bore r u n o u t again. Rotate the dowels u n t i l the
T I R is less t h a n .010 i n c h i f necessary.
I f a T I R of .053 i n c h or greater is encountered, i t
may be necessary to replace the clutch housing.
7/16- 20 THREAD NUT
10 INCHES LONG
J9006-25
Fig. 1 Dial Indicator Mounting Stud Or Rod
6 - 4 CLUTCH

MOUNTING STUD DIAL INDICATOR MEASURING CLUTCH HOUSING FACE

OR ROD RUNOUT
(1) Reposition t h e d i a l indicator plunger o n t h e
housing face (Fig. 5). Place t h e indicator plunger a t
INDICATOR the r i m o f t h e housing bore as shown.
PLUNGER
(2) Rotate t h e crankshaft u n t i l t h e indicator
plunger i s a t t h e t e n o-clock position o n t h e bore.
T h e n zero t h e d i a l indicator.
(3) Measure a n d record face r u n o u t a t four points
90 degrees a p a r t around t h e housing face (Fig. 6).
Perform the measurement a t least twice for accuracy.
(4) Subtract t h e lowest r e a d i n g from t h e highest t o
determine t o t a l r u n o u t . A s a n example, refer to t h e
CLUTCH sample readings shown i n F i g u r e 6. I f t h e l o w read-
HOUSING i n g was m i n u s .004 i n c h a n d t h e highest reading
BORE J9006-26
was p l u s .009 i n c h , t o t a l r u n o u t is actually .013
Fig. 2 Checking Clutch Housing Bore Runout inch.
(5) T o t a l allowable face r u n o u t is .010 inch. I f
r u n o u t exceeds t h i s figure, r u n o u t w i l l have t o be
.000
corrected. Refer t o Correcting C l u t c h Housing Face
+ .002 Runout.

INDICATOR DIAL INDICATOR

PLUNGER CLUTCH
+ .004 HOUSING
FACE

.001

CLUTCH
HOUSING
BORE
(SAMPLE READINGS) J9006-27
CIRCLE

Fig. 3 Housing Bore Measurement Points And

Sample Readings
INDICATOR MOUNTING
SLOT SHOWS DIRECTION STUD OR ROD J9006-29
OF OFFSET OFFSET
DOWEL Fig. 5 Measuring Clutch Housing Face Runout
CORRECTING CLUTCH HOUSING FACE
RUNOUT
Housing face r u n o u t can be corrected b y i n s t a l l i n g
shims between the c l u t c h housing and transmission
(Fig. 7). T h e shims can be made from s h i m stock or
1DOWEL SELECTION1 s i m i l i a r materials of the required thickness.
Dowel As a n example, assume t h a t face r u n o u t is t h e
TIR Dowel
\falue same as shown i n Figure 6 a n d i n step (4) above. I n
m Offset
t h i s case, three shims w i l l be needed. S h i m t h i c k -
.011 - .021 inch 1736347 .007 inch
nesses should be .009 ( a t t h e .000 corner), .012 (at
.022 - .035 inch 1736348 .014 inch the -.003 corner) and .013 i n c h (at t h e -.004 corner).
.036 - .052 inch 1736353 .021 inch After i n s t a l l i n g the c l u t c h assembly a n d housing,
t i g h t e n t h e housing bolts nearest t h e alignment dow-
els first. Correct housing bolt torques are: 30 ft-lbs
for 3/8 diameter bolts a n d 50 ft-lbs for 7/16 diameter
bolts.
J9006-28

Fig. 4 Housing Bore Alignment Dowels

• CLUTCH 6-5

D u r i n g f i n a l reassembly o f t h e transmission, i n - INSTALLATION METHODS AND PARTS

s t a l l t h e shims between t h e c l u t c h h o u s i n g a n d USAGE
transmission a t t h e appropriate b o l t locations. Distortion o f clutch components d u r i n g i n s t a l l a t i o n
and t h e use o f non-standard components are addi-
t i o n a l causes o f clutch malfunction.
Improper c l u t c h cover b o l t t i g h t e n i n g can d i s t o r t
the cover. T h e usual r e s u l t i s c l u t c h grab, chatter
and r a p i d wear. T i g h t e n t h e cover bolts as described
i n the C l u t c h Service section.
Improperly seated flywheels a n d c l u t c h housings
are other causes o f clutch f a i l u r e . Improper seating
w i l l produce m i s a l i g n m e n t a n d subsequent c l u t c h
problems. T i g h t e n a l l t h e c l u t c h housing bolts t o
proper torque before i n s t a l l i n g a n y struts. Also be
sure the a l i g n m e n t dowels are i n place and seated i n
(AT RIM the block a n d housing beforehand.
OF BORE) J900640 The use o f non-standard o r l o w q u a l i t y parts can
also lead t o problems a n d wear. Use t h e recom-
Fig. 6 Housing Face Measurement Points And
mended factory q u a l i t y parts t o avoid comebacks.
Sample Readings
CUT/DRILL INSPECTION AND DIAGNOSIS CHARTS
The c l u t c h inspection c h a r t (Fig. 8) outlines items
to be checked before and d u r i n g c l u t c h i n s t a l l a t i o n .
Use the c h a r t as a check l i s t t o help avoid overlook-
i n g potential problem sources d u r i n g service opera-
tions.
The diagnosis charts describe common clutch prob-
lems, causes a n d correction. F a u l t conditions are
listed a t the top o f each chart. Conditions, causes and
corrective action are o u t l i n e d i n t h e indicated col-
umns.
MAKE SHIM The charts are provided as a convenient reference
1-INCH when diagnosing f a u l t y c l u t c h operation.
DIAMETER J9006-31

Fig. 7 Housing Face Alignment Shims

6 - 6 CLUTCH
1 Check clutch housing bolts. Tighten if loose. Be sure
housing is fully seated on engine block.
2 Check flywheel condition. Scuff sand flywheel face
to remove glaze. Clean surface with a wax and
grease remover afterward. Replace flywheel if
severely scored, worn or cracked. Secure flywheel
with new bolts (if removed). Do not reuse old bolts.
Use Lock and Seal on bolts.
3 Tighten clutch cover bolts 2-3 threads at a time, alter-
nately and evenly (in a diagonal pattern) to specified
torque. Failure to do so could warp the cover.
4 Check release fork. Replace fork if distorted or worn.
Make sure ball stud and release bearing contact sur-
faces are lubricated.
5 Check release fork pivot. Be sure pivot is tight and
ball end is lubricated.
6 Transmission input shaft bearing will cause noise,
chatter, or improper release if damaged. Check con-
dition before installing transmission.
7 Inspect release bearing slide surface of trans, front
bearing retainer. Surface should be smooth, free of
nicks, scores. Replace retainer if necessary. Lubricate
slide surface before installing release bearing.
Fig. 8 Clutch Inspection Points
•
8 Check input shaft seal if clutch cover and disc were
oil covered. Replace seal if worn, or cut.
9 Do not replace release bearing unless actually faulty.
Replace bearing only if seized, noisy, or damaged.
10 Check clutch cover diaphragm spring and release
fingers. Replace cover if spring or fingers are bent,
warped, broken, cracked. Do not tamper with fac-
tory clutch spring setting. Clutch problems will result.
11 Check condition of clutch cover. Replace clutch cover
if plate surface is deeply scored, warped, worn, or
cracked. Be sure cover is correct size and properly
aligned on disc and flywheel.
12 Inspect clutch housing. Be sure alignment dowels are
in position and bolts are tight. Replace housing if
cracked, or damaged. If clutch problems ocurred,
check runout, to be sure housing is square with
flywheel and transmission input shaft.
13 Verify that housing alignment dowels are in position
before installing housing.
14 Clean engine block surface before installing clutch
housing. Dirt, grime can produce misalignment.
15 Make sure side of clutch disc marked "flywheel side"
is toward flywheel.
16 Check rear main seal if clutch disc and cover were
oil covered. Replace seal if necessary.
17 Check crankshaft flange (if flywheel is removed). Be
sure flange is clean and flywheel bolt threads are
in good condition.
18 Check pilot bushing. Replace bushing if scored or
seized. Lube with high temp. Grease before
installation.
19 Check transmission input shaft. Clutch disc must slide
freely on shaft splines. Lightly grease splines before
installation. Replace shaft if splines or pilot bushing
hub are damaged.
20 Check flywheel bolt torque. If bolts are loose,
replace them. Use Mopar Lock and Seal to secure
new bolts.
21 Check clutch disc facing. Replace disc if facing is
charred, scored, flaking off, or worn. Also check
runout of new disc. Runout should not exceed .5 mm
(.02 in.).
J9006-20
• CLUTCH
CLUTCH SLIPS
Condition Found Cause
1. Disc facing worn out. a) Normal wear.
b) Driver frequently "rides"
(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
contaminated with oil, grease, transmission input shaft seal.
or clutch fluid.
b) Excessive amount of grease
applied to input shaft splines.
c) Road splash, water entering
housing.
d) Slave cylinder leaking.
3. Clutch is running partially Release bearing sticking-binding.
disengaged. Does not return to normal running
position.
4. Flywheel height incorrect. Flywheel surface improperly
machined. Too much stock removed
or surface is tapered.
5. Wrong disc or pressure plate Incorrect parts order or model
installed. number.
6. Clutch disc, cover and/or a) Rough handling (impact) bent
diaphragm spring, warped, cover, spring, or disc.
distorted.
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.
8. Clutch disc facing burnt a) Frequent operation under high
(charred). Flywheel and cover loads or hard acceleration
pressure plate surfaces heavily conditions.
glazed.
b) Driver frequently "rides"
(slips) clutch. Results in rapid
wear and overheating of disc
and cover.
6 - 7
Correction
Replace clutch disc. Also replace
cover if spring is weak or pressure
plate surface is damaged.
a), b), c), d) Replace leaking
seals. Apply less grease to
input shaft splines. Replace
clutch disc (do not clean and
reuse). Clean clutch cover and
reuse only if cover is in good
condition. Replace slave
cylinder if leaking.
Verify that bearing is actually
binding, then replace bearing and
transmission front bearing retainer if
sleeve surface is damaged.
Replace flywheel.
Replace with correct parts.
Compare old and new parts before
installation.
Install new disc or cover as needed.
Follow installation/tightening
instructions.
or surface grinding. Replace
flywheel if scores-nicks are deeper
than .002-.004 inch.
Scuff sand flywheel. Replace clutch
cover and disc. Alert driver to
problem cause.
J9006-21
6 - 8 CLUTCH
IMPROPER CLUTCH RELEASE
Condition Found
1. Clutch disc warped.
2. Clutch disc binds on input
shaft splines.
3. Clutch disc rusted to flywheel
and/or pressure plate.
4. Clutch disc facing sticks to
flywheel.
5. Clutch disc too thick.
6. Pilot bushing seized or loose.
7. Clutch will not disengage
properly.
Cause
New disc not checked for axial
runout before installation.
a) Clutch disc hub splines
damaged during installation.
b) Input shaft splines rough,
damaged.
c) Corrosion, rust formations on
splines of disc and input shaft.
Occurs in vehicles stored, or not
driven for extended periods
of time. Also occurs after steam
cleaning if vehicle is not used for
extended period.
Vacuum may form in pockets over
rivet heads in clutch disc. Occurs as
clutch cools down after use.
Wrong disc installed.
a) Bushing cocked during
installation.
b) Bushing defective.
c) Bushing not lubricated.
d) Clutch misalignment.
a) Low clutch fluid level.
b) Clutch cover loose.
c) Wrong clutch disc.
d) Disc bent, distorted during
installation.
e) Clutch cover diaphragm spring
bent or wraped during
transmission instalation.
f) Clutch disc installed
backwards.
g) Release fork bent or fork pivot
is loose or damaged.
h) Clutch master or slave cylinder
fault.
•
Correction
Replace disc. Be sure runout of new
disc is less than .5 mm (.020 in.).
Clean, smooth and lubricate disc
and shaft spines. Replace disc
and/or input shaft if splines are
severely damaged.
Remove clutch cover and disc. Sand
rusted surfaces clean with 180 grit
paper. Replace disc cover, and
flywheel if corrosion is severe.
Drill 1/16 inch diameter hole
through rivets and scuff sand disc
facing With 180 grit paper.
Replace disc.
a), b), c), d) Lubricate and install
hew bushing. Check and
correct any misalignment.
a) Top off reservoir and check for
leaks.
b) Tighten bolts.
c) Install correct disc.
d) Repalce disc.
e) Replace cover.
f) Remove and reinstall disc
correctly. Be sure disc side
marked "to flywheel" is
actually toward flywheel.
g) Replace fork and pivot if worn
or damaged.
h) Replace master and slave
cylinder as assembly.
J9006-22
• CLUTCH
CLUTCH GRAB/CHATTER
Condition Found
1. Clutch disc facing covered with
oil, grease, or clutch fluid.
2. Clutch disc and/or cover
warped, or disc facings exhibit
unusual wear or appear to be
wrong type.
3. Clutch master or slave cylinder
plunger dragging-binding.
4. No fault found with clutch
components.
5. Partial engagement of clutch
disc (one side worn-opposite
side glazed and lightly worn).
Cause
a) Oil leak at rear main or input
shaft seal.
b) Too much grease applied to
splines or disc and input shaft.
Incorrect or substandard parts.
a) Master or slave cylinder
components worn or corroded.
a) Problem actually related to
suspension or driveline
component.
b) Engine related problem.
a) Clutch pressure plate position
setting incorrect or modified.
b) Clutch) cover, spring, or release
fingers bent, distorted (rough
handling, improper assembly).
c) Clutch disc damaged or
distorted.
d) Clutch misalignment.
6 *9
Correction
a) Correct leak and replace disc
(do not clean and reuse the
disc).
b) Apply lighter grease coating
to splines and replace disc (do
not clean and reuse the disc).
Replace disc and/or cover with
correct parts.
a) Replace both cylinders as
assembly (and reservoir).
a) Further diagnosis required.
Check engine/transmission
mounts, propeller shafts and
U-joints, tires, suspension
attaching parts and other
driveline components as
needed.
b) Check EFI and igniton systems.
a) Replace clutch cover and disc.
b) Replace clutch cover and disc.
c) Replace disc.
d) Check alignment and runout of
flywheel, disc, or cover and/or
clutch housing. Correct as
necessary.
J9006-23
6 - 10 CLUTCH
Condition Found
1. Clutch components damaged
or worn out prematurely.
2. Pilot bushing seized.
3. Loose components.
4. Components appear
overheated. Hub of disc
cracked or torsion damper
springs are distorted or
broken.
5. Contact surface of release
bearing damaged.
6. Release bearing is noisy.
7. Clutch pedal squeak.
CLUTCH NOISE
Cause
Incorrect or sub-standard clutch
parts.
a) Bushing cocked or scored
during installation.
b) Bushing not lubricated prior to
installation.
c) Bushing defect.
d) Clutch misalignment.
Attaching bolts loose at flywheel,
cover, or clutch housing.
Frequent high load, full throttle
operation.
a) Clutch cover incorrect, or
release fingers are bent or
distorted causing damage.
b) Release bearing defect.
c) Release bearing misaligned.
Release bearing defect.
a) Pivot pin loose.
b) Pedal bushings worn out or
cracked.
•
Correction
Replace with parts of correct type
and quality.
a), b), c) Replace bushing. Be
sure it is properly seated and
lubricated before installing
clutch.
d) Check and correct
misalignment caused by
excessive runout of flywheel,
disc, cover or clutch housing.
Replace input shaft if bearing
hub is damaged.
Tighten bolts to specified torque.
Replace any clutch bolts that are
damaged.
Replace parts as needed. Alert
driver to condition causes.
a) Replace clutch cover and
bearing.
b) Replace bearing.
c) Check and correct runout of
clutch components. Check front
bearing retainer sleeve surface.
Replace if damaged.
Replace bearing.
Tighten pivot pin. Replace bushings
if worn or damaged. Lubricate pin
and bushings with silicone base
lubricator chassis grease.
J9006-24
 • CLUTCH 6-11

CLUTCH SERVICE
INDEX
Page Page
Clutch Cover and Disc Installation 11 Clutch Pedal Removal/Installation . . . . . . . . . . . . . 15
Clutch Cover and Disc Removal . . . . . . . . . . . . . . 11 Pilot Bushing Replacement 13
Clutch Housing Removal/Installation . 12 Release Bearing Replacement . 12
Clutch Linkage Service 13

CLUTCH COVER AND DISC REMOVAL
(1) Raise the vehicle.
(2) Remove t h e transmission a n d transfer case i f
equipped. Refer t o Group 2 1 for procedures.
(3) I f the clutch cover w i l l be reused, m a r k position
of the cover on the flywheel w i t h s m a l l p u n c h m a r k s
(Fig. 1).
(3) I n s e r t a c l u t c h a l i g n m e n t tool i n the clutch disc.
(4) V e r i f y t h a t the disc h u b is positioned correctly.
Side o f h u b m a r k e d "Flywheel Side" should face fly-
wheel (Fig. 2).
(5) I n s e r t the a l i g n m e n t tool or spare i n p u t shaft i n
the p i l o t b u s h i n g a n d position t h e disc on the fly-
wheel (Fig. 3).
CLUTCH
DISC

"FLYWHEEL SIDE"
STAMPED ON
THIS SURFACE

J9006-33

Fig. 2 Clutch Disc Position (Typical)

TRANSMISSION CLUTCH
DRIVE PINION HOUSING

Fig. 1 Marking Cover And Flywheel Position

(4) I f the c l u t c h cover w i l l be reused, loosen t h e
clutch cover bolts evenly a n d i n r o t a t i o n t o relieve
spring tension. Loosen t h e bolts a few threads a t a
t i m e only to avoid w a r p i n g t h e cover.
(5) Remove t h e cover bolts a n d remove t h e cover
and disc.

CLUTCH COVER AND DISC INSTALLATION

ENGINE
(1) Check r u n o u t a n d free operation o f t h e new FLYWHEEL RF482
clutch disc. I n s t a l l the disc on t h e transmission i n p u t
shaft splines. T h e disc should slide freely o n t h e Fig. 3 Clutch Disc Alignment (Typical)
splines. Leave the disc on t h e shaft and check r u n o u t (6) Position t h e clutch cover over the disc and on
w i t h a dial indicator. Position t h e indicator plunger the flywheel (Fig. 4).
about 1/4 inch from t h e outer edge o f t h e facing. (7) I n s t a l l a l l of the clutch cover bolts finger t i g h t .
Runout should not exceed .5 m m (.020 inch). O b t a i n
another clutch disc i f r u n o u t exceeds specified l i m i t .
(2) Lubricate the crankshaft p i l o t b u s h i n g w i t h Mo-
par H i g h Temperature grease. T h e grease m u s t be a
h i g h temperature type t o be effective and r e m a i n on
the bushing surface.
6-12 CLUTCH
(8) T i g h t e n t h e cover bolts evenly (and i n rotation)
a few threads a t a t i m e . T h e c o v e r b o l t s m u s t b e
tightened evenly a n d t o specified t o r q u e t o
a v o i d d i s t o r t i n g t h e c o v e r . T i g h t e n 5/16 i n c h d i -
a m e t e r b o l t s t o 23 N - m (17 ft-lbs). T i g h t e n 3/8
i n c h d i a m e t e r b o l t s t o 4 1 N » m (30 ft-lbs).
(9) A p p l y a l i g h t coating o f M o p a r H i g h Tempera-
t u r e grease t o t h e splines o f t h e transmission i n p u t
shaft a n d t o t h e release b e a r i n g slide surface o f the
transmission f r o n t b e a r i n g retainer. D o n o t o v e r l u -
bricate t h e shaft splines. T h i s c a n result i n
grease c o n t a m i n a t i o n o f the disc.
(10) I n s t a l l t h e transmission. See Group 2 1 for pro-
cedure.
ENGINE BLOCK CLUTCH DISC AND COVER
Fig. 4 Clutch Housing Installation And Tightening
Reference
CLUTCH HOUSING REMOVAL/INSTALLATION
(1) Raise t h e vehicle and remove t h e transmission
and transfer case i f equipped.
(2) Remove the dust cover a n d c l u t c h housing bolts
and remove t h e cover a n d housing from t h e trans-
mission (Fig. 4).
(3) Clean the housing m o u n t i n g surface o f the en-
gine block w i t h a w a x and grease remover.
(4) Verify t h a t t h e clutch housing a l i g n m e n t dow-
els are i n good condition and properly seated.
•
(5) Transfer t h e slave cylinder, release f o r k a n d
boot, f o r k p i v o t s t u d and wire/hose brackets t o t h e
new housing.
(6) L u b r i c a t e the release f o r k a n d pivot contact sur-
faces w i t h Mopar H i g h Temperature wheel b e a r i n g
grease before i n s t a l l a t i o n .
(7) A l i g n a n d i n s t a l l t h e c l u t c h housing o n t h e
transmission. T i g h t e n the housing bolts closest t o t h e
a l i g n m e n t dowels f i r s t a n d t o t h e torque values i n d i -
cated (Fig. 4).
(8) I n s t a l l t h e transmission-to-engine s t r u t after i n -
s t a l l i n g t h e clutch housing. T i g h t e n the b o l t attach-
i n g t h e s t r u t t o t h e c l u t c h housing first a n d t h e
strut-to-engine bolt last.
(9) I n s t a l l t h e transmission a n d transfer case i f
equipped. Refer to t h e procedure i n Group 2 1 .
RELEASE BEARING REPLACEMENT
(1) Remove the transmission a n d clutch h o u s i n g as
a n assembly.
(2) Disconnect t h e release b e a r i n g from t h e fork
and remove the b e a r i n g (Fig. 5).
(3) Inspect t h e b e a r i n g slide surface on t h e t r a n s -
mission front b e a r i n g retainer. Replace t h e r e t a i n e r
i f the slide surface is scored, w o r n or cracked.
(4) Inspect t h e release f o r k a n d f o r k b a l l pivot. Be
sure t h e p i v o t is secure a n d i n good condition. Be
sure t h e f o r k is n o t distorted or w o r n . Also replace
the release f o r k r e t a i n e r s p r i n g i f bent or damaged i n
any way.
(5) L u b r i c a t e t h e crankshaft p i l o t bushing, i n p u t
shaft splines, b e a r i n g r e t a i n e r slide surface, f o r k
pivot a n d release f o r k p i v o t surface w i t h Mopar H i g h
Temperature wheel b e a r i n g grease.
(6) I n s t a l l t h e release fork a n d release bearing. Be
sure t h e f o r k and b e a r i n g are properly secured.
(7) I n s t a l l the transmission and clutch housing.
Fig. 5 Clutch Release Fork And Bearing
 • CLUTCH
PILOT BUSHING REPLACEMENT
(1) Remove the transmission and clutch housing.
(2) Remove t h e c l u t c h cover and disc.
(3) Remove the p i l o t b u s h i n g . Use a n i n t e r n a l type
p u l l e r tool o r collapse t h e b u s h i n g w i t h a punch and
remove i t .
(4) Clean t h e b u s h i n g bore w i t h solvent and d r y
w i t h compressed air.
(5) I n s t a l l t h e new b u s h i n g w i t h a n a l i g n m e n t tool
or spare i n p u t shaft. T h e b u s h i n g should be flush
w i t h the edge o f t h e b u s h i n g bore. Do not recess t h e
bushing.
(6) Lubricate t h e b u s h i n g w i t h Mopar H i g h Tem-
perature grease, or equivalent only. Do not use a n y
other type o f l u b r i c a n t o n t h e bushing.
(7) I n s t a l l t h e clutch cover and disc.
(8) I n s t a l l t h e transmission and clutch housing.
CLUTCH LINKAGE SERVICE
The clutch master cylinder, remote reservoir,
s l a v e c y l i n d e r a n d c o n n e c t i n g l i n e s a r e a l l ser-
v i c e d as a n a s s e m b l y . T h e s e c o m p o n e n t s c a n n o t
be serviced separately. T h e cylinders a n d con-
necting lines are sealed units. They a r e prefilled
w i t h fluid d u r i n g manufacture and must not be
disassembled n o r disconnected.
LINKAGE REMOVAL
(1) Raise t h e vehicle.
(2) Remove the n u t s a t t a c h i n g the slave cylinder t o
t h e clutch housing.
(3) Remove t h e slave cylinder a n d clip from t h e
housing.
(4) Lower t h e vehicle.
(5) Carefully remove t h e locating clip from t h e
clutch master cylinder m o u n t i n g bracket (Fig. 6).
(6) Remove t h e r e t a i n i n g r i n g , flat washer a n d
wave washer t h a t attach t h e clutch master cylinder
push rod t o t h e c l u t c h pedal (Fig. 6).
(7) Slide t h e c l u t c h master cylinder push rod off the
clutch pedal p i n .
(8) Inspect condition o f t h e bushing on t h e clutch
pedal p i n . Remove and replace t h e bushing i f w o r n or
damaged.
(9) Verify t h a t the cap o n t h e clutch master c y l i n -
der reservoir i s t i g h t . T h i s is necessary to avoid u n -
due spillage d u r i n g removal.
6 - 13
(10) Remove t h e screws a t t a c h i n g the clutch f l u i d
reservoir t o t h e dash panel.
(11) I f necessary, remove t h e reservoir m o u n t i n g
bracket screws a n d remove the bracket from the dash
panel.
(12) P u l l t h e c l u t c h master cylinder rubber seal
from t h e dash panel (Fig. 6).
(13) Rotate t h e c l u t c h master cylinder 45 degrees
counterclockwise t o unlock i t . T h e n remove t h e cyl-
inder f r o m t h e dash panel.
(14) Remove t h e c l u t c h cylinders, reservoir a n d
connecting lines from the vehicle.
LINKAGE INSTALLATION
(1) T i g h t e n t h e cap o n the c l u t c h fluid reservoir t o
avoid spillage d u r i n g i n s t a l l a t i o n .
(2) Position t h e cylinders, connecting lines and res-
ervoir i n t h e vehicle.
(3) I n s e r t t h e c l u t c h master cylinder i n t h e dash
panel. Rotate t h e cylinder 45 degrees clockwise t o
lock i t i n place.
(4) L u b r i c a t e t h e master cylinder rubber seal w i t h
l i q u i d d i s h soap t o ease i n s t a l l a t i o n . Then seat t h e
seal i n t h e dash and around the cylinder.
(5) Position t h e reservoir on the dash panel and i n -
s t a l l t h e reservoir screws. T i g h t e n t h e screws to 5
N*m (40 in-lbs) torque.
(6) I n s t a l l t h e reservoir m o u n t i n g bracket on t h e
dash panel, i f removed.
(7) I n s t a l l a replacement b u s h i n g on t h e clutch
pedal p i n i f necessary.
(8) I n s t a l l t h e c l u t c h master cylinder push rod on
the c l u t c h pedal p i n . Secure t h e rod w i t h t h e wave
washer, flat washer and retainer r i n g .
(9) I n s t a l l t h e locating clip i n t h e clutch master
cylinder m o u n t i n g bracket.
(10) Raise t h e vehicle.
(11) I n s e r t t h e slave cylinder push rod t h r o u g h the
clutch h o u s i n g opening and i n t o t h e release lever. Be
sure t h e cap o n t h e end of the r o d is securely en-
gaged i n t h e release lever. Check t h i s before i n s t a l l -
i n g t h e c y l i n d e r a t t a c h i n g nuts.
(12) I n s t a l l and t i g h t e n t h e slave cylinder attach-
i n g n u t s t o 23 N»m (200 in-lbs) torque.
(13) L o w e r t h e vehicle.
(14) I f a n e w linkage has been installed, remove
the plastic s h i p p i n g stop from t h e master cylinder
push rod—-after i n s t a l l i n g t h e slave cylinder—and
before operating t h e linkage.
(15) Operate t h e linkage a few times to verify
proper operation.
 O)
i

FLUID DASH PEDAL PREFERRED TIGHTENING TORQUE

SUPPORT
- 4

RESERVOIR
11 Nm (100 In-lbs)
y» 23 Nm (200 in-lbs)
O
© 5 Nm (40 in-lbs) 1—
(D) 5 Nm (45 in-lbs) cz
HI
O
FLUID
LINES

PEDAL
SHAFT

BRACKET

CLUTCH
SLAVE CLUTCH J900643
CYLINDER HOUSING

Fig. 6 Clutch Linkage And Pedal Components

• CLUTCH
CLUTCH PEDAL REMOVAL/INSTALLATION
(1) Remove the retaining ring, flat washer a n d
wave washer that secure the clutch master cylinder
push rod to the clutch pedal pin (Fig. 6).
(2) Remove the fastener that secures the pedal
shaft to the pedal support.
(3) Slide the pedal shaft out of the left side of the
support and out of the clutch pedal.
(4) Slide the push rod off the clutch pedal pin and
remove the clutch pedal.
(5) Remove and inspect the bushings i n the clutch
6-15
pedal shaft bore and on the bushing on the pedal pin.
Replace any bushing that is worn or damaged.
(6) lubricate the pedal shaft, pedal shaft bore and
all the bushings with Mopar multi purpose grease, or
with a silicone grease.
(7) Insert the pedal pin into the cylinder push rod.
T h e n position* the clutch pedal i n the support.
(8) Slide the pedal shaft through the clutch pedal
bore and bushings.
(9) Install the fastener that secures the pedal shaft
to the support.
(10) Secure the push rod to the pedal pin with the
wave washer, flat washer and retaining ring (Fig. 6).
 • COOLING SYSTEM 7 - 1

COOLING SYSTEM

CONTENTS
Page Page

ACCESSORY DRIVE BELTS . . 21 ENGINE BLOCK HEATERS 24

COOLING SYSTEM DIAGNOSIS 4 SERVICE PROCEDURES ...8
DIAGNOSIS 3 SPECIFICATIONS . . . . . . . . . . . . . . . . . 25

GENERAL INFORMATION A n optional factory i n s t a l l e d m a x i m u m d u t y cool-

T h r o u g h o u t t h i s group, references m a y be made t o
a p a r t i c u l a r vehicle b y letter or number designation.
A c h a r t showing t h e breakdown o f these designations
is included i n t h e I n t r o d u c t i o n Section a t t h e f r o n t o f
t h i s service m a n u a l .
COOLING SYSTEM
The cooling system regulates the engine operating
t e m p e r a t u r e by; a l l o w i n g the engine t o reach n o r m a l
operating t e m p e r a t u r e as q u i c k l y as possible, m a i n -
t a i n i n g n o r m a l operating temperature, and prevent-
i n g overheating.
The cooling system also provides a means o f heat-
i n g the passenger compartment and cooling t h e auto-
m a t i c t r a n s m i s s i o n f l u i d ( i f equipped). T h e cooling
system i s pressurized a n d uses a centrifugal w a t e r
p u m p to circulate coolant throughout t h e system.
i n g package is available o n most models. T h i s pack-
age w i l l provide a d d i t i o n a l cooling capacity for
vehicles used under extreme conditions such as
t r a i l e r t o w i n g i n h i g h a m b i e n t temperatures.
As coolant temperature reaches approximately
220°F t h e engine idle speed i s increased b y t h e en-
gine controller to provide increased cooling system
performance.
COOLING SYSTEM COMPONENTS
The cooling system consists of: a down-flow r a d i a -
tor, engine d r i v e n cooling f a n , f a n spacer ( w i t h o u t a i r
conditioning), f l u i d fan drive ( w i t h a i r conditioning),
fan shroud, radiator pressure cap, thermostat, cool-
ant reserve system, t r a n s m i s s i o n o i l cooler ( i f
equipped w i t h a n automatic transmission), coolant,
water p u m p (to circulate coolant), hoses a n d hose
clamps.
7 - 2 COOLING SYSTEM

SYSTEM COOLANT ROUTING

Coolant flow circuits for 3.9L, 5 . 2 L a n d 5.9L en-
gines w i t h w a t e r cooled i n t a k e manifolds a r e shown
i n f i g u r e 1.

SHUT OFF VALVE

NOTE: HEATER A / C ONLY COOLANT FLOW - PUMP TO
COOLANT FLOW CYLINDER BLOCK, UP THROUGH
CIRCUIT IS ALWAYS CYUNDER HEADS TO INTAKE
OPEN EXCEPT MANIFOLD WATER BOX TO
WHEN IN AAAX. 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 CLOSED-HIGH FLOW
THERMOSTAT OPEN-LOW FLOW

RR07B52

Fig. 1 Cooling System Routing

 • COOLING SYSTEM 7-3

DIAGNOSIS
INDEX
Page Page
Preliminary Diagnosis . .. 3 Symptom and Action . .. 3

PRELIMINARY DIAGNOSIS 3. A I R C O N D I T I O N I N G ; A D D - O N O R A F T E R
MARKET:
ENGINE COOLING SYSTEM OVERHEAT A m a x i m u m cooling package should have been or-
DIAGNOSIS dered w i t h t h e vehicle i f add-on or after m a r k e t A/C
Establish w h a t " d r i v i n g " conditions caused t h e is i n s t a l l e d . I f not, m a x i m u m cooling system compo-
complaint. A n y o f t h e following abnormal loads o n nents should be i n s t a l l e d for t h e model involved ac-
the cooling system m a y be t h e cause. cording t o manufacturer's specifications.
1. P R O L O N G E D I D L E , V E R Y H I G H A M B I - 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 -
ENT TEMPERATURE, SLIGHT TAIL WIND A T PAIR:
I D L E , SLOW TRAFFIC, T R A F F I C JAMS, H I G H De t e rm ine i f any recent service has been performed
SPEED, STEEP GRADES: on t h e vehicle t h a t may affect t h e cooling system
such as: engine adjustments (incorrect t i m i n g ) , slip-
D r i v i n g techniques t h a t avoid overheating are:
p i n g accessory drive belt(s), brakes (possibly drag-
(a) Idle w i t h A/C off w h e n temperature gauge
ging), changed parts (possibly wrong), recored
is a t end of n o r m a l range. radiator or cooling system r e f i l l i n g (possibly under
(b) Increase engine speed for more a i r flow. filled or trapped a i r ) .
2. T R A I L E R T O W I N G : I f i n v e s t i g a t i o n reveals none of t h e above as a
Consult t h e " T r a i l e r T o w i n g " section o f the owners cause for engine overheating complaint refer t o t h e
m a n u a l . Do not exceed l i m i t s . following symptom a n d action chart.
SYMPTOM and ACTION
(See P r e l i m i n a r y FIRST)
Symptom Action
Blinking Engine Temperature Normal during temporary operation with heavy load, towing a trailer, high outdoor temperatures,
Warning Light Or High Gauge and/or on~a steep 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 timing, engine misfiring.
Heat Damage, Hot Carpet,
Seat, Hot Catalytic
Converter, Smoke,
Burnt Odor
Hot Engine A moderate amount of sound from heating metal can be expected with any vehicle. However, a
Crackling Noise crackling sound from the thermostat housing, a hot smell and/or severe local hot spots on an
Hot Smell engine can indicate blocked coolant passages, bad casting, core sand deposits and subsequent
Severe Local Hot Spots 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 temperature. If the
Level Changes level in the bottle is between the Maximum and Minimum marks at normal engine operating tem-
perature, 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 function, if an air leak
To Radiator 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 vac-
uum leak only. Coolant return failure will be evident by a low level in the radiator. Reserve bottle
level should increase during heat-up.
7 - 4 COOLING SYSTEM
COOLING S Y S T E M DIAGNOSIS
CONDITION AND CHECK
OPTIONAL 60°F GAUGE READS LOW
(1) Verify gauge reeding. Is a low temperature indicated?
(2) Is code 17 recorded in On Board Diagnostics memory?
(3) Is the gauge reading in the cold range?
(4) Low coolant level during cold ambient temperatures
(accompanied with poor heater performance).
(5) Coolant level is correct.
GAUGE READING HIGH. NO PRESSURE BLOW OFF FROM
RADIATOR PRESSURE CAP OR STEAM FROM COOLANT
RESERVE TANK.
(1) Verify gauge reading. Is a high temperature reading indicated?
(2) Gauge reading at "H" without signs of boiling.
(3) Low coolant level in radiator and coolant reserve tank.
(4) Coolant level in radiator is low. But not low in coolant reserve
tank.
(5) Test coolant freeze point.
(6) Ensure proper coolant flow.
DIAGNOSIS
30° TO 40°
GAUGE TRAVEL
IS NORMAL
MID
Normal Gauge Travel
(1) Inspect temperature gauge sending unit. Refer to Group 8,
Electrical. Repair or replace sending unit as necessary.
(2) If code 17 is recorded, replace the thermostat. If not, the
thermostat is not the cause of the low gauge reading.
(3) Inspect for disconnected sending unit electrical connector or
incorrect sending unit. Ensure that gauge sending unit is installed
and not an indicator light switch.
(4) WARNING: DO NOT REMOVE THE RADIATOR CAP OF A
HOT, PRESSURIZED ENGINE. SERIOUS INJURY CAN
RESULT FROM SCALDING COOLANT.
Inspect coolant level in the coolant reserve tank and radiator.
Inspect system for leaks.
(5) Inspect heater door controls. Refer to Group 24, Heating and
Air Conditioning.
MAXIMUM HOT
WEATHER
HEAVY LOAD
MAXIMUM UP
TO TOP AMBIENT
High Gauge Reading — Hot Weather — Heavy Load
(1) Compare gauge reading to High Gauge Reading Illustration
above.
(2) Inspect for grounded gauge, sending unit or circuit. Refer to
Group 8, Electrical.
(3) a — Fill 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 rodiator cap upper and lower seals.
(4) a — Fill to full.
b — Inspect for leaks in the system and repair as necessary,
c — Inspect for leaks in the coolant reserve tank to radiator
hose.
d — Verify proper operation of the radiator cap upper and
lower seals.
(5) a — Adjust coolant solution to 50/50 mixture of anti-freeze and
water. Refer to Coolant in this group,
b — If a reading is not recorded or below — 50, the mixture is
too rich. Clean system and fill with a 50/50 mixture of
anti-freeze and water. Refer to Coolant in this group.
(6) a — With the thermostat open and a slight amount of coolant
removed, inspect for coolant flow through the radiator at
the filler neck opening,
b — Determine reason for lack of coolant flow and repair as
necessary.
J9007-69
• COOLING SYSTEM 7-5

COOLING SYSTEM D I A G N O S I S - C O N T I N U E D

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, odd 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
7 - 6 COOLING SYSTEM •

COOLING SYSTEM D I A G N O S I S - C O N T I N U E D
CONDITION AND CHECKS DIAGNOSIS

TEMPERATURE GAUGE IS INCONSISTENT, CYCLES AND/OR IS

ERRATIC.

(1) Is cycle normal.

(a) Normal Gauge Reaction to Thermostat Cycle.

A / 1-X \

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 UGHT 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
• COOLING SYSTEM 7-7

COOLING SYSTEM D I A G N O S I S - C O N T I N U E D
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.
DETONATION OR PREIGNITION. NOT CAUSED BY IGNITION
OR ENGINE CONDITIONS.
(2) a — Kinked coolant reserve system hose.
b — Coolant reserve system tank plastic tube plugged,
c — Pressure cap seal out of position.

(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 5 0 ° 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.
COOUNG 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 DRIVEABILITY. 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
7 - 8 COOLING SYSTEM •

COOLING SYSTEM DIAGNOSIS-CONTINUED

Condition and Check Diagnosis

POOR HEATER PERFORMANCE. SUSPECT

THERMOSTAT FAILED IN OPEN POSITION.

(1) Does gauge read low? (1) If YES, replace thermostat. If NO, inspect the auxiliary heater
vacuum water valve. The valve should be open except when the
climate controls are OFF or in the MAX A/C mode.

(2) Is coolant level low? (2) Fill cooling system and inspect for leaks. Repair as necessary.

(3) Check On-Board Diagnostics. Is code 17 set in memory? (3) If YES, replace thermostat. If NO, inspect the auxiliary heater
vacuum water valve. The valve should be open except when the
climate controls are OFF or in the MAX A/C mode.

J9007-61

SERVICE PROCEDURES
INDEX
Page Page
Coolant . . . . . . . . . . . . 11 Pressure Testing Radiator Caps . . . . . . . . . . . . . . 16
Coolant Reserve System ( C R S ) . . 15 Radiator 17
Cooling System Cleaning, Reverse Flushing . . . . . 13 Radiator Pressure Cap 16
Cooling System Fan 19 Refilling The Cooling System 13
Cooling System Hoses 18 Testing Cooling System For Leaks 14
Draining Cooling System 12 Transmission Oil Cooler . 18
Engine Thermostat 10 Water Pumps . 8

WATER PUMPS The w a t e r p u m p o n a l l models can be removed

A centrifugal w a t e r p u m p circulates t h e coolant
t h r o u g h the w a t e r jackets, passages, i n t a k e manifold,
radiator core, cooling system hoses and heater core.
The pump is d r i v e n f r o m the engine crankshaft b y a
" V " drive belt.
The water p u m p i m p e l l e r i s pressed onto the rear
of a shaft t h a t rotates i n a b e a r i n g pressed into t h e
w a t e r pump body. The body has a s m a l l hole to allow
seepage t o escape. T h e w a t e r p u m p seals are l u b r i -
cated b y t h e antifreeze i n t h e coolant m i x t u r e . N o
additional l u b r i c a t i o n i s necessary.
A quick test t o t e l l w h e t h e r or not t h e p u m p is
w o r k i n g is t o check i f t h e heater w a r m s properly. A
defective water p u m p w i l l n o t be able to circulate
heated coolant t h r o u g h the l o n g heater hose t o t h e
heater core.
w i t h o u t discharging the a i r conditioning system.
WATER PUMP REMOVAL-ALL ENGINES
I f the w a t e r p u m p is replaced because of b e a r i n g or
shaft damage, t h e mechanical cooling f a n should be
inspected for fatigue cracks, loose blades, or loose r i v -
ets t h a t could have resulted f r o m excessive v i b r a t i o n .
Replace t h e f a n i f any o f these conditions are found.
The w a t e r p u m p can be removed a n d i n s t a l l e d
w i t h o u t discharging the a i r conditioning system.
(1) D r a i n cooling system.
(2) I f equipped w i t h air-conditioning, remove t h e
radiator. Refer t o Radiator Removal i n t h i s section.
 COOLING SYSTEM 7-9

CAUTION: Do not place viscous fan in upright po- ALTERNATOR AIR PUAAP
sition. The silicone fluid in the viscous drive could ADJUSTING PIVOT SCREW
drain into the bearing assembly and contaminate (JACK) SCREW 24 FT. LBS.
(33 N m )
the lubricant.

(3) Remove f a n blade, spacer or viscous d r i v e u n i t ,

p u l l e y and bolts as a n assembly (Fig. 1). AIR PUAAP
ADJUST
WITHOUT A/C AND WITHOUT MAXIMUM COOLING W A J E R BRACKET
PUMP HUB

PULLEY
LOCK SCREW
FAN 24 FT. LBS.
N.m)
ALL 5.21/5.91 AND ALL 3.9L EXCEPT WITHOUT A/C AND
WITHOUT MAXIMUM CQOUNG

P/S ADJUST
BRACKET
PIVOT
SCREW
30 FT. LBS PIVOT & ADJUSTING SCREWS
RR07B62 (41 N-m) 40 FT. LBS. (54 N-m)

Fig. 2 Water Pump Removal/Installation—3.9L, 5.2L

VISCOUS WATER
Engines and 5.9L Engine Low Duty Cycle
DRIVE PUMP
UNIT J9007-62

Fig. 1 Radiator Fan Removal/Installation

(4) Loosen alternator adjusting strap bolt, lock n u t ADJUSTMENT , ADJUSTMENT L O C K sc R E W

LOCKNUT BRACKET
and pivot bolt (Fig. 2 or 3). Loosen adjusting screw to
release belt tension.
(5) Remove front bracket t h a t supports t h e alterna-
t o r and a i r conditioning compressor ( i f equipped) or
i d l e r pulley (not equipped w i t h a i r conditioning). The
compressor or idler pulley w i l l be supported b y t h e
rear m o u n t i n g bracket.
(6) Loosen a i r pump pivot and adjusting bolt. Re-
move drive belt.
(7) Remove a i r pump.
(8) Loosen power steering p u m p pivot a n d adjust-
i n g bolt i f equipped. Remove drive belt.
(9) Remove power steering p u m p f r o n t m o u n t i n g
bracket i f equipped. Support power steering p u m p PIVOT
w i t h mechanics wire. Do n o t l e t p u m p h a n g sup- BOLT
ported by hoses. ADJUSTMENT
(10) Disconnect heater and by-pass hoses. BRACKET
(11) Remove water p u m p m o u n t i n g bolts and water
p u m p assembly. Discard gasket a n d clean m a t i n g J9007-63
surfaces.
Fig. 3 Water Pump Removal/Installation—5.9L
Heavy Duty Cycle
7 - 10 COOLING SYSTEM
WATER PUMP INSTALLATION
(1) U s i n g a new gasket, i n s t a l l t h e w a t e r pump.
T i g h t e n m o u n t i n g bolts to 4 1 N»m (30 ft-lbs) torque.
(2) Spin t h e water pump t o ensure t h a t t h e impel-
ler does n o t r u b against the c h a i n case cover.
(3) Connect radiator lower hose, bypass hose and
heater r e t u r n hose t o water p u m p .
(4) I n s t a l l power steering p u m p a n d bracket.
(5) I n s t a l l a i r pump and bracket.
(6) I n s t a l l alternator.
(7) I n s t a l l front bracket t o a l t e r n a t o r a n d a i r con-
d i t i o n i n g compressor or idler p u l l e y . T i g h t e n bracket
m o u n t i n g bolts to 68 N n n (50 f t . lbs.) torque. T i g h t e n
the bolts t h a t mount t h e bracket a n d water p u m p to
41 N*m (30 f t . lbs.) torque.
(8) I n s t a l l water p u m p pulley, viscous fan assembly
or spacer a n d fan shroud.
(9) I n s t a l l accessory drive belts. Refer to "Accessory
D r i v e B e l t " section o f t h i s m a n u a l .
(10) F i l l cooling system. Refer t o " R e f i l l i n g Cooling
System" section i n t h i s group.
ENGINE THERMOSTAT
The thermostat is located beneath the t h e r m o s t a t
housing a t t h e front o f the i n t a k e m a n i f o l d (Fig. 4).
The thermostat has a n air bleed notch.
HOUSING
Fig. 4 Thermostat—All Engines
DESCRIPTION AND OPERATION
The thermostat is a wax pellet d r i v e n , reverse pop-
pet choke type. The wax pellet i s located i n a sealed
container a t the spring end o f t h e thermostat. W h e n
heated, the pellet expands, overcoming closing spring
tension and water pump pressure t o force t h e valve
to open. Coolant leakage i n t o t h e pellet container
•
w i l l cause t h e thermostat t o f a i l i n t h e open position.
Thermostats very r a r e l y " s t i c k " . D o n o t a t t e m p t t o
free a thermostat w i t h a p r y i n g device.
The thermostat controls t h e operating temperature
of the engine by c o n t r o l l i n g t h e amount o f coolant
flow to the radiator. T h e t h e r m o s t a t is closed below
88°C (192°F). When t h e coolant reaches t h i s temper-
ature, the thermostat begins t o open a l l o w i n g coolant
flow to t h e radiator. T h i s provides quick engine
warm-up a n d overall temperature control. T h e t h e r -
mostat is designed t o provide a m i n i m u m engine op-
e r a t i n g temperature range o f from 88 to 93°C (192 to
199°F) a n d t o be f u l l y open for m a x i m u m coolant
flow d u r i n g operation i n h o t a m b i e n t temperatures o f
approximately 104°C (220°F). Above 104°C (220°F)
coolant temperature is controlled b y t h e radiator, fan
and ambient temperature.
A n arrow plus the w o r d U P stamped on the f r o n t
flange next t o the a i r bleed and t h e words T O R A D
stamped o n one a r m o f t h e thermostat, indicate t h e
proper i n s t a l l e d position.
The same thermostat is used for w i n t e r and sum-
mer seasons. A n engine should n o t be operated w i t h -
out a thermostat, except for servicing or testing.
Operating w i t h o u t a t h e r m o s t a t causes longer engine
w a r m u p t i m e , unreliable w a r m u p performance, i n -
creased exhaust emissions, and crankcase condensa-
t i o n t h a t can result i n sludge formation.
CAUTION: Do not operate an engine without a ther-
mostat, except for servicing or testing.
TESTING
The on-board diagnostics include a mode for a t h e r -
mostat open too soon f a i l u r e condition. The check en-
gine l i g h t w i l l not be l i t b y a n open too soon
condition, b t i t i f i t has failed open, code 17 w i l l be
set. Do not change a t h e r m o s t a t for lack o f heat b y
gauge or heater performance unless code 17 i s
present. Refer to "Diagnosis" for other probable
causes.
The more common type o f thermostat failure, usu-
a l l y found o n h i g h milage vehicles, i s a thermostat
failed i n t h e shut position. The temperature gauge ( i f
equipped) w i l l give a n i n d i c a t i o n of t h i s condition.
Depending upon length o f t i m e t h a t the vehicle is op-
erated, t h e pressure cap m a y vent, expelling steam
and coolant t o the coolant reserve bottle and t o t h e
surface below t h e vehicle. Refer t o t h e "Diagnosis"
section o f t h i s group.
The thermostat opening a n d f u l l open conditions
can also be tested.
Remove t h e thermostat. Refer to "Thermostat Re-
m o v a l " section i n t h i s group. Insert a 0.076mm
(0.003-in) feeler gauge, w i t h a w i r e or s t r i n g a t -
tached, between the thermostat valve and seat (Fig.
5).
 • COOLING SYSTEM 7-11

WARNING: ANTIFREEZE IS POISONOUS. KEEP (3) Remove r a d i a t o r hose f r o m thermostat housing.

OUT OF THE REACH OF CHILDREN.
Submerge t h e thermostat i n a container o f pure a n -
tifreeze and suspend i t so t h a t i t does n o t touch t h e
sides or the b o t t o m o f the container.
Suspend a thermometer i n the antifreeze so t h a t i t
does not contact the container or thermostat.
WARNING: DO NOT BREATHE THE VAPOR. EN-
SURE THE TEST AREA IS PROPERLY VENTILATED.
H e a t the antifreeze. A p p l y a s l i g h t tension o n the
feeler gauge w h i l e the antifreeze is heated. W h e n t h e
valve opens t h e feeler gauge w i l l slip free f r o m t h e
valve. Note t h e temperature (Fig. 5). I f defective, re-
place the thermostat.
THERMOMETER
(4) Remove thermostat housing m o u n t i n g bolts,
thermostat housing, gasket, and thermostat (Fig. 4).
Discard old gasket.
(5) Clean gasket m a t i n g surfaces.
THERMOSTAT INSTALLATION
I f t h e thermostat is being replaced, ensure t h a t t h e
replacement is t h e specified thermostat for the vehi-
cle model and engine type.
(1) D i p the replacement gasket i n w a t e r a n d i n s t a l l
on i n t a k e manifold (Fig. 4).
(2) Insert t h e r m o s t a t (spring side down) t h r o u g h
gasket i n t o opening i n i n t a k e manifold. Center ther-
mostat i n manifold.
CAUTION: Tightening the housing unevenly or with-
out thermostat centered in recess in thermostat
housing may result in a cracked housing.
(3) I n s t a l l housing over thermostat. Ensure t h a t
thermostat is positioned i n t o recess i n housing.
T i g h t e n m o u n t i n g bolts to 23 N-m (200 in-lbs).
(4) Connect battery negative cable t o battery.
(5) F i l l cooling system. Refer to " R e f i l l i n g Cooling
System" i n t h i s group.

COOLANT
The cooling system is designed around the coolant.
Coolant flows t h r o u g h t h e engine water jacket ab-
8
89
-3
0C
Must Be Open 0.076 mm (0.003 inch) (192°-199°F) sorbing heat produced d u r i n g engine operation. T h e
coolant carries the heat t o r a d i a t o r and heater core
Must Be Fully Open I
O 4
0C (220°F)
where i t is transferred to t h e ambient a i r passing
t h r o u g h the radiator and heater core fins. T h e cool-
ant also removes heat from the automatic t r a n s m i s -
J9007-31
sion f l u i d i n vehicles equipped w i t h a n automatic
Fig. 5 Thermostat Calibrations transmission.

I n s t a l l t h e thermostat. Refer to "Thermostat Re- COOLANT PERFORMANCE

m o v a l " section i n t h i s group.
THERMOSTA T REMOVAL
WARNING: DO NOT LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND PRES-
SURIZED BECAUSE SERIOUS BURNS FROM THE
COOLANT CAN OCCUR.
Do n o t waste reusable coolant. I f the solution i s
clean and being drained only to service t h e cooling
system, d r a i n t h e coolant i n t o a clean container for
reuse.
(1) Disconnect b a t t e r y negative cable f r o m b a t t e r y
negative t e r m i n a l .
(2) D r a i n cooling system u n t i l coolant level i s be-
l o w thermostat. Refer to " D r a i n i n g Cooling System"
i n t h i s section.
The required ethylene-glycol (anti-freeze) and w a -
ter m i x t u r e depends upon climate and vehicle oper-
a t i n g conditions. The coolant performance o f various
m i x t u r e s follows.
P u r e W a t e r - For the purpose o f heat transfer only,
water is able t o absorb more heat t h a n a m i x t u r e o f
w a t e r a n d ethylene-glycol. B u t , water freezes a t a
h i g h e r temperature and allows corrosion.
1 0 0 % E t h y l e n e - G l y c o l - T h e corrosion i n h i b i t i n g
additives i n ethylene-glycol need t h e presence of wa-
ter t o dissolve, w i t h o u t water they f o r m deposits i n
the system w h i c h act as i n s u l a t i o n causing the t e m -
perature to rise t o as h i g h as 149°C (300°F) w h i c h i s
hot enough to m e l t plastic and soften solder. The i n -
creased temperature can result i n engine detonation.
I n addition, 100 percent ethylene-glycol freezes a t -
22°C (-8°F).
 7-12 COOLING SYSTEM
50/50 E t h y l e n e - G l y c o l a n d W a t e r -Is t h e recom-
mended m i x t u r e , i t provides protection against freez-
i n g t o -37°C (-35°F). T h e antifreeze concentration
M U S T A L W A Y S be a m i n i m u m of 44 percent, year-
r o u n d i n a l l climates. I f the percentage is lower, en-
gine parts m a y be eroded b y cavitation.
W h e r e required, a 56 percent ethylene-glycol a n d
44 percent w a t e r m i x t u r e w i l l provide a freeze-point
of-50°F.
CAUTION: Richer mixtures cannot be measured
with normal field equipment and can cause prob-
lems associated with 100%ethylene-glycol.
COOLANT SELECTION-ADDITIVES
T h e presence o f a l u m i n u m components i n t h e cool-
i n g system requires s t r i c t corrosion protection. M a i n -
t a i n t h e coolant a t the specified level w i t h a m i x t u r e
of ethylene glycol- based antifreeze and water. O n l y
use a n anti-freeze c o n t a i n i n g A L U G A R D 340-2 ™
such as Mopar Anti-freeze, Prestone, Peak or a n
equivalent. I f the coolant becomes contaminated or
looses color, d r a i n and flush t h e cooling system a n d
f i l l w i t h correctly m i x e d solution.
A .25% emulsifiable o i l is added t o t h e r a d i a t o r a t
the factory t o prevent solder corrosion.
CAUTION: Do not use coolant additives that are
claimed to improve engine cooling.
COOLANT SERVICE
I t i s recommended t h a t t h e cooling system be
d r a i n e d a n d flushed a t 84,000 kilometers (52,500
miles) or 3 years whichever occurs first. T h e n every
two years or 48,000 kilometers (30,000 miles) or 2
years whichever comes first.
COOLANT LEVEL CHECK-ROUTINE
D o n o t remove r a d i a t o r cap for r o u t i n e coolant
level inspections. T h e coolant level c a n be
c h e c k e d a t t h e coolant reserve bottle.
T h e coolant reserve system provides a q u i c k v i s u a l
method for d e t e r m i n i n g the coolant level w i t h o u t re-
m o v i n g t h e r a d i a t o r pressure cap. W i t h t h e engine
i d l i n g and a t n o r m a l operating temperature, observe
the coolant level i n t h e reserve t a n k . T h e coolant
level should be between the m i n i m u m and m a x i m u m
marks.
ADDING ADDITIONAL COOLANT-ROUTINE
D o n o t remove the r a d i a t o r cap t o a d d c o o l a n t
to t h e system.
W h e n adding coolant to m a i n t a i n the correct level,
do so a t the coolant reserve bottle w i t h a 50/50 m i x -
ture of ethylene-glycol antifreeze (containing
A l u g a r d 340-2) and water. Remove t h e r a d i a t o r cap
only for t e s t i n g or w h e n r e f i l l i n g t h e system after
•
service. Removing t h e cap unnecessarily c a n cause
loss o f coolant a n d a l l o w a i r t o enter t h e system,
w h i c h produces corrosion.
COOLANT LEVEL CHECK-SERVICE
The cooling system i s closed a n d designed t o m a i n -
t a i n coolant level t o the top o f t h e r a d i a t o r .
W h e n vehicle servicing requires a coolant level
check i n the radiator, w i t h e n g i n e o f f a n d t h e c o o l -
i n g system n o t u n d e r pressure (cold),
d r a i n several ounces o f coolant from t h e r a d i a t o r
d r a i n cock w h i l e observing t h e coolant reserve sys-
t e m (CRS) t a n k . T h e coolant level i n t h e reserve
t a n k should drop s l i g h t l y . I f not, inspect for a leak
between t h e radiator a n d coolant reserve system con-
nection. Remove t h e r a d i a t o r cap. T h e coolant level
should be t o the top o f t h e r a d i a t o r . I f not, a n d i f t h e
coolant level i n t h e reserve t a n k i s a t t h e " M I N "
m a r k , a n a i r leak exists i n the coolant reserve t a n k
or r a d i a t o r filler neck, or t h e pressure cap seal t o t h e
radiator f i l l e r neck leaks.
LOW COOLANT LEVEL-AERATION
I f t h e coolant level i n t h e r a d i a t o r drops below t h e
top o f t h e radiator core tubes a i r w i l l enter the sys-
tem.
Low coolant level can cause t h e t h e r m o s t a t pellet
to be suspended i n a i r instead o f coolant. T h i s w i l l
cause t h e thermostat t o open l a t e r w h i c h i n t u r n
causes h i g h e r coolant temperature. A i r trapped i n
cooling system also reduces t h e a m o u n t o f coolant
c i r c u l a t i n g i n t h e heater core r e s u l t i n g i n l o w heat
output.
DEAERATION
As t h e engine operates, a i r trapped i n t h e cooling
system gathers under the r a d i a t o r cap. T h e n e x t t i m e
engine is operated t h e r m a l expansion o f coolant w i l l
push trapped a i r past r a d i a t o r cap i n t o coolant re-
serve t a n k where i t escapes t o atmosphere i n the bot-
tle. W h e n engine cools down coolant w i l l be d r a w n
from reserve bottle i n t o r a d i a t o r t o replace removed
air.
DRAINING COOLING SYSTEM
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAINCOCK WITH SYSTEM HOT AND UNDER
PRESSURE BECAUSE SERIOUS BURNS FROM
COOLANT CAN OCCUR.
D O N O T W A S T E reusable coolant. I f t h e solution
is clean and is being drained only t o service t h e en-
gine or cooling system, d r a i n t h e coolant i n t o a clean
container for reuse.
 • COOLING SYSTEM
(1) Start t h e engine a n d place t h e heater c o n t r o l
temperature selector i n t h e " F u l l O n " position (en-
gine vacuum is needed t o actuate t h e heater con-
trols).
(2) T u r n the i g n i t i o n off.
(3) Do not remove the r a d i a t o r cap w h e n d r a i n i n g
t h e coolant from the reserve t a n k . Open t h e r a d i a t o r
draincock a n d when t h e t a n k is empty, remove t h e
r a d i a t o r cap. I f t h e coolant reserve t a n k does n o t
d r a i n , refer t o "Testing Cooling System for L e a k s "
section i n t h i s group. T h e coolant need n o t be r e -
moved from t h e t a n k unless the system i s b e i n g r e -
f i l l e d w i t h a fresh m i x t u r e .
(4) Remove t h e cylinder block d r a i n plugs located
on the sides o f the block towards the front o f engine
j u s t above the o i l pan.
(5) Remove radiator pressure cap.
REFILLING THE COOLING SYSTEM
Clean cooling system p r i o r t o r e f i l l i n g . Refer t o
"Cooling System C l e a n i n g " section o f t h i s group.
(1) I n s t a l l the cylinder block d r a i n plugs.
(2) Close radiator d r a i n p l u g .
(3) F i l l the cooling system w i t h a 50/50 m i x t u r e o f
w a t e r and anti-freeze.
(4) F i l l coolant reserve t a n k t o t h e " M A X " m a r k .
(5) Start and operate engine u n t i l t h e r m o s t a t opens
(upper radiator hose w a r m t o touch).
(6) I f necessary, add 50/50 w a t e r a n d anti-freeze
m i x t u r e to the coolant reserve t a n k t o m a i n t a i n cool-
a n t level between the " M A X " and " M I N " m a r k s . T h e
level i n the reserve t a n k may drop below t h e " M I N "
m a r k after three or four w a r m - u p and cool d o w n cy-
cles.
COOLING SYSTEM CLEANING, REVERSE
FLUSHING
CLEANING
D r a i n cooling system a n d r e f i l l w i t h water. R u n
engine w i t h radiator cap i n s t a l l e d u n t i l upper r a d i a -
t o r hose is hot. Stop engine a n d d r a i n w a t e r f r o m
system. I f water is d i r t y , f i l l system w i t h w a t e r , r u n
engine, and d r a i n system. Repeat u n t i l w a t e r d r a i n s
clean.
REVERSE FLUSHING
Reverse f l u s h i n g of t h e cooling system i s t h e forc-
i n g o f water t h r o u g h t h e cooling system, u s i n g a i r
pressure, i n the opposite direction o f n o r m a l coolant
flow. This is usually only necessary w i t h very d i r t y
systems w i t h evidence o f p a r t i a l p l u g g i n g .
7 - 13
REVERSE FLUSHING RADIATOR
Disconnect t h e radiator hoses from t h e r a d i a t o r i n -
let a n d outlet. A t t a c h a section o f r a d i a t o r hose t o
the radiator bottom outlet f i t t i n g a n d i n s e r t t h e
f l u s h i n g g u n . Connect a water supply hose a n d a i r
supply hose t o the f l u s h i n g g u n .
CAUTION: Internal radiator pressure must not ex-
ceed 138 kPa (20 psi) as damage to radiator may re-
sult.
A l l o w t h e r a d i a t o r t o f i l l w i t h water. W h e n t h e r a -
diator is filled, apply a i r i n short blasts, a l l o w i n g the
radiator t o r e f i l l between blasts. Continue t h i s r e -
verse f l u s h i n g u n t i l clean water flows o u t t h r o u g h
rear the r a d i a t o r cooling tube passages, have t h e r a -
diator cleaned more extensively b y a r a d i a t o r repair
shop.
REVERSE FLUSHING ENGINE
D r a i n t h e cooling system. Remove t h e thermostat
housing and thermostat. I n s t a l l the thermostat hous-
i n g . Disconnect the r a d i a t o r upper hose from t h e r a -
diator a n d a t t a c h t h e f l u s h i n g g u n t o t h e hose.
Disconnect t h e radiator lower hose f r o m t h e water
pump a n d a t t a c h a lead away hose t o t h e water
pump inlet fitting.
CAUTION: Ensure the heater control valve is closed
(heat off). This will prevent coolant flow with scale
and other deposits from entering the heater core.
Connect t h e water supply hose and a i r supply hose
to t h e f l u s h i n g gun. A l l o w the engine t o f i l l w i t h wa-
ter. W h e n t h e engine i s filled, apply a i r i n short
blasts, a l l o w i n g the system t o f i l l between a i r blasts.
Continue u n t i l clean water flows t h r o u g h t h e lead
away hose.
Remove t h e lead away hose, f l u s h i n g g u n , w a t e r
supply hose and a i r supply hose. Remove the thermo-
stat housing a n d i n s t a l l t h e thermostat. I n s t a l l t h e
thermostat housing w i t h a replacement gasket. Refer
to Thermostat Replacement. Connect t h e radiator
hoses. R e f i l l t h e cooling system w i t h the correct an-
tifreeze/water m i x t u r e . Refer t o " R e f i l l i n g the cooling
System"
CHEMICAL CLEANING
I n some instances, t h e use o f a radiator cleaner
(Mopar Radiator K l e e n , or equivalent) before flush-
i n g w i l l soften scale and other deposits and a i d t h e
f l u s h i n g operation.
CAUTION: Follow manufacturers instructions when
using these products.
7-14 COOLING SYSTEM
TESTING COOLING SYSTEM FOR LEAKS
ULTRAVIOLET LIGHT METHOD
A leak detection additive is available t h r o u g h t h e
parts department t h a t can be added to t h e cooling
system. The additive i s h i g h l y visible under u l t r a v i -
olet l i g h t (black l i g h t ) . Poor one ounce o f additive
i n t o t h e cooling system. Place t h e heater control u n i t
i n " H E A T " position. S t a r t and operate the engine u n -
t i l t h e radiator upper hose is w a r m t o the t o u c h . A i m
t h e black l i g h t , tool 7138 or a n equivalent, a t t h e
components t o be checked. I f leaks are present, t h e
black l i g h t w i l l cause t h e additive t o glow a b r i g h t
green color.
The black l i g h t can be used i n conjunction w i t h a
pressure tester t o determine i f any e x t e r n a l leaks ex-
ist (Fig. 6).
Fig. 6 Leak Detection Using Black Light—Typical
PRESSURE TESTER METHOD
The engine should be a t the n o r m a l o p e r a t i n g t e m -
perature. Recheck t h e system cold i f t h e cause of
coolant loss is n o t located d u r i n g w a r m engine exam-
ination.
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING.
Carefully remove t h e radiator pressure cap f r o m
the f i l l e r neck a n d check t h e coolant level. Push
down on the cap to disengage i t f r o m t h e stop tabs.
Wipe t h e inside of the f i l l e r neck and examine t h e
lower inside sealing seat for nicks, cracks, p a i n t , d i r t
and solder residue. Inspect t h e r a d i a t o r t o reserve
•
t a n k tube for i n t e r n a l obstructions. I n s e r t a w i r e
t h r o u g h the tube to ensure i t is n o t obstructed.
Inspect the cams on the outside o f the filler neck. I f
the cams are bent, seating o f pressure cap valve and
tester seal w i l l be affected. B e n t cams can be re-
formed i f done carefully. A t t a c h pressure tester 7700-
A or an equivalent t o the r a d i a t o r f i l l e r neck (Fig. 7).
Fig. 7 Pressure Testing Cooling System
Operate t h e tester pump to apply 103.4 k P a (15
psi) pressure t o t h e system. I f the hoses enlarge ex-
cessively or bulge w h i l e testing, replace as necessary.
Observe the gauge pointer and determine the condi-
t i o n of the cooling system according t o f o l l o w i n g cri-
teria.
H o l d s S t e a d y : I f the pointer r e m a i n s steady for
two minutes, there are no serious coolant leaks i n
the system. However, there could be a n i n t e r n a l leak
t h a t does n o t appear w i t h n o r m a l system test pres-
sure. I f i t is certain t h a t coolant is b e i n g lost and no
leaks can be detected, inspect for i n t e r i o r leakage or
perform the Combustion Leakage Test.
D r o p s S l o w l y : Indicates a s m a l l leak or seepage is
occurring. Examine a l l connections for seepage or
slight leakage w i t h a flashlight. Inspect the radiator,
hoses, gasket edges and heater. Seal s m a l l leak holes
w i t h a Sealer L u b r i c a n t , or equivalent. Repair leak
holes and reinspect the system w i t h pressure applied.
D r o p s Q u i c k l y : Indicates t h a t serious leakage is
occurring. Examine the system for e x t e r n a l leakage.
I f no leaks are visible, inspect for i n t e r n a l leakage.
Large radiator leak holes should be repaired b y a
reputable radiator repair shop.
INTERNAL LEAKAGE INSPECTION
Remove the engine o i l pan d r a i n p l u g and d r a i n a
small amount o f engine o i l . I f coolant is present i n
the pan i t w i l l d r a i n first because i t i s heavier t h a n
oil. A n alternative method is to operate t h e engine
for a short period to churn t h e o i l , t h e n remove t h e
engine dipstick and inspect for w a t e r globules. Also
inspect t h e transmission dipstick for water globules
and the transmission f l u i d cooler for leakage.
 • COOLING SYSTEM 7-15

WARNING: WITH PRESSURE TESTER TOOL 7700-A S t a r t t h e engine and accelerate r a p i d l y t h r e e

INSTALLED ON RADIATOR DO NOT ALLOW PRES- times, t o approximately 3000 r p m w h i l e observing
SURE TO EXCEED 110 KPA (20 PSI). PRESSURE the coolant. I f i n t e r n a l engine combustion gases axe
WILL BUILD UP QUICKLY IF A COMBUSTION LEAK l e a k i n g i n t o the cooling system, bubbles w i l l appear
IS PRESENT. TO R E L E A S E THE PRESSURE, ROCK i n t h e coolant. I f bubbles do not appear, there i s no
THE TESTER FROM SIDE TO SIDE. WHEN REMOV- i n t e r n a l combustion gas leakage.
ING THE TESTER, DO NOT TURN THE TESTER
MORE THAN 1/2 TURN IF THE SYSTEM IS UNDER COOLANT RESERVE SYSTEM (CRS)
PRESSURE.
The Coolant Reserve System (CRS) works i n con-
Operate t h e engine w i t h o u t t h e pressure cap on the j u n c t i o n w i t h the radiator pressure cap t o u t i l i z e
radiator u n t i l the thermostat opens. A t t a c h a Pres- t h e r m a l expansion and contraction of the coolant t o
sure Tester to the filler neck. I f t h e pressure builds keep t h e coolant free of trapped air. I t provides a vol-
up q u i c k l y i t indicates a combustion leak exists usu- ume for expansion and contraction, provides a conve-
a l l y t h e r e s u l t of cylinder head gasket leak or crack n i e n t a n d safe method for checking coolant level a n d
i n the engine. Repair as necessary. adjusting level a t atmospheric pressure w i t h o u t re-
I f there i s no immediate pressure increase, pump m o v i n g t h e radiator pressure cap. I t also provides
the Pressure Tester u n t i l the indicated pressure is some reserve coolant to cover m i n o r leaks and evap-
w i t h i n t h e system range of 110 k P a (16 psi). F l u c t u - oration or b o i l i n g losses (Fig. 8).
ation o f t h e gauge pointer indicates compression or
combustion leakage i n t o the cooling system.
Because t h e vehicle i s equipped w i t h a catalytic
converter, do not remove spark plug wires or
short out cylinders to isolate t h e compression leak.
I f the needle on the d i a l of the pressure tester does
not fluctuate, race the engine a few times t o check
for a n a b n o r m a l a m o u n t of coolant or steam e m i t t i n g
from t h e exhaust pipe. Coolant or steam from the ex-
haust pipe may indicate a f a u l t y cylinder head gas-
ket, cracked engine cylinder block or cylinder head.
A convenient check for exhaust gas leakage i n t o
the cooling system i s provided b y a commercially
available " B l o c k Leak Check" tool. Follow manufac-
turers i n s t r u c t i o n s w h e n using t h i s product.

Combustion Leakage Test (without Pressure Tester)

D O N O T W A S T E reusable coolant. I f the solution
is clean a n d is being drained only to service the cool-
i n g system, d r a i n the coolant i n t o a clean container
for reuse.

WARNING: DO NOT REMOVE THE CYLINDER

BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND UNDER
PRESSURE BECAUSE SERIOUS BURNS FROM
COOLANT CAN OCCUR.
D r a i n sufficient coolant to allow thermostat r e -
moval. Refer to Thermostat Replacement. Disconnect
the w a t e r p u m p drive belt.
A d d coolant to the radiator to b r i n g the level t o
w i t h i n 6.3 m m (1/4 i n ) o f the top o f the thermostat
housing.
CAUTION: Avoid overheating. Do not operate the
engine for an excessive period of time. Open the
draincock immediately after the test to eliminate
boil over.
Fig. 8 Coolant Reserve System
Refer to "Coolant Level Check—Service", "Deaera-
t i o n " , and "Radiator Pressure Cap" sections i n t h i s
group for CRS system operation and service. Vehicles
equipped w i t h a n electronic monitor system use a
level sensor i n the CRS t a n k , refer to Group 8, Elec-
t r i c a l , for service.
Should t h e CRS t a n k become coated w i t h corrosion
or emulsifiable o i l i t can be cleaned w i t h detergent
and water. Rinse the t a n k thoroughly before r e f i l l i n g
the cooling system as described i n the "Coolant" sec-
t i o n of t h i s group.
7 - 16 COOLING SYSTEM
RADIATOR PRESSURE CAP
Radiators are equipped w i t h a pressure cap w h i c h
releases pressure a t some p o i n t w i t h i n a range o f 97-
124 k P a (14-18 psi). T h e pressure r e l i e f point ( i n
pounds) i s engraved o n top o f t h e cap.
The cooling system w i l l operate a t pressures
s l i g h t l y above atmospheric pressure. T h i s results i n a
higher coolant b o i l i n g p o i n t a l l o w i n g increased r a d i -
ator cooling capacity. T h e cap ( F i g . 9) contains a
spring-loaded pressure r e l i e f valve t h a t opens w h e n
system pressure reaches t h e release range o f 97-124
kPa (14-18 psi).
Fig. 9 Radiator Pressure Cap and Filler Neck
A vent valve i n the center of the cap allows a s m a l l
coolant flow t h r o u g h t h e cap w h e n coolant is below
b o i l i n g temperature. T h e valve is completely closed
w h e n b o i l i n g p o i n t is reached. A s coolant cools i t con-
tracts a n d creates a v a c u u m i n t h e cooling system.
This causes t h e v a c u u m valve t o open and coolant i n
reserve bottle t o be d r a w n t h r o u g h connecting hose
into r a d i a t o r . I f the v a c u u m valve is stuck shut r a d i -
ator hoses w i l l collapse on cool down. Clean t h e vent
valve ( F i g . 11) t o ensure proper sealing.
A rubber gasket seals t h e r a d i a t o r filler neck to
prevent leakage w h e n system is under pressure and
to m a i n t a i n v a c u u m d u r i n g coolant cool down allow-
i n g coolant t o r e t u r n f r o m t h e reserve t a n k .
•
BUILDS UP IN COOLING SYSTEM. T O PREVENT
SCALDING OR INJURY, T H E RADIATOR C A P
SHOULD NOT B E REMOVED WHILE THE SYSTEM
IS HOT AND/OR UNDER PRESSURE.
There i s no need t o remove t h e r a d i a t o r cap a t a n y
time except
for t h e f o l l o w i n g purposes:
(1) Check a n d adjust anti-freeze freeze point.
(2) R e f i l l system w i t h n e w anti-freeze.
(3) C o n d u c t i n g service procedures.
(4) C h e c k i n g for v a c u u m leaks.
WARNING: IF VEHICLE H A S BEEN RUN RECENTLY,
WAIT A T LEAST 15 MINUTES BEFORE REMOVING
RADIATOR CAP. WITH A RAG, SQUEEZE RADIA-
TOR UPPER HOSE T O CHECK IF SYSTEM IS U N -
DER PRESSURE. PLACE A RAG OVER T H E C A P
AND WITHOUT PUSHING C A P DOWN ROTATE IT
COUNTER-CLOCKWISE T O THE FIRST STOP. A L -
LOW FLUID T O ESCAPE THROUGH OVERFLOW
HOSE INTO COOLANT RESERVE BOTTLE.
SQUEEZE RADIATOR UPPER HOSE T O DETER-
MINE WHEN PRESSURE H A S BEEN RELEASED.
WHEN COOLANT A N D STEAM STOP BEING
PUSHED INTO BOTTLE A N D SYSTEM PRESSURE
DROPS REMOVE RADIATOR C A P COMPLETELY.
PRESSURE TESTING RADIATOR CAPS
Remove cap f r o m r a d i a t o r . Ensure t h a t sealing sur-
faces are clean. M o i s t e n r u b b e r gasket w i t h w a t e r
and i n s t a l l t h e cap on pressure tester 7700-A o r a n
equivalent (Fig. 10).

RADIATOR CAP TO FILLER NECK SEAL,

PRESSURE RELIEF CHECK
The pressure cap upper gasket (seal) pressure r e l i e f
can be tested b y r e m o v i n g the overflow hose from t h e
radiator filler neck nipple a n d a t t a c h i n g t h e hose o f
pressure tester tool 7700-A t o t h e nipple. I t w i l l be
necessary t o disconnect t h e hose f r o m it's adapter for
the filler neck. Pump a i r i n t o t h e radiator. The pres-
sure cap upper gasket should relieve at 69- 124 k P a
(10-18 psi) a n d hold pressure a t a m i n i m u m of 55
kPa (8 psi).

WARNING: THE WARNING WORDS " D O NOT OPEN

HOT" O N T H E RADIATOR PRESSURE C A P ARE A
SAFETY PRECAUTION. WHEN HOT, PRESSURE Fig. 10 Pressure Testing Radiator Cap
 • COOLING SYSTEM 7 - 17

Operate t h e tester p u m p t o b r i n g pressure t o 104 (2) D r a i n a s m a l l amount of coolant from t h e radi-

kPa (15 psi) o n t h e gauge. I f the pressure cap fails to ator u n t i l t h e ends o f t h e r a d i a t o r tubes are visible
hold pressure of a t least 97 k P a (14 psi) replace cap. t h r o u g h t h e filler neck. Idle t h e engine a t n o r m a l op-
Refer to C A U T I O N below. e r a t i n g t e m p e r a t u r e . I f coolant i s flowing past the
I f the pressure cap tests properly w h i l e positioned exposed tubes t h e coolant is c i r c u l a t i n g .
on tool 7700-A, b u t w i l l n o t hold pressure or vacuum
when installed on t h e radiator, inspect t h e radiator RADIATOR REMOVAL
filler neck and cap top gasket for damage, d i r t or dis- (1) Disconnect b a t t e r y negative cable f r o m battery.
t o r t i o n t h a t m a y prevent t h e cap from sealing prop-
erly. WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
CAUTION: Tool 7700-A is very sensitive to small air DRAINCOCK WITH THE SYSTEM HOT AND UNDER
leaks which will not cause cooling system prob- PRESSURE BECAUSE SERIOUS BURNS FROM
lems. A pressure cap that does not have a history COOLANT CAN OCCUR.
of coolant loss should not be replaced just because
(2) D r a i n t h e cooling system. Refer t o " D r a i n i n g
it leaks slowly when tested with this tool. Add water
Cooling System".
to the tool. Turn the tool upside down and recheck
(3) Remove hose clamps a n d hoses from radiator.
the pressure cap to confirm that cap needs replace-
Remove coolant reserve t a n k hose f r o m radiator filler
ment.
neck nipple.
(4) I f equipped w i t h a n automatic transmission,
INSPECTION disconnect o i l cooler hoses at r a d i a t o r lower t a n k .
H o l d cap a t eye level, r i g h t side up. The v e n t valve (5) Remove f a n shroud m o u n t i n g screws a n d posi-
(Fig. 9) a t t h e b o t t o m of the cap should open. I f the t i o n shroud r e a r w a r d on engine (Fig. 11).
rubber gasket has swollen a n d prevents t h e vent
valve from opening, replace t h e cap.
H o l d cap a t eye level upside down. I f any l i g h t can
be seen between v e n t valve a n d rubber gasket, re-
place cap. D o n o t u s e a r e p l a c e m e n t c a p t h a t h a s
a spring to h o l d t h e vent shut.
A replacement cap m u s t be t h e type designed for a
coolant reserve system w i t h a completely sealed dia-
p h r a g m spring and a rubber gasket to seal to t h e r a -
diator filler neck top surface. Use of the proper cap
ensures coolant r e t u r n to t h e radiator.

RADIATOR
The radiator is a down-flow type (vertical tubes).
The radiator supplies sufficient heat transfer to cool
the engine a n d automatic transmission ( i f equipped).

RADIATOR COOLANT FLOW CHECK

Use the following procedure to determine i f coolant
is flowing t h r o u g h t h e cooling system.
(1) Idle engine u n t i l operating temperature is
reached. I f t h e upper r a d i a t o r hose is w a r m t o t h e
touch, the thermostat is opening and coolant is flow-
i n g to the radiator.
Fig. 11 Radiator and Fan Shroud
(6) Loosen r a d i a t o r lower m o u n t i n g screws t h e n re-
move t h e upper m o u n t i n g screws. L i f t radiator
straight u p o u t of engine compartment t a k i n g care
not to damage r a d i a t o r cooling fins or tubes.

WARNING: HOT, PRESSURIZED COOLANT CAN INSTALLATION

CAUSE INJURY BY SCALDING. USING A RAG TO (1) Position shroud r e a r w a r d on engine.
COVER THE RADIATOR PRESSURE CAP, OPEN
(2) Slide r a d i a t o r i n t o position place behind the r a -
RADIATOR CAP SLOWLY TO THE FIRST STOP, AL-
diator support w i t h lower m o u n t i n g holes (slots) rest-
LOWING ANY BUILT-UP PRESSURE TO VENT TO
i n g on loosened b o t t o m m o u n t i n g screws (Fig. 11).
THE RESERVE TANK. AFTER PRESSURE BUILD-UP
I n s t a l l upper m o u n t i n g screws. T i g h t e n a l l m o u n t i n g
HAS BEEN RELEASED, REMOVE CAP FROM
screws to 11 N * m (95 i n . lbs.) torque.
FILLER NECK.
7-18 COOLING SYSTEM
(3) Connect radiator hoses. T i g h t e n hose clamps t o
4 N-m (35 i n . lbs.) torque.
(4) Connect transmission o i l cooler lines t o bottom
tank. T i g h t e n hose clamps t o 4 N»m (35 i n . lbs.)
torque.
(5) Position fan shroud on r a d i a t o r flange. T i g h t e n
m o u n t i n g nuts t o 11 N«m (95 i n . lbs.) torque.
(6) Open heater valve.
(7) F i l l cooling system w i t h coolant. Refer t o F i l l -
i n g Cooling System i n t h i s group.
(8) Operate engine u n t i l i t reaches n o r m a l temper-
ature. Check cooling system and automatic transmis-
sion fluid levels.
RADIATOR DRAINCOCK SERVICE
The radiator draincock is replaceable. Unscrew the
draincock i n a clockwise direction and remove from
radiator. I n s t a l l replacement draincock.
•
a l e t t e r stamped on the tongue. Special pliers for re-
m o v i n g a n d i n s t a l l i n g the clamps are available from
most a u t o m o t i v e jobbers.
O r d i n a r y w o r m gear type hose clamps can be r e -
moved w i t h a s t r a i g h t screwdriver or a hex socket.
T o p r e v e n t d a m a g e t o h o s e s o r c l a m p s , these
hose c l a m p s s h o u l d b e tightened to 4.1 N»m (34
i n - l b s ) t o r q u e . D o n o t o v e r tighten hose c l a m p s .
TRANSMISSION OIL COOLER
The a u t o m a t i c transmission o i l is cooled when i t
passes t h r o u g h a cooler i n t h e radiator lower t a n k
(Fig. 13 a n d 14).
-TRANSMISSION AUTOMATIC
OIL COOLER TRANSMISSION

COOLING SYSTEM HOSES

6 AND 8 CYLINDER ENGINE RETURN LINE
Rubber hoses route coolant t o a n d f r o m the radia- RY402
tor, i n t a k e manifold, and heater core (Fig. 12). Radi-
ator lower hoses are spring-reinforced t o prevent Fig. 13 Top View of Transmission Oil Cooling
Circuit
collapse from water p u m p suction a t moderate and
h i g h engine speeds. COOLING TUBE
(CUT-A-WAY)
Inspect t h e hoses a t regular i n t e r v a l s . Replace
hoses t h a t are cracked, feel b r i t t l e w h e n squeezed or
swell excessively w h e n t h e system is pressurized.
The use of molded replacement hoses is recom-
mended. W h e n p e r f o r m i n g a hose inspection, inspect
the radiator lower hose for proper position and con-
dition o f the spring.

HOSE TO
DRAIN COCK COOLER LINE
HOSE HOSE TO
CLAMP COOLER LINE
RY401

Fig. 14 Automatic Transmission Oil Cooler

I n case o f a leak i n the transmission o i l cooler, en-
gine coolant m a y become m i x e d w i t h transmission
fluid, or transmission fluid m a y enter t h e engine
cooling system. B o t h cooling system and transmis-
sion should be drained a n d inspected i n t h e event
cooler is l e a k i n g .

REPLACING OIL COOLER IN BOTTOM TANK

Remove r a d i a t o r . Refer to Radiator Removal i n t h i s
RR07B68 group. T h e servicing should be performed by a qual-
ified r e p a i r f a c i l i t y .
Fig. 12 Radiator Hoses Once t h e repaired or replacement radiator has been
HOSE CLAMPS installed, fill t h e cooling system a n d inspect for
Constant tension hose clamps are used on some leaks. Refer t o " R e f i l l i n g Cooling System" and "Test-
cooling system hoses. T h e clamp size is identified by i n g Cooling System For L e a k s " sections i n t h i s
group. I f t h e transmission operates properly after re-
 • COOLING SYSTEM
p a i r i n g the leak, d r a i n t h e transmission a n d torque
converter w h i l e hot. Remove t h e transmission o i l pan
and inspect sludge and/or r u s t . Inspect for a d i r t y or
plugged i n l e t filter. I f none o f these conditions are
found, the transmission m a y n o t require recondition-
i n g . Refer t o Group 2 1 for automatic transmission
servicing.
TRANSMISSION OIL-TO-AIR COOLER
O i l to a i r transmission coolers are mounted ahead
of t h e radiator a n d operate i n conjunction w i t h t h e
m a i n cooler located i n t h e r a d i a t o r lower t a n k (Fig.
15). The transmission o i l is r o u t e d t h r o u g h t h e m a i n
cooler i n t h e radiator lower t a n k first, t h e n t h e aux-
i l i a r y cooler before r e t u r n i n g t o t h e transmission.
(FROM BOTTOM COOLER)
VIEW IN CIRCLE J9007-75
Fig. 15 Transmission Oil-to-Air Cooler
COOLING SYSTEM FAN
Removal
(1) Disconnect battery negative cable from battery.
(2) Loosen accessory d r i v e belts. Refer to "Accesso-
r y D r i v e B e l t " section i n t h i s group.
(3) Remove fan/viscous drive assembly t o water
pump hub m o u n t i n g bolts.
(4) Remove f a n shroud m o u n t i n g screws ( F i g . 13).
(5) Remove fan/viscous drive assembly a n d shroud
f r o m engine compartment.
(6) Remove f a n to viscous drive u n i t m o u n t i n g
screws.
7-19
Inspection
The f a n cannot be repaired i f i t is damaged. I t
m u s t b e r e p l a c e d . I n s p e c t t h e f a n as f o l l o w s .
(1) Remove f a n a n d viscous drive assembly from
engine. Refer to Removal procedure.
(2) Disconnect f a n from viscous drive u n i t .
(3) L a y f a n o n a flat surface w i t h leading edge fac-
i n g down. W i t h t i p of blade touching flat surface, re-
place f a n i f clearance between opposite blade a n d
surface is greater t h a n 2.0mm (.090 inch). Rocking
motion o f opposite blades should not exceed 2.0mm
(.090 inch). Test a l l blades i n t h i s manner.
WARNING: IF FAN IS NOT WITHIN SPECIFICA-
TIONS, DO NOT ATTEMPT TO BEND OR
STRAIGHTEN FAN.
(2) Inspect d a n assembly for cracks, bends, loose
rivets or broken welds. Replace f a n i f any damage is
found.
CAUTION: If the water pump is replaced because of
bearing or shaft damage, the mechanical cooling
fan should be inspected for fatigue cracks, loose
blades, or loose rivets that could have resulted
from excessive vibration. Replace the fan if any of
these conditions are found.
Thermal Control Fan Drive
The t h e r m a l control f a n drive consists o f t h e vis-
cous f a n drive c l u t c h and a thermostatic spring coil
mounted o n i t ' s front face. The viscous f a n drive
clutch is essentially a silicone-fluid-filled coupling
connecting t h e f a n assembly to the fan/water pump
pulley (Fig. 16). The coupling allows t h e f a n to be
d r i v e n i n a n o r m a l manner a t low engine speeds
w h i l e l i m i t i n g t h e top speed of the f a n to a predeter-
m i n e d m a x i m u m level at higher engine speeds.
Fig. 16 Thermal Control Fan Drive
7 - 20 COOLING SYSTEM
The thermostatic s p r i n g coil reacts t o the tempera-
t u r e o f the r a d i a t o r discharge a i r a n d engages t h e
drive c l u t c h for h i g h e r f a n speed i f t h e a i r tempera-
t u r e from t h e r a d i a t o r rises above a certain point.
U n t i l a d d i t i o n a l engine cooling is necessary, the fan
w i l l r e m a i n a t a reduced R P M regardless o f engine
speed. O n l y w h e n sufficient heat is present i n the a i r
flowing t h r o u g h t h e r a d i a t o r core t o cause a reaction
from t h e thermostatic s p r i n g coil w i l l t h e viscous
drive clutch engage a n d increase fan speed to provide
t h e necessary a d d i t i o n a l engine cooling.
Regardless o f increased engine speed, once the f a n
has reached i t s m a x i m u m operating speed i t w i l l not
rotate any faster. W h e n t h e necessary engine cooling
has been accomplished causing a reduction i n t h e
•
temperature o f t h e r a d i a t o r discharge a i r , the spring
coil again reacts a n d the f a n speed i s reduced t o the
previous disengaged speed.
Fan Installation
(1) I n s t a l l fan t o viscous d r i v e u n i t . T i g h t e n mount-
i n g screws t o 23 N n n (17 ft-lbs) torque.
(2) I n s t a l l fan/viscous d r i v e assembly a n d shroud.
T i g h t e n fan/viscous drive assembly t o w a t e r p u m p
hub m o u n t i n g screws t o 23 N m (17 ft-lbs) torque.
#
T i g h t e n shroud m o u n t i n g screws t o 11 N n n (95 i n -
lbs) torque.
(3) I n s t a l l a n d tension accessory d r i v e belts. Refer
to "Accessory D r i v e B e l t " section i n t h i s group.
(4) Connect b a t t e r y negative cable t o negative ter-
m i n a l o f battery.
 A C C E S S O R Y DRIVE B E L T S
INDEX
Page Page

Diagnosis 21 General Information 21

GENERAL INFORMATION lack of power steering assist, loss of air conditioning

Vehicles are available with either a 3.9L V - 6 e n -
gine o r a 5.2L or 5.9L V - 8 engine. T h e accessory
drive systems of all engines are operated by crank-
shaft driven V-belt accessory drive belts. The alter-
nator is driven by a dual belt system that also drives
the a i r conditioning compressor (if equipped).
PROPER BELT TENSION
Correct accessory drive belt tension is required to
ensure optimum performance of the belt driven en-
gine accessories. I f the specified tension i s not main-
tained, belt slippage may cause; engine overheating,
capacity, reduced alternator output rate, and greatly
reduced belt life.
BELT TENSION TESTING-USING GAUGE
There are different gauges for checking Poly " V "
serpentine (multi-ribbed) belts and conventional " V "
belts. Use the correct gauge when checking belt ten-
sion. Place gauge in. the middle of the section of belt
being used to check tension. The gauge can only con-
tact the belt or a false reading may result. Refer to
the Belt Tension C h a r t for tension specifications. A
belt i s c o n s i d e r e d a u s e d belt after 15 m i n u t e s o f
use.

DIAGNOSIS

V-Belt Diagnosis

Condition Possible Cause Correction

INSUFFICIENT (a) Belt too loose. w Adjust belt tension

Replace and tighten as
ACCESSORY OUTPUT (b) Belt excessively glazed (fe»
DUE TO BELT or worn. specified.
SUPPAGE

BELT SQUEAL WHEN (a) Belt too loose. (a) Adjust belt tension.
ACCELERATING W Belt glazed. (b) Replace belt.

BELT SQUEAK AT (a) Belt too loose. Adjust belt tension.

IDLE (b) Dirt and/or paint H Replace belt.
imbedded in belt.
W Non-uraform belt.
Misaligned pulleys.
ft)
(d)
Replace belt.
Align accessory drive
(d)
pulleys.
W Non-uniform groove or H Replace pulley.
eccentric pulley.

BELT ROLLED (a) Broken cord in belt. ft* Replace beh.

OVER IN GROOVE (b» Belt too loose or too W Adjust bete tension.
OR BELT JUMPS tight.
OFF ft) Misaligned pulley. W Adjust belt tension.
Non-uniform groove or ft* Replace pulley.
eccentric pulley.
J8907-76
7 - 22 COOLING SYSTEM

ACCESSORY DRIVE BELT SCHEMATICS

TWO
BELTS

J9007-71
BELT
TENSION TEST Fig. 3 Alternator, Air Pumps, and Power
POINT J9007-39 Steering—Heavy Duty Cycle 5.9L Engine
Fig. 1 Alternator, Air Pump and Power
Steering-3.9L, 5.2L and 5.9L Engines
TWO BELTS

J9007-72

Fig. 4 Alternator, Air Pumps, A/C, and Power

BELT TENSION Steering—Heavy Duty Cycle 5.9L Engine
TEST POINT J9007-41
ALTERNATOR AND AIR CONDITIONING
Fig. 2 Alternator, Air Pump, A/C, and Power BELTS
Steering-3.9L, 5.2L and 5.9L Engines The alternator has a matched t w o belt system.
Both belts are tightened to the correct tension at the
same time by t h e adjusting screw.
(1) Disconnect battery negative cable from battery.
(2) Loosen alternator pivot bolt (Fig. 5 or 6).
(3) Loosen alternator locknut.
 • COOLING SYSTEM 7 - 23

(4) Loosen adjusting bolt to remove or replace belt. T-BOLT ADJUSTMENT LOCK SCREW
ADJUSTMENT
(5) I n s t a l l belts. T h e b e l t s a r e a m a t c h e d set. SCREW LOCK NUT BRACKET

ALTERNATOR AIR PUMP

ADJUSTING PIVOT SCREW
(JACK) SCREW 24 FT. LBS.
(33 N.m)

AIR PUMP
ADJUST
BRACKET

PIVOT
BOLT
SCREW
ADJUSTMENT
24 FT. LBS. BRACKET
(33 Nm)
J9007-63

P/S ADJUST Fig. 6 Accessory Drive System—Heavy Duty Cycle

BRACKET 5.9L Engine
PIVOT (6) Connect battery negative cable t o battery.
SCREW
T i g h t e n cable t e r m i n a l bolt to 12 N*m (100 in-lbs)
30 FT. LBS PIVOT & ADJUSTING SCREWS
RR07B62 (41 N-m) 40 FT. LBS. (54 N-m) torque.

Fig. 5 Accessory Drive System—3.9L, 5.2L Engines POWER STEERING PUMP BELT
and 5.9L Engines Low Duty Cycle (1) Disconnect battery negative cable from battery.
(2) Loosen power steering p u m p adjusting screw
B o t h belts m u s t be r e p l a c e d a t t h e same t i m e .
and pivot screw (Fig. 5).
Tension belts b y t i g h t e n i n g t h e adjusting bolt. Refer
(3) Remove or replace t h e belt.
to " B e l t Tension C h a r t " i n t h e "Specifications" sec-
(4) Insert a 1/2 i n c h breaker b a r i n t o t h e square
t i o n for tension specifications.
hole i n t h e adjusting bracket a t t h e front o f t h e
(6) T i g h t e n l o c k n u t to 27 N * m (20 ft-lbs) torque.
p u m p and adjust belt tension. Refer to the " B e l t Ten-
(7) T i g h t e n pivot bolt and n u t t o 40 N * m (30 ft-lbs) sion C h a r t " i n the "Specifications" section for tension
torque. specifications.
(8) Connect battery negative cable to battery.
T i g h t e n cable t e r m i n a l bolt to 12 N * m (100 in-lbs)
torque. ••'T \ :

AIR PUMP BELT

(1) Disconnect battery negative cable from battery.
(2) Loosen a i r pump lock screw (Fig. 5 or 6).
(3) Loosen a i r pump pivot screw a n d remove or re-
place belt.
(4) Insert a 1/2 i n c h breaker b a r i n t o t h e square
hole i n t h e adjustment bracket a t t h e rear of t h e
p u m p and adjust belt tension. Refer to t h e " B e l t Ten-
sion C h a r t " i n the "Specifications" section for tension
specifications.
(5) T i g h t e n t h e lock screw a n d p i v o t screw to 33
N*m (24 ft-lbs) torque.
7 - 24 COOLING SYSTEM
ENGINI BLOCK HEATERS
INDEX
Page
General Information ... . 24
GENERAL INFORMATION
DESCRIPTION AND OPERATION
A n optional engine block heater i s available w i t h
for a l l models. The heater i s equipped w i t h a power
cord t h a t is located behind the g r i l l e . The cord i s at-
tached to a n engine compartment component w i t h
tie-straps. T h e heater w a r m s t h e engine p r o v i d i n g
easier engine s t a r t i n g a n d faster w a r m - u p i n l o w
temperatures. T h e heater i s m o u n t e d i n a core hole
of t h e engine cylinder block ( i n place of welsh plug)
w i t h the h e a t i n g element immersed i n engine cool-
a n t . T h e power cord is located behind t h e r a d i a t o r
g r i l l e . Connect t h e power cord t o a grounded 110-120
v o l t A C electrical outlet w i t h a grounded, three w i r e
extension cord.
WARNING: D O NOT OPERATE ENGINE UNLESS
B L O C K HEATER CORD HAS BEEN DISCONNECTED
FROM POWER SOURCE AND SECURED IN PLACE.
Fig. 1 Engine Block Heater
•
THE POWER CORD MUST BE SECURED I N ITS RE-
TAINING CLIPS A N D ROUTED A W A Y FROM EX-
HAUST MANIFOLDS AND MOVING PARTS.
REMOVAL
(1) Disconnect b a t t e r y negative cable from b a t t e r y .
(2) D r a i n coolant from r a d i a t o r a n d c y l i n d e r block.
(3) Remove power cord from heater (Fig. 1).
(4) Loosen screw a t center o f heater. Remove
heater assembly.
INSTALLATION
(1) Thoroughly clean cylinder block core hole and
heater seat.
(2) Insert heater assembly w i t h element loop point-
i n g down.
(3) W i t h heater f u l l y seated, t i g h t e n center screw
securely.
(4) F i l l cooling system w i t h recommended coolant.
Refer t o " F i l l i n g Cooling System" section i n t h i s
group.
• COOLING SYSTEM 7 - 25

SPECIFICATIONS

COOLING SYSTEM SPECIFICATIONS

ENGINE MODEL DRIVE RADIATOR CAPACITY

*C.U.-UTER WIDTH (INCHES) QUARTS-LITER

238-3.9 D150, 250 2-Wheel 26 15.1-14.0

318-5.2 D150, 250, 350 2-Wheel 26 17.0-16.0
360-5.9 D150, 250, 350 and Ramcharger 2-Wheel 26 15.5-14.5
318-5.2 Ramcharger 4-Wheel 26 16.5-15.50
360-5.9 Ramcharger 4-Wbeel 26 15.0-14.0
318-5.2 W150, 250, 350 4-Wheel 26 17.0-16.0
360-5.9 W150, 250, 350 4-Wheel 26 15.5-14.5

•Cubic Inch Displacement J9007-74

Engine Models Thermostat Calibration Water Pump Impeller Remarks

3.9L - 5.2L - 5.9L All 195°F (91 °C) 3.85 Dia. 6 Blades W/O A/C & W/ A/C
W/O A/C — Without Air CConditioning
W/ A/C — With Air Conditioning
J9007-66

CONVERSION CHART

U.S. Quart ....... 13 14 15 15-1/2 16 16-1/2 17 17-1/2 18 18-1/2

12L 13L 14L 14.6L 15L 15.6L 16L 16.5L 17L 17.5L

J9007-67

TIGHTENING REFERENCE

COMPONENT INCH POUNDS FOOT POUNDS THREAD SIZE

.— 30 (41 N-m) 3/8-16

— 20 (27 N-m) 5/16-18
200 (23 Nnn) — 5/16-18
200 (23 N*m) — 3/8-18
95 (11 N-m) — 1/4-20
95 (11 N*m) — 1/4-20
150 (17 N*m) — —
22-32 (2-4 N*m) — —
35 (4 N*m) —
50 (6 Hm) — —
15 (2 NITI) — —
H*m — Newton AAeters
J9007-73
7 - 26 COOLING SYSTEM •
ACCESSORY DRIVE BELT TENSION

Accessory Drive Bert Tension New Belt Used Belt

100-140 lbs 60-90 lbs

Alternator (dual belt drive)
444-622 N 266-400 N

100-140 lbs 60-90 lbs

Air Pump
444-622 N 266-400 N

100-140 lbs 60-90 lb*

Power Steering Pump
444-622 N 266-40DN

J9007-68
 • BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A - 1

ELECTRICAL

GROUP INDEX
Page Page
ALTERNATOR SERVICE 8C POWER MIRRORS 8T
BATTERY/STARTER SERVICE 8B POWER WINDOWS 8S
BATTERY/STARTING/CHARGING SYSTEM RADIO, ANTENNA AND SPEAKERS 8F
DIAGNOSTICS 8A RESTRAINT SYSTEMS 8M
HORNS 8G SPEED CONTROL 8H
IGNITION SYSTEM 8D TURN SIGNALS AND HAZARD WARNING
INSTRUMENT PANEL AND GAUGES 8E FLASHERS 8J
LAMPS 8L WINDSHIELD WIPERS AND WASHERS 8K
POWER LOCKS 8P WIRING DIAGRAMS 8W

Throughout these groups, references m a y be made nations is included i n the I n t r o d u c t i o n Section a t

to a p a r t i c u l a r vehicle b y l e t t e r or number designa- front of t h i s service m a n u a l .
t i o n . A chart showing t h e breakdown of these desig-

B A T T E R Y / S T A R T I N G / C H A R G I N G S Y S T E M S DIAGNOSTICS

CONTENTS
Page Page

ALTERNATOR TEST PROCEDURES DIAGNOSTIC INFORMATION . . . . . . . . . . . . . . . . 1

ON VEHICLE 14 SPECIFICATIONS 19
BATTERY TEST PROCEDURES ON VEHICLE . . . 2 STARTER TEST PROCEDURES ON VEHICLE . . . 9

DIAGNOSTIC INFORMATION
INTRODUCTION TO STARTING AND CHARGING
SYSTEM DIAGNOSTICS
The Battery, S t a r t i n g , and C h a r g i n g Systems oper-
ate i n conjunction w i t h one another, and therefore,
m u s t be t h o r o u g h l y tested as a complete system. I n
order for the vehicle t o s t a r t a n d charge .properly, i t SOLENOID
must have a b a t t e r y t h a t w i l l perform to specifica-
tions. The starter motor, alternator, w i r i n g , and elec- — r ~ STARTER
tronics also m u s t perform w i t h i n specifications. POSITIVE
MOTOR
BATTERY
Group 8A w i l l cover S t a r t i n g (Fig. 1) a n d Charging NEGATIVE
CABLE
(Fig. 2) System diagnostic procedures from t h e most BATTERY
CABLE
basic conventional methods t o " O n Board Diagnos- STARTER
t i c s " (OBD) b u i l t i n t o t h e vehicle's electronics (except
diesel). The need for conventional testing equipment 1 02}—
=» D
RELAY

has not been e l i m i n a t e d b y t h e introduction of OBD.

U| * |. —
I i I BATTERY
Use of a n ammeter, volt/ohmmeter, battery RR8AD4
charger, carbon pile rheostat (load tester), a n d 12
volt test l i g h t w i l l be r e q u i r e d . Fig, 1 Starting System Components (Typical)
8A - 2 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS

A l l vehicles are equipped w i t h O B D (except diesel).

A l l O B D sensing systems are monitored b y the Sin-
gle Board E n g i n e Controller. The Engine Controller CHECK ENGINE
w i l l store i n electronic memory any detectable f a i l u r e LAMP
w i t h i n the monitored circuits. Refer t o U S I N G O N -
B O A R D D I A G N O S T I C S Y S T E M i n t h i s group for
more i n f o r m a t i o n .

BATTERY
ALTERNATOR J908A-15

Fig. 2 Charging System Components (Typical)

B A T T E R Y 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
Battery Load Test . 5 Ignition Off Draw (IOD) 4
Causes of Battery Discharging 3 Open Circuit Voltage Test 4
Charging Battery 6 State of Charge Test 3
General Information 2 Test Indicator . 3

GENERAL INFORMATION w i t h a b u i l t - i n hydrometer (test indicator) t o assist

The battery stores, stabilizes, and produces electri-
cal current t o operate various electrical systems i n
the vehicle. T h e d e t e r m i n a t i o n of whether a b a t t e r y
is good or bad is made b y the batteries a b i l i t y t o ac-
cept a charge a n d produce high-amperage c u r r e n t
o u t p u t over a n extended period. The capability o f the
battery to store electrical current comes f r o m a
chemical reaction between the sulfuric acid solution
(electrolyte) and the lead + /-plates i n each cell o f the
battery. As the battery discharges, t h e plates collect
the acid from t h e electrolyte. When the c h a r g i n g sys-
t e m charges t h e battery, the acid is forced out o f the
plates into the electrolyte. The amount o f acid (spe-
cific gravity) i n the electrolyte can be measured w i t h
a hydrometer. A factory installed battery is equipped
i n d e t e r m i n i n g t h e batteries state-of-charge. The fac-
t o r y i n s t a l l e d b a t t e r y is also nonrefillable, water can-
not be added. The battery i s vented t o release gases
t h a t a r e created w h e n the b a t t e r y is being charged.
The b a t t e r y t o p , posts, a n d t e r m i n a l s should be
cleaned w h e n other underhood maintenance is per-
formed (Fig. 3).
WARNING: DO NOT ATTEMPT TO ASSIST BOOST,
CHARGE, OR TEST BATTERY WHEN ELECTRO-
LYTE LEVEL IS BELOW THE TOP OF THE PLATES
(YELLOW OR BRIGHT COLOR DOT IS VISIBLE).
PERSONAL INJURY MAY OCCUR.
W h e n t h e electrolyte level is below the top of t h e
plates (yellow or b r i g h t color indicator ttot), the bat-
t e r y m u s t be replaced. T h e b a t t e r y m u s t be com-
 • BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS
Fig. 3 Battery Construction and Test Indicator
pletely charged (green dot) a n d t h e top, posts, a n d
t e r m i n a l s should be properly cleaned before diagnos-
t i c procedures are performed, see Group 8B - Battery/
Starter Service, for a d d i t i o n a l i n f o r m a t i o n .
TEST INDICATOR
A test i n d i c a t o r (hydrometer) b u i l t i n t o t h e t o p of
b a t t e r y case, provides v i s u a l i n f o r m a t i o n for b a t t e r y
t e s t i n g (Fig. 4). T h e test indicator is t o be used w i t h
diagnostic procedures described i n t h i s group. I t is
i m p o r t a n t w h e n u s i n g t h e test indicator t h a t the bat-
t e r y is r e l a t i v e l y level a n d has a clean top to see cor-
rect indications. A l i g h t m a y be required t o v ie w
indicator.
WARNING: DO NOT USE OPEN FLAME. EXPLOSIVE
GASES FORM ABOVE BATTERY.
Fig. 4 Built in Test Indicator
STATE OF CHARGE TEST
USING TEST INDICATOR
The b u i l t - i n test indicator (hydrometer) measures
t h e specific g r a v i t y o f t h e electrolyte. Specific g r a v i t y
(SG) of t h e electrolyte w i l l indicate state-of-charge
(voltage); a l t h o u g h , t h e test i n d i c a t o r w i l l n o t i n d i -
cate c r a n k i n g capacity of the b a t t e r y . Refer to B a t -
t e r y Load Test for more i n f o r m a t i o n . Look i n t o t h e
8A - 3
sight glass a n d note t h e color of the indicator ( F i g .
5), refer to t h e following description as color i n d i -
cates:
G R E E N — 7 5 t o 100% state-of-charge
The battery i s adequately charged for f u r t h e r test-
i n g o r r e t u r n t o use. I f t h e vehicle w i l l not c r a n k for
a m a x i m u m 15 seconds, refer to B a t t e r y Load Test
for more i n f o r m a t i o n .
B L A C K O R D A R K — 0 t o 75% state-of-charge
The battery i s inadequately charged a n d m u s t be
charged u n t i l green dot is visible (12.4 volts o r
greater) before t h e battery is tested or r e t u r n e d to
use, refer t o Causes of B a t t e r y Discharging for more
information.
YELLOW OR BRIGHT COLOR
WARNING: DO NOT ATTEMPT TO CHARGE, TEST,
OR ASSIST BOOST BATTERY WHEN YELLOW OR
BRIGHT COLOR DOT IS VISIBLE. PERSONAL IN-
JURY MAY OCCUR.
A yellow or b r i g h t color dot indicates w a t e r (elec-
trolyte) level i n battery is below t h e test i n d i c a t o r
(Fig. 5). W a t e r can n o t be added to a maintenance
free battery. T h e battery m u s t be replaced. A l o w
electrolyte level m a y be caused by a n over c h a r g i n g
condition. Refer to A l t e r n a t o r Test Procedures O n
Vehicle i n t h i s group.
TEST INDICATOR/STATE OF CHARGE
1 71 0 REPLACE BATTERY
GREEN BLACK YELLOW 898A-3
Fig. 5 Test Indicator Sight Glass
CAUSES OF BATTERY DISCHARGING
I t is n o r m a l for a vehicle to have a s m a l l (5 to 30
milliamperes) continuous electrical draw f r o m t h e
b a t t e r y w i t h t h e i g n i t i o n i n t h e O F F position, a n d
the courtesy, dome, storage compartments, a n d en-
gine compartment lights OFF. The continuous d r a w
is due t o various electronic features or accessories
t h a t require electrical c u r r e n t w i t h the i g n i t i o n O F F
to f u n c t i o n properly. When a vehicle is not used over
an extended period (20 days) the m a i n fusible l i n k
connector (Fig. 6), located behind t h e b a t t e r y o n t h e
engine w i r i n g harness, should be disconnected. T h i s
w i l l prevent b a t t e r y discharging.
ABNORMAL BATTERY DISCHARGING
(1) Corroded b a t t e r y posts and terminals.
8A - 4 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS
(2) Loose o r w o r n a l t e r n a t o r drive belt.
(3) E l e c t r i c a l loads t h a t exceed t h e output o f the
c h a r g i n g system due t o equipment or accessories i n -
stalled after delivery.
(4) Slow d r i v i n g speeds (heavy traffic conditions) or
prolonged i d l i n g w i t h high-amperage electrical sys-
tems i n use.
(5) Defective electrical circuit or. component caus-
i n g excess I g n i t i o n O f f D r a w (IOD).
(6) Defective c h a r g i n g system.
(7) Defective battery.
MAIN FUSIBLE LINK POSITIVE
CONNECTOR
TERMINAL 4JL
POSITIVE
POST
TEST
INDICATOR 89BAS
Fig. 6 High Amperage IOD Test
IGNITION OFF DRAW (IOD)
A n o r m a l vehicle electrical system w i l l draw 5 t o
30 m i l l i a m p e r e s f r o m t h e battery, w i t h the i g n i t i o n
i n t h e O F F position a n d a l l n o n i g n i t i o n controlled
circuits i n proper w o r k i n g order. A vehicle t h a t has
not been operated for a n extended period of t i m e (20
days) m a y discharge t h e battery to a n inadequate
level. I n t h i s case, m a i n fusible l i n k connector should
be disconnected. The m a i n fusible l i n k connector is
located r e a r w a r d of t h e battery on the engine w i r i n g
harness (Fig. 6). I f t h e I O D is excessive (over 30 m i l -
liamperes), t h e defect m u s t be found and corrected.
IGNITION OFF DRAW TESTS
To test for excessive I O D , verify t h a t a l l electrical
accessories are OFF. T u r n off a l l l i g h t s , remove i g n i -
t i o n key, and close a l l doors and decklid. I f the vehi-
cle is equipped with electronic accessories
( i l l u m i n a t e d entry, automatic load leveler, body com-
puter, or h i g h line radio), allow the systems t o auto-
m a t i c a l l y shut off (time out), u p t o 3 minutes.
(1) Raise t h e hood a n d disconnect both battery ca-
bles, negative first.
(2) Connect the negative cable and connect a t y p i -
cal 12-volt test l i g h t (low wattage bulb) between t h e
positive cable clamp a n d the battery positive post
(Fig. 6). Remove the engine compartment lamp bulb.
I f t h e test l i g h t does n o t l i g h t , proceed to step 3. I f
the test l i g h t does l i g h t , proceed to step 4. T h e test
l i g h t w i l l indicate I O D greater t h a n 3 amps.
•
CAUTION: IOD greater than 3 amps may damage
milliampmeter.
(3) W i t h 12-volt test l i g h t s t i l l connected (not l i t ,
see step 2), connect a n ammeter ( m i l l i a m p e r e scale)
between t h e positive cable clamp a n d t h e b a t t e r y
positive post ( F i g . 7), disconnect test l i g h t , refer t o
instructions provided w i t h ammeter being used. A
r e a d i n g of 30 milliamperes or less indicates n o r m a l
electrical draw. I f ammeter reads more t h a n 30 m i l -
liamperes, excessive I O D m u s t be corrected.
POSITIVE AMPMETER
TERMINAL MILLIAMPERE
SCALE'
FELT
TEST POSITIVE
BATTERY 'NEGATIVE INDICATOR POST 898Ar6
Fig. 7 Low Amperage IOD Test
(4) Locate t h e fuse panel and remove fuses or cir-
cuit breakers one a t a t i m e , i f test l i g h t goes out a n d
the reading drops below 30 milliamperes w h e n a cer-
t a i n fuse or circuit breaker is removed, t h a t c i r c u i t
m a y have a defect. Refer t o Group 8 W - W i r i n g D i a -
grams, for component and splice locations.
(5) I f I O D is detected after a l l fuses a n d c i r c u i t
breakers have been removed, disconnect t h e 60-way
connector a t t h e Single Board Engine C o n t r o l
(SBEC), located outboard of the b a t t e r y , see Group
8D - I g n i t i o n , for more i n f o r m a t i o n .
(6) I f excessive I O D is detected after a l l fused cir-
cuits a n d SBEC have been verified, disconnect t h e
B + t e r m i n a l from t h e alternator. I f reading drops
below 30 milliamperes, r e i n s t a l l a l l fuses and c i r c u i t
breakers, reconnect B + t e r m i n a l a t alternator, r e -
connect battery, and perform alternator diagnostics
as o u t l i n e d i n t h i s group.
(7) I n s t a l l engine compartment l a m p bulb.
OPEN CIRCUIT VOLTAGE TEST
A n open c i r c u i t voltage (no load) test w i l l indicate
the state of charge i n a battery t h a t w i l l endure
(pass) a load test of 50%cold crank r a t i n g , see B a t -
tery Load Test i n t h i s section. I f a battery has a n
open circuit voltage reading of 12.4 volts or greater
and w i l l not endure a load test, i t is defective a n d re-
placement w o u l d be required, see Group 8 B - B a t -
tery/Starter Service for instructions. To test open
circuit voltage, perform the following operation:
 • BATTERY/STARTING CHARGING SYSTEMS DIAGNOSTICS 8A - 5

(1) Remove both battery cables, negative first. I f i n g used, check t h e open c i r c u i t voltage (no load) o f
t h e battery has been boosted, charged, or loaded j u s t the battery. Voltage should be equal t o or greater
p r i o r to t h i s operation, allow t h e battery t i m e to sta- t h a n 12.4 volts (Fig. 9) w i t h green dot visible i n test
bilize. indicator.
(2) U s i n g a voltmeter connected t o t h e battery
posts, see instructions provided w i t h voltmeter being
used, measure open c i r c u i t voltage (Fig. 8).
This voltage reading w i l l indicate state o f charge,
b u t w i l l n o t reveal c r a n k i n g capacity. Refer t o Bat-
t e r y Open C i r c u i t Voltage chart.

BATTERY OPEN CIRCUIT VOLTAGE

Open Circuit Vohs P#ra#nt Chorgo
11.7 volts or less 0%
12.0 25%
12.2 50%
12.4 75%
12.6 or more 100%
J908A3

J908A-12
898A-7
Fig. 10 Volt-Ammeter-Load Tester Connections
Fig. 8 Testing Open Circuit Voltage
(3) Rotate t h e load control knob (Carbon pile rheo-
BATTERY LOAD TEST stat) t o apply a 300 a m p load for 15 seconds to re-
move the surface charge f r o m t h e b a t t e r y and r e t u r n
A battery must have t h e c r a n k i n g capacity to sup-
p l y t h e starter motor a n d i g n i t i o n system enough the control knob to off (Fig. 11).
power to s t a r t t h e engine over a broad range of am-
b i e n t temperatures. A battery load test w i l l verify
t h e actual c r a n k i n g performance based on t h e cold
crank r a t i n g of the battery.

WARNING: IF BATTERY SHOWS SIGNS OF FREEZ-

ING, LEAKING, LOOSE POSTS, OR EXCESSIVELY
LOW ELECTROLYTE LEVEL, DO NOT TEST. ACID
BURNS OR EXPLOSIVE CONDITION MAY RESULT.

(1) Remove both battery cables, negative first. Bat-

t e r y top a n d posts should be clean. I f green dot is not
visible i n indicator, charge t h e battery, see B a t t e r y
C h a r g i n g Procedures i n t h i s section. 898A-10
(2) U s i n g a suitable Volt-Ammeter-Load tester
(Fig. 9) connected to t h e battery posts (Fig. 10), refer Fig. 11 Remove Surface Charge from Battery
to operating instructions provided w i t h the tester be-
8A - 6 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS
(4) A l l o w t h e battery t o stabilize for 15 seconds,
verify open circuit voltage.
(5) Rotate the load control knob t o m a i n t a i n a load
(50% o f cold crank rating—see specifications) for a
m i n i m u m 15 seconds (Fig. 12). A f t e r 15 seconds,
record t h e (loaded) voltage reading a n d r e t u r n t h e
load control t o off.
•
b u i l t - i n t o t h e top o f t h e b a t t e r y , indicates i t is
charged enough for f u r t h e r t e s t i n g a n d possibly re-
t u r n e d to use. A black dot indicates the battery volt-
age is below 12.4 volts a n d probably w i l l accept a
charge. A yellow or b r i g h t color dot indicates the bat-
t e r y has excessively low electrolyte level. The battery
cannot be refilled or charged, i t m u s t be replaced.

WARNING; DO NOT CHARGE A BATTERY THAT

HAS EXCESSIVELY LOW ELECTROLYTE LEVEL.
BATTERY MAY ARC INTERNALLY AND EXPLODE.

WARNING: EXPLOSIVE GASES FORM OVER BAT-

TERY, DO NOT SMOKE, USE FLAME, OR CREATE
SPARKS NEAR BATTERY.

WARNING: DO NOT ASSIST BOOST OR CHARGE A

FROZEN BATTERY, CASING MAY FRACTURE.
898A-11
WARNING: POISON, CAUSES SEVERE BURNS.
Fig. 12 Load 50% Cold Crank Rating Note Voltage BATTERY CONTAINS SULFURIC ACID, AVOID CON-
(6) Voltage drop w i l l vary according to b a t t e r y tem- TACT WITH SKIN, EYES, OR CLOTHING. IN EVENT
perature a t the time o f the load test. B a t t e r y temper- OF CONTACT, FLUSH WITH WATER AND CALL
ature can be estimated by t h e temperature of PHYSICIAN IMMEDIATELY. KEEP OUT OF REACH
exposure over the preceding several hours. I f t h e bat-
OF CHILDREN.
tery has been charged, boosted, or loaded a few m i n -
utes p r i o r t o test, t h e battery w o u l d be somewhat CAUTION: Disconnect the vehicle's battery negative
warmer. Refer to Load Test Temperature c h a r t for cable before charging battery to avoid damage to
proper loaded voltage reading. electrical systems. Do not exceed 16.0 volts while
(7) I f battery passes load test, i t is i n good condi- charging battery.
tion. No further tests are necessary. I f i t fails load
test, i t should be replaced. B a t t e r y electrolyte w i l l bubble inside o f case w h i l e
being charged properly. I f the electrolyte boils vio-
LOAD TEST TEMPERATURE l e n t l y or i s discharged f r o m t h e vent holes w h i l e
Temperature charging, i m m e d i a t e l y reduce charging rate or t u r n
Minimum Voltage
off charger and evaluate b a t t e r y condition.
P C°
Some b a t t e r y chargers are equipped w i t h p o l a r i t y
9.6 70 and above 21 and above ( + to +/- t o -) sensing devices to protect the charger
9.5 60 16 or b a t t e r y from being damaged i f improperly con-
9.4 50 10 nected. I f the battery state o f charge is too l o w for
4 the p o l a r i t y sensor t o detect, t h e sensor m u s t be by-
9.3 40
passed for charger t o operate. Refer to operating i n -
9.1 30 -1
structions provided w i t h b a t t e r y charger being used.
8.9 20 -7
8.7 10 -12 CAUTION: Charge battery until test indicator ap-
8.5 0 -18 pears green. Do not overcharge.
J908A4 I t may be necessary to jostle the battery or vehicle
CHARGING BATTERY to b r i n g the green dot i n t o view i n the test indicator
w h e n the state-of-charge has reached 12.4 volts.
A battery charged t o 12.4 volts or greater, w i t h A f t e r t h e battery has been charged to 12.4 volts or
sufficient c r a n k i n g capacity ( m i n i m u m 9.6 volts greater, perform a load test t o determine c r a n k i n g
when loaded for 15 seconds t o 50% o f cold c r a n k i n g capacity. I f the battery w i l l endure a load test, re-
amperage r a t i n g a t 21°C/70°F), is completely t u r n the battery to use. I f b a t t e r y w i l l not endure a
charged. A green dot, visible i n t h e test indicator load test, i t must be replaced. Properly clean and i n -
 • BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A - 7

BATTERY CHARGING TIME TABLE

ChorgRig Ampswgu 5 Amps 10 Amps 20 Amps 30 Amps
Open Circuit Voltage Hours Charging at 21°C (70°F)
12.25to12.39 6 Hrs 3 Hrs. 1.5 Hrs. 1 Hr.
12.00to12.24 8 Hrs. 4 Hrs. 2 Hrs. 1.5 Hrs.
11.95to12.09 12 Hrs. 6 Hrs. 3 Hrs. 2 Hrs.
10.00to11.95 14 Hrs. 4 Hrs. 3.5 Hrs. 2.5 Hrs.
10.00to0 See Charging Completely Discharged Battery
J908A-6

spect battery hold downs, t r a y , t e r m i n a l s , posts, a n d

top before completing service, see Group 8 B , Battery/
Starter Service.

CHARGING TIME REQUIRED

The t i m e required t o charge a b a t t e r y w i l l v a r y de-
pending upon the following factors:
v

(1) Size of B a t t e r y — A completely discharged

large heavy-duty b a t t e r y requires more t h a n twice
t h e recharging t i m e as a completely discharged s m a l l
capacity battery.

WARNING: NEVER EXCEED 20 AMPS WHEN

CHARGING A COLD (-1°C/30°F) BATTERY, PER-
SONAL INJURY MAY RESULT.
(2) T e m p e r a t u r e — A longer t i m e w i l l be needed
to charge a battery a t -18°C (0°F) t h a n a t 27°C
(80°F). W h e n a fast charger is connected t o a cold
battery, c u r r e n t accepted b y battery w i l l be very l o w
a t first. Then, i n t i m e , t h e battery w i l l accept a
h i g h e r rate as battery w a r m s .
(3) C h a r g e r C a p a c i t y — A charger, w h i c h can sup-
p l y only 5 amperes, w i l l require a m u c h longer pe-
r i o d of charging t h a n a charger t h a t c a n supply 30
amperes or more.
(4) State Of C h a r g e — A completely discharged
b a t t e r y requires more c h a r g i n g t i m e t h a n a p a r t i a l l y
charged battery. Electrolyte is nearly p u r e w a t e r i n a
completely discharged battery. A t f i r s t t h e c h a r g i n g
c u r r e n t amperage w i l l be low. A s acid i s forced from
t h e plates, inside t h e b a t t e r y , t h e c u r r e n t amperate
w i l l rise. Also, t h e specific g r a v i t y o f t h e electrolyte
w i l l rise, b r i n g i n g the green dot i n t o v i e w .
CHARGING COMPLETELY DISCHARGED
BATTERY
The following procedure should be used t o recharge
a completely discharged battery. Unless procedure is
properly followed, a good battery m a y be needlessly
replaced.
(1) Measure voltage a t battery posts w i t h a voltme-
ter, accurate to 1/10 v o l t (Fig. 13). I f below 10 volts,
t h e n charge current w i l l be low a n d i t could t a k e
some t i m e before i t accepts a current i n excess o f a
few milliamperes. Such l o w current m a y n o t be de-
tectable on amperemeters b u i l t i n t o m a n y chargers.
898A-12
Fig. 13 Voltmeter Accurate to 1/10 Volt Connected
(2) Connect charger leads. Some chargers feature
p o l a r i t y protection c i r c u i t r y w h i c h prevents operation
unless charger is connected t o b a t t e r y posts correctly.
A completely discharged b a t t e r y m a y n o t have
enough voltage to activate t h i s c i r c u i t r y , even
t h o u g h leads are connected properly, m a k i n g i t ap-
pear t h a t b a t t e r y w i l l n o t accept c h a r g i n g c u r r e n t .
Refer to instructions provided w i t h b a t t e r y charger
being used.
(3) B a t t e r y chargers vary i n the a m o u n t o f voltage
and current they provide. F o r t i m e r e q u i r e d f o r bat-
t e r y to accept measurable charger c u r r e n t a t various
voltages, refer t o Charge Rate chart. I f charge cur-
r e n t is s t i l l not measurable a t end o f c h a r g i n g times,
the battery should be replaced. I f charge c u r r e n t is
measurable d u r i n g charging t i m e , t h e b a t t e r y m a y
be good and charging should be completed i n t h e nor-
m a l manner.
CHARGE RATE
Voltage Hours
16.0 volts or more up to 4 hrs.
14.0 to 15.9 volts up to 8 hrs.
13.9 volts or less up to 16 hrs.
J908^7
8A - 8 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS

BATTERY DIAGNOSTICS CHART

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 AND TIGHTEN CONNECTORS
REPLACE BATTERY*

T
STARTER STILL W O N T CRANK
PROCEED TO STARTER TEST N O OBVIOUS DAMAGE
PROCEDURES ON VEHICLE IN THIS GROUP

CHECK TEST INDICATOR/OPEN CIRCUIT VOLTAGE
POSSIBLE CAUSE-IOD-REFER
TO IGNITION OFF DRAW SECTION
TEST INDICATOR/OPEN CIRCUIT VOLTAGE TEST
1. TURN HEADLAMPS ON FOR 15 SECONDS
2. TURN HEADLAMPS OFF FOR 2 MINUTES TO ALLOW
BATTERY VOLTAGE TO STABILIZE
3. REMOVE NEGATIVE, THEN POSITIVE CABLE.

YELLOW OR BRIGHT INDICATOR

1 F. C. = 2
ELIMINATE EXCESS IOD NO EXCESS IOD FOUND DO NOT CHARGE, BOOST, OR
F. C. = 3 TEST, ELECTROLYTE BELOW
INDICATOR. REPLACE BATTERY,
GREEN BALL SHOWING AND CHECK CHARGING SYSTEM
•CHARGE BATTERY—REFER CHARGE OPEN CIRCUIT VOLTAGE
TO CHARGING BATTERY ACCEPTED ABOVE 12.40 VOLTS**
STARTER STILL W O N T CRANK
PROCEED TO STARTER TEST
W O N T ACCEPT CHARGE PROCEDURES ON VEHICLE IN
F. C. = 4 THIS GROUP
1. NO GREEN BALL SHOWING
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 AND AMPERE LOAD 15 SEC. LOAD
EQUAL TO 1/2 THE COLD CRANKING AMPERE RATING OF THE BATTERY FOR 70° F (21° C) & ABOVE 9.6
15 SECONDS. OBSERVE VOLTAGE AT 15 SECONDS WITH LOAD ON. 60° F (16° C) 9.5
NOTE: ESTIMATE TEMPERATURE OF BATTERY. 50° F (16° C) 9.4
REFER TO LOAD TEST VOLTAGE CHART. 40° F (4° C) 9.3
30° F ( - 1 ° C) 9.1
20° F ( - 7 ° C) 8.9
VOLTAGE AT OR ABOVE VOLTAGE BELOW 10° F ( - 1 2 ° C) 8.7
9.6 VOLTS AT ROOM 9.6 VOLTS AT ROOM 0° F (-18°q 8.5
(70 DEG. F) TEMP. (70 DEG. F) TEMP.
VOLTMETER MUST BE ACCURATE
T TO 1/10 VOLT
FAILED LOAD TEST
PASSED LOAD TEST
F. C. = 5
RETURN BATTERY TO USE
•REPLACE BATTERY FAILURE CODE (F.C.) CHART
FAILURE CODE (F. C.)
NUMBER CONDITION

STARTER STILL W O N T CRANK BROKEN/CRACKED

1
PROCEED TO STARTER TEST YELLOW/BRIGHT INDICATOR
2
PROCEDURES ON VEHICLE IN IGNITION OFF DRAW
3
THIS GROUP 4 BATTERY WON'T ACCEPT CHARGE
5 BATTERY FAILED LOAD TEST
NOTES: * AFTER CHARGING OR REPLACING A BATTERY,
CHECK THE VEHICLE'S CHARGING SYSTEM, A N D
CLEAN A N D TIGHTEN BATTERY CONNECTORS " C H E C K I N G OPEN CIRCUIT VOLTAGE WILL
(REFER TO APPLICABLE SECTIONS O F THIS MONITOR " G R E E N BALL" INDICATION
SERVICE MANUAL). FOR ALL 6 CELLS. 898A-13
 • BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A - 9

S T A R T E R 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
Diagnostic Preparation 9 Starter Control Circuit Tests 12
General Information 9 Starter Feed Circuit Tests 9

GENERAL INFORMATION
The s t a r t i n g system o n Dodge Trucks consists o f a n
i g n i t i o n s w i t c h , starter relay, n e u t r a l safety s w i t c h
(automatic transmission), w i r i n g harness, battery,
a n d starter motor w i t h a n i n t e g r a l solenoid. These
components f o r m 2 separate circuits. A h i g h amper-
age c i r c u i t t h a t feeds t h e starter motor u p t o 300 +
amps, and a control c i r c u i t t h a t operates o n less t h a n
20 amps (Fig. 1).

IGNITION SWITCH

A 5 r
3u

— ^
Fig. 2 Volt-Amps Tester (Typical)
898Ar8

BATTERY h AUTOMATIC TRANSMISSION I

J NEUTRAL SAFETY SWITCH I
POSITIVE NEGATIVE
CLAMP CLAMP

STARTER RELAY
. ^
MOTOR
STARTER
SOLENOID
898A-14

Fig. 1 Starting System Components

DIAGNOSTIC PREPARATION INDUCTION
AMPMETER
Before proceeding w i t h s t a r t i n g system diagnostics, CLAMP
verify the f o l l o w i n g conditions: 898A-15
(1) B a t t e r y top, posts, a n d t e r m i n a l s are clean.
(2) A l t e r n a t o r drive belt tension and condition. Fig. 3 Volt-Amps Tester Connections (Typical)
(3) B a t t e r y state-of charge. (3) Verify t h a t a l l l i g h t s a n d accessories are O F F
(4) B a t t e r y w i l l endure load test. and t h e transmission shift selector is i n P A R K (au-
(5) B a t t e r y cable (+/-) connections a t t h e starter tomatic) or N E U T R A L (manual) a n d set p a r k i n g
motor and engine block a n d t h e i r condition. brake or equivalent.
(6) W i r i n g harness connector a n d t e r m i n a l condi- (4) Rotate and hold the i g n i t i o n s w i t c h (key) i n the
tion. S T A R T position. Observe t h e volt-amps tester ( F i g .
(7) Properly grounded. 4).
(a) I f voltage reads above 9.6 volts a n d amper-
STARTER FEED CIRCUIT TESTS age draw reads above 250 amps, proceed t o starter
The f o l l o w i n g procedure w i l l require a suitable feed circuit resistance test.
volt-ampere tester (Fig. 2) a n d a j u m p e r w i r e . (b) I f voltage reads 12.4 volts or greater a n d
(1) Connect a suitable volt-ampere tester (Fig. 2) t o amperage reads 0 to 10 amps, proceed t o starter
t h e b a t t e r y t e r m i n a l s (Fig. 3), refer t o t h e operating control circuit test.
instructions provided w i t h t h e tester being used.
(2) Disconnect the d i s t r i b u t o r connector.
8A - 10 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS

CAUTION: Do not overheat the starter motor or rect poor contact between the cable clamp a n d post.
draw the battery voltage below 9.6 volts during (b) Connect positive lead o f v o l t m e t e r t o t h e
cranking operations. b a t t e r y positive post, a n d negative lead t o t h e bat-
t e r y cable positive clamp (Fig. 5). Rotate a n d h o l d
t h e i g n i t i o n switch (key) i n the S T A R T position.
Observe t h e voltmeter. I f voltage i s detected, cor-
rect poor contact between the cable c l a m p a n d post.
(c) Connect positive lead of v o l t m e t e r to b a t t e r y
negative t e r m i n a l , a n d negative lead t o engine
Q o
block near t h e battery cable a t t a c h i n g p o i n t (Fig.
6).

VOLTMETER

898A-21

Fig. 4 Starter Draw Tests

(c) I f t h e starter motor cranks the engine freely
a t times, b u t a problem w i t h the s t a r t i n g system is
s t i l l suspected, engage t h e starter several t i m e s
BATTERY
w h i l e observing the volt-ampere tester. A s t a r t i n g
system t h a t has a problem should f a i l w h i l e per-
f o r m i n g t h i s procedure.
(5) A f t e r s t a r t i n g system problems have been cor-
rected, v e r i f y the b a t t e r y state-of-charge (charge bat- 898Arl7
t e r y i f necessary). Disconnect a l l testing equipment
and j u m p e r wires and connect distributor. S t a r t the Fig. 5 Test Battery Connection Resistance
vehicle several times t o assure the problem has been VOLTMETER
corrected.

STARTER FEED CIRCUIT RESISTANCE TEST

Before proceeding w i t h t h i s operation, review D i a g -
nostic P r e p a r a t i o n a n d Starter Feed C i r c u i t Tests.
The f o l l o w i n g operation w i l l require a voltmeter, ac-
curate t o 1/10 of a volt.
(1) Disconnect the d i s t r i b u t o r cap and connector.
(2) W i t h a l l w i r i n g harness and components con-
nected properly, perform the following:
(a) Connect positive lead of the voltmeter t o t h e
battery negative post, and negative lead to t h e bat-
ENGINE v ^J^snm
tery negative cable clamp (Fig. 5). Rotate a n d h o l d GROUND \ BATTERY^rfV 898A-18
the i g n i t i o n switch (key) i n the START position.
Observe t h e voltmeter. I f voltage is detected, cor- Fig. 6 Test Ground Circuit Resistance
• BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A - 11

STARTING SYSTEM DIAGNOSTICS

TEST CONDITIONS

• PLACE GEAR SELECTOR IN PARK OR NEUTRAL AND SET PARK BRAKE OR EQUIVALENT.
• VARIFY BATTERY STATE-OF-CHARGE AND CRANKING CAPACITY, SEE BATTERY SECTION.
• CLEAN BATTERY TOP, POSTS, AND TERMINALS.
• VARIFY ALTERNATOR DRIVE BEIT TENSION.
• DISCONNECT AND GROUND 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 ENGINE. DRIVE CLUTCH DISENGAGE AFTER
OR RELAY CLICKS DOME LIGHT DIMS SPINS OUT ENGINE STARTS

POSSIBLE CAUSE POSSIBLE CAUSE POSSIBLE CAUSE POSSIBLE CAUSE POSSIBLE CAUSE
1
STARTER CONTROL RESISTANCE TO RESISTANCE TO
1 IGNITION SWITCH
DRIVE CLUTCH MISADJUSTED
CIRCUIT FAULTY. HIGH IN STARTER HIGH IN STARTER
FAULTY
SEE GROUP 8W, FEED CIRCUIT FEED CIRCUIT
WIRING DIAGRAMS i
i i BROKEN TEETH IGNITION SWITCH
i STARTER CONTROL STARTER RELAY ON RING GEAR FAULTY
IGNITION SWITCH CIRCUIT FAULTY FAULTY
MISADJUSTEDOR SEE GROUP 8W, STARTER IsSEMBLY
i
FAULTY WIRING DIAGRAMS i STARTER RELAY
FAULTY
STARTER ASSEMBLY FAULTY
i i FAULTY
NEUTRAL SAFETY STARTER RELAY
FAULTY
11
SWITCH (AUTO TRANS.) STARTER ASSEMBLY
FAULTY OR FAULTY
MISADJUSTED i
STARTER ASSEMBLY
FAULTY
GEAR SELECTOR
PRNDL SWITCH
(A404 TRANS.)
FAULTY

1
STARTER RELAY
FAULTY

|
STARTER ASSEMBLY
FAULTY

• CONNECT COIL CABLE

• REFER TO APPROPRIATE GROUP AND SECTION OF THIS MANUAL

FOR PROPER SERVICE AND TEST PROCEDURES FOR THE
COMPONENTS INVOLVED

908Ar5
8A - 12 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS
(3) Rotate and hold t h e i g n i t i o n switch (key) i n t h e
START position. I f voltage reads above 0.2 volt, cor-
rect poor contact a t g r o u n d cable a t t a c h i n g p o i n t .
Voltage r e a d i n g s t i l l above 0.2 v o l t , replace g r o u n d
cable.
(4) Remove starter h e a t shield ( i f equipped) t o g a i n
access t o t h e starter motor and solenoid connections,
perform t h e following:
(a) Connect positive voltmeter lead t o t h e
starter motor housing and the negative lead t o t h e
b a t t e r y negative t e r m i n a l (Fig. 7). Rotate and h o l d
t h e i g n i t i o n switch (key) i n t h e S T A R T position. I f
voltage reads above 0.2 volt, correct poor starter t o
engine ground.
STARTER BATTERY
MOTOR
VOLTMETER
•
I f resistance tests detect no feed circuit failures, r e -
move the starter motor and proceed to Bench T e s t i n g
S t a r t e r Solenoid.
STARTER CONTROL CIRCUIT TESTS
The starter control circuit consists o f a starter so-
lenoid, starter relay, i g n i t i o n switch, safety n e u t r a l
s w i t c h (automatic transmission), and a l l t h e i r w i r i n g
a n d connections.
Testing procedures for these components are as fol-
lows and should be followed i n order as described.
CAUTION: Before performing any test disconnect
distributor connector to prevent engine from start-
ing.
STARTER SOLENOID TEST
Connect a heavy j u m p e r w i r e on starter relay be-
tween battery (1) and solenoid (3) t e r m i n a l s (Fig. 9).
I f engine cranks starter solenoid is good. Proceed t o
starter relay test.
SOLENOID TERMINAL

— \ —
BATTERY
CABLE Z HEAVY
898A-26 TO STARTER STARTER JUMPER
FIELD TERMINAL MOTOR WIRE
NEGATIVE
Fig. 7 Test Starter Motor Ground (Typical) BATTERY
CABLE BATTERY ®
(b) Connect positive voltmeter lead t o positive RELAY FEED BATT.
(f)SOL.
b a t t e r y t e r m i n a l a n d negative lead to battery cable
t e r m i n a l o n starter solenoid ( F i g . 8). Rotate a n d 0 I G . SW.
BATTERY STARTER
h o l d t h e i g n i t i o n s w i t c h (key) i n t h e S T A R T posi-
RELAY RH477A
t i o n . I f voltage reads above 0.2 volt, correct poor
contact a t battery cable to solenoid connection. I f Fig. 9 Starter Solenoid Test
reading i s s t i l l above 0.2 volt, replace positive bat-
I f the engine does not crank or the solenoid chat-
t e r y cable.
ters, check w i r i n g a n d connectors from relay t o
BATTERY starter for loose or corroded connections, p a r t i c u l a r l y
at starter t e r m i n a l s . Repeat test and i f engine s t i l l
fails to crank properly trouble is w i t h i n starter a n d
i t m u s t be removed for repairs.

STARTER RELA Y TEST

(1) Position gear selector i n n e u t r a l (manual) o r
p a r k (automatic) position.
(2) Set p a r k brake.
(3) Do not remove relay connector.
(4) Check for battery voltage between starter relay
b a t t e r y (1) t e r m i n a l and ground w i t h a test l a m p .
STARTER (5) Connect a j u m p e r w i r e on the starter relay be-
MOTOR VOLTMETER 898A-20 tween battery and (1) i g n i t i o n (4) terminals (Fig. 10).
I f engine cranks starter relay is good.
Fig. 8 Test Positive Battery Cable Resistance
(6) I f engine does n o t crank connect a second
(Typical)
j u m p e r w i r e t o starter relay between ground t e r m i -
n a l a n d to a good ground (5) (Fig. 11). Repeat test
 • BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A - 13

SOLENOID TERMINAL'

FIELD COIL SOLENOID

TERMINAL
BATTERY
TERMINAL

SOLENOID
TERMINAL
NEGATIVE FIELD COIL
BATTERY CONNECTOR
CABLE STARTER MOTOR
ASSEMBLY
r4 RR8BD31

IG. SW.0 RH481A Fig. 12 Field Coil Wire Terminal

Fig. 10 Relay Test with One Jumper Wire
and i f engine cranks starter relay is good, however,
transmission l i n k a g e is o u t of adjustment or safety
n e u t r a l s w i t c h is defective. I f engine does not c r a n k
starter relay is defective and m u s t be replaced.
(2) Check for c o n t i n u i t y between solenoid t e r m i n a l
and field coil t e r m i n a l w i t h a c o n t i n u i t y tester.
There should be c o n t i n u i t y (Fig. 13).
FIELD COIL
TERMINAL

SOLENOID TERMINAL

RR8BD32

TO STARTER FIELD STARTER

TERMINAL
Fig. 13 Continuity Test Between Solenoid Terminal
NEGATIVE MOTOR
BATTERY and Field Coil Terminal
BATTERY®
CABLE
(3) Check for c o n t i n u i t y between solenoid t e r m i n a l
and solenoid housing. There should be c o n t i n u i t y
(Fig. 14).

SOLENOID
IG. S W . ® RH482A

Fig. 11 Relay Test with Two Jumper Wires

IGNITION SWITCH TEST
After t e s t i n g starter solenoid a n d relay a n d they
check o u t okay, trouble is probably w i t h i g n i t i o n RR8BD33
switch or i t s w i r i n g .
Check a l l w i r i n g for opens and shorts and connec- Fig. 14 Continuity Test Between Solenoid Terminal
and Solenoid Case
tions for being loose or corroded.
(4) I f there is c o n t i n u i t y solenoid is good. I f there is
BENCH TESTING STARTER SOLENOID no c o n t i n u i t y i n either test solenoid has a n open cir-
Refer to Group 8 B - B a t t e r y Starter Service for cuit and is defective. Replace solenoid assembly.
starter removal procedures. (5) I n s t a l l starter as described i n Group 8B - B a t -
(1) Disconnect field coil w i r e f r o m field coil t e r m i - tery Starter Service.
n a l (Fig. 12). (6) Connect field coil w i r e to field coil t e r m i n a l
(Fig. 12).
8A - 14 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS
ALTERNATOR TEST PROCEDURES ON VEHICLE
INDEX
Page
Alternator Output Wire Resistance Test 14
Current Output Test 15
ALTERNATOR OUTPUT WIRE RESISTANCE TEST
(FIG. 1)
A l t e r n a t o r o u t p u t w i r e resistance test w i l l show
a m o u n t of Voltage Drop across alternator output
w i r e between a l t e r n a t o r B A T t e r m i n a l and battery
positive post.
PREPARATION
(1) Before s t a r t i n g test m a k e sure vehicle has a
f u l l y charged b a t t e r y . Test a n d procedures on how t o
check for a f u l l y charged b a t t e r y are shown i n Bat-
t e r y section o f t h i s Group.
(2) T u r n O F F i g n i t i o n switch.
(3) Disconnect b a t t e r y negative cable.
(4) Disconnect alternator o u t p u t w i r e f r o m alterna-
tor output B a t t e r y t e r m i n a l .
(5) Connect a 0-150 ampere scale D.C. ammeter i n
series between a l t e r n a t o r B A T t e r m i n a l and discon-
nected a l t e r n a t o r output w i r e . Connect Positive lead
to a l t e r n a t o r B A T t e r m i n a l a n d Negative lead to dis-
connected a l t e r n a t o r output w i r e .
(6) Connect Positive lead o f a test voltmeter (Range
0-18 volts m i n i m u m ) to disconnected alternator out-
put w i r e . Connect negative lead of test voltmeter t o
battery positive cable a t positive post.
(7) Remove a i r hose between Engine Controller and
air cleaner.
(8) Connect one end of a J u m p e r W i r e to ground
and w i t h other end probe green R3 lead w i r e at back
of a l t e r n a t o r ( F i g . 1). (This w i l l generate a f a u l t
code).
CAUTION: Do not connect blue J2 lead of wiring to
ground. Refer to Group 8W - Wiring Diagrams for
more information.
•
Page
How To Use Check Engine Lamp
For
For Fault Codes 18
Using On-Board Diagnostic System 16
(9) Connect a n engine tachometer and connect bat-
t e r y negative cable.
(10) Connect a variable carbon pile rheostat
(C3950) between b a t t e r y t e r m i n a l s . Be sure carbon
pile i s i n " O p e n " or " O f f ' position before connecting
leads. See B a t t e r y Section, Load Testing for i n s t r u c -
tions.
TEST
(1) S t a r t engine. I m m e d i a t e l y after s t a r t i n g , reduce
engine speed t o idle.
(2) A d j u s t engine speed and carbon pile t o m a i n -
t a i n 20 amperes f l o w i n g i n circuit. Observe v o l t m e t e r
reading. V o l t m e t e r r e a d i n g should n o t exceed 0.5
volts.
RESULTS
I f a h i g h e r voltage drop i s indicated, inspect, clean
and t i g h t e n a l l connections between a l t e r n a t o r B A T
t e r m i n a l a n d b a t t e r y Positive post. A voltage drop
test m a y be performed a t each connection t o locate
connection w i t h excessive resistance. I f resistance
tested satisfactorily, reduce engine speed, t u r n off
carbon p i l e a n d t u r n off i g n i t i o n switch.
(1) Disconnect b a t t e r y negative cable.
(2) Remove test ammeter, voltmeter, carbon pile,
and tachometer.
(3) Remove " J u m p e r W i r e " .
(4) Connect a l t e r n a t o r o u t p u t w i r e t o a l t e r n a t o r
B A T t e r m i n a l post. T i g h t e n t o 5 to 6 N-m (45 t o 75
i n . lbs.).
(5) Connect b a t t e r y negative cable.
(6) Connect hose between Engine Controller a n d
a i r cleaner.
(7) U s e D R B I I to erase f a u l t code.
 • BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A - 15

CASE GROUND FIELD BATTERY

IGNITION SWITCH
TERMINALS VOLTAGE
_ J -J2-DB—' ACCI

LESS THAN
[ GROUND ^ B A T T E R Y VOLTAGE
1Si— 1 _L
JUMPER WIRE
TO GROUND

TEST TEST
ALTERNATOR CASE VOLTMETER AAAMETER
GROUND
ALTERNATOR
BATTERY
TERMINAL
BBS

DISCONNECTED
ALTERNATOR
ENGINE GROUND OUTPUT
CONTROLLER
MES

CARBON PILE CHASSIS "

RHEOSTAT GROUND
l a
J908A-14

Fig. 1 Alternator Output Wire Resistance Test (Typical)

CURRENT OUTPUT TEST
C u r r e n t o u t p u t test determines w h e t h e r or not a l -
ternator is capable o f d e l i v e r i n g i t s r a t e d c u r r e n t
output.
PREPARATION
(1) Before s t a r t i n g any tests m a k e sure vehicle has
a f u l l y charged battery. Test a n d procedures on how
to check for a f u l l y charged b a t t e r y are shown i n
B a t t e r y section o f t h i s Group.
(2) Disconnect b a t t e r y negative cable.
(3) Disconnect a l t e r n a t o r o u t p u t w i r e a t the alter-
nator battery t e r m i n a l .
(4) Connect a 0-150 ampere scale D.C. ammeter i n
series between a l t e r n a t o r B A T t e r m i n a l a n d discon-
nected a l t e r n a t o r o u t p u t w i r e (Fig. 2). Connect Posi-
t i v e lead to a l t e r n a t o r B A T t e r m i n a l a n d negative
lead t o disconnected a l t e r n a t o r o u t p u t w i r e .
(5) Connect positive lead o f a test v o l t m e t e r (range
0-18 volts m i n i m u m ) to a l t e r n a t o r B A T t e r m i n a l .
(6) Connect negative lead o f test v o l t m e t e r t o a
good ground.
(7) Connect a n engine tachometer a n d reconnect
battery negative cable.
(8) Connect a variable carbon pile rheostat (C3950)
between b a t t e r y t e r m i n a l s . Be sure carbon pile is i n
Open or O f f position before connecting leads. See
Battery section, Load Testing for instructions.
(9) Remove a i r hose between Engine Controller and
air cleaner.
(10) Connect one end o f a J u m p e r W i r e to ground
and w i t h other and probe green R3 lead w i r e at back
of alternator (Fig. 2). (This w i l l generate a fault
code).
CAUTION: Do not connect blue J2 lead of wiring to
ground. Refer to Group 8W - Wiring Diagrams for
more information.
TEST
(1) S t a r t engine. I m m e d i a t e l y after s t a r t i n g reduce
engine speed t o idle.
(2) Adjust carbon pile and engine speed i n incre-
ments u n t i l a speed o f 1250 r p m and voltmeter read-
i n g of 15 volts is obtained.
CAUTION: Do not allow voltage meter to read above
16 volts.
(3) T h e ammeter r e a d i n g m u s t be w i t h i n l i m i t s
shown i n alternator specifications i n back o f this
group for t h a t size o f alternator being tested.
8A - 16 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS
RESULTS
(1) I f reading is less t h a n specified a n d a l t e r n a t o r
o u t p u t w i r e resistance is not excessive, t h e a l t e r n a t o r
should be replaced see, Group 8C - A l t e r n a t o r Ser-
vice for i n f o r m a t i o n .
(2) A f t e r c u r r e n t output test i s completed reduce
engine speed, t u r n off carbon p i l e and t u r n off i g n i -
t i o n switch.
(3) Disconnect b a t t e r y negative cable.
(4) Remove test ammeter, voltmeter, tachometer
and carbon p i l e .
•
(5) Remove J u m p e r W i r e (Fig. 2).
(6) Connect alternator o u t p u t w i r e t o alternator
B A T t e r m i n a l post. T i g h t e n n u t t o 5-6 N-m (45-75 i n .
lbs.).
(7) Connect b a t t e r y negative cable.
(8) Connect a i r hose between Engine Controller
and a i r cleaner.
(9) Use D R B I I t o erase f a u l t code.

CASE GROUND FIELD BATTERY

VOLTAGE IGNITION SWITCH
TERMINALS
L -J2-DB-

JUMPER WIRE
TO GROUND
TEST TEST
ALTERNATOR CASE AMMETER VOLTMETER
GROUND ALTERNATOR
BATTERY
TERMINAL

DISCONNECTED
ALTERNATOR
OUTPUT
ENGINE
WIRE
CONTROLLER

CHASSIS ~
CARBON PILE GROUND
RHEOSTAT J908A-13

Fig. 2 Alternator Current Output Test (Typical)

USING ON-BOARD DIAGNOSTIC SYSTEM fault code. T h e f a u l t code w i l l stay i n memory as

OPERATION OF ON-BOARD DIAGNOSTIC
SYSTEM
The Engine Controller monitors c r i t i c a l i n p u t and
o u t p u t circuits o f the charging system m a k i n g sure
they are okay. Some are checked continuously and
some are only checked under certain conditions.
I f the on-board diagnostic system senses t h a t one of
t h e critical circuits is bad d u r i n g a predetermined
amount of t i m e d u r i n g the m o n i t o r i n g cycle, i t w i l l
consider t h i s a real problem and puts a f a u l t code
i n t o memory. Each i n p u t a n d output c i r c u i t m o n i -
tored by the on-board diagnostic system has i t s own
long as the c i r c u i t continues t o be bad. However, i f
the problem does n o t happen again after t h e fault
code is p u t i n t o memory, t h e engine controller is pro-
grammed t o clear the memory after 50 to 100 engine
starts.
FAULT CODES
F a u l t codes are t w o - d i g i t numbers flashed on
Check E n g i n e l a m p t h a t i d e n t i f y w h i c h circuit is
bad. I n most cases they do not identify w h i c h compo-
nent i n a c i r c u i t is bad. A f a u l t description can be
read u s i n g the D R B I I . Refer t o Group 14 - F u e l Sys-
tems for more i n f o r m a t i o n . Therefore, a f a u l t code is
only a result, not necessarily t h e reason for the prob-
• BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A - 17

CHARGING SYSTEM DIAGNOSTICS

IMPROPER UNSTEADY OVER NOISY

OR LOW CHARGING ALTERNATOR
CHARGING
CHARGING

CHECK BATTERY
TEST GROUNDED WORN OR
CONDITION
ALTERNATOR ALTERNATOR FIELD FRAYED
SEE BATTERY
OUTPUT WIRE WIRE, FIELD DRIVE BELT
SECTION FOR
RESISTANCE TERMINAL, OR
DETAILS
CONNECTIONS

CORRODED CHARGING ALTERNATOR

BATTERY CABLES RESISTANCE REFE R TO MOUNTING
OR TERMINALS TOO HIGH USING O N-BOARD LOOSE
DIAGhJOSTIC
SYS TEM

DRIVE BELTS
LOOSE CORRODED OR
SHORTED CABLES
OR HIGH FAULTY FAULTY
RESISTANCE ALTERNATOR ALTERNATOR
ACROSS FUSIBLE
LOOSE OR LINK
CORRODED
WIRING
CONNECTIONS AT
ALTERNATOR
RESISTANCE • FOR MORE INFORMATION REFER TO
O.K. THE POWERTRAIN DIAGNOSTIC PROCEDURES
MANUAL COVERING THE VEHICLE INVOLVED
LOOSE OR
CORRODED • SEE GROUP 8W, WIRING DIAGRAMS FOR
WIRING CIRCUIT AND COMPONENT INFORMATION
CONNECTIONS AT TEST
TERMINAL BLOCK ALTERNATOR
CURRENT
OUTPUT

LOOSE
CHASSIS TO
BATTERY GROUND
CABLE CURRENT
OUTPUT
O.K.

LOOSE
ALTERNATOR
GROUND WIRE REFER TO
USING ON-BOARD
DIAGNOSTIC
LOOSE OR SYSTEM
CORRODED
WIRING
CONNECTIONS AT
BULKHEAD FAULTY
DISCONNECT ALTERNATOR

CHECK FOR
APPROXIMATELY
12 VOLTS AT FIELD
INPUT BRUSH
TERMINAL WITH
IGNITION SWITCH
"ON"
908A-6
8A - 18 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS
l e m . However, i n some cases, as a r e s u l t o f t h e de-
sign o f the d r i v e a b i l i t y test procedure, a f a u l t code
can be t h e reason for t h e problem. I t i s i m p o r t a n t
t h a t t h e test procedure be followed i n order t o under-
stand w h a t the f a u l t codes o f t h e on-board diagnostic
system are t r y i n g to t e l l .
HOW TO USE CHECK ENGINE LAMP FOR FAULT
CODES
To activate t h i s function cycle t h e i g n i t i o n s w i t c h
on-ofif-on-off-on w i t h i n five seconds a n d a n y f a u l t
stored i n the engine controller w i l l be displayed. T h e
Check Engine lamp w i l l display a f a u l t code b y flash-
i n g o n a n d off. There is a short pause between
flashes and a longer pause between d i g i t s . A l l codes
displayed are t w o d i g i t numbers w i t h a four second
pause between codes.
A n example o f a code is as follows:
•
(1) L a m p o n for t w o seconds, t h e n t u r n s off.
(2) L a m p flashes four (4) times pauses a n d t h e n
flashes once (1).
(3) L a m p pauses for four seconds, flashes four (4)
times, pauses a n d t h e n flashes seven (7) times.
The two codes are 4 1 and 47. A n y n u m b e r o f codes
can be displayed ( m a x i m u m o f 8 f a u l t s can be stored)
as l o n g as t h e y are i n memory. T h e l a m p w i l l flash
u n t i l a l l of t h e m ( i n c l u d i n g 55) are displayed (55 =
E n d o f test).
CHARGING SYSTEM FAULT CODES
See A l t e r n a t o r F a u l t Code C h a r t for f a u l t codes
w h i c h apply t o t h e c h a r g i n g system. Refer t o t h e
P o w e r t r a i n Diagnostic Procedures M a n u a l t o diag-
nose a n On-Board Diagnostic System, F a u l t Code.

ALTERNATOR FAULT CODE CHART

Check lift. M n n ^ J
Sensor
fault Engine By the Logic Actuator bad
Code Type Lamp Grcuit Module When Put into Memory Test lest

Alternator Field All the time when If the field control fails to
41 Fault Yes Control the ignition switch switch properly or excessive Yes None
(Charging System) is on. alt. field current detected.

If the battery sense voltage

Charging System All the time when
is more than 1 volt above
46 Fault Yes Voltage the engine is run- None Yes
the desired control voltage
ning.
for more than 20 seconds.
Battery voltage sense input below
Charging System desired charging voltage during
Voltage Engine rpm above
47 Fault Yes engine operation and no change None Yes
1,500 rpm
in voltage during internal SBEC
test performed on alternator field.
J908Ar8
• BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A - 19

SPECIFICATIONS

BATTERY SPECIFICATIONS
Load Cold
Tost Cranking Reserve
(Amps) Rating @ 0°F Capacity
200 Amp 400 Amp 100 Minutes
250 Amp 500 Amp 110 Minutes
315 Amp 625 Amp 120 Minutes
350 Amp 700 Amp 120 Minutes
CRANKING RATING is the current a battery can deliver for 30 seconds and maintain a terminal voltage of 7.2
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).
J908A-11

REDUCTION GEAR STARTER

Manufacturer Nippondenso
5.91, 5.2L & 3.9L
Part Number and 4379160
1.4 Kw
12
No. of Fields . . . . . . . . . . . . . . . . 4
4
4
Conventional
Gear Train
Free Running Test
Voltage 11
82 Amps
3625 rpm
7.5 Volts
Cranking Amperage Draw Test . . . 150-220 Amps*
* Engine should be up to operating temperature. Extremely heavy
oil or tight engine will increase starter amperage draw.
J908B-6

ALTERNATOR SPECIFICATIONS

TYPE PART N U M B E R PULLEY G R O O V E S ENGINE RATING

NIPPONDENSO 5234026 2 ALL 35/75 AMPS

NIPPONDENSO 5234199 2 ALL 50/120 AMPS

NIPPONDENSO 5234028 2 ALL 40/90 AMPS

BOSCH 5235028 2 ALL 40/90 AMPS

J908C-22
 • BATTERY/STARTER SERVICE 8B - 1

BATTERY/STARTER SERVICE

CONTENTS
Page Page

BATTERY SERVICE PROCEDURES 1 STARTER SERVICE PROCEDURES 4

SPECIFICATIONS 6

BATTERY SERVICE PROCEDURES

INDEX
Page Page
Battery Visual Inspection and Service 1 General Information . 1

GENERAL INFORMATION INCREASED SEALED TEST

ELECTROUTE VENT CAPS INDICATOR
This section w i l l cover t h e Battery service, re-
moval, and i n s t a l l a t i o n procedures only. F o r diagnos-
tic procedures, see Group 8A - Battery/
Starting/Charging Systems Diagnostics.
A b a t t e r y is t h e h e a r t of a vehicle's electrical sys-
t e m (Fig. 1). I t functions i n three ways, first i t sup-
plies electrical energy t o t h e starter motor a n d
i g n i t i o n system w h i l e t h e engine is s t a r t i n g , i t also
acts as power supply t o operate lamps, radio, and ac-
cessories w i t h engine off. Second i t i n t e r m i t t e n t l y
supplies energy for electrical loads when t h e engine
is r u n n i n g and load demands are more t h a n o u t p u t
of alternator. T h i r d i t acts as a voltage stabilizer i n
the electrical system. The battery evens o u t tempo-
r a r i l y h i g h voltages t h a t w o u l d otherwise damage
electrical system parts. To do t h i s the battery con-
ENVELOPE HOLD DOWN
verts chemical energy into electrical energy by a SEPARATORS RK92
chemical reaction.
I f a battery is not u p to specifications i t w i l l not de- Fig. 1 Maintenance Free Battery
l i v e r necessary electricity, w i l l not accept electricity tor), w h e n charging is required (black indicator), or
and w i l l n o t act as a capacitor. Consequently, the ve- w h e n replacement is required (yellow indicator).
hicle's e n t i r e electrical system w i l l be effected w h e n
t h i s happens. BATTERY VISUAL INSPECTION AND SERVICE
Standard equipment maintenance-free batteries
(Fig. 1) have no removable battery cell caps. Water (1) M a k e sure i g n i t i o n switch is on O F F position
can n o t be added to t h e maintenance-free battery. and a l l b a t t e r y feed accessories are O F F .
The b a t t e r y is completely sealed, except for s m a l l (2) Disconnect both battery cables s t a r t i n g w i t h the
Negative cable.
vent holes i n t h e cover. These vent holes allow w h a t
s m a l l a m o u n t of gasses are produced i n t h e battery
WARNING: CARE SHOULD BE TAKEN, IN THE
to escape. Special chemical composition inside t h e EVENT BATTERY CASE IS CRACKED OR LEAKING.
b a t t e r y reduces production o f gas to a n extremely TO PROTECT HANDS FROM ELECTROLYTE, A
s m a l l a m o u n t a t n o r m a l charging voltages. T h e bat- SUITABLE PAIR OF RUBBER GLOVES (NOT THE
t e r y contains a v i s u a l test indicator w h i c h signals HOUSEHOLD TYPE) SHOULD BE WORN WHEN RE-
w h e n a n adequate charge level exists (green indica- MOVING BATTERY BY HAND.
8B • 2 BATTERY/STARTER SERVICE •
(3) Remove battery h o l d down (Fig. 2) and remove (5) Inspect battery case and cover for cracks or
battery f r o m vehicle. leakage. I f cracks or leakage is present, b a t t e r y m u s t
be replaced.
(6) Inspect battery t r a y for damage caused by loss
of acid f r o m battery. I f acid damage is present i t w i l l
be necessary to clean area w i t h same solution de-
scribed i n Step (4) (Fig. 4).

Fig. 2 Battery Holddown

(4) Clean top of b a t t e r y w i t h a solution o f clean
w a r m w a t e r and b a k i n g soda. Scrub area w i t h a stiff
bristle b r u s h and wipe off w i t h a cloth moistened
w i t h a m m o n i a or b a k i n g soda i n water (Fig. 3).
Fig. 4 Battery Tray
(7) C l e a n battery post w i t h a suitable b a t t e r y post
cleaning t o o l (Fig. 5).

Fig. 3 Cleaning Battery

CAUTION: Care should be taken to ensure that so-
lution does not enter vent holes.

Fig. 5 Cleaning Battery Post

 • BATTERY/STARTER SERVICE 8B • 3

(8) Clean inside surfaces of t e r m i n a l clamps w i t h a
suitable battery t e r m i n a l cleaniiig tool (Fig. 6). Re-
place damaged or frayed cables and broken t e r m i n a l
clamps.
(12) Place felt grease washer onto Positive ( + ) bat-
tery post.
(13) Connect cable clamps to battery post m a k i n g
sure top of clamp is flush w i t h top of post (Fig. 7).
(14) T i g h t e n clamp n u t securely.

Fig. 7 Battery Cables Disconnected

Fig. 6 Cleaning Battery Cable Terminal

(9) Inspect b a t t e r y for proper or damaged h o l d
down ledge,
(10) I n s t a l l b a t t e r y i n vehicle m a k i n g sure t h a t
battery is properly positioned on battery t r a y ( F i g .
2).
(11) I n s t a l l b a t t e r y h o l d down clamp, m a k i n g sure
t h a t i t is properly positioned on battery, and t i g h t e n
bolt to 12 N*m (100 i n . lbs.).
8B - 4 BATTERY/STARTER SERVICE •
STARTER SERVICE PROCEDURES

INDEX
Page Page
General Information . ..4 Starter Motor Removal and Installation . .. 4

GENERAL INFORMATION
T h i s section w i l l cover the Starter removal and i n -
WIRE CONNECTOR TERMINAL ADAPTER
stallation. F o r diagnostic procedures, see Group 8 A -
Battery/Starting/Charging Systems Diagnostics.

STARTING SYSTEM DESCRIPTION

The starter system circuits consists o f a battery,
starter motor, starter relay switch, solenoid, switch,
i g n i t i o n s w i t c h , connecting wires and battery cables.
I n starter system circuits t u r n i n g i g n i t i o n switch to
start position closes s t a r t e r relay points a l l o w i n g cur-
r e n t t o energize s t a r t e r solenoid windings, t h i s
causes solenoid p l u n g e r a n d clutch shift lever to
move engaging c l u t c h p i n i o n gear into r i n g gear, and
also a t t h i s t i m e closing solenoid contacts causing
starter motor to crank. A s soon as engine starts r u n -
n i n g c l u t c h p i n i o n gear overruns t o protect starter
a r m a t u r e f r o m damage due t o excessive speed. Once RR8BD27 'ENGINE MOUNT
the engine starts r u n n i n g , t h e i g n i t i o n k e y switch
should be i m m e d i a t e l y r e t u r n e d to the r u n position Fig. 1 Remove or Install Starter Wire Connector
to prevent excessive starter motor damage.
MOUNTING BOLT,
WARNING: ALWAYS DISCONNECT THE BATTERY
NEGATIVE CABLE BEFORE SERVICING THE
STARTER.

STARTER MOTOR REMOVAL AND INSTALLATION

(1) Disconnect the b a t t e r y negative cable.
(2) Remove w i r e t e r m i n a l connector from t h e
starter motor (Fig. 1).
(3) Remove m o u n t i n g bolt a n d n u t securing t h e
starter t o t h e bellhousing (Fig. 2).
(4) Move t h e starter forward to clear lower mount- NUT
i n g stud and starter gear housing nose and allow t h e
starter t o come down past the exhaust pipe (Fig. 3).
To i n s t a l l , reverse t h e removal procedures.

STARTER MOTOR

Fig. 2 Remove or Install Starter Mounting Bolt and

Nut
8B - 6 BATTERY/STARTER SERVICE •
SPECIFICATIONS
REDUCTION GEAR STARTER
Manufacturer Nippondenso
Engine Application . . . . . . . . . . . . 5.91, 5.21 & 3.9L
Part Number and 4379160
1.4 Kw
Voltage 12
No. of Fields 4
No. of Poles 4
Brushes 4
Drive . . . . . . . . . . . . . . . . . . . . . . Conventional
Gear Train
Free Running Test
Voltage 11
Amperage Draw 82 Amps
3625 rpm
Solenoid Closing Voltage 7.5 Vohs
Cranking Amperage Draw Test . . . 150-220 Amps*
* Engine should be up to operating temperature. Extremely heavy
oil or tight engine will increase starter amperage draw.
J908B-6

BATTERY SPECIFICATIONS

Load Cold
lest CfonJang
(Amps) Rating @ 0°F Capacity
200 Amp 400 Amp 100 Minutes
250 Amp 500 Amp 110 Minutes
315 Amp 625 Amp 120 Minutes
350 Amp 700 Amp 120 Minutes
CRANKING RATING is the current a battery can deliver for 30 seconds and maintain a terminal voltage of 7.2
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
vohs at 27°C (80°F).
J908A-11
 • ALTERNATOR SERVICE 8C - 1

ALTERNATOR SERVICE

CONTENTS
Page

SPECIFICATIONS 2

GENERAL INFORMATION
This section w i l l cover a l t e r n a t o r removal and i n -
stallation. T h e alternator i s n o t serviceable. Informa-
t i o n covering on-vehicle t e s t i n g can be found i n
Group 8 A - Battery/Starting/Charging/System Diag-
nostics.
The standard equipment a l t e r n a t o r o n t h e D & W
bodies is the 75 amp alternator. T h e Ramcharger is
equipped w i t h the 90 amp a l t e r n a t o r . W h e n a vehicle
is equipped w i t h a heavy d u t y package, a 120 amp
alternator i s used.

ALTERNATOR REMOVAL AND INSTALLATION

(1) Remove the battery negative cable.
(2) Remove alternator d r i v e belt. See Group 7 -
Cooling System, for instructions.
(3) Remove t h e alternator m o u n t i n g n u t (top) and Fig. 1 Remove or Install Alternator Mounting Bolts
bolt (bottom) a n d separate t h e a l t e r n a t o r from t h e
m o u n t i n g plate (Fig. 1).
(4) Remove t h e B + t e r m i n a l n u t , 2 field t e r m i n a l
nuts, ground, and harness h o l d down n u t s (Fig. 2).
Remove w i r e connectors.
(5) Remove the alternator f r o m t h e vehicle.
(6) To i n s t a l l t h e alternator, reverse t h e removal
procedures.

Fig. 2 Remove or Install Wire Connector Assembly

8C - 2 ALTERNATOR SERVICE •
SPECIFICATIONS
ALTERNATOR SPECIFICATIONS

TYPE PART NUMBER PULLEY G R O O V E S ENGINE RATING

NIPPONDENSO 5234026 2 ALL 35/75 AMPS

NIPPONDENSO 5234199 2 ALL 50/120 AMPS

NIPPONDENSO 5234028 2 ALL 40/90 AMPS

BOSCH 5235028 2 ALL 40/90 AMPS

J908C-22
 • IGNITION SYSTEMS 8D - 1

IGNITION SYSTEMS
CONTENTS
Page Page

COMPONENT IDENTIFICATION 1 SERVICE PROCEDURES 11

DIAGNOSTIC PROCEDURES 9 SPECIFICATIONS 15

COMPONENT IDENTIFICATION
INDEX
Page Page

Auto Shutdown (ASD) Relay 7 Ignition Coil 8

Coolant Temperature Sensor 7 Manifold Absolute Pressure (MAP) Sensor . . . . . . . 7
Distributor Cap 1 Single Board Engine Controller ( S B E C ) . . . . . . . . . 6
Distributor Rotor 2 Spark Plug Cables 2
General Information 1 Spark Plugs 3
Hall Effect Pick-Up Assembly 6

GENERAL INFORMATION A cap t h a t is greasy or d i r t y or has a powder-like

substance on the inside should be cleaned w i t h a so-
T h i s section contains basic diagnostic procedures l u t i o n of w a r m water and a m i l d detergent. Scrub
for the i g n i t i o n systems of 3.9L V-6 engines and 5.2L w i t h a soft brush, t h o r o u g h l y rinse, and dry w i t h a
and 5.9L V - 8 engines. I n f o r m a t i o n r e g a r d i n g " O n clean soft cloth.
Board Diagnostics" can be found i n t h e Single Point
F u e l Injection and D u a l Point F u e l Injection sections BROKEN
of Group 14—Fuel Systems. A specifications section
is included a t the end o f t h i s group. General m a i n t e -
nance i n f o r m a t i o n for i g n i t i o n related items can be
found i n Group 0, L u b r i c a t i o n and Maintenance, and
t h e Operating Instructions and Product I n f o r m a t i o n
Manual.

DISTRIBUTOR CAP

INSPECTION
Remove the distributor cap and wipe i t clean w i t h
a d r y l i n t free cloth. V i s u a l l y inspect t h e cap for
cracks, carbon paths, broken towers, w h i t e deposits
on t h e inside (caused by condensation e n t e r i n g t h e
cap t h r o u g h cracks), and damaged rotor b u t t o n (Fig.
1). The machined surface o f a t e r m i n a l end (faces to-
w a r d rotor) w i l l indicate some evidence o f erosion
f r o m n o r m a l operation. T h e residue can be removed
w i t h a sharp knife. E x a m i n e t h e t e r m i n a l ends for
evidence of mechanical interference w i t h t h e rotor
tip.
-41
Fig. 1 Distributor Cap Inspection—Typical
I f replacement of the d i s t r i b u t o r cap is necessary,
transfer sparkplug wires f r o m the original cap
to the new cap one a t a time. E n s u r e t h a t each
wire is installed into t h e tower o f the n e w cap
that corresponds t o i t s tower position i n t h e
o r i g i n a l c a p . F u l l y seat t h e w i r e s i n t o t h e t o w -
ers.
80 - 2 IGNITION SYSTEMS
I f necessary, refer to the appropriate engine f i r i n g
d i a g r a m (Fig. 2 or Fig. 3).
Fig. 2 Engine Firing Order—3.9L
J908D-49
Fig. 3 Engine Firing Order—5.2L and 5.9L
DISTRIBUTOR ROTOR
Replace t h e rotor i f i t is cracked or i f the s p r i n g
t e r m i n a l does not have proper tension (Fig. 4).
A black silicone varnish covers the t i p of the rotor
electrode ( i n previous years silicone grease was
used). The coating is used t o suppress electro-
magnetic r a d i a t i o n . The coating w i l l d a r k e n w i t h age
and have a n ash l i k e appearance. T h e ash f o r m a t i o n
is n o r m a l and does affect engine performance.
SPARK PLUG CABLES
Spark Plug cables are sometimes referred to as sec-
ondary i g n i t i o n wires. The wires transfer electrical
current from t h e distributor t o i n d i v i d u a l spark
plugs a t each cylinder. The spark p l u g cables are o f
nonmetallic construction and have a b u i l t i n resis-
tance. The cables provide suppression o f radio fre-
quency emissions from the i g n i t i o n system.
•
INSUFFICIENT
SPRING
TENSION
CORRODED EVIDENCE OF
PHYSICAL
CONTACT
W I T H C A P
J908D-48
Fig. 4 Distributor Rotor Inspection—Typical
Check the high-tension cable connections for good
contact a t t h e i g n i t i o n coil, d i s t r i b u t o r cap towers
and spark plugs. T e r m i n a l s should be f u l l y seated.
The t e r m i n a l s and covers should be i n good condi-
t i o n . T e r m i n a l s should f i t t i g h t l y t o the i g n i t i o n coil,
d i s t r i b u t o r cap, and spark plugs. T h e cover (boot) o f
t h e cable should f i t t i g h t a r o u n d the coil tower, dis-
t r i b u t o r tower and spark p l u g insulator. Loose cable
connections can cause corrosion and increase resis-
tance r e s u l t i n g i n shorter cable service life. To m a i n -
t a i n proper sealing a t t h e t e r m i n a l connections, t h e
connections should n o t be broken unless they are
damaged or testing indicates t h a t h i g h resistance, a n
open c i r c u i t , or other damage.
Clean h i g h tension cables w i t h a cloth moistened
w i t h a nonflammable solvent and wipe dry. Check
for b r i t t l e or cracked i n s u l a t i o n .
W h e n testing secondary cables for damage w i t h a n
oscilloscope, follow the i n s t r u c t i o n s o f the equipment
manufacturer.
I f a n oscilloscope is not available, spark p l u g cables
may be tested as follows:
W i t h the engine r u n n i n g , remove spark p l u g cable
f r o m spark p l u g (one a t a t i m e ) and hold next to en-
gine ground. I f the cable a n d spark p l u g are i n good
condition, the engine R P M w i l l drop and engine per-
formance w i l l decrease. I f engine R P M does not drop
the cable and/or spark p l u g is not operating properly
and should be replaced.
CAUTION: Do not leave any one spark plug cable
disconnected for longer than necessary during test-
ing or possible heat damage to the catalytic con-
verter may occur. Total test time must not exceed
ten minutes.
 • IGNITION SYSTEMS 8D - 3

W i t h t h e engine n o t r u n n i n g , connect one end o f a t i o n coil tower, loosen t h e boot first, t h e n grasp t h e
test probe t o a good g r o u n d . S t a r t the engine and r u n upper p a r t of the boot and the cable and g e n t l y p u l l
t h e other e n d o f t h e test probe along t h e entire s t r a i g h t up.
l e n g t h of a l l spark p l u g cables. I f cables are cracked W h e n i n s t a l l i n g new cables, p i n c h t h e protective
or punctured, there w i l l be a noticeable spark j u m p nipple to release a n y a i r trapped between t h e tower
f r o m t h e damaged area t o t h e test probe. T h e cable and the nipple (Fig. 5 and 6).
r u n n i n g f r o m t h e coil t o t h e distributor cap can be
checked i n t h e same manner. Cracked, damaged or
f a u l t y cables should be replaced w i t h resistance type
cable w h i c h can be i d e n t i f i e d b y the words "Electron-
ic Suppression" p r i n t e d o n the cable jacket.
Use a n Ohmmeter (tool C-4845 or an equivalent) to
test for open circuits, excessive resistance or loose
t e r m i n a l s . Remove t h e d i s t r i b u t o r cap from t h e dis-
t r i b u t o r — D o not remove cables f r o m cap. Remove ca-
ble from spark p l u g . Connect ohmmeter to spark
p l u g t e r m i n a l o f cable a n d to corresponding electrode
i n d i s t r i b u t o r cap. Resistance should be w i t h i n spec-
ifications shown i n t h e resistance chart. I f not, re-
move cable f r o m d i s t r i b u t o r cap tower a n d connect
ohmmeter t o the t e r m i n a l ends of cable. I f resistance
is s t i l l n o t w i t h i n specifications, replace t h e cable.
Test a l l spark p l u g cables i n t h i s 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 coil t o d i s t r i b u t o r cap cable, do not remove

t h e cable f r o m the cap. Connect t h e ohmmeter to t h e
rotor b u t t o n (center contact) and the t e r m i n a l a t t h e
coil end o f t h e cable. I f resistance is not w i t h i n spec-
ifications i n t h e resistance chart, remove t h e cable
f r o m t h e d i s t r i b u t o r cap a n d connect the ohmmeter
to the t e r m i n a l ends o f t h e cable. I f resistance is s t i l l
not w i t h i n specifications, replace t h e cable. Inspect
t h e coil tower for cracks, corrosion or o i l leaks.
Replace cables one a t a t i m e to ensure t h a t the cor-
rect f i r i n g order is m a i n t a i n e d . Route the new cables
i n t h e same manner as t h e o r i g i n a l cables keeping
t h e m away f r o m accessory drive pulleys and exhaust
manifolds securing t h e m i n the proper retainers.
To remove cables f r o m spark plugs, t w i s t t h e r u b -
ber protector boot approximately 1/2-turn to break
t h e seal. Grasp t h e boot a n d p u l l i t from t h e p l u g
w i t h a s t r a i g h t and steady p u l l . Do not p u l l on t h e
w i r e i t s e l f because t h i s w i l l damage t h e conductor
and t e r m i n a l connection. Do not use pliers to remove
t h e cable.
To remove cables f r o m t h e d i s t r i b u t o r cap or i g n i -
Fig. 6 Coil Cable to Coil Installation
SPARK PLUGS
Remove t h e spark plugs a n d examine t h e m for
b u r n e d electrodes and fouled, cracked or b r o k e n por-
celain insulators. Keep plugs arranged i n t h e order
i n w h i c h they were removed from the engine. A n iso-
lated p l u g displaying a n abnormal condition i n d i -
cates t h a t a problem exists i n t h e corresponding
cylinder. Replace spark plugs a t the i n t e r v a l s recom-
mended i n t h e maintenance chart i n Group 0.
Spark plugs t h a t have low milage m a y be cleaned
and reused i f not otherwise defective. Refer to t h e
Spark P l u g Condition section of t h i s group. A f t e r
8D - 4 IGNITION SYSTEMS •
cleaning, file the center electrode flat w i t h a s m a l l
point f i l e or jewelers file. Adjust the gap between t h e
electrodes t o t h e specified dimension (Fig. 7). T h e
gap for 2.5L and 3.9L engines i s .88mm (.035 i n ) .

J908D-15

Fig. 8 Normal Operation and Cold (Carbon) Fouling

valves o r defective spark p l u g cables. Cold (carbon)
f o u l i n g o f t h e entire set may be caused b y a clogged
air cleaner.
Cold f o u l i n g is n o r m a l after short operating p e r i -
ods. The spark plugs do not reach a h i g h enough op-
e r a t i n g temperature d u r i n g short operating periods
to b u r n t h e carbon deposits off.
J908D-10
Electrode Gap Bridging
Fig. 7 Setting Spark Plug Gap - Typical Electrode gap b r i d g i n g may be traced to loose de-
A l w a y s t i g h t e n spark plugs to the specified torque. posits i n t h e combustion chamber. These deposits ac-
Over t i g h t e n i n g can cause distortion r e s u l t i n g i n a cumulate on the spark plugs d u r i n g continuous stop-
change i n t h e spark p l u g gap. Tighten a l l spark and-go d r i v i n g . W h e n t h e engine is suddenly
plugs t o 4 1 N»m (30 ft-lbs) torque. subjected t o a h i g h torque load, the deposits p a r t i a l l y
liquefy a n d bridge t h e gap between t h e electrodes
SPARK PLUG CONDITION (Fig. 9). T h i s short circuits t h e electrodes. Spark
plugs w i t h electrode gap b r i d g i n g can be cleaned us-
Normal Operating Conditions i n g s t a n d a r d procedures.
The few deposits present w i l l probably be l i g h t t a n
GROUND
or s l i g h t l y gray i n color w i t h most grades of commer- ELECTRODE
cial gasoline (Fig. 8). There w i l l not be evidence o f
electrode b u r n i n g . Gap growth w i l l not average more
t h a n approximately 0.025 m m (.001 in) per 1600 k m
(1000 miles) of operation. Spark plugs t h a t have nor-
m a l wear can usually be cleaned, have its electrodes
filed a n d regapped, and t h e n reinstalled.
Some fuel refiners i n several areas of the U n i t e d
States have introduced a manganese additive ( M M T )
for unleaded fuel. D u r i n g combustion, fuel w i t h
M M T causes the entire t i p of the spark p l u g to be
coated w i t h a rust colored deposit. This rust color can
be misdiagnosed as being caused b y coolant i n t h e
combustion chamber. Spark p l u g performance is n o t
J908D-11
affected b y M M T deposits.

Cold Fouling (Carbon Fouling) Fig. 9 Electrode Gap Bridging

Cold f o u l i n g is sometimes referred to as carbon Scavenger Deposits
fouling because the deposits t h a t cause cold f o u l i n g F u e l scavenger deposits may be either w h i t e or yel-
are basically carbon (Fig. 8). A dry, black deposit o n low (Fig. 10). They may appear t o be h a r m f u l , b u t
one or t w o plugs i n a set may be caused by s t i c k i n g this is a n o r m a l condition caused b y chemical addi-
 • IGNITION SYSTEMS 8D - 5

tives i n c e r t a i n fuels. These additives are designed to t i m i n g is over advanced or i f other operating condi-
change t h e chemical n a t u r e of deposits and decrease tions are causing engine overheating. (The heat
spark p l u g misfire tendencies. Notice t h a t accumula- range r a t i n g refers to t h e operating temperature o f a
t i o n o n t h e ground electrode a n d shell area m a y be p a r t i c u l a r type spark p l u g . Spark plugs are designed
heavy b u t t h e deposits are easily removed. Spark to operate w i t h i n specific temperature ranges de-
plugs w i t h scavenger deposits can be considered nor- pending upon t h e thickness and length of the center
m a l i n condition and be cleaned u s i n g standard pro- electrodes porcelain insulator.)
cedures.
GROUND
GROUND ELECTRODE
ELECTRODE STARTING
COVERED TO DISSOLVE
WITH WHITE
OR YELLOW
DEPOSITS
CENTER
CENTER ELECTRODE
ELECTRODE DISSOLVED

J908D-14
J908D-12
Fig. 12 Preignition Damage
Fig. 10 Scavenger Deposits
Spark Plug Overheating
Chipped Electrode Insulator Overheating is indicated by a w h i t e or gray center
A chipped electrode insulator u s u a l l y results from electrode i n s u l a t o r t h a t also appears blistered ( F i g .
bending t h e center electrode w h i l e adjusting t h e 13). T h e increase i n electrode gap w i l l be consider-
spark p l u g electrode gap. U n d e r certain conditions, ably i n excess o f 0.001 i n c h per 1000 miles o f opera-
severe detonation can also separate t h e insulator t i o n . This suggests t h a t a p l u g w i t h a cooler heat
f r o m the center electrode (Fig. 11). Spark plugs w i t h range r a t i n g should be used. Over advanced i g n i t i o n
t h i s condition m u s t be replaced. t i m i n g , detonation a n d cooling system malfunctions
can also cause spark p l u g overheating.
GROUND
ELECTRODE
CENTER BLISTERED
ELECTRODE WHITE OR
GRAY
COLORED
INSULATOR

CHIPPED
INSULATOR

J908D-13
Fig. 11 Chipped Electrode Insulator
Preignition Damage
P r e i g n i t i o n damage is caused by excessive combus-
t i o n chamber temperature. The center electrode dis-
solves first a n d t h e ground electrode dissolves
somewhat l a t e r (Fig. 12). Insulators appear r e l a t i v e l y
deposit free. Determine i f the spark p l u g has t h e cor-
rect heat range r a t i n g for t h e engine, i f i g n i t i o n
J908D-16
Fig. 13 Spark Plug Overheating
SPARK PLUG SERVICE
Use care w h e n disconnecting the spark p l u g a n d
coil cable boots and cables. T w i s t t h e boot 1/2 t u r n
and p u l l on t h e boot only to disconnect t h e cable.
W h e n replacing t h e spark plug and coil cables,
route t h e cables correctly and secure t h e m i n t h e ap-
8D - 6 IGNITION SYSTEMS
propriate retainers. F a i l u r e to route the cables prop-
erly can cause the radio t o reproduce i g n i t i o n noise,
cross i g n i t i o n o f the spark plugs or short c i r c u i t the
cables t o ground.
•
Refer t o Group 14, F u e l Systems, for f u r t h e r infor-
m a t i o n on the SBEC and fuel injection systems.

Spark Plug Removal

Remove t h e spark p l u g cable b y grasping a t t h e
spark p l u g boot t u r n i n g the boot 1/2 t u r n and p u l l i n g
s t r a i g h t back i n a steady motion.
(1) P r i o r t o r e m o v i n g t h e spark p l u g spray com-
pressed a i r around t h e spark p l u g hole and the area
around the spark p l u g .
(2) Remove the spark p l u g u s i n g a q u a l i t y socket
w i t h a rubber or foam insert.
(3) Inspect the spark p l u g condition. Refer to Spark
P l u g C o n d i t i o n i n t h i s section.

Spark Plug Gap Adjustment

(1) Check t h e spark p l u g gap w i t h a gap gauge. I f Fig. 14 Single Module Engine Controller (SBEC)
the gap i s n o t correct, adjust i t by bending t h e
HALL EFFECT PICK-UP ASSEMBLY
ground electrode (Fig. 7).
The d i s t r i b u t o r pick-up is a H a l l Effect device (Fig.
Spark Plug Installation 15). The pick-up supplies engine position and r p m i n -
(1) S t a r t the spark p l u g into the cylinder head b y f o r m a t i o n t o t h e SBEC.
h a n d t o avoid cross t h r e a d i n g .
(2) T i g h t e n t h e spark plugs t o 41 N*m (30 ft-lbs)
torque.
(3) I n s t a l l spark p l u g cables over spark plugs.

SINGLE BOARD ENGINE CONTROLLER (SBEC)

The Single Board Engine Controller (SBEC) is a
d i g i t a l computer c o n t a i n i n g a microprocessor. The
SBEC controls t h e i g n i t i o n system, fuel injection,
speed control, alternator output, and other vehicle
operations based upon inputs i t receives from various
sensors and switches.
The SBEC controls t h e ground p a t h for the i g n i t i o n
coil and fuel injectors. The SBEC (Fig. 14) supplies
b a t t e r y power to t h e i g n i t i o n coil, fuel injectors, fuel
p u m p , and oxygen sensor h e a t i n g element t h r o u g h
the auto shutdown (ASD) relay. Refer t o " A u t o Shut- Fig. 15 Hall Effect Distributor 3.9L Engine
down (ASD) Relay" i n t h i s section for relay opera- A shutter (sometimes referred to as a n i n t e r r u p t e r )
tion. is attached to t h e distributor shaft (Fig. 16). T h e
B y s w i t c h i n g the ground p a t h for the i g n i t i o n coil s h u t t e r contains one blade per engine cylinder. A
on and off t h e SBEC adjusts i g n i t i o n t i m i n g to meet
s w i t c h plate is mounted to t h e d i s t r i b u t o r housing
changing engine conditions.
above the shutter. The switch plate contains the dis-
The amount of electronic spark advance provided
t r i b u t o r pick-up (a H a l l Effect device and magnet)
by t h e SBEC is determined b y four i n p u t factors,
t h r o u g h w h i c h the shutter blades rotate. A s the shut-
coolant temperature, engine r p m , t h r o t t l e position
t e r blades pass t h r o u g h the pick-up, t h e y i n t e r r u p t
and available m a n i f o l d vacuum. D u r i n g engine
t h e magnetic field. The H a l l effect device i n the pick-
cranking/start-up, t h e SBEC advances t h e i g n i t i o n
u p senses t h e change i n t h e magnetic field a n d
t i m i n g a set amount.
switches o n and off (which creates pulses), generat-
Based o n inputs t h a t i t receives, t h e SBEC also
i n g the i n p u t signal to the SBEC. T h e SBEC calcu-
controls idle speed a n d evaporative canister purge
operation. T h e SBEC adjusts t h e alternator charge lates engine speed t h r o u g h t h e number o f pulses
rate t h r o u g h control o f the alternator field. generated.
 • IGNITION SYSTEMS 8D - 7

gine is r u n n i n g . T h e SBEC uses t h i s i n p u t along

w i t h i n p u t s from other sensors t o adjust air-fuel m i x -
t u r e and i g n i t i o n t i m i n g .
The M A P sensor i s located on t h e t h r o t t l e body
(Fig. 18).

Fig. 16 Distributor Pick-Up—Typical

COOLANT TEMPERATURE SENSOR
The SBEC receives i n f o r m a t i o n regarding engine
operating t e m p e r a t u r e from t h e Coolant Tempera-
t u r e Sensor (engine coolant temperature i s the same
as engine o p e r a t i n g temperature). The sensor is lo-
cated near t h e thermostat housing (Fig. 17).
The sensor is a variable resistor w i t h a range o f 5°
to 129°C (40°F t o 265°F). As coolant temperature var-
ies t h e coolant temperature sensors resistance
changes r e s u l t i n g i n a different i n p u t voltage t o t h e
SBEC.
The SBEC contains different spark advance curves
for different engine operating conditions. There are
unique spark advance schedules for cold and w a r m
engine operation t h a t have been added to reduce en- Fig. 18 MAP Sensor—3.9L Engine
gine emission a n d improve d r i v e a b i l i t y . T h e SBEC AUTO SHUTDOWN (ASD) RELAY
w i l l supply s l i g h t l y richer air-fuel mixtures a n d
h i g h e r idle speeds u n t i l n o r m a l operating tempera- The A u t o Shutdown Relay (ASD) supplies b a t t e r y
tures are reached. voltage t o t h e fuel p u m p , fuel injector, i g n i t i o n coil,
A l l spark advance testing should be done w i t h t h e and 0 sensor h e a t i n g element. T h e ground c i r c u i t
2

engine f u l l y w a r m e d . for t h e A S D relay is controlled b y t h e Single B o a r d

MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
The M A P sensor reacts to absolute pressure i n the
i n t a k e m a n i f o l d and provides a n i n p u t voltage to the
Single B o a r d Engine Controller (SBEC). A s engine
load changes m a n i f o l d pressure varies, causing t h e
M A P sensor o u t p u t voltage t o change r e s u l t i n g i n a
different i n p u t voltage t o the SBEC. The i n p u t volt-
age level supplies t h e SBEC w i t h information relat-
Engine Controller (SBEC). The SBEC controls t h e re-
lay operation b y s w i t c h i n g the ground c i r c u i t o n and
off.
The SBEC monitors t h e d i s t r i b u t o r pick-up s i g n a l
to determine engine speed and compute injector syn-
chronization. I f the SBEC does not receive a d i s t r i b -
u t o r signal w h e n the i g n i t i o n switch is i n the " R u n "
position i t w i l l n o t energize (not provide a ground)
t h e A S D relay, stopping the battery voltage supply t o
t h e fuel p u m p , fuel injectors, i g n i t i o n coil, a n d 0 2

i n g t o a m b i e n t barometric pressure d u r i n g engine sensor heater element.

start-up (cranking) a n d t o engine load w h i l e the en-
8D - 8 IGNITION SYSTEMS •
T h e A S D relay i s located i n t h e engine compart- Test c o i l according t o coil tester manufacturer's i n -
m e n t near the 50-way b u l k h e a d connector (Fig. 19). structions. Test coil p r i m a r y resistance. Test coil sec-
ondary resistance. Replace a n y coil t h a t does n o t
PART THROTTLE^A/C CLUTCH CUTOUT STARTER
meet specifications.
I f t h e i g n i t i o n coil i s replaced because o f a b u r n e d
tower, carbon t r a c k i n g , or a r c i n g a t either t h e tower,
nipple o r boot a t t h e coil end o f the secondary cable,
replace cable. A n y a r c i n g a t the tower w i l l carbonize
the n i p p l e . I n s t a l l i n g t h e cable on a n e w coil w i l l
cause t h e coil to f a i l .
I f secondary cables shows a n y signs o f damage,
they s h o u l d be replaced w i t h n e w cables. Damaged
cables can cause a r c i n g and f a i l u r e of a new coil.
The i g n i t i o n coil is mounted t o t h e dash panel a t
the r e a r o f the r i g h t side valve cover (Fig. 20).

TERMINAL ENGINE GROUND

Fig. 19 ASD Relay Location

IGNITION COIL
T h e SBEC controls i g n i t i o n coil firing t h r o u g h t h e
auto shutdown (ASD) relay. W h e n the relay is ener-
gized b y the SBEC, battery voltage is supplied t o t h e
i g n i t i o n coil positive t e r m i n a l . The SBEC w i l l not en-
ergize t h e ASD relay u n t i l i t receives i n p u t f r o m t h e
d i s t r i b u t o r pick-up. Refer t o " A u t o Shutdown ( A S D )
Relay" i n t h i s section for relay operation.
The i g n i t i o n coil i s designed t o operate w i t h o u t a n
e x t e r n a l i g n i t i o n resistor. Inspect the coil for exter-
n a l leaks and arcing. Fig. 20 Ignition Coil Connections
 • IGNITION SYSTEMS 80 - 9

DIAGNOSTIC P R O C E D U R E S
INDEX
Page Page
Coolant Temperature Sensor Test 10 Poor Performance Test . . . . . . . . . . . . . . . . . . . . . 10
Failure To Start Test 9 Spark Advance ( S B E C Controlled) Test 10
General Information 9 Testing For Spark At Coil 9
Manifold Absolute Pressure (MAP) Sensor Test . . 10

GENERAL INFORMATION FAILURE TO START TEST

For more information refer t o " O n B o a r d Diagnos- To prevent unnecessary diagnostic t i m e and w r o n g
t i c s " i n the General Diagnosis sections o f Group 14, test results, t h e " C h e c k i n g for Spark Test" should be
F u e l System. performed p r i o r t o t h i s test.

TESTING FOR SPARK AT COIL WARNING: S E T PARKING BRAKE OR BLOCK THE

Remove coil secondary cable f r o m d i s t r i b u t o r cap.
H o l d end of cable about 6 m m (1/4-inch) away f r o m a
good engine ground (Fig. 1). C r a n k t h e engine and
check for a spark a t coil secondary cable.
DRIVE WHEELS BEFORE PROCEEDING WITH THIS
TEST.
(1) Determine t h a t sufficient battery voltage (12.4
volts) is present for t h e s t a r t i n g and i g n i t i o n sys-
tems.
(2) C r a n k t h e engine for 5 seconds w h i l e monitor-
i n g the voltage a t t h e coil positive t e r m i n a l (Fig. 2).

j ^ | § l g i » ^
TERMINAL ENGINE GROUND

Fig. 1 Checking for Spark

I f a spark occurs, i t m u s t be constant. I f i t is, con-
t i n u e to crank engine a n d w h i l e slowly m o v i n g the
coil secondary cable away f r o m ground, check for arc-
i n g a t the coil tower. I f a r c i n g occurs replace coil. I f
spark is not constant o r spark i s not present, proceed
to the failure to start test.
I f a good spark is produced t h e i g n i t i o n coil is pro-
ducing h i g h secondary voltage. Inspect t h e d i s t r i b u -
t o r rotor, cap, spark p l u g cables, and spark plugs. I f
t h e y are okay, the i g n i t i o n system is n o t t h e reason
w h y the engine w i l l not s t a r t . I t w i l l be necessary to
check the fuel system a n d engine mechanical items.
Fig. 2 Coil Terminals
• I f the voltage remains near zero d u r i n g the en-
t i r e period o f c r a n k i n g , refer to "On-Board Diagnos-
t i c s " i n t h e F u e l Injection section o f Group 14 to
check the single board engine controller (SBEC) and
auto shutdown relay.
• I f voltage is a t "near-battery" voltage and drops to
zero after 1-2 seconds o f c r a n k i n g , refer to "On-Board
Diagnostics" i n t h e F u e l Injection section of Group
14 to check t h e d i s t r i b u t o r reference pickup to SBEC
circuit.
8D - 10 IGNITION SYSTEMS •
• I f voltage remains a t "near b a t t e r y " voltage d u r i n g Board Diagnostics i n the F u e l Injection General D i -
t h e entire 5 seconds, t u r n t h e k e y off a n d remove the agnosis sections o f Group 14.
60-way connector (Fig. 3) f r o m t h e SBEC. Check 60-
way connector for any spread t e r m i n a l s . COOLANT TEMPERATURE SENSOR TEST
(1) T u r n t h e i g n i t i o n k e y t o t h e off position. Dis-
connect w i r e connector f r o m coolant temperature sen-
sor.
(2) Connect one lead o f ohmmeter t o one t e r m i n a l
of coolant temperature sensor (Fig. 5).

CONNECTOR
TERMINAL SIDE OHMMETER
SHOWN J908D-42

Fig. 3 SBEC 60-Way Connector

(3) Remove test lead f r o m t h e coil positive t e r m i n a l
and connect a n 18 gauge j u m p e r w i r e between t h e
battery positive t e r m i n a l and t h e coil positive t e r m i -
nal.
RR8DG20
(4) M a k e t h e special j u m p e r shown i n F i g u r e 4. Us-
i n g the j u m p e r , m o m e n t a r i l y ground t e r m i n a l n u m - Fig. 5 Coolant Temperature Sensor Test
ber 19 o f t h e 60-way connector. A spark should be
(3) Connect the other lead of ohmmeter t o r e m a i n -
generated a t t h e coil cable w h e n t h e g r o u n d i s re-
i n g t e r m i n a l o f coolant temperature sensor.
moved.
• W i t h t h e engine/sensor a t n o r m a l operating tem-
CAPACITOR CONNECT THIS- perature, about 93°C (200°F), t h e sensor impedance
CLIP TO COIL
NEGATIVE should be approximately 700 t o 1,100 ohms.
• W i t h t h e engine/sensor a t room temperature,
GROUND
THIS about 21°C (70°F), t h e sensor impedance should be
CLIP approximately 7,000to 14,000 ohms.
Refer t o " O n B o a r d D i a g n o s t i c s " i n t h e F u e l
I n j e c t i o n G e n e r a l D i a g n o s i s s e c t i o n s o f G r o u p 14
for f u r t h e r test procedures.
ALLIGATOR CLIP PR 100.?

Fig. 4 Special Jumper—Ground to Coil Negative
Terminal
(5) I f spark is generated, replace the SBEC.
(6) I f no spark is seen, use t h e special j u m p e r to
ground t h e coil negative t e r m i n a l directly.
(7) I f spark is produced, repair w i r i n g harness for
an open condition.
(8) I f no spark is produced, replace the i g n i t i o n coil.
POOR PERFORMANCE TEST
To prevent unnecessary diagnostic t i m e a n d w r o n g
test results, t h e "Testing F o r Spark A t C o i l " should
be performed prior t o t h i s test.
WARNING: APPLY PARKING BRAKE AND/OR
BLOCK WHEELS BEFORE PERFORMING IDLE
CHECK/ADJUSTMENT, OR ANY TEST WITH AN OP-
ERATING ENGINE.
Check a n d adjust basic t i m i n g . Refer t o t h e Speci-
fication a n d Service Procedure sections. Refer t o O n
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
TEST
Refer to " O n Board Diagnostics" i n the F u e l Injec-
t i o n General Diagnosis sections o f Group 14 for M A P
sensor testing.
SPARK ADVANCE (SBEC CONTROLLED) TEST
(1) Set basic t i m i n g . (Refer to I g n i t i o n T i m i n g Pro-
cedure i n t h e Service Procedures Section of t h i s
group).
(2) Engine a t operating temperature. T h e tempera-
t u r e sensor m u s t be connected and w o r k i n g properly.
(3) Raise and m a i n t a i n engine speed t o 2000 r p m ,
w a i t one m i n u t e and check advance (the D R B I I diag-
nostic tool " S E T E N G I N E R P M " test i n " S P E C I A L
F U N C T I O N S " mode can be used t o raise and m a i n -
t a i n engine speed). Refer t o Specifications a t the rear
of this group. Advance specifications are i n addition
to basic advance.
 • IGNITION SYSTEMS 80 - 11

WARNING: WHILE PERFORMING THESE TESTS, IT RESULT IN A FIRE DUE TO HIGH TEMPERATURES
IS NECESSARY TO USE A METAL EXHAUST EVAC- AND LONG TEST PERIOD.
UATION TUBE. THE USE OF A RUBBER HOSE MAY
Replace t h e SREC i f t h e i g n i t i o n t i m i n g fails t o
reach specified settings.

SERVICE PROCEDURES
INDEX
Page Page
Coolant Temperature Sensor . . . . . . . . . . . . . . . . 11 Ignitiion Timing Procedure 12
Distributor . 13 Single Board Engine Controller (SBEC) 11
idle RPM Test 12 Spark Plug Service 12

SINGLE BOARD ENGINE CONTROLLER (SBEC)

REMOVAL

CAUTION: Do not remove the grease from the

S B E C 60-way connector. The grease is used to pre-
vent moisture from contacting the connector termi-
nals. Ensure that at least a 1/8 inch thick coating of
grease covers the bottom of connector cavities. If
not, apply a liberal coating of Mopar Multi-Purpose
Grease to the connector prior to connecting it to
the SBEC.

T h e Single Board Engine Controller (SBEC) i s lo-

cated on t h e dash panel.
(1) Remove a i r cleaner duct from SBEC.
(2) Remove (3) module m o u n t i n g screws (Fig. 1). Fig. 1 Servicing the Single Board Engine Controller
(3) Remove 60-way electrical connector f r o m t h e (SBEC)
SBEC. Remove SBEC (Fig. 1).

INSTALLATION
(1) Connect 60-Way electrical connector t o SBEC
(Fig. 1).
(2) M o u n t SBEC t o inside r i g h t f r o n t fender (Fig.
1) . I n s t a l l a n d t i g h t e n m o u n t i n g screws.
(3) I n s t a l l a i r cleaner duct t o SBEC.

COOLANT TEMPERATURE SENSOR

(1) Disconnect electrical connector from sensor. Re-
move sensor a n d i m m e d i a t e l y p l u g hole i n w a t e r
j a c k e t (Fig. 2). Some engine coolant m a y be lost.
(2) I n s t a l l sensor and t i g h t e n t o 27 N n n (20 f t . lbs.)
torque. Connect electrical connector t o sensor ( F i g .
Fig. 2 Coolant Temperature Sensor
2) .
(3) Replace any lost engine coolant. Refer to Group
7, Cooling System.
8D - 12 IGNITION SYSTEMS •
SPARK PLUG SERVICE (3) T u r n tachometer r p m s w i t c h t o 1,000 r p m posi-
tion.
(4) W i t h engine a t n o r m a l operating temperature,
SPARK PLUG REMOVAL
m o m e n t a r i l y open t h e t h r o t t l e and release i t t o en-
Remove t h e spark p l u g cable b y grasping a t t h e
sure there is no b i n d i n t h e l i n k a g e a n d t h a t t h e
spark p l u g boot t u r n i n g the boot 1/2 t u r n and p u l l i n g
t h r o t t l e lever is against i t s stop.
s t r a i g h t back i n a steady motion.
(5) Note engine r p m . Refer to Vehicle Emission
(1) P r i o r t o removing t h e spark p l u g spray com-
Control I n f o r m a t i o n ( V E C I ) label for correct engine
pressed a i r around the spark p l u g hole and the area
idle r p m . I f n o t w i t h i n specification, Refer t o " O n
around t h e spark plug.
Board Diagnostics" section o f Group 14, F u e l System
(2) Remove t h e spark p l u g u s i n g a q u a l i t y socket
for t h r o t t l e body m i n i m u m air-flow check procedure.
w i t h a rubber or foam insert.
(3) Inspect the spark p l u g condition. Refer t o Spark
IGNITION TIMING PROCEDURE
P l u g Condition i n t h e Component Identification sec-
t i o n o f t h i s group. Proper i g n i t i o n t i m i n g i s required t o obtain opti-
m u m engine performance. T h e d i s t r i b u t o r m u s t be
INSPECTION correctly indexed t o provide correct i n i t i a l i g n i t i o n
Inspect t h e spark plugs for t h e following items. timing.
Clean or replace i f necessary.
(1) Cracked or damaged threads or insulator. WARNING: APPLY PARKING BRAKE AND/OR
(2) W o r n electrodes. BLOCK WHEELS BEFORE CHECKING IGNITION
(3) Damaged or w o r n gasket. TIMING.
(4) Condition of b u r n t electrode a n d amount o f car-
bon deposit. (1) Set t h e gearshift selector i n p a r k o r n e u t r a l and
Refer t o t h e General I n f o r m a t i o n section o f t h i s apply t h e p a r k i n g brake. A l l l i g h t s a n d accessories
group for i n f o r m a t i o n regarding spark p l u g condi- m u s t be off.
tion. (2) U s i n g a magnetic t i m i n g u n i t , i n s e r t the p i c k u p
probe into t h e open receptacle i n f r o n t o f the t i m i n g
SPARK PLUG GAP ADJUSTMENT scale (Fig. 3). I f a magnetic t i m i n g u n i t is not a v a i l -
(1) Check the spark p l u g gap w i t h a gap gauge. I f able, use a conventional power t i m i n g l i g h t con-
the gap is not correct, adjust i t b y bending t h e nected to t h e n u m b e r one cylinder spark p l u g w i r e .
ground electrode.

SPARKPLUG INSTALLATION
(1) S t a r t t h e spark p l u g i n t o t h e cylinder head b y
h a n d to avoid cross threading.
(2) T i g h t e n t h e spark plugs t o 4 1 N*m (30 ft-lbs)
torque.
(3) I n s t a l l spark p l u g cables over spark plugs.

IDLE RPM TEST

WARNING: APPLY PARKING BRAKE AND/OR

BLOCK WHEELS BEFORE PERFORMING IDLE
CHECK OR ADJUSTMENT, OR ANY TESTS WITH A
RUNNING ENGINE.

E n g i n e i d l e set R P M s h o u l d b e t e s t e d a n d r e -
c o r d e d w h e n t h e v e h i c l e i s first b r o u g h t i n t o
shop for testing. This w i l l assist i n diagnosing com-
plaints o f engine stalling, creeping, and h a r d s h i f t i n g
on vehicles equipped w i t h automatic transmissions.
T e s t p r o c e d u r e s a r e a s follows:
(1) Connect red lead o f test tachometer u n i t to neg-
Fig. 3 Timing Marks
ative p r i m a r y t e r m i n a l of coil a n d black lead t o a
good ground. D o n o t p u n c t u r e cables, boots o r nipples w i t h
(2) T u r n selector switch to t h e appropriate cylinder test probes. A l w a y s use p r o p e r adapters. Punc-
position o f engine being tested. t u r i n g t h e s p a r k p l u g cables w i t h a probe w i l l
 • IGNITION SYSTEMS
d a m a g e t h e cables. T h e p r o b e c a n s e p a r a t e t h e
c o n d u c t o r a n d cause h i g h resistance. B r e a k i n g
the r u b b e r insulation may permit secondary cur-
rent to arc to ground.
(3) T u r n selector switch to the appropriate cylinder
position.
(4) S t a r t engine and r u n u n t i l operating tempera-
t u r e is obtained.
(5) W i t h engine a t n o r m a l operating temperature,
connect t h e D R B I I diagnostic tool and access " B A S I C
T I M I N G M O D E " i n " S P E C I A L F U N C T I O N S " sec-
t i o n (or disconnect coolant temperature sensor—Fig.
2). I n s t r u m e n t Panel lamp should come o n i f t h e
coolant temperature sensor is disconnected.
(6) A i m T i m i n g L i g h t a t t i m i n g scale (Fig. 3) o r
read magnetic t i m i n g u n i t .
• I f flash occurs w h e n t i m i n g m a r k is before speci-
fied degree m a r k , t i m i n g is advanced. To adjust, t u r n
d i s t r i b u t o r housing i n direction o f rotor r o t a t i o n .
• I f flash occurs when t i m i n g m a r k is after specified
degree m a r k , t i m i n g is retarded. To adjust, t u r n dis-
t r i b u t o r housing against direction of rotor r o t a t i o n .
Refer t o Vehicle Emission Control I n f o r m a t i o n
(VECI) label for correct t i m i n g specification. I f t i m -
i n g is w i t h i n ±2° of value specified on t h e label, pro-
ceed to step (8). I f outside specified tolerance, proceed
to next step.
(7) Loosen d i s t r i b u t o r hold-down a r m screw j u s t
enough so t h e d i s t r i b u t o r housing can be rotated
(Fig. 4). T u r n d i s t r i b u t o r housing u n t i l specified l a -
bel value is reached. T i g h t e n t h e hold-down a r m
screw and recheck t i m i n g .
(8) T u r n t h e engine off. Remove t i m i n g l i g h t or
magnetic t i m i n g u n i t and tachometer. I f t h e coolant
temperature sensor was disconnected, connect t h e
sensor a n d erase f a u l t codes u s i n g t h e E r a s e
F a u l t C o d e M o d e o n t h e D R B I I . Refer to Group 14
General Diagnosis " O n Board Diagnostics".
Fig. 4 Distributor Hold-Down
80 - 13
DISTRIBUTOR
REMOVAL
(1) Disconnect d i s t r i b u t o r pickup lead w i r e a t w i r -
i n g harness connectors.
(2) Unfasten d i s t r i b u t o r cap r e t a i n i n g clips and l i f t
off d i s t r i b u t o r cap.
(3) Scribe a m a r k o n t h e edge o f d i s t r i b u t o r hous-
i n g to indicate position o f rotor as reference w h e n re-
i n s t a l l i n g distributor.
(4) Remove d i s t r i b u t o r h o l d down clamp screw and
clamp.
(5) Carefully l i f t d i s t r i b u t o r f r o m engine.
INSTALLATION
(1) Position d i s t r i b u t o r i n engine. Ensure rubber O-
r i n g seal is i n groove o f d i s t r i b u t o r housing. A l i g n
rotor w i t h marks previously made on d i s t r i b u t o r
housing. Clean top of cylinder block t o ensure a good
seal between d i s t r i b u t o r baseband block.
(2) Engage tongue o f d i s t r i b u t o r shaft w i t h slot i n
d i s t r i b u t o r o i l pump drive gear. I f e n g i n e h a s b e e n
cranked while distributor is removed, i t w i l l be
necessary t o establish t h e p r o p e r relationship
between d i s t r i b u t o r shaft a n d N o . 1 piston posi-
t i o n as f o l l o w s :
(a) Rotate crankshaft u n t i l number one piston
is a t top o f compression stroke. M a r k on crankshaft
v i b r a t i o n damper should be i n l i n e w i t h " 0 " T D C
m a r k on t i m i n g chain case cover.
(b) Rotate rotor to position of number one dis-
t r i b u t o r cap t e r m i n a l .
(c) Lower d i s t r i b u t o r i n t o opening, connect
pickup coil leads and i n s t a l l d i s t r i b u t o r cap. E n -
sure a l l high-tension wires snap f i r m l y i n cap tow-
ers. I n s t a l l d i s t r i b u t o r hold-down clamp screw.
T i g h t e n screw finger t i g h t .
(3) Connect d i s t r i b u t o r pick-up lead wire(s) a t w i r -
i n g harness connectors.
(4) Adjust engine t i m i n g t o Specification (refer t o
Ignition Timing).
8D - 14 IGNITION SYSTEMS •
HALL EFFECT PICK-UP ASSEMBLY (3) Remove h a l l effect pick-up a t t a c h i n g screws o n
REPLACEMENT opposite sides o f t h e d i s t r i b u t o r housing a n d care-
f u l l y l i f t t h e h a l l effect pick-up assembly from t h e
Removal d i s t r i b u t o r housing (Fig. 6).
(1) Remove d i s t r i b u t o r cap. Refer t o " D i s t r i b u t o r
Removal a n d I n s t a l l a t i o n " .
ALIGNMENT GROVE
(2) Remove i g n i t i o n rotor from d i s t r i b u t o r shaft
(Fig. 5).
IGNITION ROTOR

DISTRIBUTOR
HALL EFFECT HOUSING
PICK-UP

DISTRIBUTOR ASSEMBLY

ATTACHING SCREW

RR8DG33

Fig. 6 Hall Effect Pick-Up Removal and Installation

RR8DG32 Installation
To r e i n s t a l l h a l l effect pick-up assembly f o l l o w t h e
Fig. 5 Ignition Rotor Removal and Installation preceding procedure i n reverse order.
• IGNITION SYSTEMS 8D - 15

SPECIFICATIONS
GENERAL INFORMATION tion. I f anything differs from the specifications on t h e
Vehicle Emission Control Information label, use the
The following specifications are published from the specifications on the label,
latest information available at the time of publica-

DISTRIBUTOR SPECIFICATIONS

Engine A p p l i c a t i o n 3.9L Engine 5.2L/5.9L Engine

Application Fed.-Cal.-Can.-Alt. Fed.-Cal.-Can.-Alt.

Transmission Manual & Automatic Manual & Automatic

Duty Cycle All All

Spark System SBEGTBI SBEC-TBI

Rotation Clockwise Clockwise

Firing Order 1-6-5-4-3-2 1-8-4-3-6-5-7-2

Basic Timing ± 2 10° BTDC 10° BTDC

Not to Exceed Not to Exceed

Shaft Side Play 0.1mm (0.004") 0.1mm (0.004")

0.08 to 0.43mm 0.08 to 0.43mm

Shaft End Play (0.003" to 0.017") (0.003" to 0.017")

SBEC—Single Board Engine Controller TBI—Throttle Body Injection

Fed.—Federal Cal.—California Can.—Canada

J908D-52
IGNITION COIL

Chrysler Chrysler
Coil Prestolite UTC Diamond

Primary Resistance at 7 0 - 8 0 ° F 1.34-1.55 1.34-1.55 1.34-1.55

Sec. Resistance at 7 0 - 8 0 ° C 9,400-11,700 9,000-12,200 15,000-19,000

J908D-53
SPARK PLUGS

S p a r k Plug
Engine Application Gap Tightening Size
Original Torque
Replacement
Equipment

3.9L RN12YC RN12YC All .035" 41 N*m 14mm

5.21/5.9L RN12YC RN12YC All (0.9mm) (30 ft. lbs.) 3/4" Reach

J908D-54
8D - 16 IGNITION SYSTEMS •
SENSOR SPECIFICATIONS

No. o f Thread Thread Size a n d

Component Terminals Resistance a t °F Compound Torque R e f e r e n c e

Coolant 2 7,000-13,000 Ohms Preapplied 3/8-18 NPTF

Temperature at21°C(70*F)* 27 N m
Sensor (20 ft. lbs.)
700-1,000 Ohms
a t 9 3 ° C (200°F)

Throttle Body 2 5,600-14,600 Ohms Mopar M12 x 1.5

Temperature at 12°C ( 7 0 ° F ) * Silicone 11 N m
Sensor Heat (100 in. lbs.)
Transfer
400-1,500 Ohms Compound
at 9 3 ° C ( 2 0 0 ° F ) *

* Temperature ratings are nominal values and will vary slightly. J908D-55
 • INSTRUMENT PANEL AND GAUGES 8E - 1

INSTRUMENT PANEL AND GAUGES

CONTENTS
Page Page

CLUSTER AND GAUGE SERVICE AND TESTING . 4 SWITCH AND PANEL COMPONENT SERVICE . 15
GENERAL INFORMATION 1

G E N E R A L INFORMATION
INDEX
Page Page
Alternator Indicating System . . . . . . . . . . . . . . . . . . 3 Message Center — Diesel Engine . . . . . . . . . . . . . 2
Distance Sensor . 4 Message Center — Gas Engine 1
Electronic Digital Clock . 2 Oil Pressure Warning Lamp . . . . . . . . . . . . . . . . . . 3
Fuel Level Indicating System , 2 Speedometer/Odometer System 4
Instrument Cluster 1 Temperature and Oil Indicating System . . . 3

INSTRUMENT CLUSTER (Fig. 1)

BRAKE
D-body t r u c k s have a n i n s t r u m e n t cluster w h i c h
includes gauges for fuel level, coolant temperature, Q/D
IS A CHECK ENGINE
o i l pressure, and charging system voltage (Fig. 1).
There is also a w a r n i n g lamp for l o w o i l pressure.
W h e n the i g n i t i o n s w i t c h is i n the OFF position a l l v SI MAINT. REQD.
CD
t h e gauges w i l l show a reading except the voltage
gauge. However, t h e readings are only accurate ANTI-LOCK
w h e n the i g n i t i o n s w i t c h is i n the O N position.
The cluster also includes w a r n i n g lamps for seat J908E-65
b e l t w a r n i n g , and liftgate open (Ramcharger only).
Fig. 2 Message Center—Gas Engine
the Check Engine Lamp and substitutes a modified
signal i n place o f the one t h a t failed u n t i l a repair is
made:
• M a n i f o l d Absolute Pressure (MAP) Sensor
• T h r o t t l e Position Sensor
• Coolant Temperature Sensor
• B a t t e r y Voltage Sense
• B a t t e r y Voltage Too H i g h
J908E-66
Refer t o the approriate P o w e r t r a i n Diagnostic Test
Fig. 11nstrument Cluster Procedures m a n u a l for f u r t h e r i n f o r m a t i o n .

MESSAGE CENTER-GAS ENGINE EMISSIONS MAINTENANCE REMINDER

The message center (Fig. 2), w h i c h is located above
t h e Heater-A/C controls, includes w a r n i n g lamps for
t h e brake systems ( p a r k i n g a n d service) anti-lock
brakes, the check engine system and maintenance re-
quired.
CHECK ENGINE
I f the i n p u t from one o f the following sensors fails
a n i n t e r n a l SBEC self check, the controller t u r n s o n
T h i s system is designed t o act as a reminder t h a t
scheduled vehicle emissions maintenance should be
performed. I t i s not i n t e n d e d to indicate a w a r n -
i n g o r that a s t a t e of e m e r g e n c y exists w h i c h
m u s t b e c o r r e c t e d to i n s u r e safe vehicle opera-
tion. The components covered by the system include
the EGR system, P C V valve, and oxygen sensor.
Refer t o Group 25 - Emissions, for f u r t h e r informa-
tion.
8E - 2 INSTRUMENT PANEL AND GAUGES
ANTI-LOCK WARNING LIGHT
T h i s l i g h t m o n i t o r s t h e A n t i - L o c k B r a k e System.
This l i g h t w i l l come o n w h e n t h e i g n i t i o n k e y is
t u r n e d to t h e O N position a n d m a y stay on for as
long as t h i r t y seconds. I f t h e A n t i - L o c k l i g h t remains
on o r comes o n d u r i n g d r i v i n g , i t indicates t h a t t h e
A n t i - L o c k p o r t i o n o f t h e brake system is n o t func-
t i o n i n g . Refer t o Group 5 - Brakes for f u r t h e r infor-
mation.
•
The d u a l b r a k e system provides a reserve b r a k i n g
capability i n t h e event of a f a i l u r e to a p o r t i o n of t h e
h y d r a u l i c system. F a i l u r e o f either o f t h e d u a l sys-
t e m is indicated b y t h e brake w a r n i n g l i g h t w h i c h
w i l l glow w h e n t h e service brake pedal is depressed.
The l i g h t w i l l r e m a i n on u n t i l the cause is corrected.
The l i g h t w i l l also come o n w h e n t h e p a r k i n g
brake is applied w i t h the i g n i t i o n i n t h e O N position.
Refer t o Group 5 - Brakes for f u r t h e r i n f o r m a t i o n .

BRAKE SYSTEM WARNING LIGHT WATER IN FUEL

The dual b r a k e system provides a reserve b r a k i n g
capability i n t h e event of a failure t o a p o r t i o n of t h e
hydraulic system. F a i l u r e of either o f the d u a l sys-
t e m is indicated b y t h e brake w a r n i n g l i g h t w h i c h
w i l l glow w h e n t h e service brake pedal is depressed.
The l i g h t w i l l r e m a i n o n u n t i l the cause is Corrected.
The l i g h t w i l l also come o n w h e n t h e p a r k i n g
brake is applied w i t h t h e i g n i t i o n i n t h e O N position.
Refer to Group 5 - Brakes for f u r t h e r i n f o r m a t i o n .
MESSAGE CENTER-DIESEL ENGINE
The message center (Fig. 3), w h i c h is located above
the Heater-A/C controls, includes w a r n i n g lamps for
the brake systems ( p a r k i n g , service brakes) anti-lock
brakes, water i n fuel, w a i t to start (controlled b y A i r
Heater Control Module) and L o w F u e l .
BRAKE © ©
WATER IN FUEL
CUMMINS
WAIT TO START
TURBO DIESEL
LOW ANTI-LOCK
FUEL
DIESEL FUEL ONLY
J908E-67
Fig. 3 Message Center—Diesel Engine
ANTI-LOCK WARNING LIGHT
This l i g h t monitors t h e A n t i - L o c k B r a k e System.
This l i g h t w i l l come o n w h e n t h e i g n i t i o n k e y is
t u r n e d to t h e O N position a n d m a y stay on for as
long as t h i r t y seconds. I f the A n t i - L o c k l i g h t remains
on or comes on d u r i n g d r i v i n g , i t indicates t h a t t h e
A n t i - L o c k p o r t i o n of t h e brake system is n o t func-
t i o n i n g . Refer t o Group 5 - Brakes for f u r t h e r infor-
mation.
BRAKE SYSTEM WARNING LIGHT
The Brake l i g h t is connected to a sensor t h a t mon-
itors vacuum i n t h e brake booster system. The B r a k e
l i g h t when l i t indicates L O W V A C U U M .
The W a t e r I n F u e l l i g h t is connected to a sensor lo-
cated i n t h e fuel f i l t e r . I f water collects i n t h e fuel/
water separator f i l t e r , t h e Water I n F u e l indicator
will light.
WAIT TO START
The W a i t To S t a r t l i g h t is connected t o a sensor
t h a t m o n i t o r s t h e i n t a k e a i r temperature i n t h e i n -
take m a n i f o l d . W h e n t h e engine a i r temperature is
low a n d t h e i g n i t i o n switch is i n the O N position, t h e
control module sends current t o t h e i n t a k e manifold
a i r heaters a n d t h e W a i t To S t a r t l i g h t . T h i s i n t a k e
m a n i f o l d preheat cycle is controlled b y a n electronic
A i r H e a t e r C o n t r o l Module.
LOW FUEL
The L o w F u e l l i g h t is connected to a sensor i n t h e
fuel t a n k . W h e n the fuel level reaches approximately
1/6 o f a t a n k , t h e words L O W F U E L w i l l i l l u m i n a t e
and r e m a i n o n u n t i l fuel is added.
ELECTRONIC DIGITAL CLOCK
The electronic d i g i t a l clock is i n t h e radio. T h e
clock a n d radio each use the display panel b u i l t i n t o
the radio. A d i g i t a l readout indicates t h e t i m e i n
hours a n d m i n u t e s whenever the i g n i t i o n switch is i n
the O N or A C C position.
W h e n t h e i g n i t i o n switch is i n the O F F position or
when t h e radio frequency is being displayed, t i m e
keeping i s accurately maintained.
The procedure for setting t h e clock varies s l i g h t l y
w i t h each radio. The correct procedure is described
under t h e i n d i v i d u a l radio operating instructions re-
ferred t o i n the Owner M a n u a l supplied w i t h the ve-
hicle.
FUEL LEVEL INDICATING SYSTEM (FIG. 4)
A h i n g e d float a r m i n t h e fuel t a n k raises or low-
ers depending on t h e fuel level. The float a r m con-
tacts a variable resistor i n t h e gauge sending u n i t
t h a t provides a change of resistance i n the fuel gauge
circuit w i t h a n y u p or down movement of the float.
This sender resistance is shown as fuel level on t h e
gauge.
W h e n t h e fuel level i n t h e t a n k is low, t h e float
a r m drops, resistance of the fuel level sender is i n -
 • INSTRUMENT PANEL AND GAUGES 8E - 3

creased, c u r r e n t flow decreases and positions the i n - 12 VOLTS

s t r u m e n t cluster gauge pointer t o empty. TO
GAUGE
W h e n the t a n k is f u l l o f fuel, t h e float a r m rises,
resistance o f t h e fuel level sender decreases, c u r r e n t TEMPERATURE/
flow increases and positions t h e i n s t r u m e n t cluster OIL GAUGE
gauge to f u l l .
12 VOLTS
TO
GAUGE

FUEL
GAUGE

TEMPERATURE/OIL
SENDING UNIT

FUEL TANK
SENDING UNIT

— - T - 4
{CONNECTOR
I — i n J908E-48

Fig. 5 Temperature/Oil Indicating System

W h e n the engine o i l pressure is low, t h e switch is
FUEL i n t h e O N or C L O S E D position a l l o w i n g current to
FLOAT TANK
SENDING flow to the o i l pressure w a r n i n g l a m p on the i n s t r u -
UNIT J098E-47 ment cluster causing t h e w a r n i n g l a m p t o be i l l u m i -
nated.
Fig. 4 Fuel Level Indicating System
TEMPERATURE AND OIL INDICATING SYSTEM ALTERNATOR INDICATING SYSTEM (FIG. 6)
(FIG. 5) The voltmeter gauge senses the voltage o f the elec-
The operation o f the temperature a n d o i l pressure t r i c a l system.
i n d i c a t i n g systems are identical. I n the temperature
system t h e sending u n i t resistance varies i n direct
relationship t o the temperature o f t h e coolant.
W h e n the engine is cold, t h e resistance o f the tem-
perature sending u n i t is h i g h and a cold temperature
w i l l be indicated on the gauge.
W h e n the engine is hot, t h e resistance o f the t e m -
perature sending u n i t is l o w and a h o t temperature
w i l l be indicated on the gauge.
I n t h e o i l pressure i n d i c a t i n g system t h e sending
u n i t resistance is actuated b y a d i a p h r a g m as the o i l
pressure increases or decreases. L o w o i l pressure
causes h i g h resistance. H i g h pressure causes low re-
sistance.
VOLTAGE f\
GAUGE U
OIL PRESSURE WARNING LAMP
The o i l pressure w a r n i n g switch, mounted on t h e
engine, is controlled b y engine o i l pressure.
J908E-49
W h e n engine o i l pressure is n o r m a l , t h e switch is
h e l d i n the O F F or O P E N position a l l o w i n g no cur-
r e n t to flow t o t h e o i l pressure w a r n i n g lamp on i n - Fig. 6 Alternator Indicating System
strument panel.
8E - 4 INSTRUMENT PANEL AND GAUGES •
SPEEDOMETER/ODOMETER SYSTEM DISTANCE SENSOR REMOVAL AND
INSTALLATION
The speedometer/odometer system consists o f a n (1) Remove harness connector f r o m sensor. Be sure
electric speedometer a n d p u s h b u t t o n reset odometer, weather seal stays on harness connector.
mounted i n t h e cluster, a w i r e harness f r o m the clus- (2) Remove sensor by loosening sensor coupling n u t
t e r to the distance sensor a t t h e transmission, and from the p i n i o n gear adapter u n t i l sensor isfree( F i g .
t h e adapter a n d p i n i o n i n t h e transmission. T h e 7).
speedometer/odometer has t h e same appearance as a (3) To i n s t a l l t h e sensor, reverse the removal pro-
conventional speedometer/odometer b u t i t eliminates cedures. T i g h t e n coupling n u t to 17 N»m (150 i n . lbs.)
t h e cable-driven mechanical system. A signal is sent
f r o m a transmission m o u n t e d distance sensortot h e
speedometer/odometer c i r c u i t r y t h r o u g h t h e w i r i n g
harness. B y e l i m i n a t i n g t h e speedometer cable, i n -
s t r u m e n t cluster service a n d r e m o v a l i s improved.
Refer t o Group 21 - Transmission for selecting t h e
proper p i n i o n , and selecting a n d i n d e x i n g t h e proper
adapter.

DISTANCE SENSOR

DISTANCE SENSOR TEST

For t e s t i n g o f the distance sensor a n d related com- RETAINER
ponents refer t o the Vehicle Diagnostics Test Proce-
dure M a n u a l .
DISTANCE SENSOR J9021-99

Fig. 7 Distance Sensor

C L U S T E R AND G A U G E
S E R V I C E AND T E S T I N G

INDEX
Page Page
Cluster Bezel ........ 8 Lamp Bulbs 14
Cluster Mask And Lens . . . . . . . . . . . . ... . . . . . . . 9 Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . 9
Fuel Tank Sending Unit Test 5 PRND21 Indicator . . . . . . . . . . . 13
Gauge And Gauge Circuit Testing . . . . . . . . . . . . 11 Sending Unit (Sensor) Test 4
Gauge Replacement 11 Specifications 14
Instrument Cluster Assembly . . . 9 Warning Lamp System Tests 6
Lamp Bulb Replacement — Message Center . . . . 14

CAUTION: Disconnect battery negative cable, in en-
gine compartment, before servicing instrument
panel. When power is required for test purposes,
connect battery cable (for test only).
Disconnect battery negative cable after test and
before continuing service procedures.
(1) Sending u n i t s and w i r i n g can be checked b y
grounding t h e connector leads, a t the sending u n i t ,
i n the vehicle.
CAUTION: When connecting an input terminal to
ground, Do Not leave the connection grounded for
more than a few seconds.

SENDING UNIT (SENSOR) TEST (2) W i t h t h e i g n i t i o n i n t h e O N position; a

grounded i n p u t w i l l cause the o i l , fuel or tempera-
W h e n a problem occurs w i t h a cluster gauge, be- t u r e gauge t o read a t or above m a x i m u m .
fore disassembling t h e cluster t o check t h e gauge,
check for a defective sending u n i t (sensor) or w i r i n g .
 INSTRUMENT PANEL AND GAUGES 8E - 5

FUEL TANK SENDING UNIT TEST RETURN FULL

TUBE POSITION
(1) Disconnect w i r e f r o m t e r m i n a l o n fuel t a n k
sending u n i t (Fig. 1).

FUEL PUMP SUPPLY

SENDING UNIT GROUND

FUEL PUMP GROUND

INPUT TO GAUGE FUEL LEVEL

J908E-64 SENDING UNIT

Fig. 1 Fuel Tank Sending Connector Terminals

(2) Connect w i r e to a k n o w n good sending u n i t .
(3) Connect a j u m p e r w i r e between sending u n i t
fuel pick u p tube and a good ground.
(4) Check fuel gauge as described i n following
EMPTY
steps. A l l o w a t least three m i n u t e s a t each test point POSITION
for gauge t o settle. L i g h t l y t a p p i n g i n s t r u m e n t clus- PICKUP
ter m a y help position pointer. RESERVOIR RR8EC69
(5) Clip float a r m o f sending u n i t t o i t s empty stop
Fig. 2 Fuel Tank Sending Unit Test
(Fig. 2) a n d t u r n i g n i t i o n k e y to O N position. The
gauge should read E m p t y , plus one pointer w i d t h , or RESULTS
m i n u s t w o pointer w i d t h s . (1) I f fuel gauge does not meet specifications, check
(6) Move a n d clip sending u n i t float a r m to f u l l following items as possible causes;
stop. The gauge should read F u l l , or above. (a) W i r i n g and connections between the gauge
sending u n i t and m u l t i p l e connector.

FUEL G A U G E SYSTEM DIAGNOSIS

FUEL G A U G E FUEL G A U G E
1
1
1
F U E L G>AUGE
DOES NOT
READ FULL
1I

1
INOPERATIVE
O R ERRATIC
FUEL G A U G E
INACCURATE
DOES NOT
READ EMPTY

CHECK FAULTY WIRING OR TANK DEFORMED TANK NOT EMPTY

TANK NOT FULL COMPONENTS CHECK CHECK

i
PROPER ALIGNMENT
CHECK ALL WIRING OF PICKUP AND
INCLUDING SENDER ASSEMBLY.
GROUND REFER TO GROUP 14

i
FAULTY PRINTED FAULTY FUEL GAUGE FAULTY FUEL
CIRCUIT BOARD SENDING UNIT GAUGE

J908E-74
8E - 6 INSTRUMENT PANEL AND GAUGES •
(b) W i r i n g a n d connections between m u l t i p l e I f t h e l a m p f a i l s t o l i g h t , inspect for a b r o k e n or
connector and p r i n t e d c i r c u i t board t e r m i n a l s . disconnected w i r e a t t h e o i l pressure combination
(c) C i r c u i t c o n t i n u i t y between p r i n t e d circuit u n i t , w h i c h i s located a t t h e rear o f t h e engine ( F i g .
board t e r m i n a l s and gauge t e r m i n a l s . 3) . I f the w i r e a t the connector checks good, p u l l con-
I f these items check okay, fuel gauge i s defec- nector loose from t h e s w i t c h a n d w i t h a j u m p e r w i r e
t i v e and m u s t be replaced. ground the l i g h t s w i t c h t e r m i n a l t o t h e engine ( F i g .
(2) I f the fuel gauge meets specifications check fuel 4) . W i t h t h e i g n i t i o n k e y t u r n e d t o t h e O N position
t a n k a n d o r i g i n a l i n s t a l l e d fuel t a n k sending u n i t as check t h e w a r n i n g l a m p . I f l a m p s t i l l fails t o l i g h t ,
follows: inspect for a burned out b u l b or disconnected socket
(a) Carefully remove fuel t a n k sending u n i t i n the cluster.
f r o m t a n k . Connect sending u n i t w i r e a n d j u m p e r I f l i g h t c o m e s o n , proceed a n d s t a r t engine. I f t h e
w i r e as described i n t h e procedure. l a m p remains on, i m m e d i a t e l y t u r n engine o f f a n d
(3) I f fuel gauge n o w checks w i t h i n specifications, check engine o i l pressure according t o procedures as
o r i g i n a l l y installed sending u n i t is electrically okay, o u t l i n e d i n Group 9 - E n g i n e o f t h i s m a n u a l . I f i t i s
check following as possible cause: determined t h a t o i l pressure is according t o specifica-
(a) Ground strap f r o m sending u n i t t o fuel l i n e tions, check for a grounded w i r e and/or replace t h e
for c o n t i n u i t y . o i l pressure sending u n i t (refer t o combination o i l
(b) Sending u n i t deformed. M a k e sure sending u n i t test).
u n i t float a r m moves freely, p i c k u p tube is n o t
bent upwards so t h a t there is n o t a n interference
f i t w i t h bottom of t a n k and inspect float.
(c) Sending u n i t i m p r o p e r l y installed. I n s t a l l
properly.
(d) M o u n t i n g flange o n fuel t a n k for sending
u n i t deformed. Feel for interference f i t o f sending
u n i t t o bottom of t a n k . I t is permissible t o bend
p i c k u p tube down a l i t t l e near m o u n t i n g flange to
g a i n interference f i t .
(e) F u e l t a n k b o t t o m deformed causing i m -
proper positioning o f sending u n i t pick up tube. Re-
place or repair t a n k a n d recheck sending u n i t .
Refer t o F u e l T a n k Section o f Group 14 - F u e l Sys-
tem.

WARNING LAMP SYSTEM TESTS

Fig. 3 Combination Oil Switch and Connection
LOW OIL PRESSURE WARNING LAMP
CIRCUIT TEST
The l o w o i l pressure w a r n i n g l a m p w i l l i l l u m i n a t e
w h e n t h e i g n i t i o n k e y i s t u r n e d to t h e O N position.
The l a m p also i l l u m i n a t e s i f the engine o i l pressure
drops below a safe o i l pressure level.
To test the system t u r n i g n i t i o n k e y t o t h e O N po-
sition.
 • INSTRUMENT PANEL AND GAUGES 8E - 7

ENGINE WARNING LAMP DIAGNOSIS The ohmmeter should read between 30 to 55 ohms,
OIL PRESSURE FUNCTION depending o n engine speed, o i l temperature, and o i l

[
viscosity.
TURN I f the above results are n o t obtained, replace t h e
IGNITION
SWITCH " O N " switch.
(DO NOT
TART ENGINE! SENDING UNIT
(GAUGE)

LAMP " O N " LAMP STAYS

LAMP " O F F "
"ON"

SWITCH
(LIGHT)
DEFECTIVE START AND IDLE TURN OFF
BULB ENGINE ENGINE
898E-2

Fig. 4 Combination Oil Unit Terminals

BULB SOCKET CHECK FOR SEAT BELT WARNING SYSTEM
LAMP GOES GROUNDED
OR WIRING For t e s t i n g o f t h i s system refer to Section 8 M -
OPEN "Off" WIRING
Seat B e l t W a r n i n g Systems.

BRAKE SYSTEM WARNING LAMP (FIG. 5)

The b r a k e w a r n i n g l a m p i l l u m i n a t e s w h e n t h e
CHECK FOR
DEFECTIVE WARNING p a r k i n g brake is applied w i t h t h e i g n i t i o n k e y
LOW OIL
SWITCH LIGHT OK
LEVEL t u r n e d O N . T h e same l a m p w i l l also i l l u m i n a t e
should one o f t h e t w o service brake systems f a i l
w h e n t h e brake pedal is applied. To test the system
t u r n t h e i g n i t i o n k e y O N , a n d apply t h e p a r k i n g
ENGINE OIL ENGINE OIL TEST ENGINE
PRESSURE PRESSURE brake. I f t h e lamp fails t o l i g h t , inspect for a burned
OIL PRESSURE
LOW OK out b u l b , disconnected socket, a broken or discon-
nected w i r e a t the switch. The l a m p also l i g h t s w h e n
the i g n i t i o n switch is t u r n e d t o the START position.

REFER TO DEFECTIVE
ENGINE SERVICE SWITCH TO BRAKE
DIAGNOSIS WARNING
PR1448C BRAKE
WARNING LAMP
COMBINATION OIL UNIT TEST (FIG. 4} LAMP
SWITCH
The combination o i l u n i t has 2 functions:
(1) The n o r m a l closed circuit keeps t h e o i l pressure
w a r n i n g l a m p on u n t i l there is o i l pressure.
(2) The sending provides a resistance t h a t varies
w i t h oil pressure.
To test t h e n o r m a l l y closed o i l l a m p switch, discon-
nect the l o c k i n g connector a n d measure t h e resis-
tance between t h e switch t e r m i n a l a n d t h e m e t a l
housing. T h e ohmmeter should read 0 ohms. S t a r t
PR1451
the engine.
I f there i s o i l pressure, t h e ohmmeter should read
a n open circuit.
Fig. 5 Brake Warning Lamp Switch
To test t h e sending u n i t , measure t h e resistance To test the service brake w a r n i n g system, raise the
between t h e sending u n i t t e r m i n a l a n d t h e m e t a l vehicle o n a hoist and open a wheel cylinder bleeder
housing. T h e ohmmeter should read open. S t a r t t h e w h i l e a ^helper depresses t h e brake pedal a n d ob-
engine. serves the w a r n i n g l a m p . I f the lamp fails t o l i g h t ,
inspect for a burned out b u l b , disconnected socket, a
8E - 8 INSTRUMENT PANEL AND GAUGES •
broken or disconnected w i r e a t t h e switch. I f the bulb Tee f i t t i n g mounted o n the frame r a i l i n the engine
is not burned out and the w i r e c o n t i n u i t y is proven, compartment below the master cylinder.
replace the brake w a r n i n g s w i t c h i n the brake line
CAUTION: If wheel cylinder bleeder w a s opened
check master cylinder fluid level.
Diesel The Brake light is also connected to a sensor
I TURN IGNITION KEY "ON' 1
that monitors vacuum in the brake booster system. The
(DO NOT START ENGINE
Brake light when lit indicates LOW VACUUM. Refer to
I RELEASE PARKING BRAKE) I
the Diesel supplement for more information.

X
I WARNING LIGHT GOES APPLY PARKING BRAKE CLUSTER BEZEL
"ON" (WARNING LIGHT
SHOULD G O "ON")
1 (LIGHT SHOULD BE "OFF")|
REMOVAL
BRAKE SYSTEM WARNING LIGHT (1) Disconnect battery negative cable.
LEAKING FLUID FAILS TO G O " O N " (2) Tape or cover steering column to prevent dam-
age to p a i n t .
(3) Remove 2 screws and remove map lamp.
GROUNDED WIRING BULB BURNED OUT (4) Remove 6 screws w h i c h attach cluster bezel to
base panel (Fig. 6). M a k e sure t h e screw below the
HeaterVC control is removed.
SHORTED PARKING BRAKE DISCONNECTED OR FAULTY (5) Place column shift lever i n Position " 1 " .
OR BRAKE WARNING SWITCH BULB SOCKET (6) Remove bezel b y p u l l i n g top edge r e a r w a r d to
clear brow. Disengage a t t a c h i n g clips around bottom
X
FAULTY BRAKE SYSTEM X
BROKEN WIRE OR WIRE
of bezel a n d complete removal o f bezel.
PROPORTIONING DISCONNECTED AT PARKING (7) I f bezel is equipped w i t h a four wheel drive i n -
VALVE UNIT* BRAKE SWITCH dicator, remove bulb socket as bezel is removed.
(8) Disconnect message center wires.
FAULTY PARKING INSTRUMENT
BRAKE SWITCH PANEL

X
APPLY SERVICE BRAKES
(WARNING LIGHT
SHOULD NOT G O "ON")

TEST SERVICE BRAKE WARNING LIGHT GOES

WARNING "ON"
SYSTEM FUNCTION*
X INSTRUMENT
WARNING LIGHT BRAKE SYSTEM CLUSTER
DOES NOT GO "ON" LEAKING FLUID ASSEMBLY
INSTRUAAENT
J908E-75
CLUSTER BEZEL
GROUNDED WIRING OR
OPEN CIRCUIT IN WIRING SHORTED BRAKE WARNING
Fig. 6 Instrument Cluster Bezel
TO SERVICE BRAKE SWITCH SWITCH INSTALLATION
(1) Connect bulb socket for four wheel drive indica-
FAULTY BRAKE SYSTEM tor i f equipped.
LOOSE BULKHEAD PROPORTIONING
CONNECTOR VALVE UNIT* (2) Connect message center wires.
(3) Engage attaching clips around bottom of bezel,
*TESTS ARE DESCRIBED r o l l bezel i n t o position.
FAULTY SERVICE BRAKE IN APPROPRIATE (4) I n s t a l l 6 m o u n t i n g screws.
SWITCH SECTION OF SERVICE (5) I n s t a l l map lamp.
MANUAL
(6) Remove tape from steering column.
X
FAULTY SERVICE BRAKE
SYSTEM PROPORTIONING
(7) Connect battery cable.
VALVE UNIT* PR1449A
 INSTRUMENT PANEL AND GAUGES 8E - 9

CLUSTER MASK AND LENS (7) Loosen heater and A/C control. P u l l r e a r w a r d t o
clear forward m o u n t on cluster housing.
(8) Remove 6 screws t h a t r e t a i n cluster. P u l l clus-
REMOVAL
ter r e a r w a r d and disconnect 2 large connectors.
(1) Disconnect battery negative cable.
(9) Remove cluster.
(2) Remove bezel.
(3) Remove 8 screws. INSTALLATION
(4) Remove mask and lens. (1) Connect 2 large connectors to cluster.
(2) Position cluster to i n s t r u m e n t panel a n d i n s t a l l
INSTALLATION
6 r e t a i n i n g screws.
(1) Position mask and lens.
(3) I n s t a l l heater A/C control.
(2) I n s t a l l 8 screws.
(4) Connect P R N D 2 1 actuator to steering c o l u m n i f
(3) I n s t a l l bezel.
equipped.
(4) Connect battery cable.
(5) Position upper steering column cover a n d slide
u p w a r d u n t i l tangs snap i n t o place.
INSTRUMENT CLUSTER ASSEMBLY (Fig. 7)
(6) Position lower steering cover a n d i n s t a l l 4
screws.
REMOVAL (7) I n s t a l l bezel.
(1) Disconnect b a t t e r y negative cable. (8) Remove protective cover from steering c o l u m n .
(2) Tape or cover steering column t o prevent d a m - (9) Connect b a t t e r y cable.
age t o p a i n t . (10) Check to see t h a t a l l instruments are function-
(3) Remove bezel. i n g properly.
(4) Remove lower steering column cover 4 screws.
(5) Spread upper steering column cover o u t o f t h e PRINTED CIRCUIT BOARD
l o c k i n g tangs and slide downward.
(6) Disconnect P R N D 2 1 actuator cable f r o m steer- A visual inspection of t h e conductors should be
i n g column i f equipped. made for cracks or damaged circuits. I f no v i s u a l
damage is evident, each circuit should be tested for

INSTRUMENT MAP LAMP

PANEL BRACKET

HEADLAMP
SWITCH

BRACKET-MAP LAMP MOUNTING CLUSTER

(W/O CLOCK) ASSEMBLY RR8EC80

Fig. 7 Instrument Panel Cluster and Switches

8E - 10 INSTRUMENT PANEL AND GAUGES •
c o n t i n u i t y w i t h a n ohmmeter or a test l i g h t . Should INSTALLATION
an open c i r c u i t be detected, the p r i n t e d c i r c u i t board
should be replaced. CAUTION; Do not overtighten mounting screws or
damage to circuit board and/or cluster housing will
REMOVAL (FIG. 8) occur.
(1) Remove i n s t r u m e n t cluster. See cluster r e -
moval. (1) Position p r i n t e d c i r c u i t board o n cluster hous-
(2) Remove l a m p socket assemblies. i n g , i n s t a l l m o u n t i n g screws and t i g h t e n .
(3) Remove gauge m o u n t i n g screws a n d remove (2) I n s t a l l gauges.
gauges. (3) I n s t a l l l a m p socket assemblies. Be sure i l l u m i -
(4) Remove p r i n t e d c i r c u i t board m o u n t i n g screws. n a t i o n lamp diffusers are installed.
(5) Remove p r i n t e d c i r c u i t board from cluster hous- (4) I n s t a l l i n s t r u m e n t cluster.
ing.
MOUNTING SCREWS (7)

PRINTED CIRCUIT
BOARD J908E-68

Fig. 8 Printed Circuit Board

 • INSTRUMENT PANEL AND GAUGES 8E - 11

GAUGE REPLACEMENT GAUGE AND GAUGE CIRCUIT TESTING

I t i s not n e c e s s a r y to r e m o v e instrument clus-
ter from v e h i c l e for gauge replacement. TEMPERATURE GAUGE CIRCUIT TEST
W h e n r e m o v i n g gauge assemblies (Fig. 9) from (1) Remove t e m p e r a t u r e gauge. Refer to Gauge Re-
cluster, gauge m u s t be p u l l e d straight out, not placement.
twisted, or damage t o gauge p i n and/or p r i n t e d cir- (2) Check c o n t i n u i t y i n the w i r e between t h e t e m -
cuit board m a y result. perature sensor a n d t h e temperature gauge (sensor

VOLTAGE SPEEDOMETER OIL PRESSURE

GAUGE GAUGE

TEMPERATURE
GAUGE FUEL GAUGE J908E-69

Fig. 9 Cluster With Mask Removed

FUEL GAUGE i n p u t p i n ) (Figs. 10 and 11).
Temperature Gauge (3) W i t h t h e i g n i t i o n switch i n the O N position,
Voltage Gauge check for battery voltage across the B + p i n a n d t h e
O i l Pressure Gauge Ground p i n .
(1) Disconnect b a t t e r y negative cable.
'S^J^K ^THERMOSTAT
(2) Remove bezel. Refer to Cluster Bezel Removal.
(3) Remove cluster mask a n d lens. Refer to Cluster
Mask a n d Lens Removal.
(4) Remove gauge m o u n t i n g screws.
(5) P u l l gauge r e a r w a r d to remove.
For I n s t a l l a t i o n , reverse Removal procedures.

SPEEDOMETER/ODOMETER
(1) Disconnect b a t t e r y negative cable.
(2) Remove bezel. Refer to Cluster Bezel Removal.
(3) Remove cluster mask a n d lens. Refer to Cluster COOLANT TEMPERATURE
Mask and Lens Removal. SENSOR 2-WAY ELECTRICAL
(4) Remove m o u n t i n g screws r e t a i n i n g speedome- CONNECTOR
ter/odometer t o housing. Fig. 10 Coolant Temperature Sensor
(5) P u l l speedometer/odometer r e a r w a r d to remove.
For I n s t a l l a t i o n , reverse Removal procedures.
 8E - 12 INSTRUMENT PANEL AND GAUGES •

DISTRIBUTOR
HOLDDOWN
OIL PRESSURE SENDING UNIT
ELECTRICAL CONNECTION
RR14G147
Fig. 11 Temperature Gauge Pins

TEMPERATURE/OIL/FUEL GAUGE DIAGNOSIS Fig. 12 Combination Oil Switch and Connection

SENDING UNIT
GAUGE INDICATES HIGHER (GAUGE)
O R LOWER THAN ACTUAL

FAULTY WIRING
•TEST
PROCEDURES
FAULTY SENDING UNIT* DESCRIBED
SWITCH
ARE (LIGHT)
IN
APPROPRIATE
FAULTY INSTRUMENT PANEL SECTION 898E-2
GAUGE* OF
SERVICE Fig. 13 Combination Oil Unit Terminals
MANUAL
ERRATIC GAUGE OPERATION GROUND OIL PRESSURE
SENSOR INPUT

LOOSE OR DIRTY ELECTRICAL CONNECTIONS

FAULTY INSTRUMENT PANEL

GAUGE* J908E-52

OIL PRESSURE GAUGE CIRCUIT TEST

(1) Remove o i l pressure gauge. Refer to Gauge Re-
placement.
(2) Check for c o n t i n u i t y i n t h e w i r e between t h e o i l
pressure sensor and t h e o i l pressure gauge (sensor
i n p u t p i n ) (Figs. 12, 13 a n d 14).
(3) W i t h t h e i g n i t i o n s w i t c h i n t h e O N position,
J908E-70
check for b a t t e r y voltage across t h e B + p i n a n d t h e
Ground p i n . Fig. 14 Oil Pressure Gauge Pins
 • INSTRUMENT PANEL AND GAUGES 8E - 13

FUEL GAUGE CIRCUIT TEST

(1) Remove fuel gauge assembly. Refer to Gauge
Replacement.
(2) Check for c o n t i n u i t y i n t h e w i r e between t h e
fuel t a n k sending u n i t a n d t h e gauge (fuel level i n -
put pin) (Figs. 15 a n d 16).
(3) W i t h t h e i g n i t i o n switch i n t h e O N position,
check for b a t t e r y voltage across t h e B + p i n and t h e
Ground p i n .

FUEL PUMP SUPPLY

SENDING UNIT GROUND

FUEL PUMP GROUND U908E-62_

INPUT TO GAUGE Fig. 17 Voltmeter Pins

J908E-64
(5) I f a l l o f above tests prove good, replace speed-
Fig. 15 Fuel Tank Sending Connector Terminals ometer.

J908E-73
^ GROUND

Fig. 16 Fuel Gauge Pins Fig. 18 Speedometer Pins

VOLTAGE GAUGE CIRCUIT TEST PRND21 INDICATOR
(1) Remove voltage gauge. Refer to Gauge Replace-
ment.
REMOVAL
(2) W i t h t h e i g n i t i o n switch i n t h e O N position,
(1) Remove bezel. Refer to Cluster Bezel Removal.
check for battery voltage across t h e B + p i n and t h e
(2) Remove cluster mask and lens. Refer to Cluster
Ground p i n (Fig. 17).
M a s k a n d Lens Removal.
T h e i n s t r u m e n t p a n e l voltmeter i n d i c a t e s elec-
(3) Remove cluster assembly. Refer to I n s t r u m e n t
trical s y s t e m b a t t e r y voltage.
Cluster Removal.
(4) Remove screws attaching P R N D 2 1 mechanism
SPEEDOMETER
to cluster housing.
(1) Remove speedometer assembly. Refer to Gauge
Replacement. (5) Remove P R N D 2 1 mechanism.
(2) Check for c o n t i n u i t y i n t h e w i r e between t h e
INSTALLATION
distance sensor connector and t h e speedometer (dis-
(1) Position P R N D 2 1 mechanism to cluster hous-
tance sensor i n p u t p i n ) (Fig. 18).
ing.
(3) W i t h t h e i g n i t i o n switch i n t h e O N position,
check for battery voltage across t h e B + p i n and the (2) Install m o u n t i n g screws.
Ground p i n . (3) Install cluster assembly.
(4) Perform distance sensor test. Refer to General (4) Install mask-lens.
Information - Distance Sensor i n t h i s section. (5) Install bezel.
8E - 14 INSTRUMENT PANEL AND GAUGES •
LAMP BULBS INSTALLATION
(1) I n s t a l l b u l b i n t o socket assembly.
(2) I n s t a l l l a m p socket assembly into p r i n t e d cir-
CLUSTER LLUMINATION LAMPS
cuit board.
T u r n S i g n a l I n d i c a t o r Lamps
(3) I n s t a l l I n s t r u m e n t Cluster bezel assembly t o i n -
Low O i l Pressure I n d i c a t o r L a m p s t r u m e n t panel. Refer t o I n s t r u m e n t Cluster i n s t a l l a -
H i g h Beam Indicator Lamp tion.
Gate Open L a m p (4) Connect b a t t e r y negative cable.
Seat B e l t W a r n i n g L a m p
FOUR WHEEL DRIVE INDICATOR LAMP
REMOVAL (1) P u l l b u l b a n d socket assembly f r o m r e a r o f
(1) Disconnect b a t t e r y negative cable. housing.
(2) Remove i n s t r u m e n t cluster. See cluster re- (2) Remove b u l b f r o m socket.
moval. (3) Reverse removal procedures to i n s t a l l .
(3) T w i s t l a m p socket assembly and remove from
p r i n t e d c i r c u i t board. SPECIFICATIONS
(4) Remove b u l b f r o m socket.
Fuel Gouge Calibration

INSTALLATION Pointer Position Resistance

(1) I n s t a l l b u l b i n t o socket. Empty Graduation 90 ohms ± 3 ohms

(2) I n s t a l l socket assembly i n t o p r i n t e d circuit Empty Stop Greater than 96.5 ohms
board. Full Graduation 12 ohm ± 3 ohms
(3) Position cluster i n t o place i n panel. See cluster Full Stop Less than 8 ohms
installation. 1/2 45.3 ohms ± 3 ohms
(4) Connect b a t t e r y negative cable.
Temperature Gauge Calibration
LAMP BULB REPLACEMENT-MESSAGE CENTER Pointer Position Resistance
Cold Graduation 655 ohms
REMOVAL Hot Graduation 64 ohms
(1) Disconnect b a t t e r y negative cable.
(2) Remove i n s t r u m e n t cluster bezel assembly. Re- Oil Pressure Gauge Calibration
fer t o I n s t r u m e n t Cluster removal. Pointer Position Resistance
(3) T w i s t l a m p socket assembly and remove from Low Graduation 100 ohms
p r i n t e d c i r c u i t board. High Graduation 12 ohms
(4) Remove b u l b f r o m socket. J908E-58
• INSTRUMENT PANEL AND GAUGES 8E - 15

SWITCH A N D PANEL COMPONENT SERVICE

INDEX
Page Page

Ash Tray 20 Heater Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Cigar Lighter 20 Hood Release 19
Four Wheel Drive Indicator 19 Illumination Bulb Replacement . 21
Fuseblock And Flashers 19 Message Center Module 19
Glove Box 20 Steering Column Lowering And Raising 15
Heater A/C Control 16 Switches 16

DISCONNECT B A T T E R Y NEGATIVE CABLE T h i s p r o c e d u r e i s not for r e m o v i n g a n d r e p l a c -

IN ENGINE COMPARTMENT B E F O R E SER-
VICING INSTRUMENT PANEL.
STEERING COLUMN LOWERING AND RAISING
When servicing t h e i n s t r u m e n t panel a n d the Low-
e r i n g and Raising o f t h e steering column i s required,
t h e following is t h e procedure for doing so:
i n g the s t e e r i n g c o l u m n . R e f e r to G r o u p - 19
Steering o f t h i s m a n u a l for the r e m o v a l a n d r e -
placement p r o c e d u r e s .
LOWERING STEERING COLUMN
(1) Disconnect battery negative cable.
(2) Remove three toe plate n u t s and washers (Fig.
1).

Fig. 1 Steering Column Mounting

8E - 16 INSTRUMENT PANEL AND GAUGES

(3) Remove one toe plate screw. INSTALLATION

(4) Remove four screws attaching lower steering (1) Position control near panel.
column cover and remove cover. The fuse block is at- (2) Connect control cables t o control (see Heater A/
tached to t h i s cover a n d should be supported when C Section).
cover is removed. (3) Connect i l l u m i n a t i o n l a m p , a n d w i r e connec-
(5) Spread upper steering column cover o u t o f lock- tors.
ing tangs and slide (4) Push control i n t o panel.
downward. (5) I n s t a l l t w o control m o u n t i n g screws.
(6) Disconnect cable f r o m shift indicator bracket. (6) I n s t a l l bezel.
(7) Remove t w o nuts and washers a t t a c h i n g steer- (7) I n s t a l l m a p lamp.
i n g column bracket t o i n s t r u m e n t panel steering col-
u m n support bracket. HEATER A/C CONTROL
(8) A l l o w column to lower and rest on seat.

RAISING STEERING COLUMN REMOVAL

(1) Remove map lamp.
(1) Raise steering column assembly against the i n -
(2) Remove cluster bezel (refer t o Cluster Bezel Re-
strument panel support b r a c k e t
moval).
(2) I n s t a l l t w o steering column bracket washers
(3) Remove t w o control a t t a c h i n g screws.
and nuts (Finger T i g h t e n Only).
(4) P u l l control rearward.
CAUTION: Check that all wiring is clear and not (5) Disconnect blower s w i t c h w i r i n g .
pinched. (6) Disconnect wires t o p u s h b u t t o n switch (three
connectors).
(3) T i g h t e n the two bracket nuts to 12 N*m (110 i n . (7) Disconnect i l l u m i n a t i o n l a m p .
lbs.) torque. (8) Disconnect vacuum harness.
(4) Slide toe plate i n t o position, i n s t a l l a t t a c h i n g (9) Disconnect temperature cable.
screw, t i g h t e n t o 4 N»m (35 i n . lbs.). (10) Remove control.
(5) I n s t a l l toe plate nuts and washers a n d t i g h t e n
to 23 N«m (200 i n . lbs.). INSTALLATION
(6) Connect cable to shift indicator bracket. (1) Position control near panel.
(7) Position upper steering column cover and slide (2) Connect temperature cable (see Group 24 -
upward u n t i l tangs snap i n t o place. H e a t i n g a n d A i r Conditioning).
(8) I n s t a l l fuse block t o cover. (3) Connect v a c u u m harness.
(9) Position lower steering column cover a n d i n s t a l l (4) Connect i l l u m i n a t i o n l a m p .
four a t t a c h i n g screws. (5) A t t a c h three w i r e connectors to pushbutton
switch.
HEATER CONTROL (6) Connect wires to blower motor switch.
(7) Push control i n t o panel.
(8) I n s t a l l t w o control m o u n t i n g screws.
REMOVAL (9) I n s t a l l cluster bezel.
(1) Remove map lamp. (10) I n s t a l l map lamp.
(2) Remove cluster bezel (refer to Cluster Bezel Re-
moval). SWITCHES
(3) Remove two control attaching screws.
(4) P u l l control rearward.
(5) Disconnect i l l u m i n a t i o n lamp, and w i r e connec- HEADLAMP SWITCH (FIG. 2)
tions.
(6) Disconnect control cables.
Removal
(7) Remove control. (1) Remove cluster bezel (refer t o Cluster Bezel Re-
moval).
(2) Reaching under i n s t r u m e n t panel, depress knob
and stem release b u t t o n located on bottom of switch
housing and a t same t i m e p u l l knob and stem assem-
bly out of s w i t c h housing located on front of panel.
(3) Remove power m i r r o r s w i t c h knob by p u l l i n g
straight off.
(4) Remove bezel.
 • INSTRUMENT PANEL AND GAUGES 8E - 17

(5) F r o m front of panel remove spanner n u t , (4) P u l l r e a r w a r d , disconnect w i r e f r o m headlamp

m o u n t i n g switch to panel. switch.
(6) Reaching under i n s t r u m e n t panel, lower s w i t c h (5) Remove a u x i l i a r y headlamp switch b y snapping
down far enough to disconnect electrical leads. out o f bezel.
(7) Remove switch.

INSTRUMENT MAP LAMP

PANEL BRACKET

HEADLAMP
SWITCH
CLUSTER
ASSEMBLY
CARGO LAMP SWITCH
HEADLAMP COVER
SWITCH MOUNTING
NUT

HEADLAMP
KNOB AND STEM

BRACKET-MAP LAMP MOUNTING CLUSTER

(W/O CLOCK) ASSEMBLY RR8EC80

Fig. 2 Instrument Panel Switches

Installation Installation
(1) Connect a l l electrical leads t o switch. (1) Snap a u x i l i a r y headlamp switch i n t o bezel.
(2) Guide switch i n t o position i n panel, i n s t a l l (2) Connect wires to switch.
spanner n u t and t i g h t e n securely. (3) Position bezel t o housing a n d i n s t a l l four
(3) I n s t a l l bezel. m o u n t i n g screws.
(4) I n s t a l l power m i r r o r switch knob. (4) Check operation o f switch.
(5) Insert knob and stem assembly i n t o s w i t c h . (5) Position housing onto t w o left side screws, i n -
(6) I n s t a l l cluster bezel. stall two r i g h t side screws and secure housing to i n -
strument panel.
(7) Check operation o f switch.
SNOW PLOW TOGGLE SWITCH (FIG. 3)
POWER MIRROR SWITCH
Refer to Group 8T - Power M i r r o r s
Removal
AUXILIARY HEADLAMP SWITCH (FIG. 3) (1) Remove t w o screws on r i g h t side o f snow plow
(USED WITH SHOW PLOW OPTION) control housing.
(2) Loosen t w o screws on left side of housing and
Removal slide housing t o the r i g h t and p u l l away from i n s t r u -
(1) Remove two screws o n r i g h t side o f snow plow ment panel.
control housing. (3) Remove four screws holding bezel t o housing.
(2) Loosen t w o screws o n left side o f housing a n d
slide housing to the r i g h t and p u l l away f r o m i n s t r u -
m e n t panel.
(3) Remove four screws h o l d i n g bezel t o housing.
8E - 18 INSTRUMENT PANEL AND GAUGES •

Fig. 3 Snow Plow Control Assembly

(4) P u l l rearward, disconnect w i r e f r o m toggle (3) Continue t o push u n t i l switch snaps i n t o place.
switch.
(4) I n s t a l l chime module on t o bracket.
(5) Remove toggle s w i t c h b y unscrewing n u t f r o m
front of bezel.
MAP LAMP SWITCH
Installation Removal
(1) Position toggle s w i t c h to bezel and i n s t a l l n u t .
(1) Remove 2 a t t a c h i n g screws.
(2) Connect wires t o toggle s w i t c h .
(2) Drop assembly down and remove w i r i n g connec-
(3) Position bezel t o housing a n d i n s t a l l four
tor, t h e n remove map l a m p assembly.
m o u n t i n g screws.
Installation
(4) Check operation o f switch.
(5) Position housing onto t w o left side screws, i n - (1) Connect w i r i n g connector t o l a m p assembly.
s t a l l two r i g h t side screws and secure h o u s i n g t o i n - (2) Position m a p l a m p assembly t o panel a n d i n -
strument panel. stall 2 m o u n t i n g screws.

CARGO LAMP SWITCH GLOVE BOX LAMP SWITCH

Removal Removal
(1) Locate chime module. Grasp chime module a n d (1) Open glovebox u n t i l stops i n b i n rest against i n -
t w i s t i t to remove i t f r o m the bracket. strument panel, depress stops t o clear i n s t r u m e n t
(2) Remove w i r i n g connector from cargo l a m p panel a n d continue p i v o t i n g glovebox assembly
switch. downward.
(3) Depress lock tabs on switch and push i t out o f (2) Disconnect w i r e to switch.
the i n s t r u m e n t panel. (3) Snap switch out of panel.

Installation Installation
(1) Hold w i r i n g connector i n s w i t c h opening. (1) Snap switch i n t o panel.
(2) Push switch on t o w i r i n g connector. (2) Connect w i r e to switch.
 • INSTRUMENT PANEL AND GAUGES 8E - 19

(3) Depress stops and close glove box door. (2) Position module on bezel and i n s t a l l screws and
clip.
OVERDRIVE LOCKOUT SWITCH (FIG. 4J (3) Connect lockout switch a n d message center con-
nectors.
Removal (4) I n s t a l l i n s t r u m e n t cluster bezel t o panel.
(1) Remove map lamp. (5) I n s t a l l map lamp.
(2) Remove cluster bezel (refer to Cluster Bezel Re-
moval). FUSEBLOCK AND FLASHERS
(3) Reach behind bezel a n d disconnect lockout
s w i t c h connector. FUSEBLOCK
(4) Depress r e t a i n i n g tabs o n t o p a n d bottom o f The fuseblock is located d i r e c t l y below the steering
s w i t c h and p u l l switch out o f module. column, on t h e lower steering column cover.

Removal
(1) Push fuseblock l o c k i n g t a b o n column cover
d o w n w a r d and lower fuseblock. T h e following compo-
nents p l u g into t h e fuseblock.
(1) Fuses.
(2) 30 amp circuit breakers.
(3) T u r n signal flasher.
(4) H o r n relay.
(5) Hazard W a r n i n g Flasher.

Installation
(1) Position fuseblock t o steering column cover.
(2) Push locking tab t o lock fuseblock i n position.

HOOD RELEASE

REMOVAL
(1) Disengage cable from hood l a t c h i n engine com-
partment.
(2) Remove four screws holding handle assembly to
i n s t r u m e n t panel.
Fig. 4 Overdrive Lockout Switch and Message (3) Remove assembly b y p u l l i n g cable r e a r w a r d
Center Module
t h r o u g h dash panel grommet.
Installation
(1) Position lockout switch i n t o module a n d p u s h INSTALLATION
until r e t a i n i n g tabs lock into place. (1) Feed cable assembly forward t h r o u g h dash
panel grommet.
(2) Connect s w i t c h connector.
(2) M o u n t handle assembly to i n s t r u m e n t panel
(3) I n s t a l l i n s t r u m e n t cluster bezel t o panel.
w i t h four screws.
(3) Connect cable to hood latch.
MESSAGE CENTER MODULE (Fig. 4)
FOUR WHEEL DRIVE INDICATOR
REMOVAL
(1) Remove map lamp.
REMOVAL
(2) Remove cluster bezel (refer t o Cluster Bezel Re-
(1) Remove map lamp.
moval). (2) Remove cluster bezel (refer to Cluster Bezel Re-
(3) Reach b e h i n d bezel a n d disconnect lockout moval).
s w i t c h and message center connectors. (3) Remove t w o screws and remove indicator from
(4) Remove three module r e t a i n i n g screws and one bezel.
clip and p u l l module from bezel.
(5) Remove overdrive lockout switch from module. INSTALLATION
(1) Position indicator to bezel and attach w i t h t w o
INSTALLATION screws.
(1) I n s t a l l overdrive lockout switch i n t o module. (2) I n s t a l l cluster bezel.
8E - 20 INSTRUMENT PANEL AND GAUGES •
(3) I n s t a l l map lamp. Installation
(1) I n s t a l l ash t r a y b i n .
CIGAR LIGHTER (Fig. 5)
(2) Push ash t r a y inwards t o closed position.

REMOVAL HOUSING
(1) Open ash receiver.
(2) Remove lighter element f r o m shell. . Removal
(3) Disconnect w i r i n g . (1) Remove ash t r a y b i n .
(4) T u r n clamp counterclockwise and remove. (2) Disconnect electrical leads f r o m cigar l i g h t e r .
(5) Remove shell t h r o u g h front o f housing. (3) Remove six screws r e t a i n i n g housing t o panel.
INSTRUMENT
PANEL
BRACE

U-NUT

VIEW IN DIRECTION
OF ARROW A

LIGHTER
ELEMENT

KNOB

ASH TRAY
ASSEMBLY

RB491

Fig. 5 Cigar Lighter and Ash Tray

INSTALLATION (4) Remove cigar l i g h t e r from housing.
(1) Insert shell t h r o u g h front o f housing.
(2) I n s t a l l clamp o n shell, t u r n clockwise and Installation
t i g h t e n securely. (1) I n s t a l l cigar l i g h t e r i n housing.
(3) Connect w i r i n g t o shell. (2) Connect electrical leads to cigar l i g h t e r .
(4) I n s t a l l l i g h t e r element. (3) Position housing to panel and i n s t a l l six mount-
(5) I n s t a l l wires and close ash receiver. i n g screws.
(4) I n s t a l l ash tray b i n .
ASH TRAY (Fig. 5)
GLOVE BOX (Fig. 6)
TRAY
DOOR AND BIN ASSEMBL Y
Removal
(1) Open ash tray. Removal
(2) Remove ash t r a y b i n . (1) Remove four screws t h a t r e t a i n glovebox to
lower reinforcement.
 • INSTRUMENT PANEL AND GAUGES 8E - 21

(2) T h e b i n is removed b y unsnapping b i n from (4) Push lock cylinder into latch assembly, a n d re-
door assembly. move key.

Fig. 6 Glove Box and Bin

Installation CATCH
(1) Snap b i n onto door.
(2) M o u n t assembly to lower reinforcement with Removal
four m o u n t i n g screws. (1) Open glove box door.
(2) Remove catch m o u n t i n g screws.
GLOVE BOX LOCK (3) Remove catch.

Removal Installation
(1) Open glove box door. (1) Position catch and spring n u t into place, i n s t a l l
(2) T u r n lock i n t o locked position and remove key. m o u n t i n g screws and t i g h t e n securely.
(3) Insert a s t i f f w i r e i n rear slot o f lock mecha- (2) Close glove box door.
n i s m and depress r e t a i n i n g t u m b l e r into cylinder.
(4) W h i l e h o l d i n g t u m b l e r down w i t h w i r e i n lock ILLUMINATION BULB REPLACEMENT
cylinder, i n s e r t key.
(5) Remove w i r e a n d p u l l out lock cylinder.
SNOW PLOW CONTROLS ILLUMINATION
(6) Remove l a t c h m o u n t i n g screws and remove as-
LAMP
sembly.
Removal
Installation
(1) Remove t w o screws on r i g h t side of snow plow
(1) Position l a t c h assembly i n t o place on glove box
control housing.
door, i n s t a l l m o u n t i n g screws and t i g h t e n securely.
(2) Loosen t w o screws on left side of housing a n d
(2) Depress r e t a i n i n g t u m b l e r into lock cylinder
slide housing to the r i g h t and p u l l away from i n s t r u -
and insert key.
m e n t panel.
(3) Position assembly so t h a t i t w i l l be i n the closed
(3) Remove four screws holding bezel to housing.
position w h e n installed.
8E - 22 INSTRUMENT PANEL AND GAUGES •
(4) P u l l r e a r w a r d a n d remove lamp bulb and FOUR WHEEL DRIVE INDICATOR
socket.
Removal
Installation (1) Remove map l a m p .
(IX I n s t a l l l a m p bulb and socket. (2) Remove cluster bezel (refer t o Cluster Bezel Re-
moval).
(2) Position bezel t o housing a n d i n s t a l l four
(3) Remove b u l b and socket.
screws.
(3) Position housing onto t w o left side screws, i n - Installation
s t a l l t w o r i g h t side screws and secure housing t o i n - (1) Snap i n b u l b a n d socket.
s t r u m e n t panel. (2) Replace cluster bezel.
(3) I n s t a l l m a p l a m p .
ASH TRAY ILLUMINATION LAMP
HEATER OR HEATER A/C ILLUMINATION
Removal LAMP
(1) Open ash receiver and remove b i n .
(2) Disconnect wires from cigar lighter. Removal
(3) Remove six screws t h a t r e t a i n assembly to (1) Remove map lamp.
panel. (2) Remove cluster bezel (refer t o Cluster Bezel Re-
(4) W h i l e dropping ash receiver, remove l a m p as- moval;.
sembly f r o m t o p of the housing. (3) Remove t w o control a t t a c h i n g screws.
(4) P u l l control r e a r w a r d .
Installation (5) Snap out i l l u m i n a t i o n l a m p .
(1) I n s t a l l l a m p assembly into top o f housing.
(2) Position housing a n d i n s t a l l s i x m o u n t i n g Installation
screws. (1) I n s t a l l b u l b i n t o socket.
(3) Connect wires t o cigar l i g h t e r . (2) Snap socket i n t o control.
(4) I n s t a l l b i n and close ash receiver. (3) Push control forward and i n s t a l l t w o a t t a c h i n g
screws.
MAP LAMP BULB (4) I n s t a l l cluster bezel.
To replace b u l b , snap lens out, replace bulb. (5) I n s t a l l map l a m p .
 RADIO, ANTENNA AND SPEAKERS 8F - 1

RADIO, ANTENNA AND SPEAKERS

CONTENTS
Page Page

SERVICE PROCEDURES 6 TEST PROCEDURES 4

INDEX
Page Page
General Information 1 Radio Reception Mode 1
Interference Elimination 1 Radio Schematics 1

GENERAL INFORMATION RADIO RECEPTION MODE

For operation o f the factory i n s t a l l e d standard and I n some instances a radio m a y be changed from
optional radios available, refer t o t h e Owner M a n u a l N o r t h A m e r i c a n t o European reception mode. W h e n
supplied w i t h t h e vehicle. t h e radio i s i n t h i s mode, poor frequency reception
w i l l r e s u l t i n b o t h A M and F M modes. To verify t h i s
RADIO SCHEMATICS condition, t u r n t h e radio on and observe t h e display
Radio repair service a n d schematic w i r i n g dia- w i n d o w a t i t s highest and lowest frequencies. I f t h e
grams are available t h r o u g h Technical Service, readout compares to the following chart, t h e radio i s
Chrysler H u n t s v i l l e D i v i s i o n , 102 W y n n D r . , H u n t s - i n t h e European mode.
v i l l e , A L 35805.
Band Lowest Highest
Type Frequency Frequency
INTERFERENCE ELIMINATION AM 531 KHZ 1602 KHZ
A number o f components are u t i l i z e d o n vehicles FM 87.5 MHZ 108.0 MHZ
equipped w i t h a radio to suppress radio frequency i n -
J908F-6
terference (static).
A capacitor is mounted inside t h e a l t e r n a t o r . CHANGING RECEPTION MODE
G r o u n d straps are u t i l i z e d from cab t o box, f r o m r a - (1) T u r n radio on.
dio chassis t o i n s t r u m e n t panel bracket a n d f r o m en- (2) Radio i n F M mode.
gine t o cowl. A l l ground straps should be securely (3) Press "set*.
mounted t o a clean ground surface t o w o r k effec- (4) Press "sel".
tively. (5) Press station memory set b u t t o n one, 5 times.
Radio resistance spark p l u g wires complete t h e i n - Radio w i l l reset t o lowest A M frequency.
terference suppression system. F a u l t y or deteriorated
spark p l u g wires should be replaced (Fig. 1).

PR513

Fig. 1 Resistance Type Spark Plug Cables

2 RADIO, ANTENNA AND SPEAKERS

RADIO CONNECTOR PINS

CHRYSLER
AM/FM STEREO
AM/FM STEREO
RADIOS
RADIOS
2 SPEAKERS
4 SPEAKERS

BLACK GRAY BLACK GRAY

©:©i©io:©jesi
BLACK GRAY BLACK GRAY
n
XL
BBIiailgmil 1 1 IBBBIlillalBil
i i i i i iqM * — i i I I J T

X52 X54 X58 X54 X54 X56 X61 X56 E2 Ml

X51 X53 X57 X55 17 X12 X53 X53 X55 X55 L7 X12

LEGEND: E2- ILLUMINATION X51-LEFT REAR X55-LEFT PNL/DR X60-FEED (RADIO SWITCHED)
17- PARK LAMPS X52-RIGHT REAR X56-RIGHT PNL/DR X61-MUTE
M l - BATTERY X53rLEFT PNL/DR X57-LEFT REAR
X12-ACC/RUN X54-RIGHT PNL/DR X58-RIGHT REAR

NOTE: FOR WIRE C O L O R S REFER T O

SECTION 8W-WIRING DIAGRAMS J908F-7
• RADIO, ANTENNA AND SPEAKERS 8F - 3

RADIO DIAGNOSIS

RADIO
INOPERATIVE
RADIO NOISE
RADIO
RECEPTION WEAK
11 RADIO RECEPTION
DISTORTED i
LOOSE POWER
OUTSIDE ELECTRICAL SHORTED
BLOWN FUSE FAULTY SPEAKER OR ANTENNA
INTERFERENCE ANTENNA LEAD-IN
CONNECTIONS

CHECK ANTENNA LOOSE RADIO

ANTENNA
MOUNTING AND FAULTY RADIO* FAULTY RADIO* (POOR GROUND)
OPEN OR SHORTED
CONNECTIONS MOUNTING

T
*REFER REPAIR OF
FAULTY RECEIVER BROKEN OR
NOISE DOES NOT NOISE VARIES RADIO TO AN
POWER CONNECTION
VARY WITH WITH AUTHORIZED SERVICE SHORTED ANTENNA
OR SPEAKER
ENGINE SPEED ENGINE SPEED STATION LEAD-IN WIRE
CONNECTIONS

±
T JL
CHECK ACCESSORY
ELECTRICAL MOTORS, CHECK
SECONDARY FAULTY
FAULTY SPEAKER SOLENOIDS AND
IGNITION SPEAKER
SWITCHES AS
RADIO FREQUENCY
NOISE SOURCES

FAULTY RADIO* FAULTY RADIO*

FAULTY RADIO*
8F - 4 RADIO, ANTENNA AND SPEAKERS •
TEST PROCEDURES

INDEX
Page
Antenna 4

ANTENNA (2) K e e p i n g one lead o n connector p i n , clip other

lead o n a n t e n n a body assembly. T h e l a m p should
N O T l i g h t . I f i t does, look f o r a short c i r c u i t i n t h e
TESTING (FIG. 2) body or i n t h e cable probably a t the connector.
A n t e n n a performance m a y be tested b y substitut- (3) Remove c l i p lead f r o m connector p i n and clip on
i n g a k n o w n good antenna. I t is also possible to outer shell o f connector. Connect other clip lead t o
check short or open circuits w i t h a n ohmmeter. or antenna body assembly. T h e l a m p should L I G H T
c o n t i n u i t y l i g h t once t h e antenna cable is discon- again. I f i t does n o t L i g h t , antenna s h i e l d i n g has a n
nected f r o m the radio as follows: open circuit.
(1) C o n t i n u i t y should be observed between t h e t i p
Wiggle cable over its entire length t o reveal i n -
of the mast and radio end p i n .
termittent 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 steps 1,
(2) N o continuity or a very h i g h resistance of sev-
2 a n d 3.
eral megohms should be observed between t h e
ground shell of the connector and radio end p i n .
(3) C o n t i n u i t y should be observed between t h e
ground shell of the connector and the m o u n t i n g h a r d -
ware on t h e fender.

Fig. 3 Antenna Bench Test Points

REMOVAL
(1) Disconnect fusible l i n k i n engine compartment.
(2) Remove glove box.
(3) Reach b e h i n d i n s t r u m e n t panel a n d u n p l u g an-
tenna cable f r o m radio (Fig. 4).

VEHICLE ANTENNA LEAD

RN1005

Fig. 4 Unplugging Antenna Lead from Radio

Fig. 2 Antenna Test Points
BENCH TEST FOR ANTENNA MALFUNCTION
(FIG. 3)
(1) W i t h test lamp and b a t t e r y i n circuit attach one
test lead t o concentric p i n on " l e a d - i n " connector and
other test lead to t i p o f mast. T h e l a m p should
"light" indicating Continuity.
 • RADIO, ANTENNA AND SPEAKERS 8F - 5

(4) W o r k i n g t h r o u g h t h e glove box opening, p u l l

antenna cable f r o m retainer clip ( F i g . 5).

Fig. 5 Removing Antenna Cable

ADAPTER PR517 A
(5) Open r i g h t door and remove cable g r o m m e t
from A p i l l a r (Fig. 6). Fig. 7 Cap Nut and Adapter

Fig. 6 Removing Grommet

(6) P u l l cable from A p i l l a r .
(7) Loosen antenna mast from a n t e n n a body. D o
not remove at this time.
(8) Loosen cap n u t using tool C4816 ( F i g . 7).
(9) W h i l e h o l d i n g antenna mast w i t h one hand, re-
move cap n u t w i t h other hand.
(10) Lower antenna assembly d o w n f a r enough to
g a i n access t o antenna body (Fig. 8).
(11) W h i l e h o l d i n g body remove a n t e n n a mast.
(12) P u l l antenna body and cable assembly f r o m
fender area and remove.
(13) Remove adapter on fender.
INSTALLATION
(1) Route anteanna cable between fender a n d dash
panel to A p i l l a r area.
Fig. 8 Removing or Installing Antenna Body
(2) Insert antenna mast t h r o u g h hole i n fender and
screw into antenna body.
(3) P u l l assembly u p a n d position into place and
hold.
(4) I n s t a l l adapter m a k i n g sure t a b indexes w i t h
opening i n fender a n d
antenna body.
(5) I n s t a l l cap n u t and t i g h t e n securely w i t h tool C-
4816.
(6) Insert cable t h r o u g h opening i n A p i l l a r a n d
f r o m inside glove box opening p u l l i n far enough to
snap grommet into place.
(7) Route cable t h r o u g h r e t a i n e r clip, over to radio,
and p l u g i n t o back of radio.
(8) I n s t a l l glove box.
(9) Connect fusible l i n k .
8F - 6 RADIO, ANTENNA AND SPEAKERS •
SERVICE PROCEDURES
INDEX
Page Page

Door Mounted Speaker 6 Rear Speaker Ramcharger 7

Radio Replacement 6 Rear Speaker Standard Cab Pickup 7
Rear Speaker - Club Cab Pickup 7

RADIO REPLACEMENT (3) I n s e r t radio i n t o panel a n d i n s t a l l m o u n t i n g

screws.
(4) I n s t a l l i n s t r u m e n t cluster bezel.
REMOVAL (5) I n s t a l l map lamp, i f equipped.
(1) Disconnect fusible l i n k i n engine compartment. (6) Connect fusible l i n k .
(2) Remove 2 screws a n d t h e m a p l a m p ( i f
equipped) (Fig. 9). DOOR MOUNTED SPEAKER
(3) Remove 6 screws a t t a c h i n g faceplate t o t h e i n -
strument panel. Be sure t h e screw below t h e
REMOVAL
Heater/C control is removed.
(1) Remove remote control handle.
INSTRUMENT (2) Remove window regulator handle, i f equipped.
PANEL (3) Remove p u l l strap i f equipped.
(4) Remove screw a t top of armrest.
(5) U s i n g a t r i m stick or other suitable f l a t tool,
gently p r y t r i m panel away f r o m door.
(6) Remove screws h o l d i n g speaker (Fig. 11).
(7) Disconnect speaker leads.
(8) Remove speaker.
SPEAKER
ASSEMBLY
INSTRUMENT
CLUSTER
ASSEMBLY
CLUSTER 898E-78
FACEPLATE

Fig. 9 Instrument Cluster Faceplate

(4) Remove two m o u n t i n g screws f r o m front o f r a -
dio (Fig. 10).
(5) P u l l radio o u t o f i n s t r u m e n t panel and discon-
nect w i r i n g and antenna.
(6) Remove screw f r o m g r o u n d strap.

DOOR TRIM
INSTRUMENT PANEL
PANEL
RP910

Fig. 11 Door Mounted Speaker

INSTALLATION
(1) Connect leads t o speaker.
(2) Position speaker into place, i n s t a l l m o u n t i n g
screws a n d t i g h t e n
securely.
RF431 (3) I n s t a l l door t r i m panel.

Fig. 10 Radio to Instrument Panel Mounting

INSTALLATION
(1) I n s t a l l ground strap.
(2) I n s t a l l w i r i n g and antenna.
 • RADIO, ANTENNA AND SPEAKERS 8F - 7

REAR SPEAKER - STANDARD CAB PICKUP

REMOVAL
(1) Remove g r i l l e a n d speaker assembly t o p i l l a r
m o u n t i n g screws (Fig. 12).
(2) P u l l speaker a n d g r i l l e away f r o m p i l l a r a n d
disconnect w i r i n g .
(3) Remove speaker t o g r i l l e r e t a i n i n g n u t s (2).

Fig. 13 Club Cap Speaker Installation

INSTALLATION
(1) I n s t a l l w i r i n g harness connector on speaker.
(2) I n s t a l l r e t a i n i n g t a b into clip.
(3) I n s t a l l screws on t h e b o t t o m o f t h e speaker
housing.

REAR SPEAKER - RAMCHARGER

(1) Remove screws holding t h e speaker a n d g r i l l e
assembly to t h e m o u n t i n g plate ( F i g . 14).
SPEAKER MOUNTING
Fig, 12 Rear Speakers
INSTALLATION
(1) Position speaker onto studs o f speaker g r i l l e
and i n s t a l l nuts.
(2) I n s t a l l w i r i n g harness connector on speaker.
(3) Position speaker a n d g r i l l e on p i l l a r a n d i n s t a l l
mounting
screws.

REAR SPEAKER - CLUB CAB PICKUP

GRILLE ASSEMBLY

REMOVAL J908F-12
(1) Remove t w o screws f r o m b o t t o m o f speaker
Fig. 14 Ramcharger Rear Speaker
housing (Fig. 13).
(2) Lower speaker housing and p u l l b o t t o m out, a l - (2) Disconnect speaker connector a n d remove
l o w i n g r e t a i n i n g t a b o n top o f housing t o clear slot. speaker.
(3) Disconnect speaker connector a n d remove (3) Remove screws holding speaker t o g r i l l e and re-
move speaker.
speaker.
(4) To i n s t a l l t h e speaker a n d g r i l l e assembly, r e -
verse t h e removal procedures.
 • HORNS 8G - 1

HORNS
CONTENTS
Page Page

SERVICE PROCEDURES 2 TEST PROCEDURES 1

GENERAL INFORMATION
The h o r n system (Fig. 1) consists of a h o r n switch,
h o r n relay (located on t h e fuse block), horns, a n d a l l
t h e i r w i r i n g and connections. The circuit is fed from
the fuse block and grounded i n t h e horn switch.
W h e n t h e h o r n switch on t h e steering column is
pressed, t h e ground circuit is completed, energizing
the relay, a n d supplying power to t h e horns.

Fig. 1 Horn System

TEST PROCEDURES

INDEX
Page Page
Horns Sound Continuously . . .. 2 Horns Will Not Sound . .. 1

HORNS WILL NOT SOUND i n t h e circuit. I f the lamp i l l u m i n a t e s when depress-

I f the horns do not sound, check for a blown horn
fuse i n cavity number 6 of the fuse block. I f the fuse
is blown, replace i t w i t h the same type fuse. I n case
the horns fail to sound and the newly replaced fuse
blows when depressing the horn switch, a short cir-
c u i t i n t h e horn or the horn w i r i n g between t h e fuse
t e r m i n a l a n d the horn is responsible.
I f t h e fuse is intact, disconnect wire connector a t
h o r n a n d connect one lead of a test lamp to t h e w i r e
connector a n d the other lead to a good body ground
(Fig. 2). Depress the horn switch. Should test lamp
i l l u m i n a t e the horn is ungrounded or faulty. Ground-
i n g can be verified by m a k i n g a temporary j u m p e r
w i r e connection between horn bracket (scratch
t h r o u g h paint) and t h e negative battery t e r m i n a l .
W i t h t h e ground jumper wire s t i l l intact a n d t h e
h o r n reconnected, i f the horn s t i l l fails to sound
w h e n horn button or r i m is depressed, replace t h e
horn.
I f the lamp fails to i l l u m i n a t e , check for a defective
h o r n relay by substituting a known good horn relay
i n g the h o r n switch, the original relay is defective. I f
the lamp fails to i l l u m i n a t e w i t h a k n o w n good relay,
u n p l u g t h a t relay and connect a j u m p e r w i r e from
the battery t e r m i n a l to the horn t e r m i n a l on t h e re-
lay t e r m i n a l board. I f the lamp, w h i c h is connected
i n place of the horns, fails to i l l u m i n a t e , inspect for
an open circuit between the horn fuse and t h e horn
t e r m i n a l on t h e relay t e r m i n a l board and between
relay t e r m i n a l board and the horn terminals. Should
the lamp i l l u m i n a t e , a defective h o r n switch or a n
open c i r c u i t i n the w i r i n g between t h e relay t e r m i n a l
and the h o r n switch is a t fault.
HORN TEST LAMP TO RELAY AND
HORN BUTTON
HORN/
PR714
TO GOOD BODY GROUND CONNECTOR
Fig. 2 Testing for Voltage
8G - 2 HORNS •
HORNS SOUND CONTINUOUSLY
Should t h e horns sound continuously, u n p l u g t h e
h o r n relay f r o m the relay connector inside the pas-
senger compartment (Fig. 3). P l u g i n a k n o w n good
relay. I f t h e horns stop b l o w i n g , relay is defective
and m u s t be replaced. Should the horns s t i l l sound,
proceed w i t h H o r n Diagnosis Chart.
Remove steering wheel p a d a n d disconnect w i r e
f r o m h o r n switch. Repeat the above test and i f t h e
test l a m p s t i l l i l l u m i n a t e s , w i r e is shorted a n d
should be repaired. I f test l a m p does not i l l u m i n a t e ,
h o r n s w i t c h is defective and m u s t be replaced.

Fig. 3 Horn Relay

SERVICE PROCEDURES

INDEX
Page Page

Horn Replacement - Diesel Engine 4 Horn Switch (Horn Pad Assembly) Replacement . . . 2
Horn Replacement - G a s Engine 2

HORN SWITCH (HORN PAD ASSEMBLY)

REPLACEMENT

REMOVAL
(1) F r o m underside o f steering wheel, remove h o r n
pad m o u n t i n g screws (Figs. 4 and 5).
(2) P u l l pad up from wheel and disconnect electri-
cal leads.
(3) Remove pad.

INSTALLATION
(1) Connect electrical leads to switch t e r m i n a l o n
horn pad.
(2) Position pad i n t o place on steering wheel, i n - SCREWS (2) J 908G-5
stall m o u n t i n g screws and t i g h t e n t o 1.5 N»m (15 i n .
lbs.). Fig. 4 Standard Steering Wheel
(2) Disconnect the horn electrical connector.
HORN REPLACEMENT - GAS ENGINE (3) Remove bolt holding the h o r n bracket to the ra-
The horns are located on either side of t h e r a d i a t o r diator support and remove the h o r n .
(4) To i n s t a l l the horns reverse the removal proce-
support (Fig. 6).
dures. T i g h t e n the bolts to 200 i n . lbs.
(1) Raise the hood.
 HORN DOES NOT HORN SOUNDS
SOUND INTERMITTENTLY.

POOR CONNECTION NOTE: IMMEDIATELY UNPLUG HORN

TEST F U S E AT H O R N C O N T A C T R I N G RELAY AND DISCONNECT WIRES
W H E N TURNING FROM HORNS

USE TEST UGHT BETWEEN HORN

FUSE BLOWN RELAY SOCKETS 1 AND 3
(SEE INSET DIAGRAM)

REMOVE H O R N PAD A N D
H O R N CIRCUIT
CHECK CONTINUITY BE-
WIRING SHORTED
T W E E N S T E E R I N G SHAFT TEST LIGHT OFF TEST UGHT ON
TO GROUND
A N D BODY G R O U N D

INTERNAL
U S E TEST L I G H T A T FAULTY WIRE T O H O R N
TEST UGHT ON SHORT CIRCUIT
HORNS (DEPRESS HORN H O R N RELAY BUTTON SWITCH
IN H O R N
B U T T O N ) ( F I G . 2) GROUNDED OR HORN
BUTTON SWITCH

ZE GROUNDED
REFER T O T E S T
HORN NOT* SHORTED PROCEDURES
TEST LIGHT OFF GROUNDED HORN RELAY

REPLACE H O R N WRONG
RELAY W I T H A FAULTY H O R N
FUSE SIZE
KNOWN G O O D ONE
( F I G . 3)

TEST LIGHT ON

HORN
FAULTY O R I G I N A L
RELAY CONNECTOR
TEST UGHT OFF ALL MODELS
RELAY

TO HORN TO FUSE
SWITCH BLOCK
UNPLUG REPLACEMENT
RELAY F R O M 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 AND 2
SEE INSET DIAGRAM

*IT IS IMPORTANT THAT H O R N S

BE A D E Q U A T E L Y G R O U N D E D . G R O U N D I N G
C A N B E 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 HORN BRACKET (SCRATCH
T H R O U G H PAINT) A N D T H E BATTERY
N E G A T I V E TERMINAL.

INSPECT F O R O P E N
CIRCUIT IN 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 WIRING BETWEEN
RELAY B O A R D T O H O R N R E L A Y TERMINAL A N D
TERMINAL HORN SWITCH

J908G-9
8G - 4 HORNS •
HORN REPLACEMENT - DIESEL ENGINE
The horns are located on the inside o f t h e left front
fender b e h i n d the battery (Fig. 7).
(1) Raise t h e hood.
(2) Remove screw a n d washer h o l d i n g t h e h o r n
bracket t o t h e fender.
(3) Lower t h e h o r n and bracket t o w a r d t h e rear of
the battery.
(4) Disconnect the h o r n electrical connector.
(5) Remove t h e h o r n a n d bracket assembly b y
w o r k i n g i t under the battery t r a y brace (Fig. 7).
(6) To i n s t a l l t h e horns reverse t h e r e m o v a l proce-
dures.

HI NOTE LOW NOTE

HORN & BRACKET HORN & BRACKET
Fig. 6 Horn Removal and Installation—Gas Engine ASSEMBLY ASSEMBLY J908G-11

Fig. 7 Horn Removal and Installation—Diesel Engine

 • SPEED CONTROL SYSTEM
SPEED CONTROL SYSTEM
CONTENTS
Page
SERVICE PROCEDURES .............. 9
GENERAL INFORMATION
The speed control system i s electrically actuated
and vacuum operated. T h e m u l t i f u n c t i o n control le-
ver o n t h e steering c o l u m n incorporates a slide
switch w h i c h has three positions OFF,, O N , and RE-
S U M E . The SET b u t t o n i s located afethe end of t h e
three position slide switch. T h i s system i s designed
to operate a t speeds above approximately 35. m p h
(58km/h).
WARNING: THE USE OF "SPEED CONTROL" IS
NOT RECOMMENDED WHEN DRIVING CONDITIONS
DO NOT PERMIT MAINTAINING A CONSTANT
SPEED, SUCH AS IN HEAVY TRAFFIC OR ON
ROADS THAT ARE WINDING, ICY, SNOW COVERED
OR SLIPPERY.
To e n g a g e : W h e n t h e desired speed i s achieved,
push and release the SET b u t t o n t o t u r n o n and en-
gage the system. Remove foot f r o m accelerator. Speed
w i l l be m a i n t a i n e d a t t h i s level. M o v i n g t h e slide
switch from O F F t o O N w h i l e t h e vehicle i s i n mo-
t i o n establishes memory w i t h o u t system engagement.
8H - 1
Page
TEST PROCEDURES . . . . . . . . . . . . . . . . . . . . . . 5
To d i s e n g a g e : N o r m a l brake application or a soft
t a p o n t h e brake pedal w i l l disengage control u n i t
w i t h o u t erasing speed memory. M o v i n g t h e slide
s w i t c h t o t h e O F F position or t u r n i n g the i g n i t i o n
O F F also disengages t h e system and i n a d d i t i o n
erases the speed memory.
T o r e s u m e a f t e r b r e a k i n g : M o m e n t a r i l y move
slide switch t o R E S U M E . Vehicle w i l l resume t o t h e
previously memorized speed.
To v a r y s p e e d s e t t i n g : To increase speed, depress
accelerator t o desired speed and m o m e n t a r i l y push
a n d release SET b u t t o n .
W h e n speed control system is engaged, t a p p i n g
SET b u t t o n w i l l increase speed setting b y approxi-
mately 2 mph.
To decrease speed, t a p brake pedal l i g h t l y disen-
gaging system. When desired speed has been ob-
t a i n e d push a n d release S E T button. Decrease i n
speed can also be a t t a i n e d b y holding S E T b u t t o n
against stop u n t i l desired speed is attained. Releas-
i n g t h e b u t t o n engages the system a t t h a t speed.
T o a c c e l e r a t e f o r p a s s i n g : Depress accelerator as
needed. W h e n passing is completed, release accelera-
t o r a n d vehicle w i l l r e t u r n t o previous speed setting.
There may be a s l i g h t (3-7 mph) speed loss before the
vehicle recovers t o the set speed.
8H - 2 SPEED CONTROL SYSTEM •

Fig. 1 Speed Control System

• SPEED CONTROL SYSTEM BH - 3

SET BRAKES, PLACE

WARNING: T H E USE O F "SPEED CONTROL* TRANSMISSION IN
IS NOT RECOMMENDED WHEN DRIVING NEUTRAL OR PARK.
CONDITIONS DO NOT PERMIT START ENGINE.
MAINTAINING A CONSTANT SPEED, SUCH
AS HEAVY TRAFFIC OR ON ROADS THAT
ARE WINDING, ICY, SNOW COVERED OR SLIPPERY.
RELEASE BRAKES A N D SPEED CONTROL
ACCELERATE VEHICLE ENGAGES WHEN
T O DESIRED S P E E D ENGINE IS STARTED

M O V E SLIDE S W I T C H
TO " O N " POSITION.

SPEED CONTROL ENGAGES PUSH A N D

WITHOUT ACTUATING THE
RELEASE " S E T " BUTTON
-SET- BUTTON

FAULTY E L E C T R I C A L C I R C U I T '
REMOVE FOOT FROM
ACCELERATOR. SPEED
SHOULD BE CONTROLLED
DEFECTIVE S E R V O

N O SPEED C O N T R O L
HUNTING SURGE EXCESSIVE SAG
OR SPEED SPEED SETTING AFTER
WHEN SET BUTTON IS ON HILLS OR LOCK-IN, TOO HIGH OR
PRESSED AND RELEASED VARIATIONS AT IN TRAILER TOO LOW
LOW SPEEDS TOWING

LOCK-UP
ENGINE
FUSE BLOWN TORQUE CONVERTER V A C U U M LEAK
PERFORMANCE
ROUGHNESS

AMPLICATION
VACUUM
V A C U U M LEAK OF ENGINE DEFECTIVE SERVO
LEAK
SURGE

EXCESSIVE LOAD
SPEED CONTROL
MAY REQUIRE DEFECTIVE V A C U U M
THROTTLE C A B L E DEFECTIVE S E R V O
MANUAL ASSISTANCE RESERVOIR
DISCONNECTED
O N HILLS

IMPROPER S T O P L A M P DEFECTIVE V A C U U M
DEFECTIVE
AND SPEED CONTROL RESERVOIR
S.B.E.C.
SWITCH ADJUSTMENT (CHECK VALVE)

FAULTY E L E C T R I C A L •TESTS AND ADJUSTMENTS ARE DESCRIBED

CIRCUIT* IN APPROPRIATE SECTION OF SERVICE
MANUAL.

DEFECTIVE SERVO

DEFECTIVE
VACUUM RESERVOIR

J908H-12
4 SPEED CONTROL SYSTEM •

DRIVE V E H I C L E
ROUGH ROAD

TAP BRAKE PEDAL LIGHTLY,

UNIT D I S E N G A G E S ON
SPEED CONTROL SHOULD
ROUGH ROAD
DISENGAGE

N O SYSTEM
IMPROPER At5 J U S T M E N T
SPEED CONTROL DISENGAGEMENT WHEN
OF STOP U AND
DISENGAGES B R A K E PEDAL IS
S P E E D C O N T R OL SWITCH*
DEPRESSED

1
DEFECTIVE O R IMPROPERLY
FAULTY
A D J U S T E D S T O P LAMP
ELECTRICAL
A N D SPEED
CIRCUIT
C O N T R O L SWITCH

SPEED CONTROL
THROTTLE CABLE
KINKED OR DAMAGED

FAULTY ELECTRICAL
THROTTLE B O D Y D O E S
CIRCUIT*
NOT RETURN TO
N O R M A L IDLE

MOVE SUDE SWITCH TO THE

THE "RESUME" POSITION
SPEED C O N T R O L THROTTLE VEHICLE SHOULD RESUME PRE- DEFECTIVE SERVO
CABLE KINKED O R VIOUSLY MEMORIZED SPEED
DAMAGED

S T A N D A R D THROTTLE
VEHICLE RESUMES
L I N K A G E FAULTS
SPEED

DEPRESS BRAKE RESUME SPEED

PEDAL, S P E E D C O N T R O L IS P O S S I B L E
SHOULD D I S E N G A G E B E L O W 20 M . P . H .

DEFECTIVE DISTANCE
N O SYSTEM D I S E N G A G E SENSOR
NO R E S U *AE W H E N SPEED CONTROL
W H E N BRAKE P E D A L IS
S U D E swrrc H IS M O V E D DISENGAGES
DEPRESSED

1r
DEFECTIVE
S.B.E.C.
DEFECTIVE E N G I N E
DEFECTIVE SWITCH
MODULE

FAULTY E L E C T R I C A L SPEED CONTROL FAULTY E L E C T R I C A L

CIRCUIT* S Y S T E M OK CIRCUIT*
J908H-13
 • SPEED CONTROL SYSTEM
TEST PROCEDURES
Page
Checking For Fault Code
Electrical Tests At Engine Controller . . . . . . . . . . . . 6
Electrical Tests At Servo
Inoperative System
Road Test
ROAD TEST
Road test vehicle to verify reports o f speed control
system malfunction. The road test should include at-
t e n t i o n to t h e speedometer. Speedometer operation
should be smooth a n d w i t h o u t f l u t t e r a t a l l speeds.
F l u t t e r i n t h e speedometer indicates a problem
w h i c h m i g h t cause s u r g i n g i n the speed control sys-
tem. The cause o f a n y speedometer deficiencies
should be corrected before proceeding.
INOPERATIVE SYSTEM
I f road test verifies a report on an inoperative sys-
t e m and of satisfactory speedometer operation, an i n -
spection should be made for loose electrical a n d
vacuum connections a t t h e servo.
Check for correct i n s t a l l a t i o n of t h e vacuum check
valve i n the hose f r o m servo t o v a c u u m source. T h e
w o r d V A C on t h e valve m u s t point t o w a r d the vac-
u u m source.
Corrosion should be removed from electrical t e r m i -
nals a n d a l i g h t coating o f Mopar Multi-Purpose
Grease, or equivalent, applied.
Inspection should also be made to verify t h a t b o t h
ends o f the speed control cable are securely attached.
CHECKING FOR FAULT CODE
(1) When t r y i n g t o verify a speed control system
electronic m a l f u n c t i o n , one o f two s i m i l a r methods
may be used. I f a D R B I I is available, p l u g i n t o t h e
diagnostic connector i n the engine compartment and
verify t h a t either a F a u l t Code 34 (S/C SERVO SO-
L E N O I D S ) or F a u l t Code 15 ( V E H I C L E SPEED SIG-
N A L ) is indicated.
Y o u c a n also r e f e r t o t h e a p p r o p r i a t e P o w e r -
train Diagnostic Procedures M a n u a l .
I f the D R B I I is not available, the F a u l t Code may
be determined w i t h the f o l l o w i n g method:
(a) W i t h k e y inserted i n i g n i t i o n switch, cycle
switch to O N position three times. O n t h i r d cycle,
leave switch i n O N position.
(b) After switch has been cycled three times,
observe C H E C K E N G I N E indicator on i n s t r u m e n t
cluster. I f a F a u l t Code is present, indicator w i l l
flash (blink) i n a series w h i c h w i l l show w h i c h
8H - 5
INDEX
Page
5 Speed Control Cable Attachment 7
Speed Control Switch (Turn Signal Lever) Test ... 7
, . 5 Speed Control System Electrical Tests 5
5 Stop Lamp Speed Control Switch Test 6
5 Vacuum Supply Test 7
F a u l t Code is t h e problem (i.e. three flashes i n
r a p i d succession, a slight pause, t h e n four flashes
i n r a p i d succession would indicate F a u l t Code 34).
(2) I f a F a u l t Code 34 is observed, determine t h e
source o f the problem by performing the tests i n the
sections E l e c t r i c a l Tests a t Servo and Electrical Tests
at E n g i n e Controller.
I f a f a u l t code 15 is observed, perform the test for a
faulty distance sensor.
(3) Correct a n y problems found w h e n performing
these tests a n d recheck for F a u l t Code i f changes
were made.
DISTANCE SENSOR TEST
For t e s t i n g o f the distance sensor and related com-
ponents refer t o the Vehicle Diagnostics Test Proce-
dure M a n u a l .
SPEED CONTROL SYSTEM ELECTRICAL TESTS
Electronic speed control systems may be tested us-
i n g t w o different methods. One involves use o f a
D R B I I . I f t h i s test method is desired, please refer t o
the Vehicle Diagnostic Test Procedures booklet.
The other test method uses a voltmeter. The volt-
meter method is described i n the following tests.
I f any i n f o r m a t i o n is needed concerning w i r i n g , re-
fer to Group 8 W - W i r i n g Diagrams.
CAUTION: When test probing for voltage or conti-
nuity at electrical connectors, care must be taken
not to damage connector, terminals, or seals. If
these components are damaged, intermittent or
complete system failure may occur.
ELECTRICAL TESTS AT SERVO
(1) T u r n i g n i t i o n switch to the O N position. W i t h
the speed control switch i n the O N position, set up a
voltmeter t o read battery voltage a n d connect t h e
negative lead t o a good chassis ground.
(2) Disconnect t h e 4-way connector going to t h e
servo. The blue w i r e w i t h the red tracer o f the m a i n
harness 4-way connector should read approximately
battery voltage. I f not, check for loose connections,
brake switch adjustment or, repair the m a i n harness
as necessary.
8H - 6 SPEED CONTROL SYSTEM
(3) Connect a j u m p e r w i r e between t h e male and
female t e r m i n a l s of the blue w i r e w i t h red tracer.
The other three male t e r m i n a l s from the servo
should show b a t t e r y voltage. I f not, replace the servo.
(4) U s i n g an ohmmeter, connect one lead to a good
body ground and w i t h the other lead touch the black
(BK) wire t e r m i n a l i n t h e 4-way connector of the
m a i n harness. The meter should show c o n t i n u i t y . I f
not, repair the g r o u n d c i r c u i t as necessary.
ELECTRICAL TESTS AT ENGINE CONTROLLER
(1) U n p l u g 60-way connector from the engine con-
troller, located on dash panel (Fig. 1).
LEFT
FENDER
J908D-56
Fig. 1 Engine Controller and Connector Location
(2) Connect negative lead of voltmeter to a good
body ground near the module.
(3) For the f o l l o w i n g tests, the i g n i t i o n switch m u s t
be i n the O N position. Refer to Fig. 2 for controller
t e r m i n a l locations. Touch the positive lead of the
voltmeter to the t e r m i n a l i n cavity number 33. W i t h
the speed control switch i n the O F F position, the
voltmeter should read 0 volts. W i t h the speed control
switch i n the O N position, the voltmeter should read
battery voltage. I f not, repair the m a i n harness as
niiiL
uutr RR8HC7
Fig. 2 Engine Controller 60-Way Connector Shown
from Terminal End
necessary.
(4) Touch the positive lead of the voltmeter to the
t e r m i n a l i n cavity number 53. As i n step (3), the
voltmeter should read 0 volts w i t h the switch i n the
•
OFF position and battery voltage w i t h the switch i n
the O N position.
(5) Touch t h e positive lead of the voltmeter to the
t e r m i n a l i n cavity
number 48. W i t h the speed control switch i n t h e
OFF position, t h e voltmeter should read 0 volts.
W i t h the s w i t c h i n the O N position, the voltmeter
should read b a t t e r y voltage. Pressing the SET b u t t o n
should cause t h e voltmeter to change from battery
voltage to 0 volts for as l o n g as t h e switch is held. I f
not, perform t h e speed control switch test. I f the
switch is not a t f a u l t , t h e n check the m a i n harness
and repair as necessary.
(6) Touch t h e positive lead of the voltmeter to the
t e r m i n a l i n cavity number 50. The voltmeter should
read 0 volts w i t h the speed control switch i n either
the OFF or O N position. W i t h switch i n either RE-
S U M E or SET position, the voltmeter should read
battery voltage. I f not, perform the speed control
switch test. I f t h e switch is not at fault, t h e n check
the m a i n harness and repair as necessary.
(7) Touch t h e positive lead of the voltmeter to the
t e r m i n a l i n cavity number 49. The voltmeter should
read 0 volts w i t h the s w i t c h i n the OFF position.
W i t h the s w i t c h i n the O N position, the voltmeter
should read b a t t e r y voltage. The voltmeter w i l l con-
tinue to read b a t t e r y voltage w h e n either the SET or
R E S U M E s w i t c h is pressed. I f not, perform the speed
control s w i t c h test. I f the s w i t c h is not at fault, t h e n
check the m a i n harness and repair as necessary .
(8) U s i n g a n ohmmeter, connect one lead to a good
body ground and touch the other lead to the t e r m i n a l
i n cavity n u m b e r 29. W i t h t h e brake pedal released,
the meter should show c o n t i n u i t y . When the pedal is
depressed, the meter should show open circuit.
STOP LAMP SPEED CONTROL SWITCH TEST
(1) Disconnect the connector at the stop lamp
switch. U s i n g a n ohmmeter, c o n t i n u i t y may be
checked at the s w i t c h side of the connector as follows
(Fig. 3):
(a) W i t h b r a k e pedal released, there should be
continuity (no resistance) between the black (BK)
and w h i t e w i t h p i n k tracer (WT/PK*) wires, and
between the yellow w i t h red tracer (YL/RD*) and
dark blue w i t h red tracer (DB/RD*) wires. There
should be no c o n t i n u i t y between the p i n k (PK) and
w h i t e (WT) wires.
(b) W i t h brake pedal depressed, there should be
continuity between p i n k (PK) and w h i t e (WT)
wires. There should be no c o n t i n u i t y between black
(BK) and w h i t e w i t h p i n k tracer (WT/PK*) wires,
or between the yellow w i t h red tracer (YL/RD*)
and d a r k blue w i t h red tracer (DB/RD*) wires.
(2) I f the above results are not obtained, the stop
lamp switch is defective or out of adjustment.
 • SPEED CONTROL SYSTEM 8H - 7

SWITCH SHOWN VACUUM SUPPLY TEST

WITH BRAKE

RiiR
PEDAL RELEASED (1) Disconnect v a c u u m hose a t the servo and i n s t a l l
a v a c u u m gauge i n t h e hose (Fig. 5).
(2) Start engine a n d observe gauge a t idle. V a c u u m
gauge should read a t least t e n inches o f mercury.
(3) Connect v a c u u m supply hose.
18DB/ mu
RD* RD* SPEED CONTROL SWITCH CONTINUITY CHART
18WT/
18BK PK* SWITCH P O S I T I O N C O N T I N U I T Y BETWEEN
OFF BR and YL

18PK 18WT/ BfeandYL

ON BR and DB
YLand DB
YL and WT
SET DB and WT
O YL and DB/WT
DB andWT
DB and YL
J908H-9 RESUME BR and YL
BR and DB
Fig. 3 Stop Lamp and Speed Control Switch Wiring BR and WT

Stop l a m p switch adjustment is detailed i n Group 5

- Brakes. J908H-18

SPEED CONTROL SWITCH (TURN SIGNAL LEVER)

TEST (Fig. 4)
(1) Disconnect t h e blade-type four w i r e electrical
connector a t base o f steering column.
(2) U s i n g a c o n t i n u i t y tester or a n ohmmeter (do
n o t use a test l i g h t ) , check for c o n t i n u i t y a t the con-
nector wires. Results should be obtained according to
t h e f o l l o w i n g chart.

22BR

Fig. 5 Vacuum Gauge Test

WIRING
CONNECTOR SPEED
(4) I f v a c u u m does n o t meet t h i s requirement,
CONTROL
SWITCH check for v a c u u m leaks or poor engine performance.
(ON
STEERING SPEED CONTROL CABLE ATTACHMENT
COLUMN)
SWITCH
SHOWN SPEED CONTROL CABLE
IN "OFF" ATTACHMENT-THROTTLE BODY
POSITION
(1) The clevis of t h e speed control cable is r e t a i n e d
RR8HC24 on t h e t h r o t t l e body w i t h a specially shaped r e t a i n -
i n g clip. V i s u a l inspection w i l l verify t h a t t h e cable
Fig. 4 Speed Control Steering Column Switch and
Wiring is securely attached. I f the cable is not attached, t h e
speed control system w i l l be inoperative.
8H - 8 SPEED CONTROL SYSTEM •
The speed control cable on D-body t r u c k s is (4) I f gap is not correct, remove adjustment clip
snapped i n t o a T-shaped slot i n t h e cable m o u n t i n g and push protective sleeve i n t o housing t o decrease
bracket (Fig. 6). gap or p u l l sleeve out of housing to increase gap ( F i g .
9).

Fig. 6 Speed Control Cable and Mounting Bracket Fig. 9 Adjustment Clip Pulled Out of Slot to Move
Sleeve
(1) G r i p cable core w i r e and l i g h t l y push t o w a r d
servo. (5) I n s t a l l adjustment clip.
(2) W h i l e l i g h t l y holding toward servo, m a r k core
SPEED CONTROL CABLE
wire next to protective sleeve (Fig. 7).
ATTACHMENT-SERVO
(1) T h e speed control cable is attached t o t h e servo
w i t h a w i r e clip (Fig. 10). A check should be made t o
verify t h a t t h e clip is i n place. I f the clip is missing
the speed control system w i l l be inoperative.

Fig. 7 Push Cable In and Mark at Protective Sleeve

(3) P u l l core w i r e away from servo. There should be
a 6 m m (.24 in.) gap between t h e m a r k o n t h e core
wire and t h e protective sleeve (Fig. 8).

Fig. 10 Speed Control Cable Attachment at Servo

Fig. 8 Pull Cable Out and Measure from Mark to

Protective Sleeve
 • SPEED CONTROL SYSTEM 8H - 9

SERVICE PROCEDURES

INDEX
Paga Page
Servo Throttle Cabel Assembly . . . . . . . . . . . . . . . . 9 Speed Control Switch 9
Speed Control Servo 9 Speed Control Vacuum Reservoir Replacement . .1 0

SPEED CONTROL SERVO (4) Route cable from servo, t h r o u g h cable support
bracket a n d clip, and i n s t a l l cable end o n stud of
t h r o t t l e body.
REMOVAL
(5) Adjust cable as described under speed control
(1) Remove t w o nuts a t t a c h i n g t h r o t t l e cable a n d
cable adjustment.
m o u n t i n g bracket t o servo.
(6) Replace a i r cleaner.
(2) Remove t w o screws a t t a c h i n g servo m o u n t i n g
bracket to U - N u t s o n battery t r a y . SPEED CONTROL SWITCH (Turn Signal Lever)
(3) Remove servo m o u n t i n g bracket.
(4) Disconnect electrical connector a n d v a c u u m
hose. REMOVAL
(5) P u l l cable away from servo t o expose r e t a i n i n g (1) Disconnect battery negative cable.
clip and remove clip attaching cable to servo. (2) Remove four screws a t t a c h i n g lower steering
column cover a n d remove cover ( F i g . 1). T h e fuse
INSTALLATION block is attached to this cover a n d should be sup-
(1) W i t h t h r o t t l e i n f u l l open position a l i g n hole i n ported w h e n cover is removed.
t h r o t t l e cable sleeve w i t h hole i n servo p i n a n d i n -
s t a l l r e t a i n i n g clip.
(2) Connect v a c u u m hose t o servo.
(3) Connect electrical connector.
(4) Position m o u n t i n g bracket a n d i n s t a l l t w o
screws a t t a c h i n g bracket to battery t r a y , t i g h t e n t o
12 N*m (105 i n . lbs.).
(5) Insert servo studs t h r o u g h holes i n t h r o t t l e ca-
ble and m o u n t i n g bracket.
(6) I n s t a l l n u t s , t i g h t e n to 9 N * m (80 i n . lbs.).

SERVO THROTTLE CABLE ASSEMBLY

REMOVAL
(1) Remove a i r cleaner.
(2) Disconnect cable a t r e t a i n i n g clamp a n d a t car-
buretor ( t h r o t t l e body), removing snap r i n g (retain- Fig. 1 Steering Column Cover
i n g clip). (3) Remove w i r i n g t r o u g h after unsnapping four
(3) Disconnect cable a t servo a n d remove cable as- plastic r e t a i n i n g clips (Fig. 2).
sembly. (4) Disconnect speed control switch electrical con-
nector from i n s t r u m e n t panel harness connector.
INSTALLATION
(5) P u l l wiper control knob from end of t u r n signal
(1) Locate cable t h r o u g h servo m o u n t i n g bracket.
lever.
(2) Connect cable sleeve to servo stud, a l i g n holes,
(6) Remove silencer from lever.
and i n s t a l l h a i r p i n clip.
(7) Remove t w o screws attaching speed control
(3) Insert servo studs t h r o u g h holes i n cable a n d
switch to column.
holes i n bracket, i n s t a l l nut-washers, a n d t i g h t e n t o
9 N i n (80 i n . lbs.).
8H - 10 SPEED CONTROL SYSTEM •
STEERING COLUMN (10) O n standard columns, remove upper steering
ASSEMBLY column lock housing cover w h i c h is retained b y t w o
screws.
(11) Remove switch and harness from c o l u m n . O n
t i l t columns p u l l wires t h r o u g h lock housing between
lock-plate a n d side of housing. T h e n disconnect guide
w i r e from harness.

INSTALLATION
(1) O n standard columns, insert harness a n d conr
nector t h r o u g h t u r n signal lever opening i n c o l u m n
WIRING T R O U G H and p u l l down and out lower end.
T O KEY-IN
"LAMP W I R I N G
(2) O n t i l t columns, insert harness connector
^TO K E Y - I N SWITCH t h r o u g h t u r n signal lever opening i n column a n d p u l l
T O TURN WIRING u p w a r d t h r o u g h upper housing. A t t a c h guide w i r e t o
SIGNAL
T O SPEED switch w i r i n g harness a n d g e n t l y p u l l d o w n w a r d
WIRING
CONTROL WIRING t h r o u g h c o l u m n opening, between lockplate a n d side
sTO INTERMITTENT WIPE of housing, t a k i n g care to avoid damaging wires.
T O WINDSHIELD C O N T R O L UNIT (3) Remove a l l slack from wires.
WIPER W I R I N G RR8JC3
(4) O n t i l t columns, remove guide w i r e .
(5) I n s t a l l w i r i n g t r o u g h w i t h plastic clips.
Fig. 2 Steering Column Connectors
(6) Connect speed control s w i t c h electrical connec-
(8) O n t i l t columns remove steering wheel with tor to i n s t r u m e n t panel harness connector.
puller C3428B (Fig. 3). (7) Secure speed control switch t o column w i t h t w o
TOOL screws.
C-3428B (8) Position silencer on lever.
(9) Push wiper control knob i n place on e n d of le-
ver.
(10) O n t i l t columns replace steering wheel.
(11) O n standard columns i n s t a l l upper steering
column lock housing cover.
(12) I n s t a l l fuse block to cover.
(13) Position lower steering column cover a n d i n -
s t a l l four a t t a c h i n g screws.
(14) Connect battery negative cable and test oper-
ation of speed control.

SPEED CONTROL VACUUM RESERVOIR

REPLACEMENT

REMOVAL
(1) Disconnect vacuum supply hose and servo hose
(Fig. 4).
(2) Remove reservoir m o u n t i n g bolts.
J908M-7 (3) Remove reservoir from left side splash shield.

Fig. 3 Removing Steering Wheel (Typical) INSTALLATION

(9) O n t i l t columns attach a flexible guide w i r e to (1) I n s t a l l reservoir to t h e left side splash shield.
lower end o f speed control switch harness. Torque screws to 6 N m (50 i n . lbs.).
#

(2) Connect vacuum supply hose to large nipple.

Connect servo hose to shielded s m a l l nipple.
 TURN SIGNALS AND HAZARD WARNING FLASHER 8J - 1

TURN SIGNALS AND HAZARD WARNING FLASHER

CONTENTS
Page Page

SERVICE PROCEDURES . . . . . . . . . . . . . . . . . . . 4 TESTING PROCEDURES 2

INDEX
Page
General Information 1

RIGHT LANE
GENERAL INFORMATION

TURN SIGNALS
The t u r n signals are actuated w i t h a lever on the
left side of the steering column j u s t below the steer-
i n g wheel. W h e n the d r i v e r wishes to signal his i n -
tentions to change direction o f travel, he moves the
lever u p w a r d to cause the r i g h t signals to flash and
downward to cause the left signals t o flash. (Fig. 1).
A f t e r completion o f a t u r n t h e system is deacti-
vated automatically. A s the steering wheel returns t o
the straight ahead position, a canceling cam i n t h e
t u r n signal switch ( w i t h standard column-rotated b y
steering wheel; w i t h t i l t column-rotated by column
lock plate) comes i n contact w i t h one of two cancel-
i n g fingers o f the t u r n signal switch. The cam push-
i n g on the switch canceling finger returns the switch
to the OFF position.
I f only momentary s i g n a l i n g such as indication o f a
lane change is desired, t h e switch is actuated to a SIGNAL POSITION
left or r i g h t intermediate detent position. I n t h i s po-
sition the signal lamps flash as described above, b u t Fig. 1 Turn Signal Lever Positions
the switch r e t u r n s to the OFF position as soon as the
lever is released (Fig. 1)
W h e n the system is activated, one o f two indicator
lamps mounted i n the i n s t r u m e n t cluster flashes i n
unison w i t h the t u r n signal lamps, i n d i c a t i n g t o the
driver t h a t the system is operating.

HAZARD WARNING SYSTEM

The hazard w a r n i n g system is actuated by a switch
knob (Fig. 2) on the r i g h t side o f the steering column
j u s t below the steering wheel. O n standard columns
the knob is p u l l e d out (away from the column) to op-
erate the hazard w a r n i n g system, and on the T i l t col-
u m n i t is pushed i n . W h e n the switch is actuated a l l
t u r n signal lamps and t u r n signal indicators flash s i -
multaneously.

Fig. 2 Hazard Warning Knob

8J - 2 TURN SIGNALS AND HAZARD WARNING FLASHER •
W h e n t h e hazard w a r n i n g switch i s actuated, t h e
t u r n signal s w i t c h should be i n the O F F position to
avoid a characteristic feed back t h r o u g h t h e acces-
sory c i r c u i t w h i c h m i g h t cause i n t e r m i t t e n t opera-
t i o n o f any accessories left w i t h switches t u r n e d on.
W h e n t h e hazard w a r n i n g switch is actuated and
the brakes applied, t h e hazard w a r n i n g lamps w i l l
continue t o flash.

TURN SIGNAL AND HAZARD WARNING

FLASHER LOCATION
The t u r n signal and hazard w a r n i n g flashers are
located o n the fuse block, w h i c h is on the lower i n -
strument panel cover under the steering column (Fig.
3).

Fig. 3 Turn Signal and Hazard Warning Flashers

TESTING PROCEDURES
INDEX
Page
Turn Signal And Hazard Warning Switch Tests . . . . 2

HAZARD WARNING SYSTEM DIAGNOSIS TURN SIGNAL AND HAZARD WARNING SWITCH
TESTS
HAZARD WARNING
The t u r n signal switch and hazard w a r n i n g s w i t c h
SYSTEM DIAGNOSIS
operate t h e same lamps, and therefore, have m u c h
common w i r i n g . A n a l y z i n g b o t h systems when there
SYSTEM DOES
NOT FLASH 1 is a f a u l t can often lead to more r a p i d identification
of the f a u l t .
OPEN CIRCUIT IN FEED
WIRE TO SWITCH Since t h e stop l a m p c i r c u i t r y feeds t h r o u g h b o t h
the t u r n signal switch a n d t h e hazard w a r n i n g
switch, these switches should be given consideration
FAULTY FUSE
w h e n there is a failure i n the stop lamp circuit. To
FAULTY CONTACT test the s w i t c h , first disconnect the battery negative
IN SWITCH
cable t h e n t h e switch wires from the body w i r i n g a t
the connector (Fig. 4).

OPEN OR GROUNDED
CIRCUIT IN WIRING
TO EXTERNAL LAMPS
J908J-2
• TURN SIGNALS AND HAZARD WARNING FLASHER 8J - 3

TURN SIGNAL SYSTEM DIAGNOSIS

TURN SIGNAL
SYSTEM DIAGNOSIS

TURN SIGNAL
MALFUNCTION

i
INDICATOR LAMP SYSTEM D O B NOT
SYSTEM D O B NOT SYSTEM DOES NOT ILLUMINATES BRIGHTLY, CANCEL AFTER
FLASH ON ONE SIDE FLASH ON EITHER SIDE | EXTERNAL LAMP GLOWS DIMLY | COMPLETION
WITH SLOW OR NO FLASH OF TURN

T
LOOSE OR CORRODED
BROKEN CANCELLING
FAULTY EXTERNAL BULB FAULTY FUSE EXTERNAL LAMP
FINGER ON SWITCH
CONNECTION

; 1
FAULTY FLASHER POOR GROUND CIRCUIT DAMAGED OR MISSING
POOR GROUND AT LAMP CAM DRIVE PIN
UNIT AT EXTERNAL LAMP
WHICH FITS INTO HOLE
IN STEERING WHEEL HUB

I
OPEN CIRCUIT IN WIRING LOOSE BROKEN OR LOOSE
TO EXTERNAL LAMP BULKHEAD CONNECTOR WRONG EXTERNAL BULB
CANCELLING CAM

LOOSE OR FAULTY 1 INDICATC>R LAMP 1 EXTERNAL LAMPS

FAULTY CONTACT 1 ILLUMINATES BRIGHTLY, 1 OPERATE PROPERLY,
IN SWITCH REAR WIRING HARNESS
OR TERMINALS 1 EXTERN/il LAMP 1 NO INDICATOR
1 DOES NC)T LIGHT 1 LAMP OPERATION

OPEN CIRCUIT TO OPEN CIRCUIT IN

FLASHER UNIT WIRE TO EXTERNAL LAMP FAULTY INDICATOR BULB
IN INSTRUMENT CLUSTER

I
OPEN CIRCUIT IN FEED
FAULTY WIRING HARNESS
WIRE TO TURN FAULTY EXTERNAL BULB
IN INSTRUMENT CLUSTER
SIGNAL SWITCH

FAULTY P.C. BOARD

FAULTY SWITCH IN INSTRUMENT CLUSTER
CONNECTIONS

FAULTY CONNECTION
IN SWITCH

J908J-1
8J - 4 TURN SIGNALS AND HAZARD WARNING FLASHER •
STEERING COLUMN
ASSEMBLY
WIRE WIRE
CAVITY COLOR APPLICATION
10 WHITE/TAN STOP LIGHT
SWITCH _n_
RIGHT REAR i n
9 BR/RED lU
8 DK GRN/RED LEFT REAR La
7 RED/BK TURN SIGNAL 8 -pi
FLASHER 7 -Ssi
6 PINK HAZARD
WARNING FLASHER 0
WIRING TROUGH 5 TAN RIGHT FRONT 5 •{9
TO KEY-IN A
"LAMP WIRING 4 LIGHT GRN LEFT FRONT % -T9
^TO KEY-IN SWITCH 3 BLACK/RED HORN 9
TO TURN JL
WIRING 2 BLACK HORN GROUND 1
SIGNAL 1 IFS

WIRING
-TO SPEED 1 "u
CONTROL WIRING
.TO INTERMITTENT WIPE Turn Signal Switch
TO WINDSHIELD CONTROL UNIT Switch Position: Left Neutral Right
WIPER WIRING RR8JC3 Continuity Between: 7 and 4 10 and 9 7 and 5
Continuity Between: 7 and 8 10 and 8 7 and 9
Continuity Between: 10 and 9 10 and 8
Fig. 4 Steering Column Wiring Connectors
U s i n g a c o n t i n u i t y tester or an ohmmeter, test for Hazarc Warning Switch
continuity (no resistance) between the t e r m i n a l s of Switch Position: Off On
the switch as shown i n t h e following c o n t i n u i t y Continuity Between: 10 and 9 6 and 4
Continuity Between: 10 and 8 6 and 5
chart. The i d e n t i t y o f each t e r m i n a l is shown i n the Continuity Between: 6 and 8
Switch C o n t i n u i t y C h a r t . Continuity Between: 6 and 9
J908J-5
SWITCH CONTINUITY CHART

SERVICE PROCEDURES
TURN SIGNAL/HAZARD WARNING SWITCH (3) P u l l pad up from wheel and disconnect electri-
cal leads.
(4) Remove pad.
REMOVAL
(5) Remove steering wheel w i t h puller C-3428B
(1) Disconnect b a t t e r y negative cable.
(Fig. 7).
(2) On the standard and optional steering wheels
(6) Remove w i r i n g t r o u g h by p r y i n g out plastic re-
(Figs. 5 a n d 6) remove t w o h o r n pad m o u n t i n g
tainer buttons.
screws from underside o f steering wheel.
(7) Position gearshift lever to its f u l l clockwise po-
ELECTRICAL sition (standard column). I f equipped w i t h t i l t col-
LEADS u m n position a t mid-point.
(8) Disconnect t u r n signal w i r i n g (Figs. 8 and 9).
(9) Disassemble steering column for switch r e -
moval.
HORN PAD
(a) Standard Column: Remove screw h o l d i n g
wiper-washer switch to t u r n signal switch pivot.
Leave the entire t u r n signal lever (control stalk) i n
its installed position.
Remove three screws attaching t u r n signal
switch to upper bearing housing (Fig. 10).
(b) T i l t Column: Depress lock plate w i t h Tool
C-4156 and p r y r e t a i n i n g r i n g out of groove w i t h
MOUNTING
SCREWS (2)' J 908G-5
screwdriver (Fig. 11). The full load of the upper
bearing s p r i n g should not be relieved; i f i t is, the
Fig. 5 Standard Steering Wheel r e t a i n i n g r i n g w i l l t u r n too easily m a k i n g removal
more difficult. Remove lock plate, canceling cam,
and upper bearing spring.
 • TURN SIGNALS AND HAZARD WARNING FLASHER 8J - 5

ELECTRICAL STEERING COLUMN

LEADS ASSEMBLY

WIRING TROUGH
TO KEY-IN
'LAMP WIRING
"TO KEY-IN SWITCH
MOUNTING. TO TURN
J908G-6 WIRING
SCREWS (3) SIGNAL
WIRING TO SPEED
CONTROL WIRING
Fig. 6 Optional Steering Wheel
J O INTERMITTENT WIPE
TOOL "TO WINDSHIELD CONTROL UNIT
C-3428B WIPER WIRING RR8JC3

Fig. 8 Steering Column Wiring Connectors

HORN AND TURN WEDGE BLOCK
SIGNAL CONNECTOR

WINDSHIELD WIPER FROM

CONNECTOR KEY-IN
SWITCH

FROM KEY-IN LAMP RF278B

Fig. 9 Disconnecting Wires

STEERING COLUMN
LOCK HOUSING
J908M-7

Fig. 7 Removing Steering Wheel (Typical)

Place t u r n signal switch i n r i g h t t u r n position. Re-
move screw w h i c h attaches l i n k between t u r n signal
switch and wiper-washer s w i t c h pivot. Remove screw
w h i c h attaches hazard w a r n i n g switch knob. Remove
three screws attaching t u r n signal s w i t c h t o steering
column.
(10) W r a p a piece o f tape around t h e t u r n signal
s w i t c h w i r i n g a n d connector t o prevent snagging
TURN SIGNAL
w h e n r e m o v i n g the switch. SWITCH RP796
(11) Remove t u r n signal a n d hazard w a r n i n g
switch assembly b y gently p u l l i n g switch u p from Fig. 10 Turn Signal Switch
column w h i l e s t r a i g h t e n i n g a n d g u i d i n g wires u p through w h i c h i t installs). Use a f i l m of L u b r i p l a t e
t h r o u g h column opening. or a l i g h t l u b r i c a n t equivalent.
(2) Maneuver connector t h r o u g h opening i n steer-
INSTALLATION
ing column, then carefully guide wires down t h r o u g h
(1) O n standard columns, lubricate t u r n signal
column.
switch pivot (entire 360° a r o u n d depth o f column hole
8J - 6 TURN SIGNALS AND HAZARD WARNING FLASHER
Fig. 11 Removing Lock Plate Retaining Ring Using
ToolC-4156
(3) O n column shift, place gear shift lever i n t o
P A R K position.
(4) Assemble upper p a r t o f steering column.
(a) Standard Column: Position t u r n signal
s w i t c h into place on upper bearing housing. I n s t a l l
three m o u n t i n g screws and t i g h t e n securely. Posi-
t i o n t u r n signal lever (control stalk) t o t u r n signal
switch pivot, t h e n p u t screw t h r o u g h p i v o t a n d
t i g h t e n securely. B e sure t h a t d i m m e r s w i t c h rod is
i n control s t a l k pocket.
(b) T i l t C o l u m n : Position t u r n signal switch i n
upper c o l u m n housing. Place switch i n r i g h t t u r n
position. I n s t a l l three m o u n t i n g screws a n d
t i g h t e n . P u l l l i n k i n position between t u r n signal
switch a n d wiper-washer switch pivot, and secure
w i t h screw. U s i n g Tool C-4156 i n s t a l l upper bear-
i n g spring, canceling cam, and lock plate, w i t h new
r e t a i n i n g r i n g . I n s t a l l hazard w a r n i n g knob w i t h
screw.
(5) Connect w i r i n g harness connector. I n s t a l l w i r -
i n g t r o u g h t o c o l u m n w i t h 4 plastic buttons.
(6) I n s t a l l lower bezel t o i n s t r u m e n t panel.
(7) I n s t a l l steering wheel, being sure t h a t i t is
properly indexed t o c o l u m n shaft. Torque wheel n u t
to 6 1 N*m (45 ft. lbs.).
(8) Connect h o r n s w i t c h leads a n d i n s t a l l h o r n
switch pad.
(9) Connect b a t t e r y negative cable.
(10) Test operation o f t u r n signals, hazard w a r n i n g
flashers, and h o r n .
 • WINDSHIELD WIPER AND WASHER SYSTEMS
WINDSHIELD WIPER AND WASHER SYSTEMS
CONTENTS
Page
INTERMITTENT WINDSHIELD WIPER FUNCTION
AND SWITCH TESTING PROCEDURES 5 WINDSHIELD WIPER SYSTEM SERVICE
TWO SPEED WINDSHIELD WIPER MOTOR AND
SWITCH TESTING PROCEDURES 1
GENERAL INFORMATION
The w i n d s h i e l d wipers can be operated w i t h t h e
w i n d s h i e l d w i p e r s w i t c h only w h e n t h e i g n i t i o n
s w i t c h i s i n t h e ACCESSORY or I G N I T I O N position.
A fuse located i n t h e fuse block protects t h e c i r c u i t r y
of t h e w i p e r system and the vehicle.
The same m o t o r i s used for standard a n d i n t e r m i t -
t e n t wipe systems.
The w i p e r motor has permanent magnet fields. The
speeds are determined by c u r r e n t flow t o t h e appro-
p r i a t e set o f brushes.
TWO S P E E D WINDSHIELD WIPER MOTOR AND SWITCH T E S T I N G P R O C E D U R E S
INDEX
Page
Standard Two Speed Wiper Motor System Test . . . 1
STANDARD TWO SPEED WIPER MOTOR SYSTEM
TEST
The f o l l o w i n g is a l i s t of general wiper m o t o r sys-
t e m problems, the tests t h a t are to be performed to
locate the f a u l t y p a r t , and the corrective action t o be
t a k e n . The same motor is used for standard a n d op-
t i o n a l systems. I f t h e malfunction involves o n l y the
Delay mode, s w i t c h , or w i r i n g , refer t o the I n t e r m i t -
t e n t W i n d s h i e l d W i p e r Motor a n d S w i t c h Service
Procedures.
CONDITION
Motor w i l l not r u n i n a n y s w i t c h position.
PROCEDURE
(1) Check for a b l o w n fuse i n the fuse block.
(a) I f fuse is good, proceed t o step No. 2.
(b) I f fuse is defective, replace and check motor
operation i n a l l s w i t c h positions.
(c) I f m o t o r is s t i l l inoperative a n d t h e fuse
does not blow, proceed to step No. 2.
(d) I f replacement fuse blows, proceed t o step
No. 5.
(2) Place s w i t c h i n low speed position.
8K - 1
Page
WINDSHIELD WASHERS .. 15
PROCEDURES
The i n t e r m i t t e n t wipe system i n a d d i t i o n t o low
and h i g h speed, has a delay mode. The delay mode
has a range o f 2 to 15 seconds. T h i s is accomplished
by a variable resistor i n the w i p e r switch a n d i s con-
t r o l l e d electrically by a relay.
The wiper system completes t h e wipe cycle w h e n
the switch is t u r n e d OFF. T h e blades p a r k i n t h e
lowest p o r t i o n o f the wipe p a t t e r n .
I f t h e washer knob is depressed w h i l e t h e system is
i n t h e O F F position, t h e w i p e r control module w i l l
t u r n t h e wiper motor on a n d allow i t t o operate
t h r o u g h 3-4 wipe cycles and t h e n t u r n OFF.
Page
Switch Test . .. 4
(3) L i s t e n to motor. I f you cannot hear i t r u n n i n g ,
proceed to step No. 4. I f you hear i t r u n n i n g , check
motor output shaft. I f output shaft i s not t u r n i n g , re-
place motor assembly. I f i t is t u r n i n g , c r a n k a r m or
drive l i n k is n o t properly connected. Replace w o r n
parts and/or properly connect d r i v e l i n k to t h e motor
o u t p u t shaft.
(4) Connect a voltmeter between motor t e r m i n a l
" L " and ground strap (Fig. 1). I f there is no voltage
or very l i t t l e voltage (less t h a n one volt) present,
move negative test lead from t h e ground strap to bat-
t e r y negative t e r m i n a l .
(a) I f a n increase i n voltage is noticed, t h e
problem is a bad ground c i r c u i t . M a k e sure t h e mo-
tor m o u n t i n g is free of p a i n t a n d t h a t n u t s or bolts
are t i g h t .
(b) I f there is s t i l l no i n d i c a t i o n of voltage, the
problem is a n open circuit i n t h e w i r i n g harness or
wiper switch.
(c) I f no noticeable increase (greater t h a n 3
volts) i n voltage is observed, t h e problem i s a
f a u l t y motor assembly.
(5) Disconnect motor w i r i n g connector a n d replace
fuse.
(a) I f fuse does not blow, motor is defective.
(b) I f fuse blows, switch o r w i r i n g is a t fault.
8K - 2 WINDSHIELD WIPER AND WASHER SYSTEMS •

I MOTOR RUNS I BLADES SLAP I

BLADES DO BUT OUTPUT AGAINST I BLADES
NOT PARK CRANK DOES WINDSHIELD I CHATTER
NOT TURN MOULDINGS I
ION DRY GLASS!
IMOTOR STOPS IMOTOR STOPS! MOTOR WILL
IN ANY NOT STOP LINKAGE NOT FOREIGN
BLADES DO
POSITION NOT PARK I WHEN SWITCH | FASTENED ARMS LOOSE* SUBSTANCE SUCH
I WHEN SWITCH IS TURNED PROPERLY TO ON PIVOT SHAFT AS BODY POLISH
IS TURNED PROPERLY "OFF" MOTOR OUTPUT ON GLASS OR
"Off" SHAFT X BLADES
X ARM SET AT
DEFECTIVE
t ARM
OPEN PARK INCORRECT IMPROPERLY TWISTED ARM
WIRING CIRCUIT POSITION MOTOR DEFECTIVE POSITIONED ON HOLDS BLADE AT
MOTOR PIVOT SHAFT- WRONG ANGLE
t : t TO GLASS
ARMS LOOSE LOOSENESS OF
FAULTY SWITCH BENT OR
ON PIVOT SHAFT THE MOTOR
MOTOR WILL DAAAAGED
CRANK OR OTHER
X NOT RUN DRIVE PARTS
BLADES

DEFECTIVE
LOOSE LINKAGE
DEFECTIVE
I AT ANY SPEED!
AT MOTOR
MOTOR MOTOR
CONNECTION
I WIPER BLADES |
WIPER OPERATING
KNOCK PROPERLY
MOTOR
WILL NOT
RUN WIPER KNOCK
WIPER KNOCKS
AT OTHER
AT EXTREME
THAN EXTREME
WIPE
CHECK WIPE
VOLTAGE X
AT MOTOR AXIAL OR WORN ARMATURE
OUT FREEPLAY END PLAY
IN LINKAGE IN MOTOR
f
VOLTAGE
PRESENT REPLACE
MOTOR

DEFECTIVE
MOTOR
NEW REMOVE
FUSE MOTOR
BLOWS CONNECTOR

CHECK
X
NEW
GROUND REPLACE
FUSE
FUSE
GOOD
I MOTOR RUNS
BLADES DO X
NOT MOVE FUSE
REPLACE
MOTOR BLOWS

OUTPUT OUTPUT
SHAFT SHAFT
STATIONARY ROTATES CHECK
CHECK
X X
WIRING SWITCH

LOOSE BAD
REPLACE ARMS LOOSE
MOTOR LINKAGE
MOTOR ON PIVOT SHAFT
CRANK CONNECTION
RF80B
 • WINDSHIELD WIPER AND WASHER SYSTEMS
Fig. 1 Voltmeter Between Terminal "L" and Ground
CONDITION
M o t o r r u n s s l o w l y a t a l l speeds.
PROCEDURE
(1) Disconnect w i r i n g harness connector a t motor.
Remove wiper arms a n d blades. Connect a n ammeter
between battery a n d t e r m i n a l " L " on motor (Fig. 2).
(a) I f motor r u n s and average ammeter reading
is more t h a n 6 amps, proceed t o step 2.
(b) I f motor r u n s and average ammeter reading
is less t h a n 6 amps, proceed t o step 3.
(2) Check to see i f w i p e r linkage or pivots are bind-
i n g or caught. Disconnect drive l i n k from motor.
(a) I f motor n o w runs and draws less t h a n 3
amps, repair linkage system.
(b) I f motor continues to draw more t h a n 3
amps, replace motor assembly.
(3) Check motor w i r i n g harness for s h o r t i n g be-
tween h i g h and low speed wires as follows:
(a) Connect a voltmeter or test lamp t o motor
ground strap.
(b) Set wiper s w i t c h to L O W position.
(c) Connect other lead of voltmeter (test lamp)
to t e r m i n a l " H " of the w i r i n g harness.
8K - 3
(d) I f voltage is present, there is a short i n the
w i r i n g or wiper switch. I f no voltage is present pro-
ceed t o step (e).
(e) Set wiper switch to H I G H position.
(f) Move voltmeter (test lamp) lead f r o m t e r m i -
n a l " H " t o t e r m i n a l " L " o f the w i r i n g harness.
(g) I f voltage is present, there is a short i n t h e
w i r i n g or wiper switch.
CONDITION
M o t o r w i l l r u n a t h i g h speed, b u t n o t a t l o w
speed. M o t o r w i l l r u n a t l o w speed, b u t n o t a t
h i g h speed.
PROCEDURE
(1) I f motor w i l l not r u n on h i g h speed, p u t switch
i n H I G H position and connect a test l a m p between
motor t e r m i n a l " H " and ground (Fig. 3).
Fig. 3 Test Lamp Between Terminal "H" and
Ground
I f motor w i l l not r u n on low speed, p u t switch i n
L O W position and connect a test l a m p between motor
t e r m i n a l " L " and ground.
(2) I f test l a m p does not l i g h t a t motor t e r m i n a l ,
there is a n open i n w i r i n g or switch. I f test lamp
l i g h t s a t motor t e r m i n a l , replace motor assembly.
CONDITION
M o t o r w i l l keep running w i t h switch i n O F F
position.
PROCEDURE
(1) Remove w i r i n g harness. Connect j u m p e r from
T e r m i n a l P2 to t e r m i n a l L of w i p e r motor (Fig. 4).
(2) Connect second j u m p e r from t e r m i n a l P I to bat-
tery. I f motor runs to P A R K position a n d stops,
wiper s w i t c h is faulty. I f motor keeps r u n n i n g and
does not p a r k , replace motor assembly.
CONDITION
M o t o r w i l l stop wherever i t i s , w h e n c o l u m n
s w i t c h is p u t i n O F F position. (Wipers d o n o t
continue r u n n i n g t o P A R K position).
8K - 4 WINDSHIELD WIPER AND WASHER SYSTEMS •
TERMINALS SWITCH TEST
To test the s w i t c h , first disconnect t h e s w i t c h wires
f r o m t h e body w i r i n g a t the connector. T h e n , u s i n g a
c o n t i n u i t y tester or an ohmmeter, test for c o n t i n u i t y
(no resistance) between t h e t e r m i n a l s o f the switch
as shown i n t h e following c o n t i n u i t y chart. The iden-
t i t y o f each t e r m i n a l is shown i n (Fig. 6).

_ — — ^ TO IGNITION
~ KUN&ACCY
1
WINDSHIELD
WIPER FUSE #6 IWASHER PUMP
MOTOR (20 AMP) AND MOTOR

BATTERY
"B + " RR8KC6 TWO SPEED
WIPER SWITCH
Fig. 4 One Jumper Wire Between Terminal "P2" and (ON STEERING
" L " . One Jumper Wire Between Terminal "P1 and COLUMN)
"B+"
PROCEDURE
(1) Remove motor w i r i n g connector and clean ter-
PARK
m i n a l s . Reconnect connector and test motor. I f prob-
SWITCH
l e m persists, proceed to step No. 2.
(2) P u t wiper switch to O F F position. Disconnect
motor w i r i n g connector. Connect a voltmeter or test
l a m p to t h e motor ground strap. Connect t h e other
lead t o t e r m i n a l " P I " of w i r i n g connector.
(a) I f voltage is not present, check for a n open
c i r c u i t i n t h e w i r i n g harness or w i p e r control
switch.
(b) I f voltage is present, proceed t o step (3).
(3) Connect a n ohmmeter or c o n t i n u i t y tester be-
tween t e r m i n a l s " L " and "P2" (Fig. 5).
TERMINALS J908K-35
OHMMETER
"L" "P "2

Fig. 6 Two Speed Wiper Motor Wiring Schematic

For test purposes, the first (or clockwise) position is
the O F F position, w i t h L O W being t h e n e x t detent
position and H I G H being the last (counterclockwise)
detent position. I n any wiper mode, i f the knob is
pushed a l l t h e w a y i n , t h e washer c i r c u i t w i l l be
completed.

TWO SPEED WIPER SWITCH CONTINUITY CHART

Off Low High

B + to P, B + to P, B + to P,
RR8KC7
LtoP 2 B + to L B + toH
Fig. 5 Ohmmeter Between Terminal "L" and "P2" H—Open P —Open
2 P —Open
2

(a) I f there is continuity between these t e r m i - H—Open L—Open

nals, the problem is a defective motor. B + toW B + to W B + toW
(b) I f there is no continuity, t h e problem i s a n (In Wash) (In Wash) (In Wash)
open circuit i n the wiper control s w i t c h or w i r i n g
J908K-20
harness.
 • WINDSHIELD WIPER AND WASHER SYSTEMS
INTERMITTENT WINDSHIELD WIPER FUNCTION A N D SWITCH
PROCEDURES
INDEX
Page
Intermittent Windshield Wiper Function Tests ..... 5
Intermittent Wipe Module Location 5
INTERMITTENT WINDSHIELD WIPER FUNCTION
TESTS
Since t h e i n t e r m i t t e n t wipe a n d standard t w o
speed motors are identical. Refer t o previous sections
for diagnosis o f system problems w h i c h do n o t i n -
volve the D E L A Y function. I f problem occurs o n l y i n
t h e D E L A Y mode, the f o l l o w i n g tests are t o be per-
formed. These tests involve disconnecting the i n t e r -
m i t t e n t wipe control u n i t w h i c h can be found on t h e
steering c o l u m n support bracket (refer t o I n t e r m i t -
t e n t Wipe Module Location).
CONDITION
E x c e s s i v e delay (more t h a n 30 seconds) o r i n -
a d e q u a t e v a r i a t i o n i n delay.
PROCEDURE
V a r i a t i o n s i n delay should be as follows:
(1) M i n i m u m delay (delay control to extreme coun-
terclockwise position before first detent) one h a l f t o
t w o seconds.
(2) M a x i m u m delay (delay control to extreme clock-
wise position before off detent) t e n to t h i r t y seconds.
(3) I f there is excessive delay or no variations i n
delay proceed to i n t e r m i t t e n t wipe switch test.
CONDITION
I n D E L A Y mode w i p e r s r u n continually w h e n
w a s h i s o p e r a t e d b u t d o n o t provide a n e x t r a
w i p e w h e n the w a s h c o n t r o l i s released.
PROCEDURE
Replace t h e control u n i t .
8K - 5
TESTING
Page
Intermittent Wipe Switch Test 5
CONDITION
Wipers start e r r a t i c a l l y d u r i n g D E L A Y mode.
PROCEDURE
(1) Verify t h a t t h e ground connection a t t h e i n s t r u -
ment panel is m a k i n g good connection (free f r o m
paint) a n d is t i g h t .
(2) Verify t h a t the motor ground strap i s m a k i n g
good contact and t h a t the motor m o u n t i n g bolts are
tight.
(3) Verify t h a t the w i r i n g ground connections for
the i n t e r m i t t e n t wipe control u n i t a n d t h e wiper
switch are t i g h t .
(4) I f condition is n o t corrected, replace control
unit.
INTERMITTENT WIPE SWITCH TEST
To test the switch, first disconnect t h e s w i t c h wires
from the body w i r i n g at the connector. T h e n , u s i n g a
continuity tester or a n ohmmeter, test for c o n t i n u i t y
(no resistance) between the t e r m i n a l s o f t h e harness
side o f the switch connector as shown i n t h e continu-
i t y chart.
For test purposes, the first (or clockwise) position is
the OFF position, next is the slide f o r t h e D E L A Y
wipe, w i t h counterclockwise r o t a t i o n , r e d u c i n g t h e
delay. Low is the next detent position a n d H I G H is
the f u l l counterclockwise detent position.
I n any wiper mode, i f the knob i s pushed a l l the
way i n , the washer circuit w i l l be completed.
INTERMITTENT WIPE MODULE LOCATION
The i n t e r m i t t e n t wipe module is located t o t h e
r i g h t o f the steering column on the back side o f the
i n s t r u m e n t panel (Fig. 2).
8K - 6 WINDSHIELD WIPER AND WASHER SYSTEMS •
INTERMITTENT WIPE SWITCH CONTINUITY CHART

VIEW FROM TERMINAL SIDE

SWITCH POSITION CONTINUITY BETWEEN
OFF PIN 1-13, PIN 3-10, PIN 4-11, PIN 5-12
DELAY PIN 1-13, PIN 3-10, PIN 4-16, PIN 4-11, PIN 4-', PIN 5-12, PIN 8-15, PIN 9-16, PIN 11-16, PIN 9-11
LOW PIN 1-13, PIN 3-10, PIN 4-7, PIN 4-11, PIN 5-12, PIN 7-11
HIGH PIN 1-13, PIN 3-10, PIN 4-6, PIN 4-11, PIN 5-12, PIN 6-11

908K-6

Fig. 11ntermittent Wipe Wiring Schematic


WINDSHIELD WIPER S Y S T E M S E R V I C E P R O C E D U R E S
Page
Linkage Replacement
Wiper Arm Replacement
Wiper Blade Element Change
Wiper Blades
WIPER BLADES
Wiper blades exposed t o the weather for a long pe-
r i o d of t i m e t e n d to lose t h e i r w i p i n g effectiveness.
Periodic cleaning of t h e w i p e r blade i s suggested t o
remove the a c c u m u l a t i o n o f salt and road f i l m . The
wiper blades, arms and w i n d s h i e l d should be cleaned
w i t h a sponge or cloth a n d a m i l d detergent or nona-
brasive cleaner. I f t h e blades continue t o streak or
smear, they should be replaced.
WIPER BLADE ELEMENT CHANGE
There are t w o types o f w i p e r blade assemblies. The
assemblies a r e identified as "Type A " (Fig. 1) and
"Type B " (Figs. 2 and 3).
Fig. 1 Removing Blade and Wiping Element from
Blade Assembly Type"A"
Fig. 2 Removing Blade from Arm Type "B"
(1) T u r n w i p e r switch O N , position blades to a con-
venient place b y t u r n i n g t h e i g n i t i o n s w i t c h O N and
OFF.
(2) L i f t w i p e r a r m to raise blade off glass.
(3) Remove blade assembly f r o m a r m and w i p i n g
element from blade, depending on type, as follows:
WINDSHIELD WIPER AND WASHER SYSTEMS 8K - 7
INDEX
Page
8 Wiper Motor Replacement 8
7 Wiper Switch Replacement—Standard Column .... 9
7 Wiper Switch Replacement—Tilt Column 10
7
T Y P E A — To remove blade assembly from a r m ,
insert a s m a l l screwdriver blade into release slot o f
w i p e r blade and p r y s l i g h t l y u p w a r d (Fig. 1).
To remove w i p i n g element from blade assembly,
p i n c h lock on end o f blade assembly and w i t h d r a w
w i p i n g element (blade) o u t o f claws.
Check each release point for positive locking w h e n
i n s t a l l i n g blade element and blade assembly.
T y p e B — T o remove blade, l i f t up on release tab on
center bridge p i v o t (Fig. 2).
L i f t lock t a b o n one of end l i n k s and squeeze l i n k
to remove f r o m center bridge. Slide end l i n k off ele-
m e n t and slide element f r o m claws of other l i n k (Fig.
3).
LIFT RELEASE TAB END LINK RH526
Fig. 3 Removing Wiping Element From Blade
Assembly Type "B"
Check each release point for positive locking w h e n
i n s t a l l i n g blade element and blade assembly.
WIPER ARM REPLACEMENT
REMOVAL
(1) L i f t the a r m to p e r m i t the latch (Fig. 4) to be
p u l l e d out to t h e h o l d i n g position and remove t h e
a r m f r o m the p i v o t using a rocking motion.
Fig. 4 Removing Wiper Arm
8K - 8 WINDSHIELD WIPER AND WASHER SYSTEMS
CAUTION: The use of a screwdriver or other pry-
ing tool to remove an arm may distort it in a man-
ner that will allow it to come off the pivot shaft in
the future, regardless of how carefully it is installed.
INSTALLATION
W i t h w i p e r motor i n p a r k position, m o u n t arms on
pivot shafts, choosing a s e r r a t i o n engagement w h i c h
locates blades so t h a t distance between t h e intersec-
t i o n o f a r m and the blade a n d t h e weatherstrip is as
shown i n F i g . 5.
ADJUST WIPER ARM SO TIP OF
BLADE IS ABOVE THE WEATHERSTRIP
IN PARK POSITION AS SHOWN J908K-34
Fig. 5 Adjusting Wiper Arms
WIPER MOTOR REPLACEMENT
REMOVAL
(1) Disconnect battery negative cable.
(2) Disconnect wires f r o m w i p e r motor.
(3) Remove motor m o u n t i n g screws.
(4) Lower motor down far enough t o g a i n access to
crank a r m to drive l i n k r e t a i n e r bushing.
(5) Remove crank a r m f r o m drive l i n k b y p r y i n g
retainer bushing f r o m c r a n k a r m p i n w i t h a suitable
size screwdriver.
(6) Remove motor.
(7) Remove n u t a t t a c h i n g c r a n k a r m to motor drive
shaft.
(8) Remove crank a r m .
INSTALLATION
(1) Position crank a r m o n motor drive shaft, m a k -
i n g sure slot is indexed properly, i n s t a l l m o u n t i n g
n u t and t i g h t e n to 11 N-m (95 i n . lbs.) torque.
(2) I n s t a l l crank a r m p i n i n drive l i n k retainer
bushing b y snapping together w i t h channel lock p l i -
ers.
(3) Position motor into place, i n s t a l l m o u n t i n g
screws, and t i g h t e n t o 6 N-m (55 i n . lbs.) torque.
(4) Connect wires t o w i p e r motor.
(5) Connect battery cable.
•
LINKAGE REPLACEMENT (Fig. 6)
CRANK ARM
REMOVAL
(1) Remove wiper motor as previously described.
(2) Remove n u t a t t a c h i n g crank a r m to motor drive
shaft.
(3) Remove crank a r m .
INSTALLATION
(1) Position crank a r m on motor drive shaft, m a k -
i n g sure slot is indexed properly, i n s t a l l m o u n t i n g
n u t a n d t i g h t e n t o 11 N-m (95 i n . lbs.) torque.
(2) I n s t a l l wiper motor.
DRIVE LINK ASSEMBLY LEFT PIVOT
ASSEMBLY
REMOVAL
(1) Remove wiper arms.
(2) Remove screws a t t a c h i n g louvered cowl cover t o
cowl panel.
(3) Remove cowl cover b y p u l l i n g forward w i t h a
s l i g h t u p w a r d movement.
(4) Reach t h r o u g h access hole and remove drive
l i n k f r o m r i g h t pivot b y p r y i n g retainer b u s h i n g
f r o m p i v o t p i n w i t h a suitable size screwdriver.
(5) Remove crank a r m from drive l i n k b y p r y i n g
r e t a i n e r bushing from crank a r m p i n w i t h a suitable
size screwdriver.
(6) Remove left pivot m o u n t i n g screws and let p i v o t
h a n g loose.
(7) W o r k i n g t h r o u g h access holes remove d r i v e
l i n k s a n d left pivot as a n assembly.
(8) Remove drive l i n k from left pivot b y p r y i n g re-
t a i n e r b u s i n g from pivot p i n w i t h a suitable size
screwdriver.
INSTALLATION
(1) I n s t a l l left pivot p i n i n drive l i n k retainer bush-
i n g b y snapping together w i t h channel lock pliers.
(2) Maneuver drive l i n k s a n d pivot assembly
t h r o u g h access hole and position into place.
(3) Position left pivot i n t o place, i n s t a l l m o u n t i n g
screws a n d t i g h t e n t o 11 N-m (95 i n . lbs.) torque.
(4) I n s t a l l crank a r m p i n i n drive l i n k r e t a i n e r
b u s h i n g b y snapping together w i t h channel lock p l i -
ers.
(5) I n s t a l l r i g h t pivot p i n i n drive l i n k retainer
b u s h i n g b y snapping together w i t h channel lock p l i -
ers.
(6) Position cowl cover into place, i n s t a l l m o u n t i n g
screws a n d t i g h t e n securely.
(7) I n s t a l l wiper arms, refer t o wiper a r m adjust-
m e n t procedure.
 • WINDSHIELD WIPER AND WASHER SYSTEMS 8K - 9

BLADE PIVOT ASSEMBLY

Fig. 6 Wiper Linkage

RIGHT PIVOT ASSEMBLY (2) Remove 4 screws a t t a c h i n g the lower steering
column cover (Fig. 7). T h e fuse block is attached to
REMOVAL t h i s cover and should be supported when cover is re-
(1) Remove w i p e r arms. moved.
(2) Remove screws a t t a c h i n g louvered cowl cover to
firewall.
(3) Remove cowl cover b y p u l l i n g f o r w a r d w i t h a
slight u p w a r d movement.
(4) Reach t h r o u g h access hole and remove drive
l i n k from r i g h t p i v o t by p r y i n g r e t a i n e r bushing
f r o m pivot p i n w i t h a suitable size screwdriver.
(5) Remove r i g h t p i v o t m o u n t i n g screws.
(6) Remove p i v o t t h r o u g h access hole.

INSTALLATION
(1) Position p i v o t i n t o place, i n s t a l l m o u n t i n g
screws, and t i g h t e n t o 11 N - m (95 i n . lbs.) torque.
(2) I n s t a l l r i g h t p i v o t p i n i n drive l i n k retainer
bushing by snapping together w i t h channel lock p l i -
ers.
(3) Position cowl cover i n t o place, i n s t a l l m o u n t i n g Fig. 7 Steering Column Cover
screws and t i g h t e n securely.
(3) O n t h e standard and optional steering wheels
(4) I n s t a l l w i p e r arms.
(Figs. 8 a n d 9) remove t w o h o r n pad m o u n t i n g
screws from underside of steering wheel.
WIPER SWITCH REPLACEMENT-STANDARD
(4) P u l l pad u p f r o m wheel and disconnect electri-
COLUMN
cal leads.
(1) Disconnect b a t t e r y negative cable. (5) Remove pad.
8K - 10 WINDSHIELD WIPER AND WASHER SYSTEMS •
ELECTRICAL STEERING
LEADS COLUMN

HORN PAD

WIRE
TROUGH RH1333
MOUNTING
SCREWS (2)' J 908G-5 Fig. 11 Wire Trough Cover
HORN AND TURN WEDGE BLOCK
Fig. 8 Standard Steering Wheel
"SIGNAL CONNECTOR
ELECTRICAL
LEADS

HORN PAD
WINDSHIELD WIPER FROM
CONNECTOR KEY-IN
SWITCH

FROM KEY-IN LAMP J908K-37

Fig. 12 Disconnecting Wires

(6) Remove steering wheel n u t and remove steering
MOUNTING- wheel w i t h p u l l e r C-3428B (Fig. 10).
SCREWS (3) J908G-6
(7) Pry out w i r i n g t r o u g h retainers and l i f t off w i r -
i n g t r o u g h . N e w retainers m a y be required for reas-
Fig. 9 Optional Steering Wheel
sembly (Fig. 11).
TOOL
C-3428B (8) Disconnect wash/wipe s w i t c h connector and, i f
equipped, i n t e r m i t t e n t w i p e module connector a n d
speed control connector (Figs. 12 and 13).
(9) Remove two screws t h a t attach the lock housing
to t h e lock housing a n d remove the lock housing
cover.
(10) Remove t h e wipe/wash switch assembly ( F i g .
14)
(11) P u l l t h e hider up t h e control stalk and remove
the two screws t h a t a t t a c h the control s t a l k sleeve to
the wipe/wash switch (Figs. 14 and 15).
(12) Remove wash/wipe s w i t c h control knob from
end of m u l t i f u n c t i o n control s t a l k (Fig. 15).
(13) Rotate the control s t a l k shaft to the f u l l clock-
wise position and remove t h e shaft from the switch
by p u l l i n g s t r a i g h t out o f the switch (Fig. 16).
For i n s t a l l a t i o n , reverse t h e removal procedures.
T i g h t e n steering wheel n u t t o 61 N-m (45 f t . lbs.).

J908M-7
WIPER SWITCH REPLACEMENT-TILT COLUMN
(1) Disconnect battery negative cable.
Fig. 10 Removing Steering Wheel (Typical) (2) Remove steering c o l u m n cover (Fig. 17).
• WINDSHIELD WIPER AND WASHER SYSTEMS 8K - 11

STEERING COLUMN ALIGNMENT SLOT

ASSEMBLY

MULTI-FUNCTION
CONTROL STALK

WASH/WIPE SWITCH
WIRING TROUGH
TO KEY-IN
"LAMP WIRING
"TO KEY-IN SWITCH RY347
TO TURN WIRING
SIGNAL Fig. 16 Remove or install Control Stalk
TO SPEED
WIRING
CONTROL WIRING
slO INTERMITTENT WIPE
TO WINDSHIELD CONTROL UNIT
WIPER WIRING RR8JC3

Fig. 13 Steering Column Wiring Connectors

WIPE/WASH
SWITCH
ASSEMBLY

ENGINE
COVER

STEERING
COLUMN
COVER
RR8EC76
RH1336
Fig. 17 Steering Column Cover
Fig. 14 Wipe/Wash Switch Assembly
ELECTRICAL
WINDSHIELD WITH LEADS
"WIPER SWITCH HIDER SPEED
CONTROL

WIPER
KNOB HORN PAD

SWITCH
AND LEVER
COVERS
HIDER
X
SILENCER
WITHOUT SPEED CONTROL RH1337
MOUNTING
Fig. 15 Multifunction Control Stalk SCREWS (2)' J908G-5
(a) Remove one screw f r o m left side of cover.
(b) Remove two screws, one on each side of Fig. 18 Standard Steering Wheel
steering column. (Figs. 18 and 19) remove t w o h o r n pad m o u n t i n g
(c) Remove one screw f r o m brace on r i g h t side screws from underside of steering wheel.
of cover and p u l l down to remove.
(3) O n the standard and optional steering wheels
 8K - 12 WINDSHIELD WIPER AND WASHER SYSTEMS •

Fig. 20 Removing Steering Wheel (Typical)

(4) P u l l pad up from wheel and disconnect electri-
cal leads.
(5) Remove pad.
(6) Remove steering wheel n u t and remove steering
wheel w i t h puller C-3428B (Fig. 20). TO KEY-IN
(7) Pry out w i r i n g t r o u g h retainers a n d l i f t off w i r - LAMP WIRING
i n g t r o u g h . New retainers m a y be r e q u i r e d for reas- KEY-IN SWITCH
TO TURN WIRING
sembly (Fig. 21). SIGNAL
(8) Depress lock plate w i t h Tool C-4156 and p r y re- WIRING TO SPEED
CONTROL WIRING
t a i n i n g r i n g out of groove w i t h screwdriver (Fig. 22).
The f u l l load of the upper bearing s p r i n g should not sTO INTERMITTENT WIPE
TO WINDSHIELD CONTROL UNIT
be relieved as the r e t a i n i n g r i n g w i l l t u r n too easily
WIPER WIRING RR8JC3
m a k i n g removal more difficult. Remove lock plate,
canceling cam, and upper b e a r i n g s p r i n g . Fig. 23 Steering Column Wiring Connectors
(9) Remove switch s t a l k actuator screw a n d a r m .
(11) Disconnect t u r n signal w i r i n g , wipe/wash
(10) Push hazard w a r n i n g knob i n a n d unscrew t o
switch connector, and i f so equipped, i n t e r m i t t e n t
remove.
 • WINDSHIELD WIPER AND WASHER SYSTEMS 8K - 13

wipe and speed control connectors (Figs. 23 and 24).

HORN AND TURN WEDGE BLOCK

WINDSHIELD WIPER cSpEf£^ FROM

CONNECTOR LjEfe®) KEY-IN
SWITCH

FROM KEY-IN LAMP J908K-37

Fig. 24 Disconnecting Wires

(12) Remove 3 t u r n signal switch attaching screws.
Place shift lever i n l o w (1) position. W r a p a piece o f
tape around the connector and wires to prevent snag-
g i n g w h e n removing t h e switch (Fig. 25). Remove Fig. 26 Ignition Key Lamp and Hazard Warning
t u r n signal switch and w i r i n g . Knob.

Fig. 25 Tape Connector and Wires

(13) Remove i g n i t i o n k e y l a m p (Fig. 26). Fig. 27 Removing Lock Cylinder
(14) The lock cylinder m a y be removed i n any po-
sition from ACCESSORY to O N . The lock position is
recommended because o f its positive location.
Insert a t h i n tool (small screwdriver or s h i m stock)
i n t o t h e slot next to t h e switch m o u n t i n g screw boss
( r i g h t h a n d slot) a n d depress spring l a t c h a t bottom
of slot, w h i c h releases lock. Remove lock (Fig. 27).
The buzzer switch can be pulled s t r a i g h t out o f the
housing (Fig. 28). A straightened paper clip or s i m i -
l a r piece o f stiff w i r e w i t h a hook bent on one end
should be inserted i n t h e exposed loop of the wedge
spring, t h e n a s t r a i g h t p u l l on t h e w i r e w i l l remove
b o t h spring and switch ( i f the lock cylinder is not re-
moved before t h e switch, i t m u s t be i n t h e O N posi-
tion).

CAUTION: If wedge spring is dropped on removal, it Fig. 28 Key Buzzer Switch and Wedge Spring
could fall into the column, requiring complete dis- (15) Remove 3 housing cover screws and remove
assembly to retrieve spring.
8K - 14 WINDSHIELD WIPER AND WASHER SYSTEMS •
housing cover (Fig. 31). W i t h t h e housing cover re- CAUTION: Use tape to hold dimmer switch rod in
moved, t h e wash/wipe switch m a y be removed. place.
(16) Press out wash/wipe switch pivot p i n w i t h a
WINDSHIELD WITH
p u n c h (Fig. 29). "WIPER SWITCH HIDER SPEED
CONTROL

WIPER
LOCK HOUSING 1
KNOB

SWITCH
AND LEVER
COVER /
WIPER SWITCH HIDER
PIVOT PIN SILENCER
WITHOUT SPEED CONTROL RH1337

PUNCH Fig. 31 Multifunction Control Stalk

(19) Remove wash/wipe switch control knob f r o m
RB25 end of m u l t i f u n c t i o n control stalk (Fig. 31).
(20) Rotate the control stalk shaft t o t h e f u l l clock-
Fig. 29 Wiper Switch Pivot Pin
wise position and remove t h e shaft f o r m t h e s w i t c h
(17) Remove the wash/wipe switch assembly (Fig. by p u l l i n g straight out o f the s w i t c h (Fig. 32).
30).
.ALIGNMENT SLOT

MULTI-FUNCTION
CONTROL STALK

WIPE/WASH
SWITCH
ASSEMBLY

WASH/WIPE SWITCH

RY347
RH1336
Fig. 32 Remove or Install Control Stalk
Fig. 30 Wipe/Wash Switch Assembly For I n s t a l l a t i o n , reverse t h e r e m o v a l procedures.
(18) P u l l the hider up the control stalk and remove T i g h t e n steering wheel n u t to 6 1 N * m (45 f t . lbs.).
the t w o screws t h a t attach the control stalk sleeve t o
the wash/wipe switch (Figs. 30 and 31).
 • WINDSHIELD WIPER AND WASHER SYSTEMS 8K - 15

WINDSHIELD WASHERS

INDEX
Page Page
General Information 15 Windshield Washer Pump Replacement 15

GENERAL INFORMATION WINDSHIELD WASHER PUMP REPLACEMENT

(Fig. 2)
A l l models are equipped w i t h electric operated
w i n d s h i e l d washer pumps.
The electric p u m p assembly i s mounted directly t o
REMOVAL
(1) Remove l i q u i d from reservoir.
t h e reservoir. A permanently lubricated sealed motor
(2) Remove reservoir m o u n t i n g screws a n d remove
is coupled t o a rotor type p u m p . F l u i d , g r a v i t y fed
reservoir a n d pump assembly.
from the reservoir, i s forced b y the p u m p t h r o u g h
(3) Disconnect electrical lead a n d r u b b e r hose f r o m
rubber hoses t o the nozzles w h i c h direct t h e streams
bottom o f pump.
to the w i n d s h i e l d .
(4) U s i n g a n extension and deep w e l l socket, reach
These vehicles are equipped w i t h special plastic
t h r o u g h reservoir f i l l e r neck, a n d remove p u m p
washer nozzles (Fig. 1). Because they are inserted d i -
m o u n t i n g n u t and plastic washer.
rectly i n t o t h e cowl panel, there is no adjustment re-
(5) Remove pump f r o m b o t t o m reservoir.
quired. (6) Remove rubber g r o m m e t from reservoir a n d
t h r o w away.

INSTALLATION
(1) I n s t a l l new rubber g r o m m e t into place i n bot-
t o m o f reservoir.
(2) Position p u m p i n t o place i n reservoir. I n s t a l l
plastic washer t h e n m o u n t i n g n u t , and t i g h t e n t o 3
N«m (25 i n . lbs.) torque. Do n o t overtighten.
(3) Connect electrical leads a n d hose to p u m p .
(4) Position reservoir into place, i n s t a l l m o u n t i n g
screws and t i g h t e n securely.
(5) F i l l reservoir w i t h w a t e r and/or washer f l u i d ,
inspect for leaks a n d test system.

Fig. 1 Windshield Washer System

Fig. 2 Washer Pump

8K - 16 WINDSHIELD WIPER AND WASHER SYSTEMS •

WINDSHIELD WASHER DIAGNOSIS

PUMP MOTOR I
PUMP R U N S - WASHER DOES DOES NOT RUN
SYSTEM OUTPUT
PUMP NOT NOT OPERATE LOW
PUMPING FLUID I PROPERLY
LOOSE WIRING
TERMINALS.
CORRODED
NO FLUID IN PINCHED OR
PUMP MOTOR RUNS TERMINALS.
RESERVOIR LEAKY HOSES

I
BROKEN WIRES
SYSTEM LEAKY OR RESTRICTED
NOHLE JETS OPERATES MOTOR R U N S -
PLASTIC HOSE
PLUGGED INTERMITTENTLY | PUMP PUMPING FLUID
CONNECTOR

POOR GROUND
BROKEN OR SYSTEM OPERATES POOR ELECTRICAL
LOOSE WIRING
WITHOUT CONNECTIONS
LOOSE HOSE CONNECTIONS
INTERRUPTION

FAULTY SWITCH
SYSTEM OUTPUT
FAULTY PUMP FAULTY SWITCH DEFECTIVE PUMP
ADEQUATE

FAULTY MOTOR
WASHER SYSTEM
FAULTY MOTOR OK
RR8KC24
 LAMPS 8L - 1

LAMPS
CONTENTS
Page Page

EXTERIOR LAMPS 1 INTERIOR LAMPS 10

EXTERIOR LAMPS SERVICE PROCEDURES 3 SPECIFICATIONS 11

E X T E R I O R LAMPS
INDEX
Page Page
Diagnostic Procedures ... 1 General Information .. . 1

GENERAL INFORMATION any good m u l t i p u r p o s e grease or petroleum j e l l y .

Each vehicle is equipped w i t h various l a m p assem-
blies w h i c h a r e
used for i l l u m i n a t i n g and/or i n d i c a t i n g purposes. A
good ground is m a n d a t o r y for proper l i g h t i n g circuit
operation. C i r c u i t g r o u n d i n g is provided by the lamp
socket w h e n i t comes i n contact w i t h the m e t a l body,
or t h r o u g h a separate g r o u n d w i r e l i n k i n g the lamp
socket to t h e body on plastic l a m p assemblies.
W h e n changing l a m p bulbs, check the socket for
corrosion. I f corrosion is present, clean i t w i t h a w i r e
b r u s h and coat t h e inside o f the socket l i g h t l y w i t h
B u l b i d e n t i f i c a t i o n a n d application for exterior and
interior lamps can be found i n Specifications.
DIAGNOSTIC PROCEDURES
Always b e g i n any electrical system failure diagno-
sis by t e s t i n g a l l o f the related fuses a n d circuit
breakers i n t h e fuse block and engine compartment
(see Group 8 W - W i r i n g Diagrams).
Conventional and halogen headlamp sealed beam
u n i t s are physically and electrically interchangeable,
b u t i t is recommended t h a t they not be i n t e r m i x e d
on a given vehicle.

HEADLAMP DIAGNOSIS

][ [
HEADLAMPS M M SEALED REAM HEADLAMPS DIM HEADLAMPS HEADLAMPS
ENGINE IDLING OR BULB BURNS ENGINE RUNNING

i
RANDOM FLASH WILL NOT LIGHT
OR IGNITION OFF OUT FREQUENTLY ABOVE IDLE

POORLY GROUNDED LOOSE CONNECTION

TEST CHARGING TEST CHARGING TEST CHARGING IN HEADLAMP
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

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

FAULTY SEALED FAULTY SEALED

BEAMS OR BULBS BEAMS OR BULBS

RR8LD21
8L - 2 LAMPS

HEADLAMP DIMMER SWITCH TEST

(1) Remove 4 screws a t t a c h i n g t h e lower steering
column cover ( F i g . 1). The fuse block i s attached to STEERING
t h i s cover a n d should be supported w h e n cover i s r e - WHEEL
moved.

STEERING
COLUMN
COVERS

CONNECTOR REMOVED
J908K-33 FROM DIMMER SWITCH

Fig. 1 Steering Column Cover

(2) To test t h e switch, leave t h e harness connected PR674 A
to t h e d i m m e r s w i t c h a n d w i t h a 12 v o l t test l i g h t
check for 12 volts a t t h e t e r m i n a l s o f t h e switch Fig. 2 Dimmer Switch Wiring Harness
(Figs. 2 a n d 3).
W i t h t h e headlamp switch i n t h e O F F or P a r k po-
sition, there should be 12 volts a t t e r m i n a l B O N L Y . A RB
W i t h t h e headlamp switch O N a n d t h e d i m m e r
switch i n H I G H B E A M position, there should be 12
volts a t t e r m i n a l s A , B , and D .
oI ID
W i t h t h e headlamp switch i n t h e L O W BEiCM po- C D C D
sition there should be 12 volts a t t e r m i n a l s A , B , and
c. VIEWED FROM WIRE END OF CONNECTOR
W i t h t h e d i m m e r switch held i n t h e Flash t o Pass
position, there should be 12 volts o n a l l four t e r m i -
nals.
HIGH BEAM LOW BEAM
POSITION POSITION
J908L-71

Fig. 3 Dimmer Switch Test Points

 • LAMPS 8L - 3

E X T E R I O R LAMPS S E R V I C E P R O C E D U R E S
INDEX
Page Page
Cargo Lamp Bulb 5 License Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Daytime Running Lights (Canada Only) 9 Sealed Beam Replacememt 3
Front Park And Turn Signal Lamp Bulb . . . . . . . . . 3 Side Marker Lamp And Bulb 3
Headlamp Aiming Procedures 7 Tail, Stop, Turn Signal, Rear Side Marker And
Headlamp Dimmer Switch 7 Back-Up Lamps . 3
Headlamp Switch 6 Underhood Retractable Lamp 10
I.D. And Clearance Lamps For Dual Wheel Model . 4

SEALED BEAM REPLACEMENT SIDE MARKER LAMP AND BULB

(1) Remove screws f r o m headlamp bezel (Fig. 1). (1) T w i s t out socket f r o m back of housing.
(2) Remove n u t s a t t a c h i n g l a m p assembly t o
HEADLAMP SEALED
BEZEL & fender.
BEAM
PARKING LAMP (3) L i f t l a m p assembly away from outside of fender.
ASSEMBLY To i n s t a l l , reverse t h e removal procedures.

TAIL, STOP. TURN SIGNAL, REAR SIDE MARKER

AND BACK-UP LAMPS

SWEPTLINE MODELS (FIG. 2)

To replace bulbs, remove lamp.

REMOVAL
(1) Remove assembly attachment screws and re-
move lamp assembly.
(2) T w i s t out socket.
J908L-72
CONNECTOR BLACK MOLD J " NUT
Fig. 1 Sealed Beam Replacement
(2) Twist o u t p a r k a n d t u r n signal l a m p socket
r
f r o m back of l a m p housing. Set Headlamp bezel
aside.
(3) Remove screws f r o m r e t a i n i n g r i n g , and remove
r i n g (Fig. 2). D o n o t d i s t u r b h e a d l a m p a i m i n g
screws.
(4) P u l l out sealed beam u n i t and u n p l u g connec-
tor, by p u l l i n g i t s t r a i g h t off.
(5) Position new sealed beam u n i t and i n s t a l l con-
nector.
(6) I n s t a l l r e t a i n i n g r i n g .
(7) Install headlamp bezel.
(8) A i m Headlamp as described i n Headlamp A i m -
i n g Procedures.

*LAMP ASSEMBLY
FRONT PARK AND TURN SIGNAL LAMP BULB
-SCREW RN991
(1) Remove screws f r o m headlamp bezel (Fig. 1).
(2) Twist o u t p a r k a n d t u r n signal l a m p socket
Fig. 2 Tail, Stop, Turn Signal, Rear Side Marker and
from back of l a m p housing. Back-Up Lamp
(3) Replace bulb.
To install, reverse r e m o v a l procedures. INSTALLATION
(1) T w i s t i n socket.
(2) Position t h e l a m p and i n s t a l l assembly mount-
i n g screws.
8L - 4 LAMPS •
CAB CHASSIS MODELS (FIG. 3)

REMOVAL
(1) Disconnect w i r i n g harness.
(2) Remove l a m p m o u n t i n g nuts a n d remove as-
sembly.

Fig. 4 Tail, Stop, Turn Signal, Rear Side Marker and

Back-Up Lamp
CAB LAMPS
(1) Remove m o u n t i n g screws (Fig. 7).
(2) P u l l lens away from m o u n t i n g plate.
ASSEMBLY PR1086
(3) L i f t l a m p u p a n d disconnect wires a n d t w i s t o u t
Fig. 3 Tail, Stop, Turn Signal, and Back-Up Lamp socket.
To i n s t a l l , reverse t h e removal procedures.
INSTALLATION
(1) Position l a m p t o bracket and i n s t a l l t w o attach-
i n g screws.
(2) Connect w i r i n g harness.

SPORT UTILITY MODELS (FIG. 4)

REMOVAL
(1) Remove assembly attachment screws a n d re-
move lamp assembly.
(2) T w i s t o u t socket.

INSTALLATION
(1) T w i s t i n socket.
(2) Position t h e l a m p and i n s t a l l assembly mount-
i n g screws.

I.D. AND CLEARANCE LAMPS FOR DUAL WHEEL

MODEL
To change bulb, remove lamp.

WHEEL FLARE MOUNTED AND REAR

CLEARANCE LAMPS
(1) P r y o u t r e t a i n i n g clamps. J908L-73
(2) P u l l lens away f r o m m o u n t i n g plate.
(3) Disconnect electrical connector f r o m bulb a n d Fig. 5 Rear Wheel Flare Mounted Clearance Lamp
lens assembly (Figs. 5 and 6).
 LAMPS 8L - S
•

Fig. 6 Rear Clearance Lamps—Sweptline with Dual Wheels

J908U59.

Fig. 8 Cargo Lamp—Standard Cab

(3) To i n s t a l l , reverse the procedures.
8L - 6 LAMPS •
CLUB CAB STEP BUMPER (FIG. 11)
(1) Remove t w o m o u n t i n g screws (Fig. 9). T o r e m o v e b u l b s , r e m o v e lic e n s e plate l a m p
(2) P u l l assembly o u t a n d disconnect w i r i n g con- a s s e m b l y f r o m step b u m p e r a n d separate l e n s
nectors. from l a m p , t w i s t out b u l b .
(1) Remove 2 l a m p assembly m o u n t i n g screws.
(2) Remove l a m p f r o m bumper.
(3) Disconnect w i r e connector.
T o install, reverse the removal procedures.
CONNECTOR

HOUSING

LENS

LAMP ASSEMBLY
LICENSE PLATE

SCREW

RN990 LAMP ASSEMBLY

SCREW
LICENSE PLATE
Fig. 9 Cargo Lamp—Club Cab (3) To install, reverse RR8LD24
the procedures.
Fig. 11 License Plate Lamps - Step Bumper
LICENSE LAMP WITHOUT REAR BUMPER
(1) Remove screws h o l d i n g lamp assembly to l i -
STANDARD BUMPER (FIG. 10) cense bracket ( F i g . 12).
(1) Remove rear license plate. (2) Disconnect electrical connector a n d remove
(2) Remove 2 lamp assembly hex head m o u n t i n g l a m p assembly.
screws. (3) I n s t a l l n e w l a m p assembly w i t h screws and con-
(3) Remove lamp assembly. nect electrical connector.
(4) Remove 2 screws a t t a c h i n g lamp lens t o hous-
TO TAIL, STOP,
ing. TURN SIG. AND BACK UP LAMPS
(5) T w i s t out bulb.
T o install, r e v e r s e t h e r e m o v a l p r o c e d u r e s .

SCREW

LAMP ASSEMBLY
LICENSE PLATE

LICENSE PLATE LICENSE PLATE LAMP AND

LAMP CONNECTOR BRACKET ASSEMBLY J908L-74

FRONT Fig. 12 License Plate Lamp Without Rear Bumper

HEADLAMP SWITCH
RR8LD23
CONNECTORS' To remove or replace t h e headlamp switch see i n -
structions i n Group 8E - I n s t r u m e n t Panel a n d
Fig. 10 License Plate Lamp - Standard Rear Bumper
Gauges.
 • LAMPS 8L - 7

HEADLAMP DIMMER SWITCH HEADLAMP AIMING PROCEDURES

REMOVAL PRE AIMING INSTRUCTIONS

(1) Disconnect battery negative cable. (1) Test d i m m e r switch operation.
(2) Remove 4 screws attaching t h e lower steering (2) Observe operation o f h i g h beam indicator l i g h t
column cover (Fig. 13). T h e fuse block is attached t o mounted i n i n s t r u m e n t cluster.
t h i s cover and should be supported w h e n cover is re- (3) Inspect f o r badly rusted or f a u l t y headlamp as-
moved. semblies. These conditions m u s t be corrected before a
satisfactory adjustment can be made.
(4) Place vehicle on a level floor.
(5) Jounce front suspension t h r o u g h 3 oscillations
by applying body
weight t o hood or bumper.
(6) Inspect t i r e inflation.
(7) Rock vehicle sideways t o a l l o w vehicle t o as-
sume i t s n o r m a l position.
STEERING
(8) I f gasoline t a n k is n o t f u l l , place a weight i n
COLUMN t r u n k o f vehicle to simulate w e i g h t of a f u l l t a n k (6-
COVERS 1/2 pounds per gallon).
(9) Thoroughly clean h e a d l i g h t lenses.

COMPENSATING THE AIMERS (C-4466) FOR

J908K-33 FLOOR SLOPE
The floor level offset d i a l m u s t coincide w i t h t h e
Fig. 13 Steering Column Cover floor slope for accurate a i m i n g . C a l i b r a t i o n fixtures
(3) Disconnect electrical connector. are included w i t h the aimers.
(4) Remove two screws o n d i m m e r s w i t c h m o u n t i n g (1) A t t a c h one c a l i b r a t i o n f i x t u r e t o each aimer.
plate to replace, switch (Fig. 14). Fixtures w i l l easily snap i n t o position on aimer w h e n
properly positioned (Fig. 1).
IGNITION SWITCH LEVEL-VIAL BUBBLE
PASSENGER SIDE
REAR — VEHICLE — FRONT
STEERING COLUMN ^HORIZONTAL KNOB

DIMMER
SWITCH

CALIBRATION
ACTUATOR FIXTURE
MOUNTING BOLT LEVER
THUMB ADJUSTING
RB1164 UNIT 0 MUST SCREWS
ADJUSTMENT PIN BE USED AT
REAR TIRE
Fig. 14 Dimmer Switch
FLOOR LEVEL OFFSET DIAL
INSTALLATION AND ADJUSTMENT UNIT (g) MUST
(1) Position new switch. I n s t a l l t w o screws, do n o t BE USED AT
FRONT TIRE CALIBRATION FIXTURE RN980
tighten.
(2) Insert p i n i n switch hole to lock s w i t c h i n ad-
Fig. 1 Determining Floor Slope
j u s t m e n t position.
(3) Adjust switch b y pushing gently up o n s w i t c h t o (2) Place aimers at center l i n e o f each wheel on one
t a k e u p the rod slack. side of vehicle (Fig. 1). U n i t A m u s t be placed a t rear
(4) T i g h t e n screws and remove p i n . wheel w i t h target facing forward.
(5) Connect electrical connector. (3) U n i t B must be placed a t f r o n t wheel w i t h tar-
(6) I n s t a l l steering column cover. get facing rearward.
8L - 8 LAMPS

(4) A d j u s t t h u m b adjusting screw o n each calibra- FLOOR LEVEL

t i o n fixture b y t u r n i n g either clockwise o r counter-
UNIT B
clockwise u n t i l level v i a l bubble registers i n a
centered, l e v e l position (Fig. 1).
(5) Look i n t o top port hole of U n i t A . T u r n horizon-
t a l knob u n t i l split image is aligned (Figs. 2 a n d 3).
OWNER

in
CALIBRATION
FIXTURE
VIEWING PORT
UNIT A
VIEWING PORT RN984

NOT ALIGNED ALIGNED

RN981 Fig. 5 Checking Aimer Calibration
(5) Rotate t h u m b adjusting screws o n each calibra-
Fig. 2 Split Image Alignment
t i o n f i x t u r e u n t i l level vials o n f i x t u r e s are centered
TRANSFER READING - (Fig. 6).
HORIZONTAL DIAL CALIBRATION FIXTURE LEVEL VIAL

RN982

Fig. 3 Floor Level Compensating Adjustment

(6) Transfer plus or m i n u s r e a d i n g indicated on VERTICAL
AIMER LEVEL VIAL DIAL KNOB
horizontal d i a l to floor level offset d i a l o n each RN985
aimer. Press floor level d i a l i n w a r d t o set reading
Fig. 6 Checking Vertical Aim Calibration
(Fig. 3).
(7) Remove c a l i b r a t i o n fixtures from b o t h u n i t s . (6) W i t h both calibration level v i a l s centered t u r n
v e r t i c a l d i a l knobs o n each a i m e r u n t i l aimer level
TESTING AIMER CALIBRATION vials are centered. I f aimer v e r t i c a l d i a l pointers
C a l i b r a t i o n o f the aimers m a y be lost due t o ex- read between 1/2 up and 1/2 down, aimers are w i t h i n
tended use. C a l i b r a t i o n fixtures used i n conjunction allowable v e r t i c a l tolerance. C a l i b r a t e u n i t s i f be-
w i t h aimers can be used t o check a n d adjust aimers. yond these l i m i t s (Fig. 6).
(1) T u r n t h u m b adjusting screw o n each c a l i b r a t i o n (7) A d j u s t horizontal d i a l knob o n each a i m e r u n t i l
f i x t u r e u n t i l i t is approximately t h e same distance as split image targets a l i g n . I f aimer h o r i z o n t a l d i a l
the s u p p o r t i n g posts (Fig. 4). pointers read between 1 left and 1 r i g h t , t h e aimers
are w i t h i n allowable tolerance l i m i t s . Calibrate u n i t s
i f beyond these l i m i t s (Fig. 3).
LEVEL VIAL-
MOUNTING AIMERS
CALIBRATION (1) Snap adaptor into position o n each aimer ( F i g .
FIXTURE 7).
THUMB ADJUSTING SCREW RN983
USE FOR 142x200 mm
Fig. 4 Calibration Fixture (5.6x7.9 INCH)
RECTANGULAR
(2) A t t a c h calibration fixtures t o each u n i t w i t h HEADLAMP
level vials o n top (Fig. 4).
(3) Locate a t r u e v e r t i c a l plate glass w i n d o w or
smooth surface and secure aimers three t o five feet
apart so s p l i t image targets can be located i n v i e w i n g
ports (Fig. 5).
(4) Set floor level d i a l a t zero (Fig. 1).
J908L-61

Fig. 7 Headlamp Adaptor

 • LAMPS 8L - 9

(2) Position aimers on headlamps by p u s h i n g piston VERTICAL ADJUSTMENT

h a n d l e forward, engaging rubber suction cup. I m m e - (1) The v e r t i c a l d i a l should be set a t zero. (For pas-
d i a t e l y p u l l back p i s t o n handle u n t i l i t locks i n place senger vehicles, a " 0 " setting i s generally r e q u i r e d .
(Fig. 8). For special setting, consult local state laws.).
(2) T u r n vertical adjusting screw (Fig. 6) u n t i l t h e
level bubble is centered between t h e lines (Fig. 9).
LEVEL BUBBLE i LEVEL BUBBLE
L
(3) Repeat the last two steps o n t h e opposite head-
VERTICAL DIAL* ERTICAL DIAL lamp.
(4) Recheck target a l i g n m e n t o n b o t h aimers a n d
HORIZONTAL^ HORIZONTAL
DIAL readjust horizontal a i m i f necessary.
DIAL
(5) Repeat a i m i n g process for a four headlamp sys-
VIEWING VIEWING t e m on t h e second p a i r of lamps.
PORT PORT (6) Remove aimers b y pressing " v a c u u m release"
'(MUST FACE EACH OTHER)* b u t t o n located o n piston handle.
UNIT B UNIT A
MUST BE USED O N MUST BE USED O N
HEADLAMP ADJUSTMENT USING AIMING
PASSENGER SIDE. DRIVERS SIDE.
RN986 SCREEN METHOD
Place vehicle on a k n o w n level floor 7.62 m (25 ft.)
Fig. 8 Headlamp Aimers in Position f r o m a i m i n g screen or other l i g h t colored area. Pre-
S t e e l i n s e r t s a r e molded into position o n a l l pare a i m i n g screen as follows:
a d a p t e r s to i n s u r e a c c u r a c y . T h e s e i n s e r t s m u s t (1) Position a vertical tape so t h a t i t i s aligned
be i n c o n t a c t w i t h t h e three guide points o n the w i t h the vehicle centerline.
l a m p s w h e n the a i m e r s a r e p r o p e r l y positioned. (2) Position a horizontal tape w i t h reference t o cen-
t e r l i n e o f headlamp.
HORIZONTAL ADJUSTMENT (3) Position a vertical tape o n t h e screen w i t h ref-
(1) Set h o r i z o n t a l d i a l to zero (Fig. 3). erence t o t h e centerline of each headlamp. A t w o
(2) Check t o see t h a t t h e s p l i t image t a r g e t lines headlamp system w i l l have t w o v e r t i c a l tapes plus
are visible i n t h e v i e w i n g port. I f necessary, rotate t h e vehicle centerline tape.
each a i m e r s l i g h t l y t o locate the target (Fig. 9). (4) Adjust top adjusting screw for v e r t i c a l adjust-
m e n t , adjust side screw for h o r i z o n t a l adjustment.
(5) A properly aimed low beam w i l l appear o n
screen s i m i l a r to the p a t t e r n shown (Fig. 10).

R H
HORIZONTAL SPLIT IMAGE
L H
SPLIT IMAGE VERTICAL CENTER LINE CEN TER VERTICAL CENTER LINE
ADJUSTING ALIGNED NOT ALIGNED AHEAD OF LEFT OF AHEAD OF RIGHT
SCREW LOW BEAM ^ VEH CLE LOW BEAM
VERTICAL BUBBLE NOT BUBBLE
ADJUSTING CENTERED CENTERED
SCREW

JHP
\
J908L-62 J F
HORIZONTAL CENTER
Fig. 9 Split Image, Bubble Alignment, and Headlamp HIGH INTENSITY LINE OF LOW BEAM
Adjusting Points AREA 898L-2
(3) T u r n horizontal screw on side of headlamp u n t i l
s p l i t image o f target l i n e appears i n m i r r o r s as one
Fig. 10 Low Beam Adjusting Pattern
solid l i n e (Fig. 9). To remove "backlash," m a k e f i n a l
adjustment b y t u r n i n g adjusting screw i n a DAYTIME RUNNING LIGHTS (Canada Only)
clockwise direction.
The headlamps on vehicles sold i n Canada w i l l i l -
(4) Repeat t h e last three steps on opposite head-
l u m i n a t e w h e n t h e vehicle is started and t h e speed
lamp.
sensor recognizes forward m o t i o n . This provides a
constant L i g h t s O n condition u n t i l the engine is
t u r n e d OFF. The lamps i l l u m i n a t e a t less t h a n 50%
of n o r m a l intensity.
8L - 10 LAMPS •
The D a y t i m e R u n n i n g L i g h t Module i s located o n UNDERHOOD RETRACTABLE LAMP
t h e r i g h t i n n e r fender forward of t h e w i n d s h i e l d
washer reservoir (Fig. 11).
REPLACEMENT
(1) Remove t h e bolt h o l d i n g t h e module a n d
(1) Remove t h e l a m p assembly a t t a c h i n g screws
bracket t o t h e vehicle. and t h e g r o u n d w i r e connection (Fig. 12).
(2) Disconnect t h e electrical connector. (2) Disconnect the l a m p connector.
(3) To i n s t a l l t h e module, reverse t h e removal pro- (3) T o i n s t a l l t h e l a m p assembly, reverse t h e r e -
cedures. m o v a l procedures.

BULB REPLACEMENT
(1) Remove t h e lens cover a n d remove t h e bulb.
(2) I n s t a l l t h e replacement b u l b a n d i n s t a l l t h e
lens cover.
T h e r e p l a c e m e n t b u l b i s t r a d e # 105.

Fig. 11 Daytime Running Light Module

Fig. 12 Underhood Lamp Removal/Installation

INTERIOR LAMPS
INDEX
Page
Dome Lamp 10

DOME LAMP

WITHOUT HEADLINER
(1) Remove t w o screws and lens (Fig. 1).
(2) T w i s t bulb to remove.

SCREW J908L-65

Fig. 1 Dome Lamp

• LAMPS 8L - 11

WITH HEADLINER
(1) Gently squeeze t h e f r o n t a n d rear o f t h e lens t o -
gether a n d p u l l down t o remove (Fig. 2).
(2) P u l l b u l b down t o remove from socket.

LENS

J908L-66

Fig. 2 Dome With Headliner

SPECIFICATIONS
INTERIOR LAMP B U L B S

Headlight Switch Rheostat Dimming Non-Dimming

Air Conditioning Control Illumination . . . . . # 158 Anti Lock Brake Indicator . . . . . . # 194
Ash Tray Illumination . . # 158 Brake Indicator Lamp . # 194
Clock Electronic (Note A) Check Engine Lamp . # 194
Gear Shift Selector (Note B) . . # 194 Dome Lamp . . . . . #1004
Heater Control Illumination . . # 158 Fasten Seat Belt Indicator Lamp . . . # 194
Instrument Cluster Illumination . . # 194 Four Wheel Drive Indicator . . . . # 158
Radio (Note C) Gate Ajar Indicator Lamp . . . . . . # 158
Snow Plow Control Illumination . . # 158 Glove Compartment Lamp . . . . . .#1891
High Beam Indicator Lamp . . . . .# 194
Ignition Key Lamp . # 53
Low Fuel Indicator Lamp . # 194
Low Voltage Indicator Lamp. . . . # 194
Map Lamp . # 562
Oil Pressure Indicator Lamp . . . . . # 158
Rear Cargo Lamp # 211-2
Temperature Indicator Lamp . . . . . # 194
Turn Signal Indicator Lamp . . . . . . # 194
Under Hood Lamp . # 105

NOTE: (A) Included in Radio. (B) Included in instrument cluster lighting. (C) Warranty service by authorized service dealer only.

J908L-68
8L - 12 LAMPS •
EXTERIOR LIGHT BULBS

Auxiliary Headlamps (Snow Plow). . #6054 Rear Bumper License Plate Lamp
Back-Up Lamps #1156 Standard Chrome Bumper . . . #1155
Cargo Lamp # 922 Sill Mounted (No Bumper) . . . # 168
Clearance Lamps . . . . . . . . . . . . . . # 194 Step Bumper # 168
Front Lamp . . . . . . . . . . . . . . . . . #2057 Side Marker L a m p s . . . . . . . . # 168
Front Side Marker Lamp # 168 Tail, Stop and Turn Lamp Note A . #2057
Headlamps, Rectangular . . . . . . . . . . #6052 Tail, Stop and Turn Lamp Note B . #1157
Park and Turn Signal (Snow Plow) Lamp . #2057

NOTES: (A) Tail Lamp Bulb Also Serves As Side Marker Lamp. (B) Cab and Chassis.

J908L-69

CIRCUIT BREAKER
Circuit Headlamps
Amp 20
Location Integral with Switch
J908L-57
 • WARNING BUZZER/CHIME MODULE 8M - 1

WARNING BUZZER/CHIME MODULE

CONTENTS

Page Page

TEST PROCEDURES ... 1 SERVICE PROCEDURES .. 3

GENERAL INFORMATION
SEAT BELT
The seat b e l t w a r n i n g system uses a l a m p on t h e WARNING
BUZZER
i n s t r u m e n t panel a n d a buzzer for both visual a n d
audible w a r n i n g signals. T h e buzzer is a: combined
"seat belt not fastened," "key i n i g n i t i o n " and "head-
lamps O N " signal.
The seat belt p o r t i o n of t h e buzzer includes a
t i m e r . T h e system w i l l always i l l u m i n a t e t h e seat
belt w a r n i n g l a m p for 4 to 8 seconds after t h e i g n i -
t i o n switch i s t u r n e d t o the O N position. Also, i f the
d r i v e r does n o t fasten h i s seat belt, t h e buzzer w i l l
sound d u r i n g t h e same i n t e r v a l . O n l y t h e driver's
seat belt buckle has a switch t h a t is connected to t h i s
system. Passenger seat belts a r e n o t connected to
t h i s system.
The seat belt w a r n i n g buzzer is located near t h e INTERMITTENT
% RR8KC23
b u l k h e a d disconnect taped t o t h e w i r i n g harness WIPE MODULE
(Fig. 1).
Fig. 1 Seat Beit Warning Buzzer Location

TEST PROCEDURES
INDEX
Page Page
Seat Belt Buckle Switch Test 2 Timed Buzzer-Relay Test . . . 1

TIMED BUZZER-RELAY TEST (Fig. 2) TERMINAL 6

TO BATTERY (+)
TERMINAL 5
PREPARATION TO SEAT BELT
(1) Remove t i m e d buzzer-relay. \ / / BUCKLE SWITCH

(2) Connect one e n d o f a j u m p e r w i r e t o a 12 volt

supply. TERMINAL 4
TO IGNITION SWITCH
(3) Connect a test l a m p between t e r m i n a l number
3 o f buzzer and g r o u n d (Fig. 2).
(4) Ground t e r m i n a l s 2 and 5 o f buzzer. TERMINAL 1 TERMINAL 3
TO KEY-IN SWITCH TO SEAT BELT
AND HEADLAMP ON WARNING LIGHT
TEST PROCEDURE SWITCH
Connect 12 volt j u m p e r w i r e t o t e r m i n a l number 4
of buzzer module, look a t test l a m p a n d listen for
TERMINAL 2
buzzer. TO GROUND J908M-8

RESULTS Fig. 2 Buzzer Module Connector (Front View)

(1) L i g h t should come on and buzzer should sound Terminal Identification
for 4 to 8 seconds a n d t h e n b o t h should go off; i f not,
(2) I f operation is okay, check w i r i n g for opens,
replace buzzer module.
shorts, or poor connections.
8M • 2 WARNING BUZZER/CHIME MODULE

SEAT BELT BUCKLE SWITCH TEST (Fig. 3) (SHOWN BUCKLED)

B+

}
SEAT
I f buzzer checks out okay, check w i r i n g from t e r m i - BELT
n a l n u m b e r 5 to t h e seat belt switch and the w i r e SWITCH
f r o m t h e seat belt switch t o t e r m i n a l number 2
(ground). I f they check out okay, replace t h e seat belt
buckle a n d switch assembly. 5 6
CZ3 CZD CZ3 CZJ

CZ3 CZJ CD CD
4 3 2 1
exD

IGN. SWITCH #
HEADLAMP
(SHOWN IGN. / ON
OFF) | SWITCH
1

KEY-IN /SHOWN
SWITCH KEY (SHOWN
REMOVED) LIGHTS
OFF)
SEATBELT
WARNING LAMP DOOR SWITCH
(SHOWN DOOR
^CLOSED)

J908M-9

Fig. 3 Warning Buzzer System Schematic

BUZZER O N FOR NO BUZZER BUZZER O N BUT BUZZER A N D

4-8 SECONDS WHEN BUT SEAT BELT NO BUZZER OR
NO WARNING W A R N I N G LAMP
WARNING L A M P
SEAT BELT WARNING LAMP O N ALL THE TIME
IS BUCKLED LAMP IS ON

CHECK RESISTANCE B E T W E E N
O P E N CIRCUIT B E T W E E N
SHORT CIRCUIT B E T W E E N
TERMINAL 5 O F BUZZER
TERMINAL NUMBER 5
MODULE A N D G R O U N D
O F BUZZER MODULE
W I T H S E A T BELT
AND GROUND
UNBUCKLED
CIRCUIT B E T W E E N
TERMINAL 3 O F BUZZER
IGNITION O N , TERMINAL 2
MODULE A N D GROUND.
V O L T A G E A T TERMINAL 4 O F BUZZER MODULE
S H O U L D BE A L M O S T Z E R O
O F BUZZER MODULE AND GROUND OPEN
O H M S (BULB F I L A M E N T
SHOULD BE Z E R O O H M S
RESISTANCE).

DEFECTIVE BUCKLE S E A T BELT B U C K L E DEFECTIVE FUSE

BULB BURNED O U T BUZZER M O D U L E
SWITCH SWITCH DEFECTIVE (OPEN) O R O P E N CIRCUIT

O P E N CIRCUIT B E T W E E N
TERMINAL 5 A N D W A R N I N G LAMP
BUZZER MODULE BUZZER MODULE
S E A T BELT B U C K L E WIRING
SWITCH

BUZZER MODULE BUZZER M O D U L E

J908M-4
• WARNING BUZZER/CHIME MODULE SM - 3

SERVICE PROCEDURES

KEY-IN SWITCH ( 3 ) Remove steering wheel w i t h puller C-3428B

REMOVAL
(1) Disconnect t h e b a t t e r y negative cable.
(2) Eemove h o r n pad assembly a n d steering w h e e l
n u t (Figs. 4 , 5).
(Fig: 6 ) .
(4) Remove 3 screws along b o t t o m edge o f steering
column cover.
(5) P u l l cover d o w n to disengage slide tabs a n d re-
move cover.
(6) P r y o u t w i r i n g t r o u g h retainers and l i f t off w i r -
i n g t r o u g h (Fig. 7). N e w retainers m a y be required
for assembly.

TOOL

Fig. 5 Optional Steering Wheel Horn Pad Removal Fig. 7 Wire Trough Cover
8M - 4 WARNING BUZZER/CHIME MODULE
WIPER WIRING RR8JC3
Fig. 8 Steering Column Wiring Connectors
HORN AND TURN WEDGE BLOCK
Fig. 9 Disconnecting Wires
(7) Disconnect t u r n signal a n d k e y - i n switch w i r i n g
connectors. (Figs. 8, 9).
(8) Disassemble steering c o l u m n for switch removal
as follows:
(a) S t a n d a r d C o l u m n : Remove screw holding
wiper-washer switch to t u r n signal switch pivot.
Leave the entire t u r n signal lever (control stalk) i n
its installed position.
Remove 3 screws a t t a c h i n g bearing retainer
and t u r n signal switch t o upper bearing housing
(Fig. 10). P u l l t u r n signal s w i t c h out o f column f a r
enough to set aside. D O N O T completely remove
switch and w i r i n g assembly.
(b) T i l t C o l u m n : Depress lock plate w i t h Tool
C-4156 and pry r e t a i n i n g r i n g out o f groove w i t h
screwdriver (Fig. 11). T h e f u l l l o a d o f t h e u p p e r
b e a r i n g s p r i n g s h o u l d n o t b e r e l i e v e d ; i f i t is,
the r e t a i n i n g r i n g w i l l t u r n too easily m a k i n g re-
moval more difficult. Remove lock plate, cancelling
cam, and upper bearing s p r i n g .
•
STEERING SHAFT STEERING COLUMN
Fig. 10 Turn Signal Switch
Fig. 11 Remove Lock Plate Retaining Ring Using
Tool C-4156
Place t u r n signal s w i t c h i n r i g h t t u r n position. Re-
move screw w h i c h attaches l i n k between t u r n signal
switch and wiper-washer switch pivot. Remove screw
w h i c h attaches hazard w a r n i n g switch knob ( F i g .
12). Remove 3 screws a t t a c h i n g t u r n signal switch to
steering column.
(8) P u l l t u r n signal and hazard w a r n i n g switch out
of column far enough t o set aside (Fig. 10). DO N O T
completely remove s w i t c h and w i r i n g assembly.
(9) Remove screw m o u n t i n g k e y - i n switch (Fig. 13).
(10) G e n t l y p u l l the k e y - i n switch up from column
w h i l e s t r a i g h t e n i n g and g u i d i n g wires and wire con-
nector u p t h r o u g h column opening.
INSTALLATION
(1) Guide k e y - i n s w i t c h w i r i n g and connector down
t h r o u g h column opening.
1
(2) Secure key-in s w i t c h t o column (Fig. 13).
(3) Assemble upper p a r t o f steering column.
(a) S t a n d a r d C o l u m n : Position t u r n signal
switch a n d bearing retainer into place on upper
bearing housing. I n s t a l l 3 m o u n t i n g screws and
t i g h t e n securely. Position t u r n signal lever (control
• WARNING BUZZER/CHIME MODULE
Fig. 12 Hazard Warning Switch Knob
stalk) to t u r n signal switch pivot, t h e n p u t screw
t h r o u g h pivot and t i g h t e n securely. Be sure t h a t
d i m m e r switch rod is i n control stalk pocket.
(b) T i l t C o l u m n : Position t u r n signal switch i n
upper column housing. Place switch i n r i g h t t u r n
position. I n s t a l l three m o u n t i n g screws a n d
t i g h t e n . P u l l l i n k i n position between t u r n signal
s w i t c h and wiper-washer switch pivot, and secure
w i t h screw. U s i n g Tool C-4156, i n s t a l l upper bear-
8M - 5
Fig. 13 Key-In Switch
i n g spring, cancelling cam and lock plate w i t h n e w
r e t a i n e r s p r i n g . I n s t a l l hazard w a r n i n g knob w i t h
screw.
(4) Connect w i r i n g harness connectors (Figs. 8, 9).
(5) I n s t a l l w i r i n g t r o u g h t o column w i t h four plas-
tic buttons.
(6) Position steering wheel master serration over
missing tooth on steering shaft.
(7) I n s t a l l h o r n switch a n d steering wheel nut.
T i g h t e n steering wheel n u t t o 6 1 N » m (45 f t . lbs.).
(8) Place gearshift lever i n P a r k position, connect
battery negative cable and test operation o f t u r n sig-
n a l , hazard w a r n i n g , h o r n and d i m m e r switch.
 • 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 CAUTION: Grid lines can be damaged or scraped

The electrically heated rear w i n d o w defogger is
available on Ramcharger w i t h sunscreen glass only.
The system consists o f a rear w i n d o w w i t h t w o ver-
t i c a l bus bars a n d a series of electrically connected
g r i d lines baked on the inside surface.
C i r c u i t protection for the heated g r i d circuit is pro-
vided by a 18 gauge fusible l i n k w i r e located i n t h e
engine compartment. T h e relay c i r c u i t is protected
by a 20 amp fuse, located i n the fuse block.
W h e n the rear window defogger s w i t c h is placed i n
the O N position, c u r r e n t is directed t o rear w i n d o w
g r i d lines. T h e heated g r i d lines i n t u r n heat t h e
rear window t o clear the surface o f fog or snow.
off with sharp instruments. Care should be taken in
cleaning the glass or removing foreign materials,
decals or stickers. Normal glass cleaning solvents
or hot water used with rags or toweling is recom-
mended.
SYSTEM DESCRIPTION
CONTROL SWITCH/TIMER RELAY MODULE
The control s w i t c h and t i m e r relay are integrated
i n t o a single panel mounted assembly. A c t u a t i n g t h e
switch energizes t h e electronic t i m i n g c i r c u i t w h i c h
allows current to flow t h r o u g h t h e g r i d system for
approximately 10 minutes, or u n t i l either t h e control
switch or i g n i t i o n is t u r n e d off. A n i n d i c a t i n g l a m p
i l l u m i n a t e s a lens i n l a i d i n the control switch.

TEST PROCEDURES

INDEX
Page Page
Control Switch/Timer Module Test . . . . . . . . . . . . . 2 System Test . 1
Rear Window Grid Lines Test . . . . . . . . . . . . . . . . . 2

SYSTEM TEST VOLTMETER

Electrically heated rear window defogger operation

can be checked in-vehicle i n the f o l l o w i n g manner:
(1) T u r n the i g n i t i o n O N .
(2) T u r n rear window defogger control switch O N .
(3) M o n i t o r vehicle voltmeter. W i t h t h e control
switch O N , a distinct needle deflection should be
noted.
(4) T h e rear window defogger operation can be
checked by feeling the glass. A d i s t i n c t difference i n
temperature between t h e g r i d lines a n d adjacent
clear glass can be detected i n 3 to 4 m i n u t e s of oper-
ation.
(5) U s i n g a D C voltmeter (Fig. 1), contact t e r m i n a l Fig. 1 Grid Line Test
" B " w i t h the negative lead (passenger side), and ter-
O n l y steps (3) and (4) or (5) above w i l l c o n f i r m sys-
m i n a l " A " w i t h t h e positive lead (driver side). T h e
t e m operation. Indicator l i g h t i l l u m i n a t i o n means
voltmeter should read 10-14 volts.
8N - 2 REAR WINDOW DEFOGGER
t h a t there is power available a t the o u t p u t o f t h e r e -
lay only, a n d does n o t necessarily verify system op-
eration.
I f the rear window defogger does not operate, t h e
p r o b l e m should be isolated i n t h e following manner:
(1) C o n f i r m t h a t i g n i t i o n switch is O N .
(2) Ensure t h a t t h e heated rear window feed w i r e
is connected to t h e t e r m i n a l or p i g t a i l a n d t h a t t h e
g r o u n d w i r e is i n fact grounded.
(3) Ensure t h a t the fuse is operational a n d a l l elec-
t r i c a l connections are secure.
W h e n the above steps have been completed and t h e
system is s t i l l inoperative, one or more of the follow-
i n g is defective:
(a) Control switch/timer relay module.
(b) Rear window g r i d lines (all g r i d lines w o u l d
have to be broken) or one of the feed wires are n o t
connected for the system to be inoperative.
The following paragraphs outline component
check-out procedures.
I f t u r n i n g t h e switch O N produces severe volt-
meter deflection, t h e circuit should be closely
checked for a s h o r t i n g condition.
I f system operation has been verified b u t i n d i -
cator b u l b does n o t l i g h t , check and replace bulb.
For detailed w i r i n g information, refer t o Group
8 W - W i r i n g Diagrams.
•
and Point B . A reading o f 10-14 volts indicates a
break between Mid-Point C a n d g r o u n d Point A .
Move t o w a r d break and voltage w i l l change as soon
as break is crossed.
CONTROL SWITCH/TIMER MODULE TEST
Control switch/timer relay module m a y be tested
in-vehicle or bench tested. I n vehicle t e s t i n g i s ac-
complished i n t h e following m a n n e r :
(1) Remove t h e switch from t h e i n s t r u m e n t panel
(refer to Control Switch Replacement) a n d leave t h e
switch connector, plugged i n .
(2) T u r n i g n i t i o n O N .
(3) U s i n g a D C voltmeter w i t h 0-15 range, check
voltage a t t e r m i n a l s B , I and L (Figs. 2 and 3). Ter-
minals B and I should confirm a voltage o f 10 t o 14
volts to ground. T e r m i n a l L should c o n f i r m 0 volts to
ground. W h e n t e r m i n a l s B a n d I show n o voltage,
trace circuit upstream o f switch/relay module for
problem ( w i r i n g cut, fusible l i n k o r c i r c u i t breaker
inoperative, b u l k h e a d connector n o t operative, etc.).
I f t e r m i n a l L indicates voltage, place s w i t c h i n O F F
position. I f voltage a t L is s t i l l i n d i c a t e d or indicator
lamp remains on, t h e switch/relay module should be
replaced.
P - T - I F U S E # 1 4 r - T - i F U S E # 1 3
BATTERY
4 3 A M P *) 20 A M P

REAR WINDOW GRID LINES TEST

The horizontal g r i d lines and vertical bus b a r lines
p r i n t e d a n d baked on inside surface of rear w i n d o w
glass (Fig. 1) comprise an electrical p a r a l l e l circuit.
HEATED REAR
The electrically conductive lines are composed o f a WINDOW DEFOGGER
18 GAUGE
silver-ceramic m a t e r i a l w h i c h when baked o n glass SWITCH
(INSTRUMENT PANEL) FUSIBLE
becomes bonded to t h e glass and is h i g h l y resistant LINK
to abrasion. I t is possible, however, t h a t a break may
exist or occur i n a n i n d i v i d u a l g r i d line r e s u l t i n g i n
no current flow t h r o u g h the line. To detect breaks i n ON/OFF
g r i d lines, t h e following procedure is required:
(1) T u r n i g n i t i o n on and push control switch to O N .
T h e indicator l i g h t should come on.
(2) U s i n g a DC voltmeter w i t h 0-15 volt range, con-
t a c t vertical bus b a r connecting g r i d lines o n passen-
ger side of vehicle (point A of Fig. 1) w i t h negative
lead of voltmeter. W i t h positive lead of voltmeter,
contact vertical bus bar on driver side o f vehicle
(point B of Fig. 1). The voltmeter should read 10-14
volts.
(3) W i t h negative lead of voltmeter, contact a good
body ground point. The voltage reading should n o t
change. A different reading indicates a poor ground
connection.
1
REAR WINDOW GRID LINE STRUCTURE
(4) Connect negative lead of voltmeter to Point A J908N-9
on passenger side bus bar and touch each g r i d line a t Fig. 2 Systems Electrical Circuit
M i d - P o i n t w i t h positive lead. A reading o f approxi-
m a t e l y 6 volts indicates a line is good. A r e a d i n g of 0
volts indicates a break i n line between M i d - P o i n t C

L - TO BACK GLASS
B - HIGH AMP SUPPLY
I-IGNITION
fnra G - GROUND
S - ILLUMINATION LIGHT
RELAY-TIMER
SWITCH ASSEMBLY J908N-8
Fig. 3 Rear Window Defogger Switch, Timer, Relay
Connector
(4) I f the relay checks out t o t h i s point, momen-
t a r i l y operate switch t o O N position. The indicator
REPAIR P R O C E D U R E S (GRID L I N E S , TERMINALS, AND
The repair of g r i d lines or the t e r m i n a l is possible
u s i n g the M O P A R Repair K i t No. 4267922 or equiv-
alent.
WARNING: REPAIR KIT MAY CAUSE SKIN OR E Y E
IRRITATION.
CONTAINS EPOXY RESIN AND AMINE TYPE
HARDENER, HARMFUL IF SWALLOWED. AVOID
CONTACT WITH SKIN AND E Y E S . FOR SKIN, WASH
AFFECTED AREAS WITH SOAP AND WATER. DO
NOT TAKE INTERNALLY. IF TAKEN INTERNALLY,
INDUCE VOMITING; CALL A PHYSICIAN IMMEDI-
ATELY. IF IN CONTACT WITH E Y E S , FLUSH WITH
PLENTY OF WATER. USE WITH ADEQUATE VENTI-
LATION. DO NOT USE NEAR FIRE OR FLAME.
CONTENTS CONTAIN 3%FLAMMABLE SOLVENTS.
KEEP OUT OF REACH OF CHILDREN.
(1) Mask repair area so conductive epoxy can be ex-
tended onto t h e line or the bus bar (Fig. 4).
BREAK GRID LINE
MASKING TAPE PR1509A
Fig. 4 Grid Line Repair (Typical)
REAR WINDOW DEFOGGER 8N - 3
lamp should come o n a n d r e m a i n o n f o r approxi-
mately 10 minutes. T e r m i n a l L should confirm volt-
age. I f t h e indicator l a m p fails to l i g h t or voltage a t
t e r m i n a l L i s not confirmed the switch/relay module
should be replaced.
Bench checking o f t h e relay may be accomplished
i n the following manner. B y f o l l o w i n g the in-vehicle
procedure except Step 2: W i t h a D C power supply,
apply 12 volts to t e r m i n a l B and I a n d ground t e r m i -
n a l G.
PIGTAILS)
(2) Follow instructions i n repair k i t for p r e p a r i n g
damaged area.
(3) Remove package separator clamp and m i x plas-
tic conductive epoxy t h o r o u g h l y . Fold i n h a l f a n d cut
center corner to dispense epoxy.
(4) For g r i d line, m a r k off area to be repaired w i t h
m a s k i n g tape or a template (Fig. 4).
(5) A p p l y epoxy t h r o u g h s l i t i n m a s k i n g tape.
Overlap b o t h ends of t h e break by at least 1 9 m m (.75
in).
(6) For a t e r m i n a l or p i g t a i l replacement, mask ad-
jacent areas so epoxy can be extended onto l i n e as
w e l l as bus bar. A p p l y a t h i n layer of epoxy to area
where t e r m i n a l was fastened and to adjacent l i n e .
(7) A p p l y a t h i n layer o f conductive epoxy on ter-
m i n a l and place t e r m i n a l on desired location. To pre-
vent t e r m i n a l from m o v i n g w h i l e the epoxy is c u r i n g ,
i t m u s t be wedged or clamped.
(8) Carefully remove m a s k i n g tape from g r i d l i n e .
CAUTION: Do not allow the glass surface to exceed
400°F, glass may fracture.
(9) A l l o w epoxy to cure 24 hours at room tempera-
t u r e or use heat g u n w i t h a 260°-371°C (500°-700°F)
range for 15 minutes. H o l d g u n approximately
254mm (10 inches) f r o m repaired area.
(10) A f t e r conductive epoxy i s properly cured re-
move wedge from t e r m i n a l and check out operation
of rear window defogger. Do not attach connectors
u n t i l c u r i n g is complete.
8N - 4 REAR WINDOW DEFOGGER •
SERVICE PROCEDURES
HEATED REAR WINDOW CONTROL SWITCH tangs and p u l l switch f r o m rear o f bezel.
REPLACEMENT (3) Remove connector f r o m switch.

REMOVAL
(1) Locate chime module. Grasp chime module a n d
t w i s t i t to remove i t f r o m t h e bracket.
(2) Squeeze rear window defogger s w i t c h r e t a i n i n g
INSTALLATION
(1) Connect electrical connector to s w i t c h .
(2) Insert switch i n t o bezel m a k i n g sure r e t a i n i n g
tangs lock i n t o position.
(3) I n s t a l l chime module on to bracket.
 POWER LOCKS 8P - 1

POWER LOCKS

CONTENTS
Page Page

SERVICE PROCEDURES ... 2 TEST PROCEDURES ... 1

GENERAL INFORMATION B o t h doors can be locked or unlocked mechanically

B o t h doors, w h e n electrically equipped, can be
locked or unlocked electrically by operating t h e
switch o n a door panel.
w i t h t h e l o c k i n g knob regardless of electrical locking
and u n l o c k i n g actuation.
The r i g h t and left f r o n t door on a l l vehicles can be
locked or unlocked mechanically f r o m t h e outside
w i t h t h e k e y or electrically as described above. The
left door can also be unlocked by actuation of t h e i n -
side remote door handle.

T E S T PROCEDURES
CIRCUIT BREAKER TEST VOLTAGE TEST
Locate t h e c i r c u i t breaker i n fuse cavity number 10 The following w i r i n g test sequence determines
on t h e fuse block. P u l l c i r c u i t breaker o u t s l i g h t l y whether or n o t voltage is continuous t h r o u g h t h e
b u t be sure t h a t c i r c u i t breaker t e r m i n a l s s t i l l con- body harness to switch.
tact t e r m i n a l s i n fuse block. Connect ground w i r e o f A f t e r removing switch from t r i m panel for testing
voltmeter t o a good g r o u n d . W i t h probe o f voltmeter purposes, carefully separate m u l t i p l e t e r m i n a l block
positive w i r e , check b o t h t e r m i n a l s of c i r c u i t breaker on w i r i n g harness from switch body. Connect one
for battery voltage. I f only one t e r m i n a l checks a t lead o f test l i g h t t o black w i r e t e r m i n a l a n d touch
battery voltage, c i r c u i t breaker i s defective a n d must other test l i g h t lead t o red w i r e t e r m i n a l . I f t h e test
be replaced. I f n e i t h e r t e r m i n a l shows battery volt- l i g h t comes on, t h e w i r i n g circuit between t h e bat-
age, check for open or shorted c i r c u i t t o circuit tery a n d switch is functional. I f l i g h t does n o t come
on, check 30 amp c i r c u i t breaker or for a broken
breaker.
wire.
SWITCH TEST
ELECTRIC MOTOR TEST
For s w i t c h t e s t i n g , remove t h e switch f r o m i t s
M a k e certain battery is i n normal condition before
m o u n t i n g location. U s i n g a n ohmmeter, refer t o (Fig.
circuits are tested.
1) t o determine i f c o n t i n u i t y is correct i n t h e Lock
To determine w h i c h motor is defective, check each
and Unlock s w i t c h positions. I f these results are not
i n d i v i d u a l door for electrical lock and unlock or dis-
obtained, replace t h e s w i t c h .
connect t h e motor connections one a t a t i m e , w h i l e
operating door lock switch. I n t h e event t h a t none o f
the motors w o r k , the problem may be caused b y a
SWITCH CONTINUITY shorted motor. Disconnecting the defective motor w i l l
POSITION BETWEB4
allow t h e other to work.
PINS 1 & 4 Should the motor defect be a result o f a broken pig-
OFF
PINS 2 & 5
t a i l w i r e , i t should have no effect on t h e operation of
PINS 2 & 3 other motors.
LOCK PINS 1 & 4

PINS 3 & 4
UNLOCK PINS 2 & 5

PIN IDENTIFICATION
PIN SIDE OF SWITCH 898P-5

Fig. 1 Door Lock Switch Continuity

 SERVICE PROCEDURES
DOOR LOCK MOTOR REPLACEMENT

REMOVAL
(1) Remove remote control handle (Fig. 2).

Fig. 2 Door Trim Panel

(2) Remove power window/lock switch b y i n s e r t i n g
a standard blade screwdriver into notch o n forward
end o f switch housing a n d push to depress locking
tab. P u l l o u t a n d f o r w a r d to remove switch bezel
f r o m door panel.
(3) Remove 2 screws a t bottom front a n d rear of
t r i m panel.
(4) Remove screw behind remote handle.
Fig. 3 Door Lock Motor Replacement
(5) U s i n g a device such as a t r i m stick, p r y t r i m
panel away f r o m door around perimeter. INSTALLATION
(6) R o l l door watershield away from lower rear cor- (1) A t t a c h motor m o u n t i n g bracket to door inside
panel a n d i n s t a l l 2 screws.
ner o f door t o reveal inside panel access opening.
(2) Connect l i n k t o motor r o d and connect wires.
(7) Remove motor l i n k a t motor (Fig. 3).
(3) Reset watershield a t lower rear corner o f door.
(8) Disconnect motor lead wires.
(4) I n s t a l l door t r i m panel.
(9) Remove 2 motor m o u n t i n g bracket screws and (5) I n s t a l l door panel a t t a c h i n g screws.
remove motor assembly from m o u n t i n g . (6) I n s t a l l remote control handle.
(7) I n s t a l l power window/lock switch.
 • —
POWER WINDOWS
CONTENTS
Page
SERVICE PROCEDURES
GENERAL INFORMATION
Power w i n d o w motors a r e o f t h e permanent mag-
net type. A positive a n d negative battery connection
to either o f t h e t w o motor t e r m i n a l s w i l l cause t h e
motor to rotate i n one d i r e c t i o n . Reversing c u r r e n t
t h r o u g h these same t w o connections w i l l cause t h e
motor t o rotate i n t h e opposite direction.
B o t h motors are grounded t h r o u g h t h e master
switch by a black w i r e attached t o the ground stud
w h i c h is located o n the back o f t h e i n s t r u m e n t panel,
on t h e r i g h t side o f the steering column.
TEST PROCEDURES
Page
Circuit Breaker Test
Switch Test
SWITCH VOLTAGE TEST
The following w i r i n g test sequence determines
whether or n o t voltage i s continuous t h r o u g h t h e
body harness t o switch.
A f t e r r e m o v i n g left door s w i t c h from t r i m panel for
testing purposes, carefully separate m u l t i p l e t e r m i -
n a l block o n w i r i n g harness from switch body. Con-
nect one lead o f test l i g h t t o black ( B K ) w i r e
t e r m i n a l a n d touch other test l i g h t lead to t a n ( T N )
w i r e t e r m i n a l . I f t h e test l i g h t comes on, t h e w i r i n g
c i r c u i t between t h e b a t t e r y a n d switch is functional.
I f l i g h t does n o t come o n , check 30 a m p c i r c u i t
breaker, or for a broken w i r e o r poor ground.
POWER WINDOWS 8S - 1
Page
4 TEST PROCEDURES 1
I t i s necessary t h a t t h e w i n d o w be free t o slide u p
and down i n t h e glass channels or tubes a n d tracks.
I f t h e w i n d o w i s n o t free t o move u p a n d down, t h e
w i n d o w motor w i l l n o t be able t o move t h e glass.
The most positive w a y t o determine i f the glass is
free is t o disconnect t h e electric window regulator l i f t
a r m sliders from t h e glass l i f t channels a n d t h e n
slide t h e w i n d o w u p a n d d o w n b y hand.
A less positive method i s t o shake t h e glass i n t h e
door, ( w i t h glass positioned between the u p a n d down
stop positions). I f t h e glass w i l l move s l i g h t l y from
side t o side, front t o rear, a n d u p a n d down, t h e n
there i s a good chance t h a t t h e window is n o t bound
tight i n the tracks.
INDEX
Page
1 Switch Voltage Test 1
3 Window Motor Test 3
CIRCUIT BREAKER TEST
Locate t h e c i r c u i t breaker i n fuse cavity number 2
on fuse block. P u l l o u t s l i g h t l y b u t be sure t h a t cir-
c u i t breaker t e r m i n a l s s t i l l contact t e r m i n a l s i n fuse
block. Connect ground w i r e o f voltmeter t o a good
ground. W i t h probe o f v o l t m e t e r positive w i r e , check
b o t h t e r m i n a l s o f c i r c u i t breaker for battery voltage.
I f only one t e r m i n a l checks a t battery voltage, circuit
breaker is defective a n d m u s t be replaced. I f neither
t e r m i n a l shows battery voltage, check for open or
shorted c i r c u i t t o c i r c u i t breaker.
8S - 2 POWER WINDOWS

POWER WINDOW SYSTEM DIAGNOSIS

SYSTEM OPERATES SYSTEM SYSTEM

BUT GLASS DOES NOT OPERATES
TRAVEL IS COCKED OPERATE CORRECTLY
OR INCOMPLETE

1
CHECK FOR
MANUALLY
12 VOLTS AT NO VOLTAGE
CHECK TRAVEL
MOTOR CHECK WIRING
OF GLASS
TERMINAL AND/OR SWITCHES

i
GLASS TRAVEL
1

VOLTAGE OKAY
OKAY REMOVE CHECK FOR SYSTEM BINDING
REMOVE MOTOR REGULATOR BINDING OF GLASS CORRECT
FROM REGULATOR GUIDANCE SYSTEM
FROM DOOR BINDING
ASSEMBLY
CONDITION

i
REPLACE
ARM & SECTOR GLASS MOVES ©2 ) REGULATOR
BENCH TEST
REGULATOR
PORTION OF FREELY
ASSEMBLY OPERATES
REGULATOR
CORRECTLY

i i
REASSEMBLE REGULATOR
REMOVE REINSTALL
REGULATOR DOES NOT
MOTOR FROM REGULATOR
OPERATE
REGULATOR* INTO DOOR

i i
REINSTALL CHECK
REGULATOR ARM & SECTOR NONE OF THESE
INTO DOOR ASSEMBLY FOR CONDITIONS EXIST
FREE MOVEMENT,
ANY OF THESE
i
IF PROBLEM
MISSING AND/OR
DAMAGED
GEAR TEETH,
CONDITIONS EXIST
REPLACE
ARM & SECTOR

L STILL EXISTS
CORRECT GLASS
GUIDANCE
MISSING OR DAMAGED
ROLLER,
OR BENT ARM
ASSEMBLY

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
it *~
ASSEMBLY
TEETH CHECK
GEAR & PINION
REMOVED
OKAY APPLY VOLTAGE TO
MISSING AND/OR
DAMAGED GEAR TEETH MOTOR TERMINAL
REPLACE AND CHECK FOR
GEAR & PINION ARMATURE
ASSEMBLY SHAFT ROTATION
ARMATURE SHAFT
•COUNTERBALANCE SPRING
MUST BE REMOVED BEFORE
REMOVING MOTOR FROM
REPLACE MOTOR I
REGULATOR. IF NOT, REASSEMBLE ARMATURE SHAFT
INJURY MAY RESULT REGULATOR - ROTATES
ASSEMBLY CORRECTLY
RP922
• POWER WINDOWS 8S - 3

SWITCH TEST
For switch testing, remove t h e s w i t c h from i t s
m o u n t i n g location. U s i n g a n ohmmeter, refer t o f

(Figs. 1 and 2) to determine i f c o n t i n u i t y is correct i n

t h e U P and D O W N s w i t c h positions. I f c o n t i n u i t y is
correct perform window l i f t motor test.

PIN IDENTIFICATION SHOWN

FROM PIN SIDE OF SWITCH
® 2 ®
O
4 • 6
O 5 o

© SWITCH
POSITION
CONTINUITY
BETWEEN
PIN IDENTIFICATION SHOWN
FROM PIN SIDE OF SWITCH
PINS 1 & 4
MASTER WINDOW LIFT SWITCH OFF
PINS 2 & 5

PINS 3 & 4
SWITCH CONTINUITY UP
POSITION BETWEEN PINS 2 & 5

PINS1&2 PINS 2 & 3

PINS 2 & 3 DOWN
PINS 1 &4
OFF PINS 2 & 4
PINS 2 & 6
898S-12
PINS 3 & 5
DRIVER'S Fig. 2 Passenger's Door Mounted Switch Continuity
UP PINS 2 & 6
PINS 1 & 5 WINDOW MOTOR TEST
PASSENGER'S
PINS 2 & 4 (1) Connect positive lead (from a test battery) t o ei-
PINS5&6 ther of t h e t w o motor t e r m i n a l s .
DRIVER'S (2) Connect negative lead (from test battery) to re-
PINS 2 & 3
m a i n i n g motor t e r m i n a l .
DOWN
PINS 1 & 2 (3) T h e motor should now rotate i n one direction to
PASSENGER'S
PINS 4 & 5 either move window u p or down.
89SS-11 (a) I f window happens to already be i n f u l l U P
position and motor i s connected so as to rotate i n
Fig. 1 Master Window Lift Switch Continuity U P direction no movement w i l l be observed.
(b) Likewise, motor connected to D O W N direc-
t i o n r o t a t i o n , no movement w i l l be observed i f w i n -
dow i s already i n f u l l down position.
(4) Reverse b a t t e r y leads (opposite to steps 1 and 2)
and window should n o w move. I f window does n o t
move, remove motor. Refer t o Service Procedures for
motor removal f r o m vehicle for bench test.
I f window moved completely u p or down, motor
should be reversed one more t i m e (reverse leads from
step 4) to complete a f u l l w i n d o w t r a v e l inspection.
8S - 4 POWER WINDOWS •

SERVICE PROCEDURES

INDEX
Page Page
Gear And Pinion Replacement And Lubrication ... 4 Regulator And Motor Assembly ... 4

GEAR AND PINION REPLACEMENT AND (5) U s i n g a device such as a t r i m stick, p r y t r i m

LUBRICATION
W h e n gear and p i n i o n assembly is replaced i n gear
box, l u b r i c a t i o n of gear box, gear p i n i o n and seal is
necessary i f these parts have been disassembled.
I n the event there i s no l u b r i c a n t i n gear box, f i l l
w i t h M O P A R , multi-mileage l u b r i c a n t or equivalent.
A p p l y a l i b e r a l amount o f l u b r i c a n t t o inside area o f
seal and sealing surface a t center area o f gear and
p i n i o n coupling. Also l u b r i c a t e center housing shaft
and w o r m gear.
REGULATOR AND MOTOR ASSEMBLY
REMOVAL
To repair or inspect t h e e n t i r e electric window reg-
ulator, remove from door as follows:
(1) Remove remote control handle (Fig. 3).
panel away f r o m door a r o u n d perimeter and remove
t r i m panel.
(6) R o l l door watershield away f r o m b o t t o m o f door
to reveal inside panel access opening.
(7) Disconnect w i r i n g connectors from motor and i f
equipped, the speaker.
(8) Remove speaker i f equipped.
(9) Connect switch and lower glass t o f u l l down po-
sition.
(10) Remove i n n e r weatherstrip b e i n g careful not
to scratch t h e beltline p a i n t .
(11) Free t h e clip on t h e i n n e r section of t h e weath-
erstrip w i t h a w i r e hook or suitable tool.
(12) P u l l back upper glass r u n 8 t o 20-25 c m (10
inches).
(13) Remove upper and lower vent w i n g a t t a c h i n g
screws.
(14) Remove vent w i n g , being careful t o avoid
paint damage from glass lower p i v o t adjusting
screws.
(15) Remove down stop bumper bracket (Fig. 4).

SECTOR GEAR
TRIM PANEL
CLIPS (6)

REMOTE
CONTROL
HANDLE
SCREW

TRIM
PANEL
TRIM PANEL SCREWS (2)
J908P-12
CLJPS RIVET

Fig. 3 Door Trim Panel

(2) Remove power window/lock switch b y i n s e r t i n g
a standard blade screwdriver i n t o notch on f o r w a r d
end of s w i t c h housing and push to depress locking
tab. P u l l o u t and f o r w a r d t o remove switch bezel
f r o m door panel. RB1372
(3) Remove screws a t b o t t o m f r o n t and rear of t r i m
panel. Fig. 4 Electric Window Regulator Mounting
(4) Remove screw behind remote handle. (16) Disengage glass f r o m regulator arms a n d
lower to door bottom.
 • POWER WINDOWS
(17) D r i l l out regulator m o u n t i n g rivets.
(18) Remove regulator t h r o u g h large access hole.
BENCH REPAIR
I f entire regulator is not being replaced, repair as
follows:
(1) Remove regulator as previously described.
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 NOT DONE BEFORE MOTOR R E M O V A L
I N J U R Y M A Y RESULT.
(2) Secure regulator i n vise to prevent sector gear
from rotating.
(3) Remove counter balance spring. ( M u s t be done
for safety before removing motor).
(4) Remove 3 motor attaching screws a n d remove
motor.
(5) Inspect regulator for:
(a) Sector gear teeth must not be b r o k e n or se-
verely w o r n .
(b) A l l rivets and sliders m u s t be securely at-
tached.
(c) Parts must not be bent or cracked.
(d) Sector gear m u s t rotate freely.
(e) Perform w i n d o w l i f t motor test as described
above.
(6) I n s t a l l motor and attach w i t h three motor at-
t a c h i n g screws.
(7) I n s t a l l counter balance spring.
8S - §
INSTALLATION
(1) Insert upper regulator a r m i n t o door mounted
channel.
(2) M o u n t regulator to door panel w i t h 1/4-20
screws and n u t s torqued to 10 N»m (90 i n . lbs.).
(3) Slide glass onto r e g u l a t o r arms and i n t o rear
glass r u n .
(4) Connect motor electrical connector.
(5) I n s t a l l plastic n u t a n d " U " n u t on vent w i n g as-
sembly.
(6) I n s t a l l vent w i n g assembly i n t o door.
(7) I n s t a l l upper a n d lower v e n t w i n g attachment
screws.
(8) Move glass r u n back to v e n t w i n g by placing
r u n adjacent to door channel a n d press into channel
using wide blade screwdriver or s i m i l a r tool. Press i n
both inside corners to ensure h i d d e n l i p engages i n
channel.
(9) I n s t a l l belt w e a t h e r s t r i p b y a l i g n i n g clips to
holes i n door and press i n .
(10) Raise or lower v e n t to m a i n t a i n a 1.6mm (.06
in.) fore-aft glass freeplay t h e n w i t h glass up, t i g h t e n
upper screws.
(11) H o l d vent against glass (glass down) and
t i g h t e n lower screws.
(12) Raise glass to f u l l up position.
(13) I n s t a l l speaker i f equipped.
(14) I n s t a l l down stop bumper.
(15) I n s t a l l watershield a n d t r i m panel.
 • POWER MIRRORS 8T - 1

POWER MIRRORS

CONTENTS
Page Page

SERVICE PROCEDURES ... 2 TEST PROCEDURES ... 1

GENERAL INFORMATION
Electrically-operated remote control m i r r o r s a r e
available as a n option o n D-body vehicles. T h e m i r -
rors are controlled b y a single s w i t c h assembly lo-
cated on t h e i n s t r u m e n t panel t o t h e r i g h t o f t h e
headlamp s w i t c h (Fig. 1).
D-body vehicles use a toggle-type s w i t c h w h i c h i s
rotated clockwise (Right m i r r o r ) o r counterclockwise
(Left m i r r o r ) f o r m i r r o r selection, a n d moved U P ,
D O W N , R I G H T , or L E F T for m i r r o r movement direc-
tion.
The motors w h i c h operate t h e m i r r o r s are p a r t o f
t h e m i r r o r assembly a n d cannot be serviced sepa- SWITCH
rately. BEZEL

MIRROR
SWITCH
KNOB
POWER
MIRROR HEADLAMP SWITCH
SWITCH K N O B A N D STEM

RR8TC7

Fig. 1 Power Mirror and Headlamp Switches

TEST PROCEDURES
INDEX
Page Page
Mirror Motor Test Procedure 1 Mirror Switch Test Procedure ... 2

MIRROR MOTOR TEST PROCEDURE MIRROR TEST CHART

(1) Remove power m i r r o r switch from m o u n t i n g po- MIRROR IREACTION

s i t i o n (refer t o Service Procedures). 12 Volts Ground Right Left
(2) Disconnect w i r i n g harness a t s w i t c h connector. YL/BK WT/BK UP
(3) U s i n g 2 j u m p e r wires, one connected t o a 12- YL WT UP
v o l t source, a n d t h e other connected t o a good body WT/BK YL/BK DOWN
ground, refer t o the M I R R O R TEST C H A R T for w i r e WT YL DOWN
hookups a t t h e switch connector (harness side, n o t WT/BK DB/WT RIGHT
switch side). WT DB RIGHT
(4) I f results shown i n chart a r e n o t obtained, DB/WT WT/BK LEFT
check for b r o k e n or shorted circuit, or replace m i r r o r DB WT LEFT
assembly as necessary.
J908K-22
8T - 2 POWER MIRRORS •
MIRROR SWITCH TEST PROCEDURE
MIRROR SWITCH CONTINUITY CHART
(1) Remove power m i r r o r s w i t c h from m o u n t i n g po- Mirror Selector Knob In "I" Position
s i t i o n (refer t o Service Procedures). MOVE LEVER CONTINUITY BETWEEN
(2) Disconnect w i r i n g harness a t s w i t c h connector. WT and BK
YL and PK and YL/BK and PK
(3) U s i n g a c o n t i n u i t y tester or ohmmeter, test for
WT and PK,
c o n t i n u i t y (no resistance) between t h e t e r m i n a l s o f DB/WT and BK and DB & BK
t h e s w i t c h as shown i n the M I R R O R S W I T C H C O N - YL/BK and BK, YL and BK
T I N U I T Y CHART. DB and PK
(4) I f results shown i n the c h a r t are not obtained, WT and BK, DB/WT and PK
DB and PK
replace t h e switch.
Mirror Selector Knob in "R" Position
MOVE LEVER CONTINUITY BETWEEN
WT/BK and BK, YL and PK
YL/BK and PK
WT/BK and PK, DB and BK
i 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
J908T-9

SERVICE PROCEDURES
MIRROR SWITCH REPLACEMENT
REMOVAL
(1) Remove 2 screws holding map l a m p and remove
map l a m p .
(2) Remove 6 screws w h i c h attach i n s t r u m e n t clus-
ter bezel t o i n s t r u m e n t panel (Fig. 2). M a k e sure the
screw below the H e a t e r \ A / C control is removed.
(4) Remove bezel by p u l l i n g top edge r e a r w a r d t o
clear brow. Disengage a t t a c h i n g clips a r o u n d bottom
of bezel and complete removal of bezel.
(5) I f the bezel has a four wheel d r i v e indicator, re-
move bulb socket as bezel is removed.
(6) Disconnect message center wires.
(7) Remove i n s t r u m e n t cluster bezel assembly.
(8) Remove headlamp s w i t c h knob a n d stem b y
reaching under i n s t r u m e n t panel a n d depressing but-
t o n on side of switch w h i l e p u l l i n g stem out.
(9) Remove switch bezel r e t a i n i n g screws a n d p u l l
bezel out o f i n s t r u m e n t panel (Fig. 1).
(10) P u l l harness o u t t h r o u g h opening i n i n s t r u -
m e n t panel and disconnect m i r r o r s w i t c h connector.
(11) Remove 2 switch mounting-plate-to-bezel re-
t a i n i n g screws.
(12) Remove switch-to-mounting-plate n u t .
For I n s t a l l a t i o n , reverse removal procedures.

MIRROR ASSEMBLY REPLACEMENT

REMOVAL
(1) Remove remote control handle (Fig. 3).
Fig. 2 Instrument Cluster Bezel (2) Remove power window/lock s w i t c h b y i n s e r t i n g
a standard blade screwdriver i n t o notch o n f o r w a r d
(3) Place column shift lever i n Position 1.
 • POWER MIRRORS 8T - 3

Fig. 3 Door Trim Panel

end o f switch housing and p u s h to depress l o c k i n g
tab. P u l l o u t a n d forward t o remove switch bezel
from door panel.
(3) Remove 2 screws a t b o t t o m front and rear o f
t r i m panel.
(4) Remove screw behind remote handle. Fig. 4 Power Mirror Replacement
(5) U s i n g a device such as a t r i m stick, p r y t r i m
panel away f r o m door around perimeter.
(6) Roll door watershield away from lower rear cor-
ner o f door t o reveal inside panel access opening.
(7) Reach inside door and disconnect m i r r o r w i r i n g
at connector.
S p r a y grommet o n m o u n t i n g b r a c k e t c o v e r
w i t h silicone to a v o i d grommet coming off w h e n
c o v e r i s m o v e d u p o n m i r r o r stem.
(8) Remove m i r r o r m o u n t i n g bracket cover ( 1
screw) and slide u p on m i r r o r stem (Fig. 4).
(9) Remove 3 m i r r o r m o u n t i n g bracket nuts.
(10) P u l l m i r r o r loose f r o m door, and feed w i r i n g
harness out t h r o u g h hole i n outer door panel.
For I n s t a l l a t i o n , reverse Removal procedure.
 WIRING DIAGRAMS—ELECTRICAL 8W - 1

ELECTRICAL WIRING DIAGRAMS

INDEX
Page Page
Charts Fusible Link Replacement 3
Fuseblock . . . . .. 6 Multiple Fusible Link Replacement 4
Fusible Link Chart .,.".. 3 Single Fusible Link Replacement 4
Wire Color Code Chart . . . . . . . . .... 2 Fusible Links 3
Electrical Wiring and Components Identification General Information 1
Index 7 Locating a System or Component 3
Electrical Wiring Diagram Wire Routing and Main Circuit Identification Codes 2
Component Location Index . . . . . . . . . . . . . . . . 37 Splice Locations . . . . . . . . . . . . . . . . . . . . . . . . . 3
Splice Location Index . . . 27 Symbols, Fuses and Connectors 4
Wiring Diagrams 44

WIRING DIAGRAMS
GENERAL INFORMATION
SPARK PLUGS
Master w i r i n g diagrams contain t h e latest informa-
RIGHT BANK
t i o n available a t t i m e o f publication. These diagrams
contain various wires, w i r e r o u t i n g , w i r e color codes,
switches components, fuses, splices, connectors, con-
nector cavities a n d other i n f o r m a t i o n except distrib-
u t o r secondary w i r i n g . T h i s is shown i n (Figs. 1 and

SPARK PLUGS
LEFT BANK
EIGHT CYUNDER DISTRIBUTOR-CIOCKWISE ROTATION
FOR 318 AND 360 CUBIC INCH ENGINES
FIRING ORDER-1-8-44-65-7-2 RP899

Fig. 2—Distributor Secondary Wiring

8'Cylinder S.2L and 5.9L Engine

3.9L SIX-CYLINDER ENGINE

DISTRIBUTOR—CLOCKWISE ROTATION
FIRING ORDER 1-6-5-4-3-2 RN755

Fig. 1—Distributor Secondary Wiring

6-Cylinder 3.9L Engine
8W - 2 WIRING DIAGRAMS—ELECTRICAL

MAIN CIRCUIT IDENTIFICATION CODES

Al Battery Positive Circuit. M l Lighting Circuit Feed (Interior Lamps).

A9 Battery Negative Circuit. M 2 Lighting Circuit Ground (Interior Lamps).
B Back Up Lamp Circuit. P Brake Checking Circuit.
C Air Conditioning and Heater Circuits, Heated Rear Q2 Accessory Buss Bar Feed (Fuse Block).
Window. Q3 Battery Buss Bar Feed (Feed).
D Emergency, Stop Lamp and Turn Signal Circuits, R3 Alternator Circuit to Electronic Regulator (Field).
Diagnostic Connector. R6 Alternator Circuit Feed.
E Instrument Panel Cluster, Switches and Illumination S Starter Motor and Starter Relay Circuit.
Circuits. T Tachometer.
G Gauges, Warning Lamp Circuits. V Windshield Wiper and Washer Circuit.
H Horn Circuit. W Power Window Circuit, Power Lock Circuit.
Jl Ignition Switch Feed Circuit. X Grounds For Radio Speakers, Cigar Lighter, Lamps,
J2 Ignition System Run Circuit. Clock, Speed Control, Power Antenna, Power
J3 Starter Relay to Ballast Resistor. Amplifier, Power Windows, Power Mirrors,
J10 Ignition Switch Accessory Feed. Door Locks.
K Single Board Engine Controller. Y Injectors.
L Lighting Circuit Feed (Exterior Lamps). Z Fuel Injection System Grounds.

J908W-63

Each w i r e shown i n t h e diagrams contains a code To identify w h i c h m a i n circuit code applies t o a

(Fig. 3) w h i c h identifies t h e wires circuit, gage, a n d system, refer t o t h e M a i n C i r c u i t Identification Code
color. The color is shown as a t w o letter code w h i c h Chart.
can be identified by r e f e r r i n g t o the W i r e Color Code
C h a r t . I f t h e w i r e has a tracer a n d i t s a standard WIRE COLOR CODE CHART
color a n asterisk w i l l follow t h e m a i n wire color, i f STANDARD COLOR STANDARD
COLOR
the tracer color is non-standard t h e m a i n w i r e code CODE COLOR TRACER CODE COLOR TRACER
COLOR CODE
w i l l have a slash (/) after i t followed b y t h e tracer
color. BK OR
BK BLACK WT " PK PINK
WH

18 LB/Yl* BR BROWN WT RD RED WT

DARK
COLOR OF WIRE DB ' WT TN TAN WT
BLUE
(Light Blue witH Yellow Tracer).
DARK
DG' WT VT VIOLET WT
GREEN
GAGE OF WIRE
GY GRAY BK WT WHITE BK
(ISGcige)
LIGHT
LB BK YL YELLOW BK
PART OF MAIN CIRCUIT BLUE
"(Maries Depending on Equipment) LIGHT
LG BK WITH TRACER
GREEN

-MAIN CIRCUIT IDENTIFICATION OR ORANGE BK

RR8WH24
908W-192

Fig. 3 - Wire Color Code Identification

 • • : WIRING DIAGRAMS—ELECTRICAL 8W - 3

W i r i n g harnesses t h a t have substitute wires o f a

different color t h e n called o u t o n w i r i n g diagrams
should have a n i d e n t i f y i n g tape w i t h specified w i r e
color code (Fig. 4).

Fig. 4—Identification of Substitute Wiring Codes

LOCATING A SYSTEM OR COMPONENT
I n order t o locate a system or component use alpha-
betical index t o determine d i a g r a m sheet n u m b e r
and t u r n t o t h a t sheet for w i r i n g d i a g r a m .
Sheet n u m b e r s for each w i r i n g d i a g r a m are located
a t lower r i g h t or left h a n d corner o f each sheet. P a g e
n u m b e r s a t top of p a g e d o n o t a p p l y to d i a g r a m
sheets.
Fig. 6—Locating a Wiring Harness Splice
FUSIBLE LINKS
Vehicle w i r i n g harnesses are equipped w i t h fusible
l i n k s t o protect against harness damage i n event o f a
short i n electrical system.
Fusible l i n k s are color coded as t o w i r e gauge size.
See fusible l i n k chart.

SPLICE LOCATIONS FUSIBLE LINK CHART

Splice locations are indicated o n master w i r i n g d i - Wire a n d G a u g e Color Code Color
agrams b y a diamond w i t h splice c i r c u i t code w i t h i n 12 G a . BK Black
i t (Fig. 5). I f there is more t h a n one splice per circuit 14 G a . RD Red
splice code a s m a l l box w i l l be connected t o t h e dia- 16 G a . DB Dark Blue
mond w i t h t h e splice n u m b e r i n i t (example 2) ( F i g . 18 G a . GY Gray
5). 20 G a . OR Orange
22 G a . WT White

O <3B
J908W-79

FUSIBLE LINK REPLACEMENT

EXAMPLE 1 EXAMPLE 2 RP35
CAUTION: Do not replace blown fusible links with
Fig. 5— Wiring Splice Examples standard wire. Only fusible type wire with hypalon
insulation can be used or damage to the electrical
I n order t o locate a p a r t i c u l a r splice determine
system will occur. Also make sure correct gauge of
splice n u m b e r f r o m the w i r i n g d i a g r a m . Refer t o pic-
wiring is used. Refer to Master Wiring Diagrams for
t o r i a l splice index to f i n d figure n u m b e r t h e n t u r n t o
proper gauge size.
t h a t figure t o determine splice location w i t h i n a w i r -
i n g harness (Fig. 6). (1) W h e n a fusible l i n k blows i t is very i m p o r t a n t
All connectors a r e v i e w e d from t e r m i n a l e n d to f i n d out w h y i t blew. They are placed i n vehicle
unless o t h e r w i s e specified. electrical systems for protection against dead shorts
to g r o u n d w h i c h can be caused by electrical compo-
nent f a i l u r e or various w i r i n g failures. D o n o t j u s t
replace fusible l i n k t o correct problem.
(2) W h e n replacing fusible l i n k s t h a t are connected
8W - 4 WIRING DIAGRAMS-ELECTRICAL
t o t h e b a t t e r y t e r m i n a l o f s t a r t e r relay, they are to
be serviced w i t h the same t y p e o f pre-fabricated fus-
ible l i n k .
A l l other fusible l i n k s are replaced w i t h a piece o f
fusible l i n k w i r e cut f r o m b u l k reels. Care m u s t be
t a k e n t h a t t h e same gauge a n d color w i r e as t h e
o r i g i n a l fusible l i n k be used (see Fusible L i n k
Chart).
Multiple Fusible Link Replacement
(1) Disconnect negative b a t t e r y cable.
(2) C u t o f f any r e m a i n i n g p o r t i o n of blown fusible
l i n k flush w i t h m u l t i p l e connection insulator, t a k i n g
care not t o c u t i n t o other fusible links.
(3) Remove 1 i n c h o f i n s u l a t i o n from m a i n harness
w i r e about 1 i n c h f r o m m u l t i p l e connection insulator.
(4) Remove 1 i n c h o f i n s u l a t i o n from one end o f SYMBOLS, FUSES AND CONNECTORS
new fusible l i n k a n d w r a p i t around m a i n harness
w i r e t h a t was stripped.
(5) Heat splice w i t h a h i g h temperature soldering
g u n , apply r o s i n type solder u n t i l i t flows freely, and
remove soldering g u n . D o n o t use a c i d c o r e s o l d e r
(Fig. 7).
•
(6) A l l o w to cool a n d w r a p new splice w i t h a m i n -
i m u m o f 3 layers o f suitable electrical tape.
Single Fusible Link Replacement
(1) Disconnect negative b a t t e r y cable.
(2) C u t fusible l i n k i n c l u d i n g connection i n s u l a t o r
from m a i n harness w i r e .
(3) Remove 1 i n c h o f i n s u l a t i o n f r o m b o t h new fus-
ible l i n k a n d m a i n harness w i r e and w r a p together.
(4) H e a t splice w i t h a h i g h temperature soldering
g u n , apply r o s i n type solder u n t i l i t flows freely a n d
remove soldering g u n . Do n o t use a c i d c o r e s o l d e r
(Fig. 7).
(5) A l l o w to cool a n d w r a p new splice w i t h a m i n -
i m u m o f 3 layers o f suitable electrical tape.
V a r i o u s symbols a r e used o n w i r i n g diagrams.
These symbols can be identified b y r e f e r r i n g t o sym-
bol i d e n t i f i c a t i o n (Fig. 8)
For fuse identification refer to t h e fuse c h a r t .
CAUTION: When replacing a blown fuse, it is impor-
tant to replace it with a fuse having the correct am-
perage rating. The use of a fuse with a rating other
than indicated may result in a dangerous electrical
overload. If a proper rated fuse continues to blow, it
indicates a problem that should be corrected.

STRIP ONE INCH INSTALL ANY STRIP ONE INCH

OF INSOLATION EXISTING OF INSULATION
FROM BOTH WIRES TIE WRAPS FROM BOTH WIRES

Fig. 7 -Fusible Link Repair

• WIRING DIAGRAMS-ELECTRICAL 8W - 5

LEGEND OF SYMBOLS USED ON WIRING DIAGRAMS

+ POSITIVE CONNECTOR
— NEGATIVE MALE CONNECTOR

GROUND >— FEMALE CONNECTOR

FUSE S DENOTES WIRE CONTINUES ELSEWHERE

DENOTES WIRE GOES TO ONE OF TWO
G A N G FUSES WITH BUSS BAR CIRCUITS
CIRCUIT BREAKER SPLICE
-K-
CAPACITOR SPLICE IDENTIFICATION

n
•AAA-*
OHMS

RESISTOR |
cFtf

TIMER
3

|
THERMAL ELEMENT

TIMER

VARIABLE RESISTOR 1 4f ^ 4? |MULTIPLE CONNECTOR

"YY Y'
SERIES RESISTOR
•-i OPTIONAL
WIRING WITH

oJ WIRING WITHOUT

COIL y " Y " WINDINGS

-vflib STEP UP COIL

BB--BB DIGITAL READOUT

OPEN CONTACT SINGLE FILAMENT LAMP

- 0 -
CLOSED CONTACT DUAL FILAMENT LAMP

CLOSED SWITCH L.E.D. - LIGHT EMITTING DIODE

OPEN SWITCH THERMISTOR

:c: CLOSED GANGED SWITCH GAUGE

OPEN GANGED SWITCH SENSOR

TWO POLE SINGLE THROW SWITCH FUEL INJECTOR

DENOTES WIRE GOES THROUGH

PRESSURE SWITCH
E | #36
BULKHEAD DISCONNECT

SOLENOID SWITCH
#
" ST.C DENOTES WIRE GOES THROUGH
STEERING COLUMN CONNECTOR
——
" COLUMN """*"
1 1#14 DENOTES WIRE GOES THROUGH
MERCURY SWITCH N
IAN
STEL
Tffn. P INSTRUMENT PANEL CONNECTOR
1 1#7 DENOTES WIRE GOES THROUGH GROMMET
DIODE OR RECTIFIER ENG
TO ENGINE COMPARTMENT

BY-DIRECTIONAL ZENER DIODE DENOTES WIRE GOES THROUGH GROMMET

O MOTOR HEATED GRID ELEMENTS

0 ARMATURE AND BRUSHES

908W-19!

Fig. 8—Symbol Identification

CAVITY FUSE/ ITEMS FUSED FUSE/
CAVITY ITEMS FUSED
COLOR COLOR

30 AMP
LG A/C AND HEATER BLOWER MOTOR 20 AMP BACK-UP LAMPS, HEATED REAR WINDOW
13
YL SWITCH AND TIMER
30 AMP
POWER WINDOWS
C/BRKR
INSTRUMENT PANEL LAMP, A / C HEATER CONTROL
3 AMP LAMPS, ASH TRAY LAMP, SNOW PLOW CONTROL
14
VT LAMP, RADIO LAMPS, O/D SWITCH LAMP
20 AMP
YL HAZARD FLASHERS

15 AMP CIGAR LIGHTER

15
10 AMP BL
RADIO AND CLOCK
RD

20 AMP TURN SIGNALS, TRANSMISSION OIL TEMPERATURE

YL LAMP, SNOWPLOW CONTROLS, R.W.A.L MODULE
TURN
SIGNAL
30 AMP FLASHER AMPS FUSE COLOR CODE
CIRCUIT 3 VT VIOLET
20 AMP WINDSHIELD WIPERS, BREAKER
5 TN TAN
YL DIESEL A/C CLUTCH
10 RD RED
15 BL BLUE
20 YL YELLOW
30 LG LIGHT GREEN
15 AMP
BL HORNS, HORN RELAY

20 AMP TAIL, PARKING, SIDEMARKER, LICENSE

AND CLEARANCE LAMPS HAZARD
YL
FLASHER

20 AMP
YL STOP LAMPS, KEY-IN-BUZZER

30 AMP
10 POWER DOOR LOCKS
C/BRKR

RADIO AND CLOCK MEMORY, POWER MIRRORS,

11 10 AMP GLOVE BOX, DOME, READING, MAP AND
RD CARGO LAMPS, UNDERHOOD LAMPS

GAUGES, BRAKE WARNING LAMP, SEAT BELT

WARNING LAMP AND BUZZER, LOW OIL- CHECK
5 AMP ENGINE-EMR-ANTI-LOCK-TAILGATE-AND4WD
12 TN LAMPS, SPEED CONTROL, LOW FUEL LAMP,
WAIT TO START LAMP, WATER IN FUEL LAMP
J908W-80

Fig. 9—Fuse Block

• WIRING DIAGRAMS—ELECTRICAL 8W - 7

COMPONENT IDENTIFICATION

INDEX
Caption Fig, Caption Fig,
A/C and Heater Wiring.............................. 14 Interior Wiring.... 6
Cab Wiring... 7 Roof Wiring. 5
Clearance Lamp Wiring with Dual Rear Wheels , 3 Snow Plow Control Wiring 15
Cowl Panel Wiring 10 Snow Plow Wiring 23
Door Wiring 9 Starter Wiring 18
Engine Compartment Wiring Diesel Engine 17 Steering Column Wiring 11
Engine Compartment Wiring EFI Engine 16 Stop Lamp and Parking Brake Switch Wiring.... 13
Engine Wiring EFI Engine 22 Tail Lamp Wiring 1
Extended Cab Wiring 8 Tailgate Wiring 4
Four Wheel Drive Wiring 19 Transmission Wiring 21
Frame Wiring 2 Underhood Lamp Wiring 20
Instrument Panel Wiring 12
 WIRING DIAGRAMS—ELECTRICAL
10

TO MAIN
HARNESS

TO
SIDE
MARKER
LAMPS

J908W-83

LENS

Wiring with Dual Rear Wheels

Fig. 3-Clearance Lamp TO ROOF
WIRING
LIFTGATE
AJAR
SWITCH
• WIRING DIAGRAMS—ELECTRICAL 8W - 11

TO FRONT REAR DOME

DOME LAMP LAMP

TO
ROOF
WIRING

TO
VIEWX

VIEWX J908W-85
SPEAKER

Fig. 5 — R o o f Wiring
TO DOME TO INSTRUMENT
TO LAMP
TAILGATE PANEL
WIRING

TO SEAT
BELT
WIRING

GROUND
TO REAR
SPEAKER
J908W-86
Fig. 6—Interior Wiring
Fig. 7— Cab Wiring
• WIRING DIAGRAMS—ELECTRICAL 8W - 15

TO DOOR
WIRING

TO INSTRUMENT PANEL
WIRING

TO
POWER
MIRRORS TO
REAR
SPEAKERS
TO
DOOR
WIRING
J908W-89
Fig. 10—Cowl Panel Wiring
IGNITION
SWITCH

WINDSHIELD
WIPER
WIRING
(8 WAY)

KEY-IN LAMP
WIRING
(2 WAY)
TURN
SIGNAL
WIRING
(10WAY)
INTERMITTENT KEY-IN
WIPER WIRING BUZZER WIRING
(8 WAY) (2 WAY)
J908W-90
Fig. 11—Steering Column Wiring
GLOVE BOX TO A/C HEATER CONTROL TO OVERDRIVE 4 WHEEL LOW OIL SPEEDO €30
MESSAGE CENTER LOCKOUT DRIVE PRESSURE RIGHT
LOCK METER
INDICATOR LAMP PRINTED
HEATER A/C CIRCUIT
^ ^ C O N T R O L LAMP LAMP
BOARD
CONNECTOR.

GLOVE
BOX
LAMP 2
CD
0

LEFT TURN
INDICATOR >
LAMP
TO RIGHT CD
DOOR 30
SWITCH
>
REAR WHEEL s
ANTI-LOCK w
DIAGNOSTIC
CONNECTOR m
1
P-
m
TO REAR WHEEL o
—i
ANTI-LOCK . 33
BRAKE CONTROL
o
MODULE

TO
>
COURTESY CLEARANCE
LAMP AND
SWITCH IDENTIFICATION
LEFT HEADLAMP i m p S

POWER PRINTED SWITCH

MIRROR CIRCUIT BOARD
I SWITCH CONNECTOR
VIEWR 50-WAY
(REAR WHEEL ANTI-LOCK VIEWP TO CLUTCH
VIEWT (R.W.A.L TEST CONNECTOR) BULKHEAD
(LEFT SIDE SHOWN! CONTROL MODULE) DISCONNECT INTERLOCK STEREO
(RIGHT SIDE TYPICAL! TO R.WA.L. SWITCH RADIO
TO PARK
IGNITION CONNECTOR BRAKE SWITCH VIEWW
SWITCH VIEWP KEY-IN (STEREC
MAIN STEERING
WIRING BUZZER
COLUMN MAIN WIRING
HARNESS 25-WAY HARNESS
CONNECTOR

INTERMITTENT
VIEWZ VIEWW WIPE CONTROL * FUSE BLOCK AND^
WIRE (IGNITION & (CLUTCH INTERLOCK SWITCH) RELAY BANK
J908W-91
RETAINER VIEWU DIPPER SWITCH) (DIESEL) VIEW IN DIRECTION OF ARROW S VIEW IN DIRECTION OF ARROW T

Fig, 12—Instrument Panel Wiring

 WIRING DIAGRAMS—ELECTRICAL 8W - 17

PARK STEERING
COLUMN CONNECTOR
BRAKE
SWITCH SUPPORT

PARK STOP LAMP

BRAKE SWITCH
LEVER

J908W-92

Fig. 13—Stop Lamp and Parking Brake Switch Wiring

INSTRUMENT BLOWER
PANEL SWITCH

TO BLOWER MOTOR
RESISTOR BLOCK J908W-93
Fig. 14—A/C Heater Wiring
 SNOW 00
PLOW
CONTROL

2
CD
o

>
CD
30
>
S
GO
O
HI
2
>

RAISE/LOWER
BLADE CONTROL
SWITCH

INSTRUMENT
PANEL
Fig. 15—Snow Plow Control Wiring
 TO UNDERHOOD
BLOWER
LAMP T O TRANSMISSION
MOTOR
WIRING
WINDSHIELD
WASHER
PUMP
DAYTIME R U N N I N G G R O U N D STRAP
LIGHT M O D U L E
(CANADA ONLY)

WINDSHIELD
T O RIGHT WIPER
HEADLAMP MOTOR

RIGHT PARKING
A N D TURN S I G N A L
LAMP

TO
STARTER
RELAY
PART
THROTTLE
UNLOCK
RELAY O BATTERY

,H-VALVE

TO SINGLE BOARD
CHASSIS ENGINE CONTROLLER
.SPEED C O N T R O L
WIRING
SERVO

VIEW IN D I R E C T I O N O F
ARROW W
VIEW IN DIRECTION O F ARROW Z J908W-94

Fig. 16—Engine Compartment Wiring EFI Engine

 T O U N D E R H O O D LAMP VOLTAGE REGULATOR
A / C DAMPED WINDSHIELD
PRESSURE WIPER
SWITCH MOTOR

DAYTIME R U N N I N G
LIGHT M O D U L E
(CANADA ONLY)

CD
O
>
CD
30
T O RIGHT >
HEADLAMP
s
w
\
m
r—
RIGHT PARK m
AND TURN SIGNAL o
LAMP ^
o
>
T O AIR
HEATER RELAY

LEFT PARK A N D
TURN SIGNAL
LAMP

HEATER
CONTROL
MODULE

NGINE CONTROLLER

TO CHASSIS
WIRING
VIEWZ STARTER J908W-95
RELAY
fig, 17—Engine Compartment Wiring Diesel Engine
• WIRING DIAGRAMS—ELECTRICAL 8W - 21
OVERDRIVE
SOLENOID

SAFETY NEUTRAL AND OXYGEN AUTO TRANS, SPEEDOMETER

(W/OVERDRIVE) SENSOR 4 X 4 TRANSFER CASE J908W-99
BACK-UP LAMP SWITCH SENSOR
Fig. 21—Transmission Wiring
 GROUND THROTTLE THROTTLE IDLE COMPRESSOR CAPACITOR IGNITION
CANISTER AIR DISTRIBUTOR
PURGE SWITCHING BODY BODY SPEED
SOLENOID SOLENOID TEMPERATURE CONTROL
SENSOR ACTUATOR

TO RIGHT
SIDE
SHIELD
WIRING

EGR
SOLENOID

EXHAUST
MANIFOLD

V I E W IN DIRECTION
V I E W IN DIRECTION ^ ^ I„ ,A OF ARROW Z
T
COOLANT
VIEW IN DIRECTION VIEW IN DIRECTION OF ARROW W
TEMPERATURE J908W-100
OF ARROW X (EHB E N G I N E )
NUTS OF ARROW Y TO V I E W V SENSOR

Fig. 22-Engine Wiring EFI Engine

 PARK, TURN AND TO CAB CONTROL RELAY BATTERY GROUND
HEADLAMP WIRING WIRING
ASSEMBLY

SOLENOID

HYDRAULIC
CYLINDER

COWL

VIEW IN DIRECTION
OF ARROW Z
U/W AUTO TRANSMISSION ONLY
YELLOW (SEE VIEW Y FOR MANUAL
MOLD TRANSMISSIONS
VIEW IN DIRECTION VIEW IN CIRCLE V
OF ARROW X (TYPICAL LEFT & RIGHT SIDES) RP988

Fig. 23—Snow Plow Wiring

8W - 26 WIRING DIAGRAMS-ELECTRICAL
• WIRING DIAGRAMS-ELECTRICAL 8W - 27

S P L I C E LOCATION

INDEX
Splice Number Rg^ Splice Number Fig.
A1 5,6 L7-4 .3
A1-1 ..8 L7-5 3
AH-9 6 L9 5,6
B2 3 L9-1 5,6
C4 9 M1 4
C7 9 MM 1
C9 5, 6 M2 4
C13 4 M2-1 1
D1 10 N5 6
E2 4 N51 ...5,11
G5 4 P51 6
G7 .........5,6 R9 11
H4-1 4 W1 7
H4-2 4 W8-1 7
H4-3 4 W8-2 7
J2 6 X2 3
J2-1 6, 11 X2-1 3
J2-2 .....5 X2-2 3
J9 6 X2-3 4
J9-2 6, 11 X2-4 3
K5 5, 6 X2-5 3
K5-1 6, 11 X2-6 3
K8 11 X2-7 2,3
K9 ...... 5 X2-8 3
L1 4 X33-1 1
L6 1 X34-1 1
L7 6 X53 7
L7-1 4 X54 7
L7-2 3 Z1 5
L7-3 3 Z1-1 11
8W - 30 WIRING DIAGRAMS-ELECTRICAL
WIRING DIAGRAMS-ELECTRICAL 8W -
 WIRING DIAGRAMS-ELECTRICAL 8W - 33
•
 J908W-108
Fig. a—Snow Plow Wiring Splices
• WIRING DIAGRAMS—ELECTRICAL 8W - 37

E L E C T R I C A L WIRING DIAGRAMS
WIRE ROUTING AND COMPONENT L O C A T I O N
ALPHABETICAL INDEX
Wiring Diagram Wiring Diagram
Name Sheet Number Name Sheet Number
A/C Heater System With Diesel Engine 65, 66 Resistor. 26
Blower Motor............................................................... 65 Sensor 26
Clutch............... 66 Stop Lamp Switch...... 26
Compressor 66 Back-Up Lamp Switch With Diesel Engine 7
Damped Pressure Switch 66 Back-Up Lamp Switch With EFI Engine 7
Diodes .. 66 Battery................................................................ 1, 3, 5, 17
Fuse 65 Brake Warning Indicator Lamp Diesel Engine.............. 53
Lamp-Switch Illumination 44 Brake Warning Indicator Lamp EFI Engine........ 54
Low Pressure Switch.. 66 Brake Warning Indicator Lamp
Resistor 65 Switch Diesel Engine..... 28
Switch-Blower 65 Brake Warning Indicator Lamp
Switch Illumination.................... 44 Switch EFI Engine 26
Switch-Vacuum.......... 65 Bulkhead Disconnect 50-Way 79, 80
Vacuum Control Switch . 65 Cavity 1 4, 6, 31, 43
A/C Heater System With EFI Engine........ 63, 64 Cavity 2........... 62, 63, 65
Blower Motor...... 63 Cavity 3................................................................. 25, 27
Clutch 64 Cavity 4... 25, 27
Compressor................ 64 Cavity 5 39, 41, 43
Damped Pressure Switch........................................... 64 Cavity 6.......................................................... 39, 41, 43
Diodes. 64 Cavity 7 30
Fuse.......... 63 Cavity 8 30
Lamp-Switch Illumination 44 Cavity 9 30
Resistor... 63 Cavity 10..... 30
Switch-Blower................. 63 Cavity 11 17
Switch Illumination.... 44 Cavity 12....... 39, 42
Vacuum Control Switch ...1.................... 63 Cavity 13.. 42, 43
Wide Open Throttle Cutout Relay...... 64 Cavity 14.... 25, 27
Air Heater Controller Diesel Engine .............................. 18 Cavity 15 52, 75
Air Heater Relay Diesel Engine. 17 Cavity 16....... 52, 75
Air Intake Heater Diesel Engine 17 Cavity 17 21, 22
Alternator With Diesel Engine.......................:... 6 Cavity 18 21, 22
Alternator With EFI Engine 4 Cavity 19............................................................... 21, 22
Anti-Lock Rear Brake System With Cavity 21 ;39 41, 42
Diesel Engine............. 27, 28 Cavity 22.... 40, 42, 52
Brake Warning Switch. 28 Cavity 23 3, 5, 52
Diagnostic Connector R.W.A.L 27 Cavity 24 25, 27
Diagnostic Connector Service 27 Cavity 25.. 25, 27
Electronic Vacuum Time Delay Sensor..................... 28 Cavity 26....... 37, 39, 41, 43, 75
Fuse.... 27 Cavity 27 7
Ground 28 Cavity 28 73
Module......................................................................... 27 Cavity 29....................... 49, 51
Resistor. 28 Cavity 31.. 8, 17
Sensor 28 Cavity 32 31
Anti-Lock Rear Brake System With Cavity 33..................................................................... 20
EFI Engine. 25, 26 Cavity 34............ 10, 28
Brake Warning Switch 26 Cavity 35... 50, 51
Diagnostic Connector R.W.A.L................................... 25 Cavity 36.............................. 50, 51
Diagnostic Connector Service 27 Cavity 37.. 63, 65
Dual Solenoid Hydraulic Valve 26 Cavity 38 15, 18
Fuse...... 25 Cavity 39.......... 73, 74
Ground................... 26 Cavity 40..................................................................... 67
Module 25 Cavity 41 26, 28, 30
Park Brake Switch 25 Cavity 42 15
8W - 38 WIRING DIAGRAMS—ELECTRICAL

Wiring Diagram Wiring Diagram

Name Sheet Number Name Sheet Number
Cavity 43 16, 23 Distance Sensor 16
Cavity 44 11, 12 Distributor 16
Cavity 45 50, 51 Exhaust Gas Recirculation Solenoid 14
Cavity 46 50, 51 Ground 15
Cavity 47 10, 73,74 Heated Oxygen Sensor 13
Cavity 48 3, 5, 20, 35 Ignition Coil 14
Cavity 49 4, 6, 10 Injectors 13
Cavity 50 4,6, 10 Map Sensor 16
Buzzer-Combined Headlamp, Key In, and Oxygen Sensor.... 13
Seat Belt.... 73, 74 Purge Solenoid 14
Cargo Lamp 46 Single Board Engine Connector 13, 14, 15, 16
Cargo Lamp Switch...... 45 Throttle Kicker Motor 15
Charging System With Diesel Engine 5, 6 Throttle Position Sensor 15
Alternator 6 Emission Maintenance Reminder Lamp. 54
Battery 5 Engine Wiring Diesel 17, 18, 19
Voltage Regulator 6 Air Heater Controller 18
Charging System With EFI Engine 3, 4 Air Heater Relay 17
Alternator 4 Air Intake Heater 17
Battery 3 Battery 17
Cigar Lighter 48 Cold Start Advance 19
Circuit Breakers Fuel Heater 19
Electric Door Locks............................. 69 Fuel Pump 19
Electric Windows......... 68 Oil Pressure Switch 20
Clearance Lamps Duel Rear Wheels.... 37, 38 Temperature Sending Unit.. 20
Clearance Lamps Roof Mounted 36 Temperature Sensor 18
Control Module Overdrive Transmission 11,12 Water In Fuel Sensor 18
Controller Intake Air Heater Diesel Engine 18 Filter-Water in Fuel Diesel 18
Controller-Single Board Engine... 13, 14, 15, 16 Flasher-Hazard Warning 52
Coolant Sensor With EFI Engine. 16 Flasher-Turn Signal 52
Diagnostic Connectors Four Wheel Drive Indicator Lamp Switch 67
Automatic Transmission 24 Front End Lighting 39, 40
Rear Wheel Anti-Lock-Service Diesel Engine 27 Fuel Gauge 55
Rear Wheel Anti-Lock-Service EFI Engine.... ...25 Fuel Gauge Sending Unit Diesel Engine 73
Diesel Engine Wiring 17, 18, 19 Fuel Gauge Sending Unit With EFI Engine 74
Air Heater Controller 18 Fuel Heater Diesel Engine 19
Air Heater Relay 17 Fuel Pump Diesel Engine 19
Air Intake Heater • 17 Fuel Pump EFI 74
Battery •• 17 Fuse Application Chart 1, 2
Cold Start Advance 19 Fuse Block Module and Relay Bank 83
Fuel Heater 19 Fuses
Fuel Pump 19 Fuse 1 2, 10, 45, 62, 63, 65
Temperature Sensor 18 Fuse 3 1, 52
Water in Fuel Sensor.. 18 Fuse 4 2, 10, 57, 59, 61
Dimmer Switch-Headlamp 32, 43 Fuse 5. 2, 10, 25, 27, 52
Diode and Mold Assembly 47 Fuse 6....... 2, 10, 50, 51
Distance Sensor....................................... 16, 23 Fuse 7 1, 31
Distributor EFI Engine 16 Fuse 8.. 1, 43
Door Jamb Courtesy Lamp Switches 45, 46 Fuse 9 1, 73, 74
Left Switch 45 Fuse 11........... 2, 20, 47, 48, 57, 59, 61, 71
Right Switch 45 Fuse 12... 2, 10, 12, 54, 67, 73, 74
Door Locks-Electric 69, 70 Fuse 13 2, 7, 10, 35
Electronic Fuel Injection Ignition System Fuse 14 1, 43, 48, 57, 59, 61
3.9, 5.2, 5.9L Engine 13, 14, 15, 16 Fuse 15 1, 10, 48
Air Switching Solenoid 14 Fusible Links 1 2, 3, 4, 5, 6, 17
5

Auto Shutdown Relay 14 Gauge-Fuel 55

Coolant Sensor With EFI Engine 16 Gauge-Oil Pressure 55
Diagnostic Connector 13 Gauge-Temperature 55
• — WIRING DIAGRAMS—ELECTRICAL 8W - 39

Wiring Diagram Wiring Diagram

Name Sheet Number Name Sheet Number
Glove Box Lamp Switch 48 Dome Lamp. 46
Hazard Warning System 52 Emission Maintenance Reminder Lamp 54
Flasher............ 52 Four Wheel Drive Indicator 67
Fuse 52 Glove Box Lamp 48
Switch 52 Headlamp-Left 39, 41
Headlamp Dimmer Switch 43 Headlamp-Left Auxiliary Snow Plow 32
Headlamp Switch 43 Headlamp-Right 40, 42
Headlamps 39, 40, 41, 42 Headlamp-Right Auxiliary Snow Plow 32
Heater System 62 Headlamp Switch Controlled Interior Lamps 44
Blower Motor 62 Headlamp Switch Title Lamp. 44
Fuse.... 62 Heater Switch Lamp 44
Ground. 62 High Beam Indicator Lamp 55
Resistor.. 62 Ignition Switch Lamp 45
Switch 62 Instrument Panel Illumination Lamps 53, 54, 55
Switch Illumination Lamp 45 Key In Lamp... 45
Horn System 31 License Lamp... 76
Horns 31 Liftgate Ajar Lamp. 47
Horn Relay 31 Low Oil Pressure Lamp Diesel Engine............ 55
Horn Switch........................................................ 31 Low Oil Pressure Lamp EFI Engine......... 55
Identification Lamps-Dual Rear Wheels... 37, 38 Map Lamp............. 45
Identification Lamps-Roof Mounted............ 36 Oil Temperature-Transmission.. 33
Ignition Switch 2, 10 Parking Lamp-Left Auxiliary Snow Plow 32
Ignition Time Delay Relay 45 Parking Lamp-Left Front 39, 41
Instrument Panel To Steering Column Parking Lamp-Right Auxiliary Snow Plow 32
25-Way Connector 81, 82 Parking Lamp-Right Front 40, 42
Cavity 2... 31 Parking Lamps-Snow Plow 32
Cavity 3 31 Reading Lamps.............. 46
Cavity 4 52 Rear End Lighting System................................... 75, 76
Cavity 5....... 52 Seat Belt Warning Lamp 55
Cavity 6........ 52 Side Marker Lamp Left Front 39, 41
Cavity 7....... 52 Side Marker Lamp Right Front 40, 42
Cavity 8 52 Snow Plow Switch Illumination 44
Cavity 9 52 Stop Lamp-Left Rear 76
Cavity 10 26, 28, 30, 52 Stop Lamp-Right Rear 75
Cavity 12. 49,51 Switch Illumination-Snow Plow 44
Cavity 13 49, 51 Tail Lamp-Left Rear 75
Cavity 14.. 49, 51 Tail Lamp-Right Rear.... 76
Cavity 15........... 49, 51 Temperature Indicating 55
Cavity 16.... 51 Turn Signal Indicator Lamps 55
Cavity 18.. 44, 49 Turn Signal Lamp-Left Front 39, 41
Cavity 19 45 Turn Signal Lamp-Right Front 40, 42
Cavity 20 45 Turn Signal Lamp-Left Rear 75
Cavity 24.... 45 Turn Signal Lamp-Right Rear.... 76
Cavity 25..... 31, 45 Turn Signal Lamps-Snow Plow 32
Key-In Switch 45 Underhood Lamp 20
Key-In Warning Buzzer 73, 74 Left Printed Circuit Board 55
Lamps Left Printed Circuit Board Connector 56
Air-Conditioning and Heater Switch Lamp 44 Limiter-Voltage 55
Anti-Lock Rear Brake Lamp..... 53 Liftgate Ajar Switch 47
Ash Receiver 44 Low Oil Pressure Lamp Switch With Diesel 21
Back-Up Lamps 75, 76 Low Oil Pressure Lamp Switch With EFI 22
Brake Warning Indicator Lamp........... 54 Map Lamp Switch 45
Cargo Lamp. 46 Message Center Diesel Engine 53
Clearance Lamps-Dual Rear Wheels..... 37 Anti-Lock Brake Lamp 53
Clearance Lamps Roof Mounted.. 36 Brake Warning Indicator Lamp.. 53
Cluster Illumination Lamps 53, 54, 55 Check Engine Lamp 53
Courtesy Lamps Rear 47 Diodes 53
8W - 40 WIRING DIAGRAMS—ELECTRICAL

Wiring Diagram Wiring Diagram

Name Sheet Number Name Sheet Number
Electronic Low Fuel Relay 53 Switch.......... 11
Low Fuel Lamp..................... 53 Parking Brake Switch.................... 25, 27
RearWheel Anti-Lock Lamp... 53 Part Throttle Unlock Relay With EFI Engine 9
Water In Fuel Lamp. 53 Park Throttle Unlock Solenoid With EFI Engine 11
Wait To Start Lamp. 53 Power Door Lock System............... 69, 70
Message Center EFI Engine 54 Circuit Breaker............................................................. 69
Anti-Lock Brake Lamp 54 Left Door Motor.................. 69
Brake Warning Indicator 54 Left Door Switch 69
Check Engine Lamp 54 Right Door Motor 70
Diode 54 Right Door Switch.............................. 70
Rear Wheel Anti-Lock Lamp 54 Power Mirrors 71, 72
Modules Fuse.... 71
Headlamp On 73, 74 Left Motor.............. 71
Intermittent Wipe..... 50 Right Motor. 72
Key-In 73, 74 Switch 72
Overdrive.... 23 Power Window System 68
Overdrive Transmission......... 11, 12 Circuit Breaker...... 68
Seat Belt 73, 74 Left Door Switch 68
Seat Belt Warning 73, 74 Left Motor....... 68
Motors Right Door Switch...................... 68
Blower-A/C With Diesel Engine........... 65 Right Motor 68
Blower-A/C with EFI Engine... 63 Printed Circuit Board Connectors
Blower-Heater.............................................................. 62 Left........................... 16, 21, 22, 23, 47, 52, 54, 73, 74
Intermittent Wipe Washer.... 49 Right 21, 22, 39, 41, 44, 52, 54, 73, 74
Intermittent Wipe Windshield Wiper 50 Radio-AM/FM Stereo 57, 59, 61
Power Door Lock-Left.. 69 Radio Speakers AM/FM Stereo or Cassette.......... 58, 60
Power Door Lock-Right.... 70 Rear Lighting System........ 75, 76
Power Mirror Left 71 Rear Wheel Anti-Lock Brake System (Diesel) 27, 28
Power Mirror Right............... 72 Brake Warning Switch 28
Power Window-Left 68 Diagnostic Connector R.W.A.L...... 27
Power Window-Right 68 Diagnostic Connector Service 27
Snow Plow... 45 Electronic Vacuum Time Delay Sensor 28
Starter With Diesel Engine.............. 7 Fuse............................................................................. 27
Starter With EFI Engine..... 7 Ground 27
Throttle Kicker 15 Module.. 27
Neutral Start Switch With Diesel Engine... 7 Resistor....................... 28
Neutral Start Switch With EFI Engine.... 7 Sensor. 28
Oil Pressure Sending Unit With Diesel Engine 21 Rear Wheel Anti-Lock Brake System (EFI) 25, 26
Oil Pressure Sending Unit With EFI Engine 22 Brake Warning Switch 26
Oil Pressure Switch With Diesel Engine............ 21 Diagnostic Connector R.W.A.L.. 25
Oil Pressure Switch With EFI Engine 22 Diagnostic Connector Service 25
Oil Pressure Warning Lamp 55 Fuse 25
Overdrive Transmission (Diesel) 12 Ground............................................... 26
Control Module.. 12 Module 25
Diode 12 Park Brake Switch 26
Fuse 12 Resistor............................................ 26
Ground........ 44 Sensor 26
Solenoid • 12 Regulator-Voltage With Diesel Engine 6
Switch 12 Relays
Overdrive Transmission (EFI)... 11 Air Heater Diesel Engine............................................ 17
Control Module • 11 Auto Shutdown With EFI Engine 14
Diode 11 Horn 31
Fuse....................................... 11 Part Throttle Unlock................... 9
Ground............... - 44 Starter Motor With Diesel Engine 7
Indicator Lamp • 11 Starter Motor With EFI Engine... 7
L.E.D 11 Wide Open Throttle Cut-Out EFI Engine............ 64
Solenoid. 11 Right Printed Circuit Board 55
 WIRING DIAGRAMS—ELECTRICAL 8W - 41

Wiring Diagram Wiring Diagram

Name Sheet Number Name Sheet Number
Right Printed Circuit Board Connector 56 Cavity 5 13
Seat Belt Warning System Diesel Engine 73 Cavity 6 13
Time Delay Relay 73 Cavity 7 , ......v........... .16
Warning Buzzer 73 Cavity 8 14
Warning Buzzer Switch 73 Cavity 9 14
Warning Lamp 73 Cavity 11 13
Seat Belt Warning System-Gas Engine 74 Cavity 12 : 13
Time Delay Relay 74 Cavity 15 13
Warning Buzzer . 74 Cavity 16 13
Warning Buzzer Switch 74 Cavity 19 14
Warning Lamp 74 Cavity 20 :.. 15
Sending Units Cavity 21 16
Fuel Gauge-Diesel Engine 73 Cavity 22 13
Fuel Gauge-EFI Engine 74 Cavity 24 16
Oil-Diesel Engine 21 Cavity 25 13
Oil-EFI Engine 22 Cavity 27 13
Temperature-Diesel Engine 21 Cavity 28 15
Temperature-EFI Engine..,.,..... 22 Cavity 29 15, 29
Sensors Cavity 30 15
Distance With Diesel 23 Cavity 32 15
Distance With EFI Engine 16 Cavity 33 29
Engine Coolant With EFI Engine 16 Cavity 34... 13
Electronic Vacuum Time Delay-Diesel Engine.......... 28 Cavity 35 : -14
Oxygen With EFI Engine 13 Cavity 36 . 14
Map With EFI Engine 16 Cavity 40 , 15
Rear Wheel Anti-Lock Brake Electronic Cavity 41 13
Vacuum Delay-Diesel Engine 28 Cavity 45 13
Rear Wheel Anti-Lock Brake Electronic Cavity 47 16
Vacuum Delay Relay EFI Engine.. 26 Cavity 48 29
Temperature Sending Diesel Engine 18 Cavity 49 29
Temperature Sending EFI Engine 13 Cavity 50 29
Throttle Body Temperature EFI Engine 16 Cavity 51 14
Throttle Position with EFI Engine.. 13 Cavity 52 ....v..y.., 14
Water In Fuel-Diesel Engine 18 Cavity 53 29
Single Board Engine Controller Cavity 56. ......v...... 15
60-Way Connector Diesel Cavity 60.. 15
Cavity 3 23 Snow Plow Controls 33, 34
Cavity 4 24 Ground 34
Cavity 5 24 Fuse 33
Cavity 6 24 Left-Right Switch 33
Cavity 9 23 Left Solenoid 34
•. Cavity 11 24 Motor.. 34
Cavity 12... 24 Right Solenoid 34
Cavity 22 24 Solenoid-Down 34
Cavity 25 , .
T 24 Solenoid-Left 34
Cavity 29 23 Solenoid-Right :34
Cavity 30 23 Solenoid-Up.... 34
Cavity 44 12 Switch Illumination... 44
Cavity 45 24 Transmission Oil Temperature Lamp 33
Cavity 47 23 Transmission Oil Temperature Switch 34
Cavity 55 ............ 12 Snow Plow Lamps.......... 32
Single Board Engine Controller Dimmer Switch.... 32
60-Way Connector EFI 77 Headlamps 32
Cavity 1 16 Headlamp Switch 32
Cavity 2 16 Left Parking Lamp 32
Cavity 3 15 Left Turn Signal Lamp.. 32
Cavity 4 16 Right Parking Lamp 32
8W - 42 WIRING DIAGRAMS—ELECTRICAL

Wiring Diagram Wiring Diagram

Name Sheet Number Name Sheet Number
Right Turn Signal Lamp 32 Splice W1 68
Solenoids Splice W8-1 68, 69, 71
Air Switching With EFI Engine............ 14 Splice W8-2 68, 69
Exhaust Gas Recirculating With EFI Engine... 14 Splice X2-1 75, 76
Overdrive Transmission 11, 12 Splice X2-2 37, 75
Part Throttle Unlock With EFI Engine 9 Splice X2-3 73, 74
Purge With EFI Ignition 14 Splice X2-4 37
Speed Control System..... 29, 30 Splice X2-5... 37
Brake Warning Lamp Switch 30 Splice X33-1 70
Control Switch 30 Splice X34-1 70
Fuse ..' 44 Splice X53.. 61
Servo .....29 Splice X54 61
Single Board Engine Controller 29 Splice Z1 14
Stop Lamp Switch 30 Starter System 7, 8
Splices Automatic Transmission Jumper 8
Splice A1 1, 2, 4, 6 Back-Up Lamp Switch 7
Splice A1-1... 34 Fuse 7
Splice AH9.. 17 Manual Transmission Clutch Switch 8
Splice B2 75 Motor 7
Splice C4 63 65
r
Neutral Start Switch 7
Splice C7 63, 65 Relay.......... 7
Splice C9 51 Steering Column To Instrument Panel
Splice C13............ 35 25-Way Connector 81, 82
Splice D1 33 Cavity 2 31
Splice E2 44, 48, 57, 59, 61 Cavity 3..... 31
Splice G5........... 12, 13, 54, 73, 74 Cavity 4 52
Splice G7 63, 65 Cavity 5 52
Splice H4-1 44 Cavity 6 52
Splice H4-2 44, 48 Cavity 7 52
Splice H4-3 73, 74 Cavity 8 52
Splice J2. 5 Cavity 9 52
Splice J2-1................................................................... 19 Cavity 10..... 26, 28, 30, 52
Splice J2-2.......... 14 Cavity 12 49, 51
Splice J9 24 Cavity 13 49, 51
Splice J9-2 19 Cavity 14 49, 51
Splice K5 13, 18 Cavity 15 49, 51
Splice K5-1 - 15, 18 Cavity 16.... 51
Splice K8 13 Cavity 18.......... 44, 49
Splice K9..... 13 Cavity 19 45
Splice L1 - 31, 43 Cavity 20 45
Splice L6 46 Cavity 24 45
Splice L7 37, 39, 41, 75 Cavity 25 31, 45
Splice L7-1 36, 37, 43, 57, 59, 61 Stop Lamp Switch 30
Splice L7-2..... 37, 75 Switches
Splice L7-3 37 A/C Damped Pressure With Diesel Engine 66
Splice L7-4 - 37 A/C Damped Pressure Switch With EFI Engine 64
Splice L9 39, 41 A/C Heater Blower With Diesel Engine 65
Splice L9-1 40, 42 A/C Heater Blower With EFI Engine. 63
Splice L31 32 A/C Vacuum With Diesel Engine 65
Splice L41. 32 A/C Vacuum With EFI Engine 63
Splice M1 20, 45, 47, 48, 57, 59, 61, 71 Automatic Transmission Neutral Start With Diesel
Splice M1-1 47 Engine 7
Splice M2 45 Automatic Transmission Neutral Start With EFI
Splice M2-1 47 Engine 7
Splice N5 16, 24 Back-Up Lamp... 7
Splice P51 28 Brake Warning Lamp Diesel Engine 28
Splice R9.. 4 Brake Warning Lamp EFI Engine 26
 WIRING DIAGRAMS—ELECTRICAL 8W - 43

Wiring Diagram Wiring Diagram

Name - Sheet Number Name Sheet Number
Cargo Lamp... 45 Windshield Wiper-Intermittent . 49
Courtesy Lamp 47 Temperature Gauge.. .... 55
Dimmer-Headlamp 43 Temperature Sending With Diesel Engine 21
Dome Lamp-Front 45 Temperature Sending Unit With EFI Engine........... 22
Dome Lamp-Rear 45 Temperature Sensor Diesel Engine 21
Door Jamb......................... 45 Temperature Sensor EFI Engine 22
Four Wheel Drive Indicator......... 67 Transmission Oil Temperature Switch 34
Glove Box Lamp................ 48 Transmission Part Throttle Unlock Relay... 7
Hazard Warning 52 Transmission Part Throttle Unlock Solenoid 7
Headlamp 43 Turn Signal System 52
Horn 31 Flasher 52
Ignition 10 Fuse. 52
Illumination Lamp-A/C Switch..... ..44 Lamps-Front 39, 40, 41, 42
Illumination Lamps-Instrument Panel 55 Lamps-Rear 75, 76
Intermittent Wipe 49 Switch Control 52
Intermittent Wipe Park 50 Switch Stop 30
Key-In 45 Underhood Lamp 18
Lift Gate Ajar... 47 Fuse 18
Low Pressure-Oil With Diesel Engine 21 Lamp • 18
Low Pressure Oil With EFI Engine 22 Switch 18
Manual Clutch 8 Voltage Limiter 55
Map Lamp 45 Voltage Regulator 6
Overdrive Transmission.. 11, 12 Wide Open Throttle Cutout Relay EFI Engine 64
Power Door Lock-Left 69 Windshield Wiper-Intermittent 49, 50
Power Door Lock-Right. 70 Circuit Breaker-Wiper Motor 50
Power Mirrors 71, 72 Control Unit 50
Power Window Left 68 Park Switch 50
Power Window Right • 68 Switch 49
Seat Belt Warning With Diesel Engine 73 Washer Motor 49
Seat Belt Warning With EFI Engine 74 Washer Pump.. 49
Snow Plow Lamps 32 Washer Switch 49
Snow Plow Switch 34 Wiper Motor 50
Speed Control 30 Wiper Switch 50
Speed Control Brake - . • 30 Windshield Wiper-Standard 51
Speed Control Clutch 30 Circuit Breaker-Wiper Motor 51
Standard Windshield Wiper • 51 Fuse.. 51
Stop Lamp 30 Park Switch 51
Transfer Case Switch 67 Washer Motor 51
Transmission Oil Temperature 34 Washer Pump 51
Turn Signal 52 Washer Switch............................................................ 51
Underhood Lamp.... 18 Wiper Motor.. 51
Windshield Washer Intermittent Wipe . . . . 49 Wiper Switch 51
Windshield Washer-Standard 51
8W - 44 WIRING DIAGRAMS—ELECTRICAL

ENGINE
GROUND

BODY -jf M—|

GROUND | jj

FUSIBLE LINK
(lODG)50/120 AMP
R6
BATTER-Y ( L E F T FRONT WHEELHOUSE)
FUSIBLE LINK 6BK
A3 22WT- I
(LEFT BRONT WHEELHOUSE) CHARGING
^ - FUSIBLE L I N K LI
(22WT) 12RD SYSTEM
(LEFT FRONT WHEELHOUSE) WT* SH 3 . 4 . 5 . 6
A3
16PK

•ZJ FUSE #3
5
D 3 0 AMPS a FOSE # 7
5•ZJ 20 AMP FUSE #8
| D 20 AMP
10 f"_J
CIRCUIT
BREAKER
FUSE # 9
J—[| 20 AMP
1 5 AMP

LT
"TTCAVITY # 1 0
W5
031 14RD XI
L8 16RD
18BK* LI
18PK
12RD
RD*
POWER DOOR LOCKS
SH 6 9 STOP LAMPS
HAZARD
FLASHER SH 7 5 . 7 6
CIRCUIT K E Y - I N I HEADLAMP ON
SH 5 2 BREAKER HORNS
BUZZER
SH 3 1
-L2 14LG-1 SH 7 3 . 7 4
REAR WHEEL
HEADLAMP ANTI LOCK
# V W f SWITCH HEADLAMPS SH 2 5 , 2 6 . 2 7 . 2 8

\
DIMMER
SH 4 3 . SWITCH
SH 4 3

EI -17 18BK7YL*-
18TN

1
02 14BKX-
FUSE # 1 4 PARKING LAMPS
3 AMP SH 3 9 . 4 0 . 4 1 . 4 2
T A I L LAMPS
SH 7 5 . 7 6
E2 LICENSE LAMP FUSE # 1 5
200R SH 7 6
X FRONT SIDE MARKER 15 •ZD .15 AMP

LAMPS
CLUSTER LAMPS SH 3 9 . 4 0 . 4 1 . 4 2
SH 55 RADIO DISPLAY INTENSITY
RADIO LAMPS SH 5 7 . 5 9 . 6 1 L22
SH 5 7 . 5 9 . 6 1 CLEARANCE AND 16RD
A/C i HEATER I D E N T I F I C A T I O N LAMPS TN*
CONTROL LAMP SH 3 6 . 3 7
SH 44
ASH RECEIVER LAMP
SH 44
CIGAR LIGHTER
SNOW PLOW CONTROL LAMP
SH 44 SH 4 8
OVERDRIVE LAMP
SH 1 1

AD 1 FUSE APPLICATION CHART J908W-14

 WIRING DIAGRAMS—ELECTRICAL 8W - 45

FUSIBLE LINK
(186Y)
FUSIBLE L I N K FUSIBLE L I N K
(200R) (200R)
(LEFT FRONT ( L E F T FRONT
WHEELHOUSE) WHEELHOUSE)

C13 12BK/RDX

TO HEATED
IGNITION STARTER
REAR WINDOW
SH 3 5 SWITCH -S2 14YL- SYSTEM
SH 10 SH 7,8

FUSE # 1 1
10 AMP 02
14BKX
J2
Ml 14DB
i—020 12BK/RD*-
20PK
30 AMPS
UNDERHOOD LAMP CIRCUIT FUSE # 1
SH 20 BREAKER , 30 AMP
GLOVE BOX LAMP CAVITY # 2
SH 48
RADIO ELECTRONICS o o
SH 5 7 . 5 9 . 6 1 FUSE #13 FUSE #12
MAP LAMP Wl CI £J—J 20 AMP J—ft 5 AMP
SH 45 12TN
12BR
IGNITION BK*
SWITCH LAMP G5
SH 45 20DB*
DOME LAMPS
SH 4 6 . 4 7 -
CARGO LAMPS WINDOW L I F T
A/C I HEATER
BLOWER MOTOR
Bl
18WT
1
WAIT TO START LAMP
SH 4 5 . 4 6 SH 68 SH 6 2 . 6 3 . 6 5
POWER MIRRORS
J2
i SH 53
LOW FUEL LAMP
SH 71 BACK-UP LAMPS SH 53
14DB SH 7 5 . 7 6 GAUGES
SH 56
BRAKE LAMP
SH 53.54
SEAT BELT LAMP
AND BUZZER
AUTO SHUTDOWN SH 73.74
a o RELAY
SH 14
WATER IN FUEL LAMP
FUSE #6 FUSE #4 FUSE #5 SH 53
J — 1 2 0 AMP |—p 10 AMP |—[| 20 AMP OVERDRIVE SPEED CONTROL
SOLENOIDS SH 30
LT SH 11.12 4 WHEEL DRIVE
VOLTAGE REGULATOR INDICATOR LAMP
Dl
V6 SH 6 SH 67
18RD
18DB 20RD ALTERNATOR LOW OIL LAMP
YL*
SH 4 . 6 SH 56
VACUUM SENSOR
i SH 28
CHECK ENGINE LAMP
SH 54
WINDSHIELD RADIO I CLOCK TURN SIGNAL AIR SWITCHING ANTI LOCK LAMP
WIPER SH 5 7 . 5 9 . 6 1 FLASHER SOLENOIDS SH 53.54
SWITCH SH 52 SH 14 LIFTGATE OPEN LAMP
SH 50.51 SNOW PLOW ENGINE MODULE SH 56
DIESEL A/C LAMP I SOLENOIDS SH 1 3 . 1 4 . 1 5 . 1 6 . 2 3 O/D CONTROL MODULE
CLUTCH SH 33.34 AIR HEATER SH 11.12
SH 66 REAR WHEEL CONTROLLER EMISSION
ANTI-LOCK SH 18 MAINT LP
MODULE FUEL HEATER SH 54
SH 2 5 . 2 7 AND PUMP
SH 19

J908W-14 FUSE APPLICATION CHART AD 2

8W - 46 WIRING DIAGRAMS-ELECTRICAL

TO A/C CLUTCH
TO STARTER
f

(SEE SH 64) r C9 12BK

MOTOR t- -Al 6RD-
(SEE SH 7) >

(REAR OF BATTERY)

BLACK RED
fa Al 6BK

Al
6BK
Ml u BLACK

BATTERY
(LEFT FRONT TO FUSE #11
OF ENGINE) (SEE SH 45)
AND
ENGINE T0<C13> SPLICE
GROUND
(LEFT FRONT (SPORT U T I L I T Y ONLY)
BODY OF ENGINE) (SEE SH 35)
GROUND
(LEFT YOKE
FRONT OF
BATTERY)

BLACK-

(REAR OF
BATTERY)

#48
Al
6BK

FUSIBLE LINK-
(HYPALON WIRE)

Al 6BK-
#23

C13 18GY-

FUSIBLE LINK
HYPALON WIRE)
TO HAZARD TO STARTER
FLASHER RELAY t- Al 12RD -
[SEE SH 52) (SEE SH 7 ) >

CHARGING SYSTEM WITH ELECTRONIC

AD 3 FUEL INJECTION IGNITION JMSU-M
 WIRING DIAGRAMS—ELECTRICAL 8W - 47

•
-C9 12BK R9 6BK*

R9
#6BK*

GROUND
(REAR OF ENGINE)

TO SINGLE
BOARD ENGINE v

CONTROLLER }
CAVITY 25
(SEE SH 15)

TO<(j2>SPLICE £

(SEE SH 14)

50/120 ALTERNATOR
(RIGHT SIDE FORWARD OF ENGINE
(RIGHT FENDER SIDE SHIELD)

R6 • 8 GA WIRE FOR
6BK + 35/75 I 40/90 ALTERNATOR
(50/120 ALTERNATOR-SHOWN)

FUSIBLE LINK
(HYPALON WIRE) TO WIDE OPEN
(12BK) •C26 14BR-
(FOR 75 I 90A THROTTLE RELAY
ALTERNATOR) (SEE SH 64)

#50

J10 120R- -J10 12PKX— J10 12PKX-

FUSIBLE LINK TO IGNITION

(HYPALON WIRE) #49 Q Q SWITCH
(SEE SH 10)
J l 120R- •Jl 1 2 R D — — » - •Jl 12RD-

. TO AUTO SHUTDOWN
FUSIBLE LINK - J l 1 14RD- "1 RELAY
HYPALON WIRE) (SEE SH 14)
TO SINGLE BOARD
4 ENGINE CONTROLLER
• J l l 22WT- -Jll 16RD•
^ CAVITY 3
(SEE SH 15)

-Al 12RD LI 18GY -Ll 12RDX- -»- -Ll 12RDX- -£T0 ^ > SPLICE

#1 (SEE SH 43)

CHARGING SYSTEM WITH ELECTRONIC

J908W-H FUEL INJECTION IGNITION AD 4
8W - 48 WIRING DIAGRAMS—ELECTRICAL •

TO SINGLE
BOARD ENGINE TO TRANSMISSION
CONTROLLER C jo IC R D
J2 14DB WIRING
CAVITY 9 > J Z 1 6 0 8
(SEE SH 12)
(SEE SH 23)

TO IGNITION f

SWITCH >
(SEE SH 10)

TO LEFT •
ENGINE WIRING5"
(SEE SH 19)

TO AIR HEATER r

CONTROLLER >
(SEE SH 18)

TO VACUUM f

SENSOR >
(SEE SH 28)

TO A/C CLUTCH ,
CYCLING SWITCHV
(SEE SH 66)

BODY
GROUND
(LEFT YOKE
FRONT OF
BATTERY)

•FUSIBLE LINK
-BLACK (HYPALON WIRE)
TO STARTER TO STARTER
MOTOR (REAR OF BATTERY) RELAY
(SEE SH 7 ) (SEE SH 7 )

CHARGING SYSTEM WITH DIESEL

AD 5 5.9L ENGINE J908W-14
 WIRING DIAGRAMS—ELECTRICAL 8W -49

•R9 6BK*
GROUND
(ON ENGINE)
VOLTAGE
REGULATOR
(CENTER OF DASH PANEL) •
R6
6BK

BLACK BLACK
J2 / R3
14DB /• 18DG
/
-R3 18DG-
^ J 2 18DB-

J2
14DB
50/120 ALTERNATOR
(RIGHT SIDE FORWARD OF ENGINE)

TO DAYTIME
RUNNING LAMP
MODULE R6
BLACK
(SEE SH 42) 6BK
(CANADA ONLY)

(RIGHT FENDER SIDE SHIELD)

R6
6BK

FUSIBLE LINK
(HYPALON WIRE)

TO STARTER
Al 12RD- -Al 12RD- RELAY
(SEE SH 7)
FUSIBLE LINK
(HYPALON WIRE)
#50 D Q

JIO 20OR- • JIO 12PK* »- -JIO 12PKX-

TO IGNITION
SWITCH
(SEE SH 10)
Jl 200R - J l 12RD - J l 12RD —

#49
DO
C13 20OR TO AUTO/TRANS
> ENGINE CONTROLLER
FUSIBLE LINK - -Jll 22WT- - J l l 16RD- "i. CAVITY 3
(HYPALON WIRE) (SEE SH 23)

#1
T0<L1>SPLICE
•LI 18GY- •Ll 12RDX- -Ll 12RDX-
(SEE SH 43)

CHARGING SYSTEM WITH DIESEL

J908W-H 5. 9L ENGINE AD 6
8W - 50 WIRING DIAGRAMS—ELECTRICAL

TO CHARGING
SYSTEM
SEE SH 3 , 6 )

STARTER MOTOR ~ =
(LEFT LOWER ~~
(SEE SH 10) REAR OF ENGINE)
TO EBL FUSE # 1 3
SWITCH (20 AMP)
[SEE SH 3 5 )

AD 7 STARTER SYSTEM J908W-14

 WIRING DIAGRAMS—ELECTRICAL 8W - 51

•GAS ENGINE
TO IGNITION.
*S2 14YL- — — - S4 14YL SWITCH
(SEE SH 10}
DIESEL ENGINE

S2
14YL

-S2 16YL )X L
-S2 14YL*-

#31 DIESEL ENGINE-

(NEAR CLUTCH ROD)
BLACK - ft

/ \

MANUAL AUTOMATIC
TRANSMISSION TRANSMISSION

BLACK 7 BLACK 7
18BK 18BK

CLUTCH SWITCH S2 14YL-

(ON CLUTCH ROD)
BYPASS JUMPER
[TAPED TO WIRE HARNESS)

SWITCH CLOSES WHEN

CLUTCH I S DEPRESSED

J908W-14 STARTER SYSTEM AD 8

8W - 5 2 WIRING DIAGRAMS—ELECTRICAL •

TO
DIAGNOSTIC CONNECTOR f-
{IGNITION FEED)
(SEE SH 13)

TO
4 CHASSIS WIRING
' ( S E E SH 3 7 . 7 5 )

X2
16GY
GRAY
J22 14DB*

U3 .'20OR/BK*- -X9 14BK- TO <C9> GROUND

CE
U3 200R/BK*- J2 14DB L-—-
(SEE SH 51)
PART THROTTLE
UNLOCK RELAY
X9 14BK X2 16GY (LEFT SIDE
DASH PANEL)
J2 14DB
U —. _ . I

SINGLE 54 U3 200R/BK*- U3
BOARD 200R
ENGINE BK*
CONTROLLER
(SBEC) J22
14DB*
CONNECTOR
(SEE SH 77)

PART THROTTLE
UNLOCK SOLENOID
[3 SPEED AUTO-TRANS)

J22
J22 14DB*
14DBX

TO
OVERDRIVE
LOCK OUT
U3 2 0 0 R / B K * — ( TRANSMISSION
>
( S E E SH 11)

BLACK
REAR OF ENGINE)

PART THROTTLE UNLOCK

AD 9 3-SPEED AUTOMATIC TRANSMISSION U908W-14
 WIRING DIAGRAMS—ELECTRICAL 8W - 53

TO EBL SWITCH C •Bl 18WT-

(SEE SH 35) y TO BACK-UP
FUSE #13 LAMP SWITCH
(20 AMP) (SEE SH 7)
TO CHARGING
SYSTEM Bl 18WT
(SEE SH 4,6) IGNITION SWITCH r J 2 14DB-{{
>-G5 20DBX—5 <65>SPLICE
T
(ON STEERING COLUMN) T 0

• ACC FUSE #12 (SEE SH 54)

Jl X

(5 AMP)
12RD
i RUN -)>-J2 14DB J2 14DB—i TO <J2>2 T0<J2
I OR
#49 Bl #S1
FSTART
•Jl 12RD-<f SPLICE SPLICE
(SEE SH 14) (SEE SH 5)
#47 DIESEL
GAS

, Al
STARTER f -52 14YL—<f TO
SYSTEM S2 l START AIR CONDITIONING
(SEE SH 8) AND HEATER FEED
• ACC (SEE SH 62.63.65)
FUSE# 1
(30 AMP)
JIO 12PK* — ( f
-020 12BK/RDX -CI 12BR- TO
GROUND
(THRU STEERING
COLUMN
!• /A2
Q2
FUSE #2
(30 AMP >-Wl 12TN/BK*-! ! S s H

Y:
#50 ATTACHMENT) 14BKX CIRCUIT (SEE SH 68)
JIO I #ACC BREAKER)
12PKX
_i^4fOFF
i #RUN P51 20BK/GYX-
TO CHARGING STARTS P51 20BK/GYX-
SYSTEM
(SEE SH 4,6)
J2 14DB
52 14YL FUSE# 15
(15 AMP) LBJ
0 FUSE # 4
JO AMP)
#34

FUSE # 5 TO CIGAR LIGHTER TO

Al BRAKE WARNING
(20 AMP) (SEE SH 48)
02 14BKX LAMP SWITCH
FUSE # 6
Bl D • Al
(20 AMP) TO WIPER
(SEE SH 26.28)

SYSTEMS
' V6 18DB (SEE SH 50.51)
J l 12RD
JIO 12PKX P51
14RD/YLX• 20BK
I — 020 12BK/RDX
B3 Bl GYX TO
MESSAGE
ODD CENTER
(SEE SH 54)

X12
20RDX P51
20BK
BLACK GYX
P51 20BK/GY X
P51 20BK/GY X
BASE OF STEERING COLUMN TO R.W.A.L.
TO RADIO TO TURN SIGNAL TO R.W.A.L. MODULE
(SEE SH SYSTEM MODULE (SEE SH 25)
57.59.61) (SEE SH 52) (SEE SH 25.27)

J908W-14 I G N I T I O N S W I T C H AD 10
8W - 54 WIRING DIAGRAMS—ELECTRICAL

TO G5 20DBX- -U4 200R/WTX-

MESSAGE
CENTER
(GAS)
(SEE SH 5 4 ]

#44

OFF |6 CONTROL
SWITCH »<2_ MODULE
01
H4 20BK— 1
E2 200RX
G5 2 2 D B X
1
U4 200R/WT*- LED
LAMP U4
G5 22DBX 200R
i WT*
I 2 OVERDRIVE MODULE
(LEFT CENTER OF
Y INSTRUMENT PANEL)
H4
E2
20BK
200R
T0<(E2> SPLICE GROUND
SPLICE
(SEE SH 4 4 )
(SEE SH 4 4 )

44
•U3 200R/BK*- 54 SINGLE
BOARD
ENGINE
U3 CONTROLLER
200R (SBEC)
BK*
BLACK
— U40 2 0 0 R / L G * - 55 CONNECTOR
(SEE SH 7 7 )
•J2 14DB

£3

T0<J2>21 SPLICE
(RIGHT REAR OF
ENGINE)
(SEE SH 14)

PART T H R O T T L E
UNLOCK S O L E N O I D
(ON T R A N S M I S S I O N )

U3 200R/BKX

J 2 14DB

•U40 200R/LGX

OVERDRIVE LOCKOUT
SOLENOID

OVERDRIVE LOCKOUT SYSTEM (GAS)

AD 11 A518 AUTO/TRANSMISSION) J908W-14
 WIRING DIAGRAMS—ELECTRICAL 8W - 55

•J2 14DB «• 65 20DB*-

FUSE #12
(5 AMP) G5
TO IGNITION 20DB*
SWITCH
(SEE SH 10) (SEE SH 54)<G5

XL — G5 20DBX
OVERDRIVE -U50 20YL/DB X j
QQ
LOCKOUT G5 E10 2 0 0 R / Y L *
SWITCH 20DB* / ._,«.«». i

E10
200R
YL*
•U4 200R/WT*-
-<f

1
—U5 20YL/BK* (f CONTROL #44
— U50 20YL/DBX- (f MODULE

OVERDRIVE MODULE
(RIGHT S I D E . ON BRAKE
U50 2 0 Y L / D B *
G5 20DB* SUPPORT BRACKET) U4
H4 200R
20BK WT*
U5 2 0 Y L / B K * y NATURAL
a a
H4 20BK T 0 < H 4 ^ l l SPLICE

E10 20OR/YL* (SEE SH 44)

SINGLE
BOARD 44 U4 200R/WT*- -U4 200R/WTX-
ENGINE
CONTROLLER
(SBEC)
CONNECTOR
(SEE SH 78)
55 T0<J2> SPLICE

(SEE SH 5)

U40
200R J2 (ON TRANSMISSION)
DB* 14DB (REAR OF ENGINE)

o o
o o CF
U40 2 0 0 R / L G * - o U40 2 0 0 R / D B *
[ ^O
o o
O - J 2 14DB

^BLACK
OVERDRIVE LOCKOUT
SOLENOID

OVERDRIVE LOCKOUT SYSTEM (DIESEL)

J908W-14 (A518 AUTO/TRANSMISSION) AD 12
8W - 56 WIRING DIAGRAMS—ELECTRICAL •

-J9 18WT -J9 18WT

BLACK
( 5 . 2 AND Zl
3 . 9 ENGINE ONLY) 5 . 9 ENGINES 14DG
HEATED ONLY) X-nJ^rTjn
K8 20VT
BK*
OXYGEN SENSOR HEATED-- K7 180R/DB * — 0=jh
(ON Y PIPE NEXT
TO TRANSMISSION
OXYGEN SENSOR
fON LEFT
N5 18BK/LB X-^jQ-^
EXHAUST
MANIFOLD)
V5»L> (CENTER OF
l * r a X _ BLACK ENGINE)

N13 Nil K5 K9 K9 K7 DK20 DK21

C20
V Q

20DB 18WT 18TN 18BK 18LB 18LB ^Ll80R 20LG 20PK

18BR 16BKX
o

OR* DB* DG* RD* RD* i Q

* DB*
y i

27 34 16 15 41 5 11 12 6 22 45 25
SINGLE BOARD ENGINE CONTROLLER 60 WAY SINGLE BOARD
(SBEC) ENGINE CONTROLLER CONNECTORS
(CENTER OF DASH PANEL) (SEE SH 77)

ELECTRONIC FUEL
AD 13 INJECTION IGNITION SYSTEM J908W-14
• WIRING DIAGRAMS—ELECTRICAL 8W - 57

f TO FUEL
-Zl 14DG/BK* Zl 16DG/BK*- 3 PUMP
(SEE SH 74)

16DG/BK*-
Zl TO DAYTIME fTO OVERDRIVE
14DB RUNNING LAMPy J2 14DB- "1 TRANSMISSION
BK* MODULE J — J2 1 4 D B - — i (SEE SH 11)
(SEE SH 42)
(CANADA ONLY) . TO IGNITION
DJ2 14DB J2 14DB- i SWITCH
(SEE SH 10)
-J2 14DB-
S6 20GY/YL* I Zl
J2 14DB
J2 14DB I 16DG
JT RED SEAL BK*
TO A/C CLUTCH
CYCLING SWITCH
(SEE SH 64) J2 14DB I
Kl 20PK* I
-Zl 16DG/BK* GREEN.SEALJ

Zl I
16DG N23 20BK/0R*
BK* J2 14DB
BLUE SEAL

J2 Zl K19
14DB 14DG 20DB
BK* YL*

AIR
SWITCHING
AUTO SHUTDOWN PURGE EGR
RELAY IGNITION
(LEFT SIDE Kl S6
N23 20PK* 20GY COIL
SHIELD) (RIGHT
20BK YL*
OR* VACUUM FENDER
SOLENOIDS SIDE
TO CHARGING #37 SHIELD)
J l 14RD—i , SYSTEM v
i ENG
(SEE SH 4) J5
#35 18BK
- ENG - YL*
H ENG h
#36
Zl N23 S6 TO
TO A/C „ 16DG 20BK Kl 20GY ALTERNATOR
WIDE OPEN BK* OR* 20PK* YL* (SEE SH 4)
THROTTLE RELAY
(SEE SH 64)

51 9 8 36 52 35 19
SINGLE BOARD ENGINE CONTROLLER 60 WAY SINGLE BOARD
(SBEC) ENGINE CONTROLLER CONNECTOR
(CENTER OF DASH PANEL) (SEE SH 77)

ELECTRONIC FUEL
J908W-14
INJECTION IGNITION SYSTEM AD 14
8W - 58 WIRING DIAGRAMS—ELECTRICAL

N2
18BRX

30 28 40 60 29 3 20 32 56
SINGLE BOARD ENGINE CONTROLLER 60 WAY SINGLE BOARD
(SBEC) ENGINE CONTROLLER CONNECTOR
(CENTER OF DASH PANEL) (SEE SH 77)

ELECTRONIC FUEL
AD 15 INJECTION IGNITION SYSTEM J908W-14
 WIRING DIAGRAMS—ELECTRICAL 8W - 59

THROTTLE BODY G7 20WT/OR* (ON REAR OF

BLACK
TEMP SENSOR TRANSMISSION)

N5 18BK/LBX- 18BK/LB*
p (RIGHT REAR
OF ENGINE)
G7 20WT/0R*-
BLACK
K13 1
— N 5 20BK/LB*•
18BK TO LEFT
RD* PRINTED CIRCUIT
N TO OXYGEN BOARD CONNECTOR
I SENSOR (SEE SH 58)
(SEE SH 1 3 )
IsL
L K13 18BK/RD* ! OO, OOJ
TO THROTTLE
BODY WIRING 5 4 3 2
(SEE SH 13) 2 067
WT 2
N5 18BK/LB* ls
18BK/LB*— 1 OR* o m

#43 DISTANCE
N5 18BK/LB*- SENSOR
G7 (ON REAR OF
K10 20TN* 20WT
18BK/LB*- N5 TRANSMISSION)
OR*
18BK
18BK/LBX—I LB*

-G7 20WT/0R*-
DISTRIBUTOR
(CENTER REAR
OF ENGINE) GRAY
ENGINE N5
18BK o K8 20VT/WT*[
COOLANT SENSOR
(TOP LEFT LB* a K4 20DG/RD*|
FRONT OF N5 18BK/LB*!
ENGINE) o
N7
N6 18GY*
K10
180R
20TN* #3 THROTTLE
MAP
~[ ENG |- SENSOR BODY

N5 TO
K13
18BK
18BK K8 20VT/WT*—£ <K8
LB* 1

RD* K4
20DG SPLICE
RD* (SEE SH 13)
#17 #23 #11 #32 " #10
i ENG ENG h H ENG h -| ENG |- - ENG -

N5 G7
N6 18BK 20WT
180R LB* OR*
K10 K13 N7 K4
20TN* 18BK 20DG
18GY*
RD* RD*

i i
T
•1 24 1 47

SINGLE BOARD ENGINE CONTROLLER 60 WAY SINGLE BOARD

(SBEC) ENGINE CONTROLLER CONNECTOR
(LEFT FENDER SIDE SHIELD) (SEE SH 77)

ELECTRONIC FUEL
J908W-14 INJECTION IGNITION SYSTEM AD 16
8W - 60 WIRING DIAGRAMS—ELECTRICAL

TO
-A5 12BK C@ TTEI
BATTERY
POSITIVE

6) BATTERY
(LEFT FRONT
OF ENGINE)
FUSIBLE
LINK
TO CHASSIS <
A5 WIRING >
6BK (SEE SH 75)

X2
16GY

•A5 6BK- L
A4 6BK H Z © S~ZZ>—AH9
, 18BK-

(LEFT (LEFT
FENDER FENDER
SIDE SIDE
SHIELD) SHIELD)

•A6 6BK

AX9 16BK
TO STARTER SYSTEM
(SEE SH 8)
S21 c; 9 TO COLD START
18YL
9 r

A7 iftnp ADVANCE ) 1
BK*
H
%

6BK l8
(SEE SH 19)

-S21 18YL/BK*-
— S2 16YL
A7 6BK- -J2 14DB-

•S2 16YL T — DJ2 14DB-

15"
J32 18DB/WT*-
J32 18DB/WT*-
-S21 18YL/BK*

S2
16YL
E5
#11 20DG -J2 14DB-
"WT* S2
18YL
TO MESSAGE ^ ^ -S22 180R/BK*-

TO STARTER — S 2 18YL
RELAY
(SEE SH 7) •E5 20DG/WT*-

AD 17 DIESEL ENGINE WIRING J908W-14

 WIRING DIAGRAMS—ELECTRICAL 8W - 61

NTO GROUND EYELET

-K5 18BK* -K5 16BK*- "1 (SEE SH 19)

^5 -K5 18BK*-

•K32 20TN/BK*

K32 K5
20TN isBK*
BK*

K5 BLACK
18BK*

TO SINGLE
BOARD TO VACUUM
ENGINE SENSOR
CONTROLLER (SEE SH 28)
CAVITY 5)
(AUTO/TRANS)
20TN
(SEE SH 24
18BK

SPLICE
TO (SEE SH 24)
I K5 K5
<^C9> I fgj 18BK* 18BK*
SPLICE K32 BK*
(SEE SH 51] #AAA# J9 20TN
16BK BK*
T
AX9 WATER-IN-FUEL SENSOR TEMPERATURE
16BK (IN FUEL F I L T E R ) SENSOR

-K5 14BK*
TO
K5 \
18BK* \
<§> K31 2 0 B K / P K * — ( f - K 3 1 20BK/PK * -
SPLICE
(SEE SH 5)
CO#38
T TO MESSAGE /Q
J2 CENTER f^T
14DB (DIESEL)
(SEE SH 53

N TO DIAGNOSTIC CONNECTOR
-DJ2 14DB 1 (SEE SH 24) >-
(AUTO/TRANSMISSION ONLY)

J32 18DB/WT*
S21 18YL/BK*-

AIR
-J2 14DB- HEATER -K5 18BK*
CONTROLLER
-S22 180R/BKX-

—S2 18YL -S20 18LB/BK*

-E5 20DG/WT*-

J908W-14 DIESEL ENGINE WIRING AD 18

8W - 62 WIRING DIAGRAMS—ELECTRICAL

TO AIR
HEATER c U32 18DB * -
CONTROLLER >
(SEE SH 17)

SPLICE
(SEE SH 5)

-K5 16BKX
FUEL PUMP
(CENTER OF
ENGINE)

(REAR OF
ENGINE) FUEL
HEATER
(REAR OF
ENGINE)
~5TO <K5> SPLICE

(SEE SH 18)

AD 19 DIESEL ENGINE WIRING J908W-14

 WIRING DIAGRAMS—ELECTRICAL SW - 63

BLACK

#33 TO BODY
WIRING
•L22 18BK/RD*- -»- -L22 18PK/RD X (SEE SH 4 6 . 4 7 )

TO

SPLICE
(SEE SH 4 0 . 4 2 )

Ml
18PK
L29
18BK

L28 18BK

(RIGHT SIDE FUSE #11

COWL PANEL) (10 AMP)

•Ml 20PK-

C13
12BK
RD*

L29 #48
16BK TO CHANGING ,
SYSTEM y C13 12BK/RDX-
(SEE SH 3 . 5 )

L29 16BK F
MERCURY
SWITCH
L22 16BK/RDX-

REEL TYPE
BLACK UNDERHOOD LIGHT
(CENTER OF
HOOD INNER PANEL)

J908W-14 UNDERHOOD LAMP AD 20

8W - 64 WIRING DIAGRAMS-ELECTRICAL •

TO LEFT
PRINTED CIRCUIT
BOARD CONNECTOR
6(SEE
5 SH 256) #17|
W G20 20VT/YL* - G 2 0 20VT/YL*-
ooo oo
1
GRAY

G6 20GY ( f — 66 20GY-
BLACK

G60 20GY/YL* « G60 20GY/YLX

TO RIGHT
PRINTED CIRCUIT
BOARD CONNECTOR
(SEE SH 56)

BLACK
(REAR OF ENGINE)

OIL PRESSURE
SENDING UNIT
AND SWITCH

OIL PRESSURE AND TEMPERATURE

AD 21 SYSTEM FOR DIESEL ENGINE J908W-14
 WIRING DIAGRAMS—ELECTRICAL 8W - 65

BLACK
TO LEFT
GRAY
PRINTED CIRCUIT
BOARD CONNECTOR
(SEE SH 56)

TO RIGHT
PRINTED CIRCUIT
BOARD CONNECTOR
(SEE SH 5 6 )

#19 #18 #17

660 G20
66
20GY 20VT
OR* 20GY YL*

#15 #16 #26

~| ENG |- H ENG h H ENG h

G60
20GY
OR*

OIL PRESSURE
SENDING UNIT
AND SWITCH

TEMPERATURE
SENDING UNIT
(RIGHT SIDE
FRONT OF
ENGINE)
G60 20GY/0R*
G6 206Y*
i_ « . — — —

OIL PRESSURE AND TEMPERATURE SYSTEM

FOR ELECTRONIC -
J908W-14 FUEL INUECTION IGNITION AD 22
8W - 66 WIRING DIAGRAMS—ELECTRICAL

SINGLE BOARD ENGINE CONTROLLER

(AUTO/TRANS-DIESEL)
CONNECTOR SEE SH 78

29 30 47

Jll J2
D40
T
S4
G7
18WT 20WT
16RD 16DB 20BR
PK* OR*
YL*

TO FUSIBLE SPLICE TO STOP LAMP TO STARTER

TO
LINK RELAY
(SEE SH 6) SW1 TO DAYTIME
(SEE SH 5) (SEE SH 28) (SEE SH 7)
RUNNING LAMP
MODULE
(CANADA ONLY)
(SEE SH 42)

BLACK

-67 20WT/0R* •G7 20WT/0R*

G7
20WT
•N5 20BK/LB* REAR OF ENGINE) OR*

N5 20BK/LB*-
(ON REAR OF
TRANSMISSION)

#43

67
20WT
OR*

TO LEFT
PRINTED CIRCUIT
BOARD CONNECTOR
(SEE SH 56)

DISTANCE SENSOR
(ON REAR OF
TRANSMISSION)

AD 23 AUTOMATIC TRANSMISSION WIRING-DIESEL JSOBU-M

 WIRING DIAGRAMS-ELECTRICAL 8W - 67

SINGLE BOARD ENGINE CONTROLLER

(AUTO/TRANS-DIESEL)
CONNECTOR SEE SH 78

11 12 5 29 45 4 6 47

T
DK20

K5 DK21 20LG
DIAGNOSTIC K8 K7
16BK* 20PK CONNECTOR 20VT 180R
WT* DB*

N5
18BK
LB*
J9
T0<Q<521 DK5
14BK 16BK*
SPLICE
(SEE SH 18) J2
14DB
TO DAYTIME I H N 5 18BK/LB*-!—l
RUNNING LAMP DU2
MODULE TO VACUUM SENSOR 14DB
(CANADA ONLY) (SEE SH 2 8 )
(SEE SH 42)

TO AIR HEATER ,
TO ENGINE WIRING f CONTROLLER $- BLACK
(SEE SH 1 8 . 1 9 ) r (SEE SH 18)
(REAR OF ENGINE)

•N5 20BK/LB*-

i
-N5 18BK/LB*-

I -K7 180R/DB*-

- K 8 20VT/WT*-

THROTTLE POSITION
TRANSDUCER

J908W-14 AUTOMATIC TRANSMISSION WIRING-DIESEL AD 24

8W - 68 WIRING DIAGRAMS—ELECTRICAL •

TO
TO
< IGNITION
TURN SIGNAL 02 14BK• > SWITCH
FLASHER f
(SEE SH 10)
(SEE SH 52) y -Dl 18RD/YLX

3 -Dl 14RD/YLX

I -IS1 16LGX IS1 16LG X

8 -DS1 14WT/BKX- DS1 14WT/BR X

#3
II -VS1 18LB — VS1 18LB
TO #141
f 4WD INDICATOR '
4 -X4 20LG/BR X - "J - LAMP SWITCH #24
(SEE SH 67)
14 -B01 18RD/VTX • •B01 18RD/VTX
REAR 7 < f

WHEEL
ANTI-LOCK 13 -»- -B02 18WT/VTX B02 18WT/VTX
CONTROL TWISTED PAIR
7 t
MODULE

B01 18RD/VTX- #25

ROLLS TEST CONNECTOR
B02 18RD/VTX -

— D4 18WT/TNX- D4 18WT/TNX
(BEHIND
INSTRUMENT D3 20PK/DBX
•—D3 20PK/DBX-
PANEL
RIGHT S I D E )
»- P5 20GY/BK X

-ATI 180R-
10 12 6

T_ -P51 20BK/GYX-

TO
DK 18BKX MESSAGE CENTER
TO (GAS)
INTERMITTENT (SEE SH 54)
-H40 20BK/LGX- WIPER MODULE
(SEE SH 49) BLACK
P51
20BK
-GRAY GYX

D4 18WT/TNX" -BOl 18RD/VTX

SERVICE
P51 20BK/GYX- ft) (0> -B02 18WT/VTX DIAGNOSTIC
CONNECTOR TO A
P5 20GY/BKX- -DK 18BKX
(LOWER RIGHT IGNITION
X4 20LG/BRX- -VS1 18LB SIDE COWL) SWITCH
(SEE SH 10)
Dl 14RD/YLX- -H40 20BK/LGX
AT1 180R- -D3 20PK/DBX
IS1 16LGX- -DS1 14WT/BRX

PARK BRAKE
SWITCH

REAR WHEEL ANTI-LOCK BRAKE SYSTEM

AD 25 (GAS ENGINE) J908W-14
 WIRING DIAGRAMS—ELECTRICAL 8W - 69

-B09 18GY*-

-#10
, TO HAZARD
D4 1SWT—(FLASHER SWITCH
(SEE SH 5 2 )

O
STOP LAMP AND STOP LAMP SWITCH
R.W.A.L. SENSOR SPEED CONTROL SWITCH WITHOUT SPEED CONTROL
(IN REAR DIFFERENTIAL) WITH SPEED CONTROL
REAR WHEEL ANTI-LOCK BRAKE SYSTEM
J908W-14 (GAS ENGINE) AD 26
8W - 70 WIRING DIAGRAMS—ELECTRICAL

TO
TO < IGNITION
TURN SIGNAL
FLASHER
02 14BK- > SWITCH
r
(SEE SH 10)
(SEE SH 52) y -Dl 18RD/YLX

3 -Di 14RD/YLX

I -IS1 16LG*
IS1 16LG %
8 -DS1 14WT/BKX-
•DS1 14WT/BR*
#3
II -VS1 18LB
TO # 1 4
VS1 18LB
f 4WD INDICATOR
4 X4 20LG/BR % - ~y LAMP SWITCH
(SEE SH 67)
14 -B01 18RD/VT*- B01 18RD/VT*
REAR
WHEEL
ANTI-LOCK 13 -B02 18WT/VTX • B02 18WT/VT*
CONTROL TWISTED PAIR
MODULE
B09 18RD/VTX
ROLLS TEST CONNECTOR f
B02 18WT/VT*

D4 18WT/TN*- D4 18WT/TN*
(BEHIND
INSTRUMENT —D3 20PK/DBX- D3 20PK/DB*
PANEL
RIGHT SIDE)
» P2 20BK/GYX-

- ATI 180R- TO
10 12 MESSAGE CENTER
;DIESEL)
(SEE SH 53)
•P5 20GY/BK X • P2 18BK/GYX

DK 18BK*
TO
INTERMITTENT
-H40 20BK/LGX- WIPER MODULE
(SEE SH 49) BLACK

-GRAY

D4 18WT/TN*- -B01 18RD/VTX

SERVICE
P2 20BK/GYX- -B02 18WT/VTX DIAGNOSTIC
CONNECTOR TO
P5 20GY/BKX- -DK 18BKX (LOWER RIGHT IGNITION
-VSi 18LB SIDE COWL) SWITCH
X4 20LG/BRX-
(SEE SH 10)
Dl 14RD/YLX- -H40 20BK/LGX
AT1 180R- -D3 20PK/DBX
IS1 16LGX- -DS1 14WT/BRX

PARK BRAKE
SWITCH

REAR WHEEL ANTI-LOCK BRAKE SYSTEM

AD 27 (DIESEL ENGINE) J908W-14
• WIRING DIAGRAMS-ELECTRICAL 8W - 71

-B09 18GY*-

RESET SWITCH

ISO SOL

DUAL SOLENOID
HYDRAULIC VALVE

V pc)1 N

20 GY
BY
C*
# 1 0 - STRG TO
COLUMN] HAZARD
-D4 18WT/TN*- "<—D4 16WT 1 FLASHER
^ SWITCH

•
(SEE SH 52)
-D3 20PK/DB*-

D3 D4
>1 TO
O
#34 18WT
1
s
y
20PK B01 B02
20 GY BUZZER TN* 18RD 18RD
BY<* DB*
(SEE SH 73) VT* VT*
P2
18BK
GYX 1
D3 18PK/DBX- -D4 20WT/TN*- TWISTED
H4 18BK — PAIR

r
TO
ir

H4 20BK
TO BLACK
RESISTOR
L
-D40 18WT/PK*-i
<K5H1
GROUND
SPLICE SPLICE B01 B02
(SEE SH 18) SEE SH 44) 20PK 20LG
OR*
#41

D40
18WT
18WT PK*

, 1 C
1\ I1,
1
TO SINGLE
BOARD ENGINE
CONTROLLER
CAVITY 29
O (SEE SH 23)
SPLICE
(SEE SH 5) STOP LAMP SWITCH R.W.A.L. SENSOR
(LEFT FENDER IN REAR DIFFERENTIAL)
SIDE SHIELD) R E A R L ^ E E L ANT I - L O C K B R A K E SYSTEM
AD 28
J808U-M ' (DIESEL ENGINE)
8W - 72 WIRING DIAGRAMS—ELECTRICAL

SINGLE BOARD
ENGINE CONTROLLER
(SBEC)

ON/OFF 49 X32 20YL/RD*-

SET 48 -X31 20BR/RD* •

RESUME 50 •X33 20WT/LG* -

BRAKE •D40 18WT/PK* -

29
SENSE

VACUUM 33 -X36 20TN/RD* -

VENT 53 -X35 20LG/RD*-

CONNECTOR
(SEE SH 77)

X30 20DB/RD*-

TO R.W.A.L.
(SEE SH 2 6 , 2 8 )
TO TRANSFER
CASE SWITCH
(SEE SH 67) X9 20BK-
D40 -D3 18PK/DB* •
H
L

18WT
PK*

BLACK

D3
18PK
DB*

T0<(C9>SPLICE

(SEE SH 51)

TO SEAT
BELT WARNING
SYSTEM
(SEE SH 7 3 . 7 4 )
FUSED BATTERY
FEED

SPEED CONTROL
SERVO

AD 29 ELECTRONIC SPEED CONTROL SYSTEM J908W-14

 WIRING DIAGRAMS—ELECTRICAL 8W - 73

TO

SPLICE
(FUSED IGNITION FEED)
(SEE SH 54)

G5
20DB*

•X32 20YL/RD*

-X31 20BR/RD*

. GROUND SPLICE
(SEE SH 44) 20BK

•D3 18PK/DB*

D3 18PK/DB*

D40 18WT/PKX—-))—D40 18WT/PKX

#41

SPEED CONTROL
SWITCH
(ON STEERING
COLLUMN

STOP LAMP AND STOP LAMP SWITCH

SPEED CONTROL SWITCH WITHOUT SPEED CONTROL
WITH SPEED CONTROL

J908W-H ELECTRONIC SPEED CONTROL SYSTEM AD 30

8W - 74 WIRING DIAGRAMS-ELECTRICAL

TO FUSIBLE
LINK (HIGH NOTE)
(LOW NOTE) HORN

T
(SEE SH 4 , 6 )
HORN .

(LEFT SIDE (RIGHT SIDE

OF RADIATOR OF RADIATOR
LI SUPPORT) SUPPORT)
12RD*

*1 BLACK
BLACK

LI H2 18DG/RD*
12RD*

TO A/C
CONNECTOR
(SEE SH 6 4 . 6 6 )
SPLICE
(SEE SH 43) T
H4 #2
LI 18BK
12RD* STRG
COLUMN
#32 -H4 18BK-
FUSE # 7
(15 AMP)

H4
20BK

H4
TO IGNITION , 18BK
KEY-IN LAMP } — H 4 18BK—«•
(SEE SH 45)-
H2 #25
18DG STRG
HORN RELAY COLUMN
(ON FUSE BLOCK) R
°*
(SEE SH 83) (STEERING COLUMN)

#3
STRG
COLUMN
}) -H3 18BK/RD: •H3 18BK/RD*
HORN
SWITCH

RETAINER
PLATE H4
18BK

STEERING ~
COLUMN
GROUND

AD 31 HORN SYSTEM J908W-14

• WIRING DIAGRAMS—ELECTRICAL 8W - 75

TO FRONT TO FRONT
END MIRING END WIRING
(SEE SH 39) (SEE SH 40)

BLACK
BLACK

(RIGHT
SIDE
RADIATOR
YOKE
PANEL)

BLACK (RIGHT
UPPER
SNOW
PLOW
FRAME)

BLACK
BLACK

TO FRONT
END LIGHTING
LEFT AUXILIARY (SEE SH 43) RIGHT AUXILIARY
PARK AND TURN PARK AND TURN
LEFT AUXILIARY RIGHT AUXILIARY SIGNAL LAMP
SIGNAL LAMP
HEADLAMP HEADLAMP

J908W-14 SNOW PLOW EXTERIOR LIGHTING AD 32

8W - 70 WIRING DIAGRAMS—ELECTRICAL •

FUSE # 5
TO TURN (20 AMP)
SIGNAL FLASHER V- Dl 18RD/YL*
(SEE SH 52)
TO R.W.A.L.
MODULE U •Dl 18RD/YL*
(SEE SH 2 5 , 2 7 ) >

I4BKX

BLACK TO
IGNITION
SWITCH
(SEE SH 10)

I-SP4 18WT/BR*- SP4 18WT/BRX•

-SP4 18WT/BRXj
-SP4 18WT/BR* I

UP
•Dl 18RD/YL*- DOWN
PLOW . SP1 18WT/BKX l
UP CONTROL
SWITCH Dl 18RD/YLX
DOWN
UP i DOWN
i SP3 18WT/RDX i1

SP3 18WT/RDX •
SP1 18WT/BKX-

SP4 18WT/BRX—i
•SP4 18WT/BR*j
r-SP4 18WT/BRX—
• SP4 18WT/BRXI
Dl
18RD
YL*
#L
1
—Dl 18RD/YL*-
tT PLOW
CONTROL
SP4 18WT/BRXl
SWITCH •Dl 18RD/YL*
LEFT TO
1i
•. SP5 18WT/LG*
RIGHT
i — , — — .

L
-SP4 18WT/BRX— 1
SP5 18WT/LG*

Dl 18RD/YLX T2 18LG/RDX•

TRANSMISSION OIL
TEMPERATURE LAMP

AD 33 SNOW PLOW CONTROL J908W-14

 WIRING DIAGRAMS—ELECTRICAL 8W - 77

TO CHARGING
SYSTEM
(SEE SH 3)

TO BATTERY
CABLE Al 6R0
(SEE SH 3)

(REAR OF
-SP4 18WT/BR*- SNOW PLOW
BATTERY)
MOTOR
SOLENOID
(LEFT
WHEELHOUSE)

Ml 6RD

•Ml 6RD

s1
•SP4 18WT/BRX
SNOW PLOW

1 i MOTOR

P
(FRONT SNOW
BODY GROUND PLOW FRAME)
(FRONT SNOW
PLOW FRAME) E i

G9 6BK- -E6
BLACK — SNOW PLOW
(FRONT SNOW UP SOLENOID
PLOW FRAME) (FRONT SNOW
PLOW FRAME)

-SP3 18WT/RDX —I SP3 16RD-

SP3 18WT/RDX •
SP1 18WT/BK*-

18WT/BKX SP1 16BK-

SNOW PLOW
BLACK DOWN SOLENOID
(FRONT SNOW (FRONT SNOW
PLOW FRAME) PLOW FRAME)

SP5 18WT/LGX SP5 16LG- -nrn-

SNOW PLOW
SP5 18WT/LG* BLACK RIGHT SOLENOID
(FRONT SNOW (FRONT SNOW
PLOW FRAME) PLOW FRAME)

12 18LG/RDX
TRANSMISSION OIL
TEMPERATURE SWITCH
(RIGHT SIDE
BELOW RADIATOR)

J908W-14 SNOW PLOW CONTROL AD 34

8W - 78 WIRING DIAGRAMS—ELECTRICAL

TO BACK-UP LAMP TO
FUSE #13 SWITCH FUSIBLE
(20 AMP) (SEE SH 7 ) LINK
(SEE SH 3)

TO Bl 18WT-
SW
(SEE SH 10)
Bl 18WT-
C13
C13 H4 T0<H4>1 GROUND 12BK/RD*
12BK/RD* SPLICE
20BK
(SEE SH 44)
Bl
T 0 < £ > SPLICE f 18WT
H4
E D O 20BK #48
(SEE SH 44) E2
(ILLUM LAMP FEED) 220R

CIS Bl E2
12BK/0RX 18WT 220R
ON 0=
TIMER
OFF*

MECHANICAL-
OFF/ON SWITCH
L.E
JO -C13 12BK/RD*

HEATED REAR
WINDOW DEFOGGER
C13
SWITCH CIS 12BK/RD*
(INSTRUMENT 12BK/0RX
PANEL)
BLACK

TO FUSE BLOCK
CIS 12BK/0R- CAVITY #11
(SEE SH 45)
C15
12BK/0RX
BLACK
LEFT ' C ' P I L L A R )

-BLACK
(IN TAIL GATE)

, ELECTRICALLY HEATED REAR WINDOW

AD 35 (SPORT UTILITY) JSOSH-M
 • WIRING DIAGRAMS—ELECTRICAL 8W - 79

TO
HEADLAMP
SWITCH SPLICE
(SEE SH 43) (SEE SH 43)

L7 18BK/YL* L7 18BK/YL *

17 18BK/YL *

CLEARANCE
LAMP

L7
18BK BLACK
YL*

L7 18BK-
IDENTIFICATION
LAMP

L7
18BK
YL*

L7 18BK-
I DENT I F I CAT I ON
LAMP

L7
18BK
YL*

L7 18BK-
IDENTIFICATION
LAMP
(AT LAMP)
L7
-BLACK
18BK
YL*

L7 18BK-
CLEARANCE
LAMP
(AT LAMP)

FRONT CLEARANCE AND IDENTIFICATION

J908W-14 LAMPS (ROOF) AD 36
8W - 80 WIRING DIAGRAMS—ELECTRICAL •

SPLICE
(SEE SH 3 9 , 4 1 )

18GY

L7 18BK/YL*-
-L7 18BK/YL* L7 18BK/YL*-

CLEARANCE AND IDENTIFICATION LAMPS

AD 37 (DUAL REAR WHEELS J9G8W-14
 • WIRING DIAGRAMS—ELECTRICAL 8W - 81

-L7 16BK- on
-X2 16GY- an:
LEFT FENDER
CLEARANCE
LAMPS

-L7 16BK- an-

-X2 16GY-
on:

X2
16GY
-L7 16BK- OLX

-X2 16GY- an
RIGHT FENDER
CLEARANCE
BLACK LAMPS
(REAR-UNDERBODY
LEFT SIDE)
-L7 16BK-
an-
-X2 16GY-
on-

L7
X2
18GY 16BK
X2
16GY

BL

)—BLACK
(REAR-UNDERBODY
RIGHT SIDE)

-X2 18GY-

•L7 18BK/YL*•

FENDER CLEARANCE LAMPS

J908W-14 (DUAL REAR WHEELS) AD 38
8W - 82 WIRING DIAGRAMS—ELECTRICAL

BLACK TO DIMMER SWITCH -L4 16VT*

(SEE SH 43) -L3 14RD/OR*

TO RIGHT -D5 18TN

PRINTED CIRCUIT TO TURN -05 18TN
BOARD CONNECTOR SIGNAL SYSTEM
L33 (SEE SH 56) (SEE SH 52)
16RD -D6 18LG
BK*
-D6 18LG

#12
T0<L7^T| SPLICE 5 L7 18BK/YL*
(SEE SH 43)

L3 14RD/0RX

LEFT
HEADLAMP

LEFT SIDE
MARKER LAMP

-L7 18BK/YL*

D6 18LG-

BLACK
-18LG-

LEFT
HEADLAMP
18BK-
GROUND

-L7 18BK/YLX
•18BK/YLX-
•L7 18BK/YL * L7 18BK/YL * •
LEFT PARK
AND TURN (LEFT REAR RADIATOR
SIGNAL LAMP YOKE PANEL)
(GAS ENGINE ONLY)

TO REAR
LIGHTING
(SEE SH 75)

AD 39 FRONT END LIGHTING J908W-14

 WIRING DIAGRAMS-ELECTRICAL 8W - 83

L9 18BK

C9 14BK-

TO

RIGHT HEADLAMP
SPLICE
GROUND
(SEE SH S i )

RIGHT
HEADLAMP

RIGHT SIDE
MARKER LAMP

RIGHT PARK
AND TURN
SIGNAL LAMP

18BK-
TO (RIGHT REAR
UNDERHOOD RADIATOR YOKE)
LAMP (GAS ENGINE ONLY)
(SEE SH 20)

J908W-14 FRONT END LIGHTING AD 40

8W - 84 WIRING DIAGRAMS—ELECTRICAL

•L33 16RD/BK* L33 16RD/BKX-

(LEFT REAR RADIATOR

YOKE PANEL)
[GAS ENGINE ONLY)

TO REAR
LIGHTING
(SEE SH 75)

AD 41 FRONT END LIGHTING (CANADA) J908W-14

• WIRING DIAGRAMS—ELECTRICAL 8W - 85

TO HEADLAMP f
DAYTIME RUNNING
SWITCH y L20 20LG/BK*- L20 1 4 L G / B K * - LIGHT MODULE
(SEE SH 43)

i
#13[OJ
ft—
L33 16RD/BK*- L33 16RD/BKX- o O
o o
#12 o o :
o o
O o

^
—y
L7 1 8 B K / Y L * - G7
20WT
- J 9 16BK- OR* (ENGINE COMPARTMENT
J2 LEFT S I D E )
D5 14DB
18TN L4
D5 TO L7 16VT* TO<G7>SPLICE
18TN 18BK
YL* (SEE SH 23)
SPLICE TO <J2>2| SPLICE
nj#22 (SEE SH 24)
(SEE SH 14)
L3 (GAS ENGINE)
•L4 16VT* 14RD
OR* _fT0 ENGINE WIRING
•L3 14RD/OR*- > (SEE SH 6)
(DIESEL ENGINE)

L9 20BK —
•L4 16VT*
RIGHT
L4 16VT*-
HEADLAMP

L3 14RD/0R*-

TO
L29 18BK \ UNDERHOOD LAMP
J
(SEE SH 20)

RIGHT SIDE
MARKER LAMP

LEFT PARK
AND TURN
SIGNAL LAMP

RIGHT ^
HEADLAMP (Q
GROUND

J908W-14 FRONT END LIGHTING (CANADA) AD 42

8W - 86 WIRING DIAGRAMS—ELECTRICAL •

, , io n*--4 T 0
FUSIBLE
LI 12RDX—}
R
LINK
FUSE #14
(3 AMP)

TO
LEFT DOOR
SWITCH
(SEE SH 45)

TO DAYTIME
RUNNING LAMP
MODULE
(SEE SH 42)
(CANADA ONLY)

TO
FRONT END
L « - L 4 16VT X — £ LIGHTING
< f - L 3 14RD/OR * — £ (SEE SH
39.41)
AD 43 HEADLAMP SWITCH #6
J908W-14
• WIRING DIAGRAMS—ELECTRICAL 8W - 87

TO CIGAR
LIGHTER
(SEE SH 4 8 )
r TO CARGO
> LAMP SWITCH
(SEE SH 4 5 )
f TO A/C i
> HEATER WIRING
SEE SH 6 3 . 6 5 )
TO GLOVE
BOX LAMP
TO EBL SWITCH (SEE SH 4 8 )
(SEE SH 35
(SPORT UTILITY ONLY)

HEADLAMP SWITCH CONTROLLED

J908W-14 INTERIOR LIGHTING AD 44
8W - 88 WIRING DIAGRAMS-ELECTRICAL •

TO COMBINED
BUZZER
K9KKKM KM
(SEE SH 73.74) KM KM KM

TO BODY WIRING
(SPORT UTILITY ONLY)
(SEE SH 47)

AD 45 DOME LAMP, MAP LAMPf AND CARGO LAMP • JSOSW-M

 WIRING DIAGRAMS—ELECTRICAL 8W - 89

DOME
CARGO LAMP
TO <H4^3] SPLICE LAMPS

(SEE SH 7 3 . 7 4 )

18BK 18BK

AA
H4
18BK
BLACK
DOME (NEAR LAMP)
LAMP

r©i
-BLACK

YL6 YL6
r-n^ (NEAR LAMP)
CARGO
LAMP
180R I80R
VT* VT*

M2 Ml
18BK 18BK
YL* PK*

L6
180R
VT* M2 18BK/YL*

fcLJEL (LEFT SIDE

OF STEERING
rum COLUMN) -Ml 18BK/PK*

BLACK BLACK

STANDARD \ / CLUB CAB

CAB \

TO UNDERHOOD
L22 18BK/RD* 4" LAMP
>
(SEE SH 2 0 )

BLACK

TO BODY WIRING
M2 20YL- - M 2 20YL 5 (SPORT UTILITY ONLY)
(SEE SH 47)
•Ml 18PK
-L6 180R/VT*

J908W-14 DOME LAMP AND CARGO LAMP AD 46

8W - 90 WIRING DIAGRAMS-ELECTRICAL •

BATTERY FEED -Ml 20PK-

(SEE SH 3 . 5 •C13 12BK/RD*-

FUSE #11
(10 AMPS)
2(0^)1
TO LEFT 3
® •GRAY (SEE SH 45)
PRINTED CIRCUIT
BOARD CONNECTOR M4 20TN/BK*
REAR DOME LAMP
2
4

(SEE SH 56)

Ml
GREEN 18PK
LEFT ' B ' PILLAR)

M2 18BK/YL*
M2 18BK/YLX
Ml 18PK/PK*

18BK
RD*

TO UNDERHOOD
LAMP
(SEE SH 20)

FRONT DOME/ BODY

READING LAMP GROUND

BLACK
BLACK
(LEFT ' C
-M4 18TN/BK*
PILLAR)

• -HB- © Z > K2 12BK

LIFTGATE
AJAR SWITCH
(LIFTGATE LATCH)

LIFTGATE AJAR WARNING SYSTEM & REAR

AD 47 DOME LAMPS (SPORT UTILITY ONLY) JSOSW-M
 WIRING DIAGRAMS—ELECTRICAL 8W - 91

BATTERY FEED v -Mi 20PK

(SEE SH 3 . 5 ) C C13 12BK/RDX-

FUSE # 11
(10 AMP)

-Ml 20PK
GLOVE
BOX LAMP
AND
SWITCH CIGAR
LIGHTER

n n tit
u U <
(CENTER OF
X22
INSTRUMENT 16RD
H4 PANEL) TN*
20BK

(SEE SH 44) -BLACK

FUSE #15
(15 AMP)

-H4 20BK H4 1 8 B K — 1

Q2
14BKX

TO HEADLAMP N

SWITCH )—El 18TN E2 200R TO IGNITION

(SEE SH 43) SWITCH
FUSE# 14 (SEE SH 10)
H4 (3 AMP)
20BK

ASH E2 200R
RECEIVER
LAMP dx •H4 20BK
(SEE SH 44)

H4 20BK

CIGAR LIGHTER,ASH RECEIVER LAMP

J908W-14 g G L O V E BOX LAMP AD 48
8W - 92 WIRING DIAGRAMS—ELECTRICAL •

-V10 20BR-

JQJ—VIO 20BR WINDSHIELD WASHER

V9 20BK PUMP MOTOR
V9
(UNDER WINDSHIELD
20BK
WASHER RESERVOIR)

#29 TO BLOWER
f5fl MOTOR V- V9 20BK-
|£J (SEE SH 6 2 . 6 3 . 6 5 )

V10
20BR
#16
STRG
COLUMN!
V17 18DG/YLX-
VIO 18BR VIO 18BR—
V8 18VT—
•VIO 18BR- V9 18WTX-
V7 18DG*-
V6 18DB—
V5 1 8 D G -
H40 18BK/LGX -

V6 18DB- •V6 18DB-

V8 18VT- STRG
COLUMN -

INTERMITTENT
WIPER SWITCH
(ON STEERING
COLUMN)
STRG
#12
V9 18WT* COLUMN

V3 18BR*- V3 18BRX-
STRG
#14
COLUMN
V4 18RD-
-V5 18DG-

V3 V4 18RD/YLX-
V7 18DGX- 18BRX
STRG
STRG # 13
TCOLUMN
COLUMN
#18 [\ TO REAR WHEEL
V17 18DG/YLX-
H 4 Q -H40 20 BK/LG^lc ^"ANTI "J^QQ^^^^^^^
18BK (SEE SH 2 5 . 2 7 )
LG*
STRG
COLUMN •#ll: H4 16BK $T0 <H4^2]

SPLICE
V3A 18BR/YLX- (SEE SH 44)
PANEL GROUND

AD 49 INTERMITTENT WIPER SYSTEM J908W-14

 WIRING DIAGRAMS—ELECTRICAL 8W - 93

•NOT USED ON 2 SPEED

WIPER SYSTEM
1

V8 18VT
-V17 18DG/YLX
V7 18DGX-
H40 18BK/LG* —
-V5 18DG
V6 18DB -
-VIO 18BR
V9 18WTX-

TO IGNITION
SWITCH
(SEE SH 10)
INTERMITTENT WIPER (MOUNTED ON BRACKET
2 CONTROL UNIT UNDER STEERING
V17 7 1 8 3 6 5 4 COLUMN)
18DG
YL*
02
14BKX
-VIO 1 8 B R - FUSE # 6
- V8 18VT — (20 AMP)

- V 9 18WT *
- V7 18DG *
- V6 18DB
-V5 18DG -
H40 18BK/LGX-

V6 18DB -V6 1 8 D B — « — V6 18DB-

#36 fill

TO A/C
SYSTEM
(DIESEL ONLY)
(SEE SH 66}
#45]
V3 18BRX (f V3 18BR*

#35 ^
V5 18DG »- •V5 18DG

V4 18RD/YLX )Y V4 18RD/YL*-

#46 nn
INTERMITTENT WINDSHIELD
WIPER MOTOR
(IN PLENUM-LEFT SIDE)

V6 18DB- V3 18BRX PARK

(DIESEL ONLY) V6 18DB SWITCH
V5 18DG
V4 18RD/YLX

J908W-14 INTERMITTENT WIPER SYSTEM AD 50

8W - 94 WIRING DIAGRAMS—ELECTRICAL

TO FOUR
WHEEL DRIVE TO MANUAL TO PART
TO<L9> 1| SPLICE INDICATOR TRANSMISSION THROTTLE TO TRANSMISSION
LAMP WIRING UNLOCK RELAY WIRING ( D I E S E L )
(SEE SH 4 0 . 4 2 ) (SEE SH 67) (SEE SH 7) (SEE SH 9 ) (SEE SH 6 7 )

T
X9
20BK

DIESEL
ONLY

STRG STRG STRG SPLICE

COLUMN COLUMN N COLUMN (SEE SH 18)
#16
V6 VIO
18DB 20BR
TO A/C
V6 \%m—^ BLOWER MOTOR
•V6 18DB FUSE # 6 (SEE SH 6 2 . 6 3 . 6 5 )
(20 AMP) 02
14BK*
#46 fnl #29
TO IGNITION . ,
SWITCH tr 1

(SEE SH 10)
V6 VIO
18DB 20BR

WINDSHIELD WASHER
PUMP MOTOR
(UNDER WINDSHIELD
TO A/C SYSTEM WASHER RESERVOIR)
PARK (DIESEL ONLY)
SWITCH (SEE SH 66)
2 SPEED WINDSHIELD
WIPER MOTOR
(CENTER OF PLENUM) 18BR*
V3
V6 18DB
• a V5 18DG
V4 18RD/YL*

AD 51 WINDSHIELD WIPER SYSTEM JSOSW-M

 WIRING DIAGRAMS—ELECTRICAL 8W - 95

^ TO IGNITION . TO CHARGING
4 SWITCH
%
5 SYSTEM
(SEE SH 10) (SEE SH 3 . 5 )
HAZARD
WARNING
FLASHER

MOUNTED ON
FUSE BLOCK
(SEE SH 83)

TO REAR
LIGHTING
(SEE SH 75)

BLACK

U908W-14 STOP/TURN AND HAZARD FLASHER SYSTEMS AD 52

8W - 96 WIRING DIAGRAMS—ELECTRICAL •

E5 20DG* WAIT-TO-START SWITCH

(SEE SH 17)

K31 20BK/PKX WATER-IN-FUEL ATI 180R ANTI-LOCK MODULE

(SEE SH 18) (SEE SH 27)

P5 20GY/BK* PARK BRAKE WARNING SWITCH G5 20DBX IGNITION-12V FEED

(SEE SH 27) (SEE SH 54)

P51 20BK/GYX IGNINTION SWITCH GROUND H4 20BK GROUND - <H4^Y] SPLICE

BULB TEST (SEE SH 44)
(SEE SH 27)

P2 20BK* BRAKE WARNING SWITCH i G40 20DB/RDX FUEL TANK

VACUUM SWITCH LOW FUEL SWITCH
(SEE SH 27) (SEE SH 73)

AD 53 MESSAGE CENTER (DIESEL) JSOSU-M

• WIRING DIAGRAMS—ELECTRICAL 8W - 97

TO OVERDRIVE
SWITCH I MODULE
(DIESEL ONLY
(SEE SH 12) RED
TO MESSAGE
CENTER
(DIESEL)
TO FOUR
(SEE SH 53/(3)
WHEEL DRIVE
INDICATOR LAMP
(SEE SH 67) P51 20BK/GY* TO R.W.A.L. MODULE
G5 (SEE SH 25)
20DBX P51 20BK/GY* IGNITION SWITCH GROUND
r G5 20DBX -»
(SEE SH 10)
„ TO R.W.A.L.
ATI 180R 4 MODULE
BLACK (SEE SH 25)
G29 22GY/PKX EMISSION MAINTENANCE
REMINDER (SEE SH 15)
G5
22DBX K3 20BK/PK X CHECK ENGINE LAMP
SEE SH 15)
P5 20BK/GY X TO R.W.A.L. MODULE
TO OVERDRIVE "SEE SH 25)
SWITCH P5 20GY/BK X BRAKE LAMP WARNING SWITCH
(SEE SH 11) (SEE SH 25)

TO LEFT
PRINTED CIRCUIT
G5 BOARD CONNECTOR
TO RIGHT 20 DB* (SEE SH 56)
G5
PRINTED CIRCUIT 20DB*
BOARD CONNECTOR
(SEE SH 56)

. TO IGNITION
TO TO SPEED J2 14DB SWITCH
COMBINED CONTROL (SEE SH 10)
BUZZER (SEE SH 30) FUSE #12
(SEE SH 7 3 , 7 4 ) 5 AMP)

J908W-14 MESSAGE CENTER (GAS) AD 54

8W - 98 WIRING DIAGRAMS-ELECTRICAL •

AD 55 CLUSTER - PRINTED CIRCUIT BOARD JSOSW-M

 WIRING DIAGRAMS—ELECTRICAL 8W - 99

GRAY

G20 20VT/YL* TEMPERATURE GAUGE SENDING UNIT G i l 20DB/RDX SEAT BELT WARNING LAMP SWITCH
(SEE SH 2 1 , 2 2 ) (SEE SH 7 3 . 7 4 )

D6 18LG LEFT TURN SIGNAL LAMP

(SEE SH 52)
M4 20TN* TAILGATE AJAR LAMP
(SPORT UTILITY ONLY) (SEE SH 47)

G7 20WT/0R* SPEEDOMETER SPEED SENSOR G5 20DB* IGNITION FEED-12 VOLTS

(SEE SH 54)
(SEE SH 16,23)

LEFT CONNECTOR

G6 20GY OIL PRESSURE LAMP SWITCH

(SEE SH 2 1 . 2 2 )
BLACK
G5 20DB* IGNITION FEED-12 VOLTS
(SEE SH 5 4 . 7 3 . 7 4 )
E2 200R ILLUMINATION LAMP FEED
(SEE SH 44)
L33 16RD/BKX HI-BEAM INDICATOR LAMP
H4 20BK GROUND (SEE SH 3 9 . 4 1 )
(SEE SH 44)
05 18TN RI6HT TURN SIGNAL LAMP
G4 20DB/YLX FUEL GAUGE SENDING UNIT (SEE SH 52)
(SEE SH 7 3 . 7 4 )

660 20GY/YL* OIL PRESSURE GAUGE

SENDING UNIT
(SEE SH 2 1 . 2 2 )

RIGHT CONNECTOR

J908W-H PRINTED CIRCUIT BOARD CONNECTORS AD 56

8W - 100 WIRING DIAGRAMS—ELECTRICAL •

-BLACK

TO
HEADLAMP
SWITCH
(SEE SH 43)
TO IGNITION
SWITCH 18BK
(SEE SH 10) YLX
(SEE SH 43)

02
14BKX

El GRAY-
18TN (BEHIND
RADIO)

FUSE # 4 X56 18DG

(10 AMP)

•X55 18BR/0RX-

FUSE # 1 4
TO (3 AMP) •X58 18DB/0RX-
X55
BATTERY 20BR
FEED RDX
( S E E SH 3 , 5 ) X12
20RD X57 18BR/LBX-
L7
18BK -X54 18VT
YL X
- X53 18DG
E2
200R
X52 18DBX

X51 18BR/YLX-
(SEE SH 44) \

X56
20DB
RDX
E2
200R

X12 20RD-
Ml 20PK-
JL
1 In • • • • nl • • • • • • •
GRAY BLACK FOR 2 SPEAKERS
WIRING
(SEE SH 6 1 )

STEREO RADIO

AD 57 STEREO RADIO-4 SPEAKERS J908W-14

 WIRING DIAGRAMS—ELECTRICAL 8W - 101

+ + +
LEFT + RIGHT
REAR
SPEAKER ••
-X51 18BR/YL X-
X57 188R/LGX •
X52 18DB/WT X- • 9 REAR
SPEAKER
-X58 18DB/0RX-

Lb d GREEN
(BELOW BULKHEAD)

X56 18DG- (COWL TOP-

BLACK- RIGHT SIDE)

X55 18BR/0RX-

•X58 18DB/0R*-
X56 18DG
X57 18BR/LBX-
- X54 18VT
X56
-X53 180G 18DG

-X52 18DB*
X51 18BR/YLX-

-X53 18DG
X55
BLACK 18BR
ORX

X53 S- X56
20GN CAT SPEAKER) X54 20BK
X55 20GN
20BK
LEFT FRONT
DOOR SPEAKER
RIGHT FRONT |»UL/+l
DOOR SPEAKER

J908W-14 STEREO RADIO-4 SPEAKERS. AD 58

8W - 102 WIRING DIAGRAMS—ELECTRICAL •

BLACK

TO
HEADLAMP
SWITCH
(SEE SH 43)
TO IGNITION
SWITCH
(SEE SH 10)

GRAY
(BEHIND
RADIO)

X56 18DB/RD*-

X55 18BR/RDX-

TO •X58 18DB/0R*-
BATTERY
FEED
(SEE SH 3 . 5 )
X57 18BR/LB*-

-X54 18VT

-X53 18DG

- X 5 2 18DB* ~

X51 18BR/YL*-

BLACK FOR 2 SPEAKERS

WIRING
(SEE SH 61)

K|P^QQQQQ][|

STEREO RADIO

STEREO RADIO-4 SPEAKERS

AD 59 (SPORT U T I L I T Y ) J908W-14
• WIRING DIAGRAMS-ELECTRICAL 8W - 103

+
LEFT + RIGHT
REAR
SPEAKER
B
^
r-
1
REAR
SPEAKER

+ +

GREEN

X56
20BK

RIGHT FRONT WxjM

DOOR SPEAKER ^

STEREO RADIO-4 SPEAKERS

J908W-14 (SPORT U T I L I T Y ) AD 60
8W - 104 WIRING DIAGRAMS—ELECTRICAL

-BLACK

•D t=» 33 nl
TO HEADLAMP
SWITCH • 6 2 ^ uu]
(SEE SH 43)
i H
e BiQ
TO IGNITION L7
SWITCH 18BK
(SEE SH 10) YL*
(SEE SH 43)

02
14BKX

GRAY
(BEHIND
RADIO)
FUSE # 4 •X58 20DB/RD X
(10 AMP)

-X55 20BR/RD X
TO SPEAKER
FUSE #14
WIRING
(3 AMP)
X55 (SEE SH 5 7 . 5 9 )
TO BATTERY
20BR BLACK
FEED
X12 RDX
(SEE SH 3 . 5 )
20RD
L7
18BK
YL X

(SEE SH 44) \

X56
20DB
RDX
E2
200R

X12 20RD
Ml 20PK-

• • • • • • •]
GRAY BLACK

SEE SH 45)

STEREO RADIO

AD 61 STEREO RADIO-DUAL SPEAKERS • JSOSW-M

• WIRING DIAGRAMS—ELECTRICAL 8W - 105

TO
IGNITION •Cl 12BR
SWITCH •020 12BK/RD*- -<f
(SEE SH 10)
FUSE* 1
(30 AMP)

NATURAL

[ J p r - C S 16LG

C7 1 6 D G - 4 { | ] [ 2 } - - C 4 18TN

HEATER
BLOWER
SWITCH
HEATER
BLOWER C4 18TN
MOTOR
RESISTOR -C5 16LG
(RIGHT SIDE C7 16DG
OF PLENUM)

Cl
12BR
C7 12DG

BLACK

C7 12DG—,

LEFT CENTER
NATURAL OF INSTRUMENT
12BK
PANEL)
HEATER BLOWER #2
MOTOR
(RIGHT SIDE
DASH PANEL) C7 12DG

TO
WINDSHIELD „
WASHER V SPLICE
MOTOR (SEE SH 51)
(SEE SH 4 9 . 5 1 )

J908W-14 HEATER AD 62
8W - 106 WIRING DIAGRAMS—ELECTRICAL •

FUSE # 1
NATURAL (30 AMP)
" W ^ X - C 5 16LG
TO IGNITION _
SWITCH 7- -Q20 12BK/RDX—(' Cl 12BR
C6 1 4 L B - { ^ [ T ] - - - C 3 12WT/DG* (SEE SH 10)

C7 1 2 D 6 - - C 4 12TN

•BLACK

HEATER
C7 BLOWER
BLOWER 12DG SWITCH
(INSTRUMENT C4 AIR CONDITIONER
MOTOR AND HEATER
RESISTOR PANEL) 10TN
r 7 VACUUM SWITCH
(RIGHT SIDE g /
(INSTRUMENT
PLENUM) 12DG
PANEL)

H4
-»- 18BK
C4 10TN
C2
Cl 18DB
C7 12DG 10BR OR*

:c7

•C3 12WT/DGX--«-

1—C7 12DG
BLACK
NATURAL

C7 12DG Cl 10BR
(IN CENTER OF Cl
H4 18BK
INSTRUMENT 12BR
PANEL)
-C2 18DB/0R*-

1
—C9 12BK— 1 TO <H4>21 SPLICE
/-H4 18BK-7 ,
HEATER BLOWER V9
MOTOR 20BK s r n ^ y -H4 18BK- ( S £ E S H , 4 )

(RIGHT SIDE
DASH PANEL) C7 12DG- •Cl 12BR
SPLICE
(SEE SH 51) •NATURAL
TO WASHER -C2 18DB/0RX- » C20 18DB/0R*-
MOTOR
(SEE SH 4 9 , 5 1 )
#37
A/C & HEATER-
AD 63 GAS ENGINE J908W-H
 WIRING DIAGRAMS—ELECTRICAL 8W - 107

AIR CONDITIONING
COMPRESSOR
J2 14DB—^ I — J 2 14DB
(RIGHT SIDE
FORWARD OF
TO ENGINE)
-C26 14BR
C2 14DB/BK*-S|IJJ[|g

SPLICE L—N13 20DB/0R* I

(SEE SH 3) t . 1

TO SINGLE TO SINGLE
C9 BOARD ENGINE TO AUTO BOARD ENGINE
12BK (LEFT OF CONTROLLER SHUTDOWN CONTROLLER
COMPRESSOR) CAVITY 8 RELAY CAVITY 27.34

T
SEE SH 14 (SEE SH 14) (SEE SH 13)

TT
-C9 12BK

J2 N13
14DB C20
20DB
18BR
BI-DIRECTIONAL OR*
ZENER DIODE

(LEFT
WIDE OPEN FENDER
THROTTLE
SIDE
CUTOUT RELAY
SHIELD)

TO FUSIBLE LINK C C26 14BR -N13 20DB/0R*-

(SEE SH 4) >

PROBE , ,

A/C LOW (RIGHT ELECTRONIC

PRESSURE SWITCH SIDE CLUTCH
C20 -<f (RIGHT FENDER SHIELD) CYCLING
18DB SIDE SHIELD) SWITCH
OR*
C20

A
TO STEERING 18DB BLACK
COLUMN WT*

T
(SEE SH 31)
C20 18DB/0R*

H4 — J2 14DB
18BK C20 18BR-
J2
14DB

i C20 18BR

TO <J2>2| SPLICE
C20 18DB/0R*
(SEE SH 14)

A/C AND HEATER-

J908W-14 GAS ENGINE AD 64
8W - 108 WIRING DIAGRAMS-ELECTRICAL •

FUSE #1
NATURAL (30 AMP)
C5 16LG
TO I G N I T I O N
v

SWITCH >
C6 MLB—0[l3— C3 1 2 W T / D G
* (SEE SH 10)

C7 12DG— 5 [ 2 ] — C4 12TN

HEATER BLOWER
MOTOR
(RIGHT SIDE
DASH PANEL)
NATURAL
C20 18DB/0RX »- C20 18DB/0R*-
TO WASHER
MOTOR
#37
(SEE SH 4 9 , 5 i ;

AD 65 A/C & HEATER-DIESEL ENGINE J908W-14

 WIRING DIAGRAMS—ELECTRICAL 8W - 109

A/C COMPRESSOR
CLUTCH
(FRONT OF ENGINE)

TO
V6 180B

SPLICE
BI-DIRECTIONAL (SEE SH 5 )
ZENER DIODE

C20 C20
V6 I8BR 18DB
18DB OR*

(RIGHT FENDER J2
SIDE SHIELD) BLACK \ A/C LOW PRESSURE
14DB
\ SWITCH
\ (RIGHT FENDER
TOP \ SIDE SHIELD)

-C20 18DB/0R*
V6
18DB

TO
WIPER MOTOR
(SEE SH 5 0 . 5 1 )

ELECTRONIC
CLUTCH
TO STEERING CYCLING
COLUMN C20 SWITCH
(SEE SH 31) 18DB
OR*

BLACK

H4
18BK

J2 14DB-

C20 18BR-

C20 18DB/0R*

J908W-14 A/C & HEATER-DIESEL ENGINE AD 66

8W - 110 WIRING DIAGRAMS—ELECTRICAL

TO
J2 14DB
65
20DB*
SPLICE
TO IGNITION
( S E E SH 5 4 )
SWITCH
( S E E SH 10) FUSE #12
F O U R WHEEL
(5 AMP)
DRIVE INDICATOR
LAMP

X4
20LG
BR*
R E A R WHEEL
ANTI-LOCK t_ X4 20LG/BRX-
MODULE >
( S E E SH 2 5 . 2 7 ) #40

DIESEL-

TO <C9> S P L I C E
•59 14BK X4 20LG/OR*
(SEE SH 51)

BLACK
( R E A R OF
ENGINE) •GAS ENGINE

TRANSFER
CASE
SWITCH
7=pu I—X4
—X9
20LG/BRX
18BK—

205 TRANSFER BLACK

CASE (ON TRANSFER
CASE)

TRANSFER
-X4 20LG/BR*
CASE
SWITCH —X9 18BK X9 20BK-
^£3
205 TRANSFER BLACK
CASE (ON TRANSFER BLACK X9
(LEFT SIDE 18BK TO S P E E D
CASE)
DASH P A N E L ) CONTROL S E R V O
( S E E SH 2 9 )

TRANSFER
•X4 20LG/BR*-
CASE
SWITCH —X9 18BK
T0<C9> SPLICE

(SEE SH 51)
241 TRANSFER (LEFT SIDE
CASE FRONT A X L E )

AD 67 4 WHEEL DRIVE INDICATOR LAMP JBOSW-M

 WIRING DIAGRAMS—ELECTRICAL 8W - 111

ELECTRIC WINDOW LIFT CONNECTOR AND SWITCH FUNCTIONS

LEFT DOOR W8 12BK

B* B- SWITCH WINDOW AND
POLARITY POLARITY SELECT MOVEMENT W12 14BR
W1I 16BL
LB WT LEFT FRONT UP
W21 16WT W22 14VT FORWARD
WT LB LEFT FRONT DOWN IN CAR"
BR VT RIGHT FRONT UP
VT BR RIGHT FRONT DOWN Wl 12TN UP-
TN BK SWITCH FEED AND GROUND FRONT SIDE OF CONNECTOR SHOWN
CONNECTOR GANG LEFT FRONT DOOR
MASTER SWITCH

RIGHT DOOR

B* 8- W22 14WT- W22 14BR

WINDOW MOVEMENT AND SWITCH
POLARITY POLARITY FORWARD IN CAR
Wl 12TN-
WT LB DOWN FROM DOOR SWITCH
LB WT UP FROM DOOR SWITCH W22 14VT- W12 14LB I UP
VT BR DOWN FROM MASTER SWITCH
BR VT UP FROM MASTER SWITCH
RIGHT FRONT WINDOW L I F T SWITCH CONNECTOR
TN FEED

TO IGNITION
SWITCH t
(SEE SH 10) >

RIGHT DOOR
WINDOW L I F T MOTOR
W22 14VT

J908W-14 ELECTRIC WINDOW LIFTS AD 68

8W - 112 WIRING DIAGRAMS-ELECTRICAL •

TO SPLICE
Ll 12RD*
(SEE SH 43)

FUSE CAVITY # 1 0
(30 AMP CIRCUIT
BREAKER)

TO <H4>T1 SPLICE
W5 14RD H4 12BK-
(SEE SH 44)
BLACK

TO POWER TO POWER
WINDOWS _ X2 j i MIRROR
(SEE SH 68) 18BK~ SWITCH
( S E E SH 71)
LEFT FRONT DOOR SWITCH W5
(VIEW FROM TERMINAL END) 14RD

X36 18PK

X34 14PK*
• X33 140R*

RIGHT DOOR
COWL TOP
DISCONNECT
(OVER HEATER
OR A/C UNIT)

W5 14RD

X36 14PK

-X33 140R*
X35 1 4 0 R -

-X34 14PKX- X33 140RX

X34 14PK*
(NEAR MOTOR)

AD 69 ELECTRIC DOOR LOCKS J908W-14

• WIRING DIAGRAMS— ELECTRICAL 8W - 113

RJ GHT_ DOOR _S_W_I TC^_^NECTOR_

LEFT DOOR SWITCH CONNECTOR

n n n n
X33 140R- X36 14PK
X35 140R- -W8 14BK
(LOCK)
(LOCK)
-W5 14RD
-W5 12RD
(FEED)
X35 140R- -X34 14PK
W8 14BK- -X36 14PK (UNLOCK)
(UNLOCK)
FORWARD UP
FORWARD UP
TERMINAL END
TERMINAL END
. . . , J >.

RIGHT FRONT DOOR

SWITCH
(VIEW FROM /
TERMINAL END) /
RIGHT FRONT
BLACK-—^ [TOPI / DOOR MOTOR
i LK

MI
UNLK

X36 X34 W5 X35 .

14PK 140RX 14RD 140R

X33
180R

W5 14RD
X33
140R*
(NEAR MOTOR)

X34
I40RX
X36 14PK X34
18PK

X35 140R

X33 1 40R X

X34 14PK X X34 14PKX

J908W-14 ELECTRIC DOOR LOCKS AD 70

8W - 114 WIRING DIAGRAMS—ELECTRICAL

BLACK

(AT LEFT
DOOR)

I TO < H 4 H ] SPLICE
LEFT MIRROR
BATTER? FEED M 0 T 0 R S
(SEE SH 44)
(SEE SH 3.5

AD 71 POWER REMOTE MIRRORS J908W-14

• WIRING DIAGRAMS-ELECTRICAL 8W - 115

GRAY
S24 18 OB
Did

S14 18YL-
j-BLACK (AT
RIGHT
DOOR)
1I1J1' S24 S12
18DB* 18WT*
COWL TOP S14
18YL*
BLACK HORIZONTAL S12
18DBX!— 18DG
S14 i i
18YL* v — y p
LT RT
T

S12
18WT*

UP^^
VERTICAL
RIGHT MIRROR
MOTORS
POWER MIRROR SWITCH

X2 I OK EI • L H G M# IF J O
20BK DN -UP LT - RT
#p OR

LEFT RIGHT
MIRROR MIRROR

S13 20YL %-
- S l l 20WT -
S12 20WT %
•S23 20DB -
•S24 20DB
S14 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
VIEW OF SWITCH INDEXING
FROM FRONT OF SWITCH
J908W-14 POWER REMOTE MIRRORS AD 72
8W -116 WIRING DIAGRAMS—ELECTRICAL •

TO < J 2 > SPLICE

03 18PK/DB*
(SEE SH 5)

TO IGNITION r M26 20LB — I f f i E 5

D3 18PK/DB* — = - i K
SWITCH J2
(SEE SH 10) 14DB H4 20BK — ^ E E

Gil-20LG/HT* — ^ ^
J2 14DB • G5 20DB * — ^

14DB G10 20LG

13

(I\\

FUSE #12
(5 AMP)

TO RIGHT
PRINTED CIRCUIT
BOARD CONNECTOR
(SEE SH 56)

BLACK-

GRAY
[LEFT
WHEELHOUSE) X2 16GY-N0T USED!
G4 18DB/YLX

TO <X2^2] GROUND FUEL TANK SENDING

$ — X 2 16GY UNIT WITH LOW FUEL
SPLICE LAMP SWITCH
(SEE SH 7 5 )
DIESEL FUEL TANK GAUGE
AD 73 AND SEAT BELT WARNING SYSTEM J908W-14
• WIRING DIAGRAMS—ELECTRICAL 8W - 117

TO IGNITION
SWITCH
(SEE SH 10)

FUEL TANK SENDING

UNIT WITH LOW FUEL
SWITCH AND PUMP

ELECTRONIC FUEL INUECTION TANK GAUGE

J908W-14
AND SEAT BELT WARNING SYSTEM AD 74
8W - 118 WIRING DIAGRAMS—ELECTRICAL

TO FRONT f
. T O TRANSMISSION
END LIGHTING h L7 18BK/YLX B2 18VT/BK*- -J WIRING
(SEE SH 3 9 , 4 1 ) (SEE SH 7)

L7 18BK/YLX —i
(LEFT WHEELHOUSE)
-GRAY

TO <L7>1|SPLICE #26|B|
5—L7 18BK/YLX ( f ^ L 7 18BK/YL*
(SEE SH 43) n

*15|a]

TO TURN 5—D8 18DG/YLX « — D 8 18DG/YL*

SIGNAL SWITCH
(SEE SH 52) 5—D7 18BR/YL* <f-D7 18BR/YL*

#16
B2
I18VT
TO <AH9> SPLICE ^ J PART THROTTLE L7 BK*
, V x V 3 UNLOCK RELAY 18BKJ
(SEE SH 17) >
(SEE SH 9) YL*
(DIESEL). (GAS)

D8
LEFT BLACK 18DG
TAIL. YL*
STOP I -L7 18BK/YLX-
TURN X2
SIGNAL 18GY

SPORT
UTILITY
LAMP
ri'JfEkiT ^ _ L
- 18GY
B2 18VT/BK*-^OQj
O O

E^^Jj L
B 2 18VT/B!

D8 18DG/YL*-
LEFT
BACK-UP
LAMP

LEFT -L7 18BK/YLX

TAIL,
STOP I |2<X2
TURN -X2 18GY
SIGNAL
CAB I LAMP •X2 18GY
•X2 18GY
CHASSIS
(RIGHT REAR
LEFT FRAME RAIL)
BACK-UP •D8 18DG/YLX
LAMP BLACK X2
-B2 18VT/BK* 16GY

LEFT B2 18VT/BK*
TAIL.
STOP 1
TURN
SIGNAL
LAMP
SWEPT- DO
LINE TO <X223]SPLICE
BOX
(SEE SH 7 3 . 7 4 )
-BLACK
LEFT
BACK-UP
LAMP

AD 75 REAR LIGHTING J908W-14

 WIRING DIAGRAMS—ELECTRICAL 8W - 119

LICENSE
LAMP
•H4 18BK- WITHOUT
BUMPER
L7 18BK/YL*

LICENSE
H4 18BK- LAMP
(LEFT REAR /
FRAME R A I L ) /
L7 18BK/YLX STEP
BLACK BUMPER
LICENSE
X2 18GY H4 18BK LAMP
L7 18BK/YL*

L7 18BK/YL*
BLACK-
CENTER OF REAR BUMPER)
LICENSE
•L7 18BK LAMP
STANDARD
BUMPER
BLACK

RIGHT
X2 18GY TAIL,
STOP i
-L7 18BK/YLX—. X2 TURN
18GY SIGNAL
O0 LAMP
SPORT
QQ#-D7 18BR/LG* UTILITY

L7
18BK BLACK RIGHT
YLX BACK-UP
LAMP
B2 18VT/BKX

RIGHT
BLACK TAIL.
STOP 8
X2 18GY—' TURN
SIGNAL
LAMP CAB i
X2 18GY •L7 18BK/YLX
CHASSIS
•D7 18BR/YL*
RIGHT
BACK-UP
X2 18GY
LAMP
(RIGHT
REAR
FRAME L7 18BK/YLX
-B2 18VT/BK* RAIL) RIGHT
TAIL.
STOP 8
BLACK -D7 18BR/YLX TURN
SIGNAL
LAMP
I—X2 18GY SWEPT-
LINE
BOX

RIGHT
BACK-UP
B2 18VT/BKX LAMP

J908W-14 REAR LIGHTING AD 76

8W - 120 WIRING DIAGRAMS-ELECTRICAL

CAV IGNITION SYSTEM CIRCUITS SHEET NO.

1 K4 20DG/RDX MAP SENSOR 16
2 K10 20TN* COOLANT SENSOR 16
3 J l l 16RD DIRECT BATTERY 15
4 N5 18BK/LBX SENSOR RETURN 16
5 K5 16BK/WT* SIGNAL GROUND 13
6 K8 20VT/WT* 5 VOLT SUPPLY 13
7 N6 180R 8 VOLT INPUT 16
3 Zl 16DG/BKX AUTO SHUT DOWN-BATTERY SUP. 14
9 J2 14DB IGNITION FEED 14
10 — — —
11 K9 18LB/RDX POWER GROUND 13
12 K9 18LB/RD* POWER GROUND 13
13 — —
14 — — —
15 Y12 18TN INJECTOR DRIVER 2 13
16 Y l l 18WT/DB* INJECTOR DRIVER 1 13
17 — — —
18 — .— .—
19 J5 18BK/GY* IGNITION COIL DRIVER 14
20 R3 18DG ALTERNATOR FIELD DRIVER 15
21 K13 18BK/RDX THROTTLE BODY TEMP. SENSOR 16
22 K7 180R/DBX THROTTLE POSITION SENSOR 13
23 — — —
24 N7 18GYX REFERENCE PICKUP 16
25 DK21-20PK SCI TRANSMIT 13
SHORT TAB 26 • — — .—
27 C20 18BR A/C CLUTCH INPUT 13
28 N31 18VT CLOSED THROTTLE SWITCH 15
29 040 18WT/PKX BRAKE SENSE 15.29
30 S4 20BR/YLX PARK/NEUTRAL SWITCH 15
31 — —- —
32 K3 20BK/PKX CHECK ENGINE LAMP 15
33 K36 20TN/RDX SPEED CONTROL - VACUUM 29
34 N13 20DB/0RX A/C W.O.T. CUTOUT RELAY 13
35 S6 20GY/YLX EGR SOLENOID 14
36 N23 20BK/0R* AIR SWITCHING SOLENOID 14
LONG TAB 37 • — — —
38 — — —
VIEWED FROM WIRE 39 — — —
END OF CONNECTOR 40 N2 18BRX AUTOMATIC IDLE SPEED MOTOR 15
41 N i l 18BK/DGX OXYGEN SENSOR 13
42 — — —
43 — — —
44 U4 200R/WTX OVERDRIVE LOCKOUT CONT. 11
45 DK20 20LG SCI RECEIVE 13
46 — — •• —
47 G7 20WT/0RX SPEED SENOR PICKUP 16
48 X31 20BR/RDX SPEED CONTROL - SET 29
49 X32 20YL/RDX SPEED CONTROL - ON/OFF 27
50 X33 20WT/LGX SPEED CONTROL - RESUME 29
51 K19 20DB/YLX AUTO SHUT-DOWN RELAY 14
52 Kl 20PK/BKX PURGE SOLENOID 14
53 X35 20LG/RD X SPEED CONTROL - VENT 29
54 U3 200R/BKX PART THROTTLE UNLOCK SOL 9.11
55 U40 200R/LGX OVERDRIVE LOCKOUT SOLENOID 11
56 G29 20GY/PK X EMISSIONS MAINT.REMINDER LAMP 15
57 — — —
58 .— — —
59 — — —
60 Nl 18GY/RDX AUTOMATIC IDLE SPEED MOTOR 15

S I N G L E BOARD
AD 77 ENGINE C O N T R O L L E R CONNECTOR (GAS) J908H-14
• WIRING DIAGRAMS—ELECTRICAL 8W - 121

CAV IGNITION SYSTEM CIRCUITS SHEET NO.

Jll 16RD DIRECT BATTERY FEED 23

N5 18BK/LB* SENSOR RETURN 24
K5 16BK* SIGNAL GROUND 24
K8 20VT/WT* 5 VOLT SUPPLY 24

J2 14DB IGNITION FEED 23

10
11 J9 16BK POWER GROUND 24
12 J9 16BK POWER GROUND 24
13
14
15
16
17
18
19
20
21
22 K7 180R/DBX THROTTLE POSITION SENSOR 24
23
24
25_ DK21 20PK SCI TRANSMIT 24
SHORT TAB 2£
27
28
29 D40 18WT/PK* BRAKE SENSE 23
10|g|*|7|6|g|4|3l2|l| 30 S4 20BR/YLX PARK/NEUTRAL SWITCH 23
31
32
33
34
35
36
LONG TAB
37
38
VIEWED FROM WIRE
39
END OF CONNECTOR
40_
41
42
43
44 U4200R/WTX OVERDRIVE LOCKOUT CONTROL 12
45_ DK20 20LG SCI RECEIVE 24
_46_
47 G720WT/0RX SPEED SENSOR PICKUP 23
48
49
50
51
52
53
51
55_ U40 200R/LGX OVERDRIVE LOCKOUT SOLENOID 12
56
57.
5£
59_
60

SINGLE BOARD ENGINE CONTROLLER CONNECTOR

J908W-14
AUTOMATIC TRANSMISSION) (DIESEL) AD 78
8W - 122 WIRING DIAGRAMS—ELECTRICAL

CAVITY ENGINE COMPARTMENT CIRCUITS

I LI 12RD/WT* HEADLAMP SWITCH
C7 12DG A/C a HEATER BLOWER MOTOR
DS1 14WT/BRX REAR WHEEL ANTI LOCK
IS1 16LGX REAR WHEEL ANTI LOCK
L4 16VT/WTX HEADLAMP LOW BEAM (2 WIRES)
L3 14RD/0RX HEADLAMP HIGH BEAM (2 WIRES)
X30 20DB/RDX SPEED CONTROL (GAS ENGINE ONLY)
X31 20BR/RDX SPEED CONTROL (GAS ENGINE ONLY)
X33 20WT/LGX SPEED CONTROL (GAS ENGINE ONLY)

10 X32 20YL/RDX SPEED CONTROL (GAS ENGINE ONLY)

11 E5 20DG/WTX WAIT TO START LAMP (DIESEL ONLY)

12 L33 16RD/BKX HIGH BEAM INDICATOR LAMP
13 L20 14LG/BKX HIGH BEAM FEED ( D . R . L . MODULE)
14 VS1 18LB REAR WHEEL ANTI LOCK
15 D8 18DG/YL* LEFT REAR TURN SIGNAL LAMP
16 D7 18BR/YL* RIGHT REAR TURN SIGNAL LAMP

17 G20 20VT/YL* WATER TEMPERATURE SENDING UNIT

18 G6 20GY OIL PRESSURE SWITCH

19 660 20GY/YLX OIL PRESSURE SENDING UNIT

20
21 D6 18LG LEFT TURN SIGNAL LAMP

22 05 18TN RIGHT TURN SIGNAL LAMP

SMALL 23 A3 16PK BATTERY-HAZARD FLASHER
' INDEX
24 B01 18RD/VTX REAR WHEEL ANTI LOCK
25 B02 18WT/VTX REAR WHEEL ANTI LOCK
26 L7 18BK/YL* PARKING LAMPS
27 Bl 18WT BACK-UP LAMP SWITCH
50 49 48 47 46 45 28 G40 18DB/RDX LOW FUEL RELAY (DIESEL ONLY)
44 43 42 41 40 39 38 37 36 35 29 VIO 20BR WINDSHIELD WASHER MOTOR
34 33 32 31 30 29 30
28 27 26
22 21 20
© 25 24 23
19 18 17
31
32
S2 16YL
H2 18DG/RDX
STARTER RELAY-IGNITION
HORN
33 L22 18BK/RDX UNDERHOOD LAMP
16 15 14 13 12 11 10 9 8 7
34 P51 20GY/BKX BRAKE WARNING LAMP SWITCH
6 5 4 3 2 1
35 V5 18DG WINDSHIELD WIPER MOTOR
36 V6 18DB WINDSHIELD WIPER MOTOR
37 C20 18DB/0RX AIR CONDITIONING DAMPED PRESSURE SWITCH
K3 20BK/PKX CHECK ENGINE LAMP GAS ENGINE ONLY)
38
LARGE K31 20BK/PKX WATER IN FEUL LAMP (DIESEL ONLY)
INDEX 39 G4 20DB/YL* FUEL TANK SENDING UNIT
TERMINAL END 40 X4 20LG/BRX 4 WHEEL DRIVE SWITCH
OF DISCONNECT
41 D40 18WT/PK* BRAKE SENSOR
42 G29 20GY/PKX EMR LAMP (GAS ENGINE ONLY)
43 G7 20WT/0R* SPEED SENSOR
44 U4 200R/WTX OVERDRIVE LOCKOUT
45 V3 18BR/WTX WINDSHIELD WIPER MOTOR
46 V4 18RD/YLX WINDSHIELD WIPER MOTOR

47 J2 14DB SPLICE-IGNITION RUN CIRCUIT

48 C13 12BK/RDX IGNITION OFF DRAW

49 J l 12RD IGNITION SWITCH
50 JIO 12PKX IGNITION SWITCH

AD 79 50 -WAY BULKHEAD DISCONNECT J908W-14

• WIRING DIAGRAMS—ELECTRICAL 8W - 123

CAVITY INSTRUMENT PANEL CIRCUITS SHEET

1 LI 12RD X BATTERY FEED 4 , 6 , 3 1 43
C7 12DG A/C a HEATER BLOWER MOTOR 62.63,65
DS1 14WT/BRX REAR WHEEL ANTI LOCK 25.27
IS1 16LGX REAR WHEEL ANTI LOCK 25,27
L40 16VT/WT* HEADLAMP-LOW BEAM 39,41.43
L30 14RD/0R* HEADLAMP-HIGH BEAM 39,41,43
X30 20DB/RDX SPEED CONTROL 30
X31 22BR/RDX SPEED CONTROL 30
X33 22WT/LG* SPEED CONTROL 30
X32 22YL/RD*
10 30
X32 20YL/RDX SPEED CONTROL
11 E5 20DG/WTX WAIT TO START LAMP (DIESEL ONLY) 17
12 L33 16RD/BKX HIGH BEAM INDICATOR LAMP 39.42
13 L20 20LG/BKX HIGH BEAM FEED (DRL MODULE) 42.43
14 VS1 18LB REAR WHEEL ANTI LOCK 25.27
15 D8 18DG/YLX LEFT REAR SIGNAL LAMP 52.75 TERMINAL END
16 D7 18BR/YLX RIGHT REAR SIGNAL LAMP 52.75 OF DISCONNECT
17 G20 20VT/YLX TEMPERATURE-SEND/UNIT OR SWITCH 21,22
18 G6 20GY OIL PRESSURE LAMP 21.22 r— SMALL
19 G60 20GY/YL* OIL PRESSURE GAUGE-SEND/UNIT 21,22 \ INDEX
20
21
D6 18LG
D6 18LG
LEFT FRONT TURN SIGNAL LAMP 39.41.52 5
45 46 47 48 49 50
D5 18TN
22 RIGHT FRONT TURN SIGNAL LAMP 39.41.52 35 36 37 38 39 40 41 42 43 44
05 18TN
23 A3 16PK/WTX HAZARD FLASHER 3.5,52 28 30 31 32 33 34
24 BOl 18RD/VT X REAR WHEEL ANTI LOCK (2 WIRES) 25,27 23 24 25 26 27 28
25 B02 18WT/VT X REAR WHEEL ANTI LOCK (2 WIRES) 25,27 17 18 19 20 21 22
26 L7 18BK/YLX PARKING LAMPS 37,39.41.43,75 7 8 9 10 11 12 13 14 15 16
27 Bl 18WT BACK-UP LAMP FEED 7 1 2 3 4 5 6
28 G40 20DB/RDX LOW FUEL RELAY 73
29 VIO 20BR WINDSHIELD WASHER MOTOR 49.51
30
31 S2 14YL IGNITION START 8.17 LARGE
32 H2 18DG/RDX HORNS 31 INDEX
33 L22 18BK/RDX UNDER HOOD LAMP 20
34 P51 20BK/GYX BRAKE WARNING LAMP SWITCH 10.28
35 V5 18DG WINDSHIELD WIPER SWITCH 50.51
36 V6 18DB WINDSHIELD WIPER SWITCH 50.51
37 C2 18DB/0RX A/C CLUTCH 63.65
K3 20BK/PKX CHECK ENGINE LAMP I GAS ENGINE ONLY) 15
38
K31 20BK/PKX WATER IN FEUL LAMP (DIESEL ONLY) 18
39 G4 20DB/YLX FUEL TANK SENDING UNIT 73.74
X4 20LG/BRX 4 WHEEL DRIVE SWITCH
40 67
X4 20LG/BRX
41 D40 18WT/PKX BRAKE SENSOR 26,28,30
42 G29 22GY/PKX EMR LAMP 15
43 G7 20WT/ORX SPEED SENSOR 16.23
44 U4 200R/WTX OVERDRIVE LOCKOUT SWITCH 11.12
45 V3 18BRX WINDSHIELD WIPER LOW SPEED 50.51
46 V4 18RD/YLX WINDSHIELD WIPER HIGH SPEED 50.51
J2 14DB
47 IGNITION-RUN i START 10.73.74
J2 14DB
48 C13 12BK/RDX BATTERY FEED 3.5.20.35
49 J l 12RD IGNITION SWITCH ( B l ) 4.6.10
50 JIO 12PK X IGNITION SWITCH (B3) 4.6.10

J908W-14 50-WAY BULKHEAD DISCONNECT AD 80

8W - 124 WIRING DIAGRAMS-ELECTRICAL •

STRG VIEWED FROM WIRE END

COLUMN

CAV CIRCUIT DESCRIPTION

20 19
1 •
HORN AND KEY-IN LAMP GROUND
2 H4 18BK ( 2 ) (STANDARD COLUMN)
3 H3 18BK/RDX GROUND FROM HORN SWITCH
4 D6 18LG LEFT FRONT TURN SIGNAL
11
5 D5 18TN RIGHT FRONT TURN SIGNAL
6 D32 18PK X HAZARD FLASHER FEED
7 D2 18RD/BKX FEED FROM TURN SIGNAL FLASHER
8 D8 18DG/YLX LEFT REAR TURN SIGNAL 12
9 D7 18BR/YLX RIGHT REAR TURN SIGNAL
25
10 D4 18WT/TN X ( 2 ) FEED FROM BRAKE SWITCH
11 V3 18BRX WINDSHIELD WIPER
13
12 V3 18BRX ( 2 ) WINDSHIELD WIPER LOW SPEED
13 V4 18RD/YLX WINDSHIELD WIPER HIGH SPEED
14 V5 18DG WINDSHIELD WIPER MOTOR
15 V6 18DB WINDSHIELD WIPER SWITCH FEED
14
16 VIO 20BR WINDSHIELD WASHER MOTOR
17 NOT USED
WITH 2
18 H40 18BK/LGX ( 2 ) INTERMITTENT WIPER MODULE GROUND — SPEED
19 M26 22LB WINDSHIELD
KEY-IN BUZZER
WIPER SYSTEM
20 M16 20BK/LBX LEFT FRONT DOOR JAMB SWITCH GROUND
21
22
23
24 J15 20YL/RDX IGNITION KEY LAMP FEED
25 H4 20BK IGNITION KEY LAMP GROUND

(LEFT OF STEERING COLOUM)

INSTRUMENT PANEL TO
AD 81 STEERING COLUMN WIRING J908W-14
• WIRING DIAGRAMS-ELECTRICAL 8W - 125

STRG
"COLUMN"

CAVITY DESCRIPTION SHEET

1
1
2
2 H4 18BK HORN AND KEY-IN LAMP GROUND 31 3
3 H3 20BK/RD* HORN SWITCH GROUND 31
1 TURN SIGNAL
4 D6 18LG LEFT FRONT TURN SIGNAL 52 5 SWITCH
5 D5 18TN RIGHT FRONT TURN SIGNAL 52 6 CONNECTOR
6 D32 16PK HAZARD FLASHER FEED 52
7 D2 18RD/BK* TURN SIGNAL FLASHER FEED 52 8
8 D8 18DG/RD* LEFT REAR TURN SIGNAL 52 9
9 D7 18BR/RDX RIGHT REAR TURN SIGNAL 52 10
L-r
26,28.
10 D4 16WT BRAKE SWITCH FEED 30.52

11 V3A 1 8 B R / Y L * INTERMITTENT WIPER SWITCH 49

V3 18BR* INTERMITTENT WIPER MODULE J"t_
12 49.51
V3 18BRX WINDSHIELD WIPER LOW SPEED 11
13 V4 18RD WINDSHIELD WIPER HIGH SPEED 49.51 12
¥ 5 18DG INTERMITTENT WIPER MODULE 13 WINDSHIELD
14 49.51 14 WIPER SWITCH
¥ 5 18DG WINDSHIELD WIPER MOTOR
15 CONNECTOR
15 ¥ 6 18DB WINDSHIELD WIPER SWITCH FEED 49.51 16
¥ 1 0 18BR INTERMITTENT WIPER MODULE 17
16 51
¥ 1 0 18BR WINDSHIELD WASHER MOTOR 18
17 .
18 iH4 18BK INTERMITTENT WIPER MODULE GROUND 44.49

19 M26 20LB KEY-IN BUZZER OR CHIME 45 JB1 19 KEY-IN BUZZER

45 nriJI 20 SWITCH CONNECTOR
20 M16 2 0 B K / L B * LEFT FRONT DOOR JAMB SWITCH GROUND

24 J15 18YLX IGNITION KEY LAMP FEED 45

IGNITION KEY LAMP GROUND flMn 24 IGNITION KEY LAMP
25 H4 18BK 31.45
( T I L T COLUMN) LhHJ 25 SWITCH CONNECTOR

(PLUGGED INTO STEERING COLUMN

25 WAY CONNECTOR)

STEERING COLUMN SWITCH

TO PANEL WIRING A n Q O
J908W-14 AU OZ
8W - 126 WIRING DIAGRAMS—ELECTRICAL •

E l 18TN E2 200R

X12 20RDX XI 16RD

BLUE DOT 02 14BKX ..
L22 16RD/TN X
18 18PK/RD X
TURN SIGNAL D2 18RD/BK* D3 18PK/DB X
FLASHER Dl 18RD/YLX C13 14BK/RD X
(SEE SH 52) Dl 18RD/YL*
Ml 20PK
Cl 12BR
GREEN DOT
G5 20DBX

Q20 12BK/RDX D32 18PKX~ HAZARD

HAZARD FLASHER
A3 16PK/WT* (SEE SH 52)
D31 18BKX

D31 18BKX H3 18BK/RDX HORN

Wl 12TN/BKX XI 18RDX RELAY
Q2 14BKX H2 18DG/RDX (SEE SH 31)
V6 18DB
J2 14DB
Dl 14RD/YLX W5 14RD
Dl 18RD/YLX LI 12RDX

FUSE COLOR
AMPS SHEET
NUMBER STRIPE

1 30 GREEN 2,10,62.63.65

. CIRCUIT SILVER CAN

2 n
2.10.68
J U
BREAKER

3 20 YELLOW 1,52

4 10 RED 2.10.57.59,61

5 20 YELLOW 2.10.25.27.33.52

6 20 YELLOW 2.10,50,51

7 15 LT BLUE 1.31

8 20 YELLOW 1,43

9 20 YELLOW 1.73.74

. CIRCUIT SILVER CAN

10 n
1,69
J U
BREAKER

1 1 10 RED 2,20,45.47.48,57.59,61,71

12 5 TAN 2,10.12.54.67,73.74

13 20 YELLOW 2.7.10.35

14 3 VIOLET 1.43,48.57.59.61

15 15 LT BLUE 1.10.48

AD 83 FUSE BLOCK MODULE AND RELAY BANK JSOBH-M

• WIRING DIAGRAMS—ELECTRICAL 8W - 127

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16 - ENG -

17 18 19 20 21 22 23 24 25 26
o
27 28 29 30 31 32 33 34

35 36 37 38 39 40 41 42

VIEW FROM WIRE END

CAV IGNITION SYSTEM CIRCUITS SHEET NO

1 J2 14DB IGNITION FEED 14
2 Nil 18BK/DG* OXYGEN SENSOR 13
3 N5 18BK/LB* SENSOR RETURN 16
4
5
6
7 Y12 18TN INJECTOR DRIVE #2 13
8 Y l l 18WT/DBX INJECTOR DRIVE #1 13 an arm Cl J
9 Zl 14DG/BKX INJECTOR FEED-BATTERY 13
10 K4 20DG/RD* MAP SENSOR 16 uuuuu O anaan
11 N6 180R 8 VOLT INPUT 16 u bmmx)
12 uuuuu
13
14
15 G60 20GY/YL* OIL PRESSURE SENDING UNIT 22 9

16 66 20GY OIL PRESSURE SWITCH (LAMP) 22

17 K10 20TN/WTX COOLANT SENSOR 16
pnnnn
18 p on, n o bxxcrcrd
19
20
21
9
22
23 K13 18BK/RD* THROTTLE BODY TEMP SENSOR 16
24
25
26 G20 20VT/YLX TEMPERATURE SENDING UNIT 22
27 Nl 18GY/RDX AUTOMATIC IDLE SPEED MOTOR 15
28 N2 18BR/WTX AUTOMATIC IDLE SPEED MOTOR 15
29 K8 20VT/WTX 5 VOLT SUPPLY 13
30
31 N31 18VT THROTTLE KICKER MOTOR 15
32 N7 18GY/BK* DISTRIBUTOR REF PICKUP 16
33 K7 180R/DBX THROTTLE POSITION SENSOR 13
34 C2 14DB/BKX A/C CLUTCH 64
35 56 20GY/YLX EGR SOLENOID 14
36 Kl 20PK/BKX PURGE SOLENOID 14
37 N23 20BK/0RX AIR SWITCHING SOLENOID 14
38
39
40 K5 16BK/WTX SIGNAL GROUND 13
41 R3 18DG ALTERNATOR FIED DRIVER 15
42 J9 14BK POWER GROUND 13

J908W-14 ENGINE WIRING CONNECTOR AD 84


ENGINE
CONTENTS
Page
3.9L ENGINE SERVICE PROCEDURES 10
5.2L/5.9L ENGINE SERVICE PROCEDURES . . . 39
ENGINE DIAGNOSIS 7
G E N E R A L INFORMATION
INDEX
Page
3.9L Engines . .. . 1
3.9L ENGINES
The 3.9 L i t e r (238 CID) six-cylinder engine is a 90°
V-Type, l i g h t w e i g h t , single cam, overhead valve en-
gine (Fig. 1). T h e cylinder block and cylinder heads
are cast i r o n . S p l i t crankpins are offset b y 22°. T h e
f i r i n g intervals alternate between 128° and 112°.
This engine is designed for unleaded fuel.
The cylinders are numbered f r o m f r o n t to rear; 1,
3, 5 on t h e left bank and 2, 4, 6 o n t h e r i g h t bank.
The f i r i n g order is 1-6-5-4-3-2 (Fig. 2).
C R A N K S H A F T : T h e nodular i r o n crankshaft is
supported b y four m a i n bearings. T h e No. 2 bearing
is t h e t h r u s t bearing. Crankshaft end sealing is pro-
vided by a f r o n t rubber seal a n d a rear "rope t y p e "
seal. The crankshaft r o t a t i o n is clockwise, w h e n
viewed f r o m t h e front of the engine.
Fig. 1 Six-Cylinder Engine—3.9 Liter
ENGINE 9-1
Page
GENERAL INFORMATION 1
STANDARD SERVICE PROCEDURES 4
Page
5.2L/5.9L Engines . .. 3
P I S T O N S : The pistons are cast a l u m i n u m (alloy
t i n coated). Three rings are used. Piston pins (press
f i t t e d i n t o t h e rods) j o i n t h e pistons to forged steel
connecting rods.
C A M S H A F T : The cast i r o n camshaft is mounted
i n four steel backed babbitt bearings. A t h r u s t plate
located i n front of the first bearing, and bolted t o the
block, controls end play. A helical gear located be-
tween t h e 12th cam lobe a n d rear bearing j o u r n a l ,
operates t h e o i l pump driveshaft a n d d i s t r i b u t o r . E i -
t h e r a d u a l roller chain or a n improved silent c h a i n
is used to drive t h e camshaft. These chains are en-
closed b y a cast a l u m i n u m cover. This cover holds
t h e front crankshaft seal, provides front o i l p a n clo-
sure, water pump m o u n t i n g a n d is embossed w i t h
raised t i m i n g m a r k s for strobe t i m i n g .
C Y L I N D E R H E A D S : Cylinder heads incorporate
valve shrouding to create turbulence-producing com
8909-70
9 - 2 ENGINE

EXHAUST GAS RECIRCULATION

PASSAGES
FUEL/AIR MIXTURE PASSAGES A
EXHAUST CROSSOVER
PASSAGE

COOLANT
PASSAGES RP116

3.9L SIX-CYLINDER ENGINE Fig. 3 Water Cooled Intake Manifold

DISTRIBUTOR—CLOCKWISE ROTATION
FIRING ORDER 1-6-5-4-3-2 RN755
Fig. 2 Engine Firing Order—3.9 Liter
b u s t i o n chambers, described as "fast b u r n " . Valve
guides a n d seats are i n t e g r a l a n d machined (hard-
ened, where required) w i t h t h e cylinder head. A steel
flange composition type gasket i s used between head
a n d block. H i g h turbulence cylinder heads allow a
9:1 compression r a t i o .
V A L V E C O V E R S : The valve covers are sealed
w i t h rubber-and-cork gaskets. Gasket compression is
controlled b y t h e use o f stop-collared studs i n s t a l l e d
i n t h e cylinder heads.
I N T A K E M A N I F O L D : This i n t a k e m a n i f o l d i s a
w a t e r cooled, a l u m i n u m casting (Fig. 3). The m a n i -
fold provides for single plane air/fuel induction, ex-
h a u s t heat a n d coolant (thermostat water box)
crossover. The u n i t is also cored w i t h passages rout-
i n g " m e t e r e d " coolant flow below t h e exhaust heat
crossover a n d t h r o u g h t h e f u l l l e n g t h o f the m a n i -
fold. T h i s metered coolant flows t h r o u g h t h e r i g h t
a n d left manifold side gaskets. The sealing o f t h e
m a n i f o l d is accomplished b y steel embossed side gas-
kets w i t h front and rear molded gaskets. T h e i n t a k e
m a n i f o l d is also cored w i t h upper level E G R passages
for balanced (cylinder to cylinder) E G R d i s t r i b u t i o n .
V A L V E T R A I N : Valve t r a i n has h y d r a u l i c r o l l e r
lifters and exhaust valve rotators. Rocker arms are
e i t h e r r i g h t or left, a n d i n s t a l l e d on a rocker a r m
shaft attached t o the cylinder head. V i t o n valve stem
seals provide positive i n t a k e valve sealing. C u p
shields are installed on exhaust valve stems. Conven-
t i o n a l types o f push rods, springs, retainers a n d
valve stem locks are used.
E X H A U S T M A N I F O L D S : E x h a u s t manifolds are
" l o g " type w i t h rear exits t h a t a t t a c h d i r e c t l y t o t h e
cylinder heads. B o t h manifolds provide for a i r injec-
t i o n , w h i l e t h e r i g h t m a n i f o l d incorporates a heat
control valve.
The 3.9L engine description is listed below (Fig. 4):

Type... 90°V-6
Bore and Stroke 99.3 x 84.0 mm (3.91 x 3.31 inch)
Displacement 3.9 Liters (238 cubic inch)
Compression Ratio 9.0:1
Engine Torque 265 N-m (195 ft-lbs) @ 2,000 rpm
Firing Order 1-6-5-4-3-2
Lubrication . . . . Pressure Feed—Full Flow Filtration
Engine Oil Capacity 3.8 Liters (4 Quarts)
Cooling System . . . . Liquid Cooled—Forced Circulation
Cooling System Capacity 13.2-13.5 Liters (14-14.3 Quarts)
Cylinder Block Cast Iron
Crankshaft Nodular Iron
Cylinder Head . . . . . . . . . . . . . . . . . . . Cast Iron
Combustion Chambers "Fast Burn" Design
Camshaft . . . . . . . . . . . . . Cast Iron
Pistons Aluminum Alloy with Strut
Connecting Rods Forged Steel

J9009-94

Fig. 4 Engine Description—3.9 Liter

 • ENGINE 9-3

5.2L/5.9L ENGINES The cylinders are n u m b e r e d from f r o n t to rear; 1,

3, 5, 7 o n t h e left b a n k a n d 2, 4, 6, 8 o n t h e r i g h t
The 5.2 L i t e r (318 C I D ) a n d 5.9 L i t e r (360 C I D ) b a n k . T h e f i r i n g order i s 1-8-4-3-6-5-7-2.
eight-cylinder engine are a V-Type v a l v e - i n head E n g i n e l u b r i c a t i o n system consists of a rotor type
t y p e w i t h h y d r a u l i c tappets. o i l p u m p a n d a f u l l flow o i l f i l t e r .
The 5.2L a n d 5.9L engine description i s listed be-
l o w ( F i g . 5):

90° V-8
. . . 99.3 x 84.0 mm (3.91 x 3.31 inch)
(5.9L). . . . 101.6 x 90.9 mm (4.0 x 3.58 inch)
5.2 Liters (318 cubic inch)
5.9 Liters (360 cubic inch)
. . . . . . . . . . . . 9.0:1
(5.9L) 8.1:1
191 N-m (260 ft. lbs.) @ 2,000 rpm
(5.9L) . 208 Ntn (283 ft. ibs.) @ 1,600 rpm
. . . 1-8-4-3-6-5-7-2
Pressure Feed-Full Flow Filtration
3.8 Liters (4 Quarts)
Liquid Cooled-Forced Circulation
. . 15.6 Liters (16.5 Quarts)*
(5.9L) j . 14.2 Liters (15.0 Quarts)*
Cast Iron
Nodular Iron
Cast Iron

(5.9L)
Cast Iron
. Aluminum Alloy with Strut
Forged Steel

*Add 0.9 Liters (1.0 Quart) with Rear Seat Heater Wedge

Fig. 5 Engine Description—5.2/5.9 Liter

9 - 4 ENGINE
STANDARD SERVICE
Page
Engine Performance
Form-ln-Place Gaskets
Honing Cylinder Bores
FORM-IN-PLACE GASKETS
There are numerous places where form-in-place
gaskets are used on the engine. Care m u s t be t a k e n
w h e n a p p l y i n g form-in-place gaskets. Bead size, con-
t i n u i t y and location are of great importance. Too t h i n
a bead can result i n leakage w h i l e too m u c h can re-
sult i n spill-over. A continuous bead o f t h e proper
w i d t h is essential to obtain a leak-free j o i n t .
ROOM TEMPERATURE VULCANIZING (RTV}
R T V silicone form-in-place gasket, n o r m a l l y black
i n color, is available i n three ounce tubes. Moisture
i n t h e a i r causes the RTV m a t e r i a l to cure. T h i s ma-
t e r i a l i s n o r m a l l y used on flexible m e t a l flanges. I t
has a shelf life of one year a n d w i l l not properly cure
i f over age. Always inspect t h e package for t h e expi-
r a t i o n date before use.
DISASSEMBLY
Parts assembled w i t h form-in-place gaskets may be
disassembled w i t h o u t unusual effort. I n some i n -
stances, i t may be necessary t o l i g h t l y t a p t h e p a r t
w i t h a m a l l e t or other suitable tool to b r e a k the seal
between the m a t i n g surfaces. A flat gasket scraper
may also be l i g h t l y tapped i n t o the j o i n t b u t care
must be t a k e n not t o damage t h e m a t i n g surfaces.
SURFACE PREPARATION
Scrape or w i r e brush a l l gasket surfaces t o remove
a l l loose m a t e r i a l . Inspect stamped parts t o ensure
gasket r a i l s are flat. F l a t t e n r a i l s w i t h a h a m m e r on
a flat plate, i f required. Gasket surfaces m u s t be free
of o i l and d i r t . M a k e sure t h e old gasket m a t e r i a l is
removed f r o m b l i n d attaching holes.
APPLICATION
Assembling parts using a form-in-place gasket re-
quires care. The R T V gasket m a t e r i a l should be ap-
plied i n a continuous bead approximately 3 m m (0.12
inch) i n diameter. A l l m o u n t i n g holes m u s t be cir-
cled. F o r corner sealing, a 1/8 or 1/4 i n c h drop is
placed i n the center of the gasket contact area. U n -
cured R T V may be removed w i t h a rag. Components
should be torqued i n place w h i l e the R T V i s s t i l l wet
to the touch ( w i t h i n 10 minutes). The usage o f a lo-
cating dowel is recommended d u r i n g assembly to pre-
vent smearing of m a t e r i a l off location.
•
PROCEDURES
INDEX
Page
4 Measuring With Plastigage 5
4 Repair Of Damaged Or Worn Threads 6
5
ENGINE PERFORMANCE
To provide best vehicle performance and lowest ve-
hicle emissions, i t is most i m p o r t a n t t h a t the tune-up
be done accurately, u s i n g the specifications listed on
the Vehicle Emission Control I n f o r m a t i o n label
found on the engine compartment hood.
(1) Test battery specific g r a v i t y . A d d water, i f nec-
essary. Clean and t i g h t e n battery connections.
(2) Test c r a n k i n g amperage d r a w (see Group 8B,
Battery/Starter Service for the proper procedures).
(3) T i g h t e n the i n t a k e m a n i f o l d bolts (see Group
1 1 , E x h a u s t System a n d I n t a k e M a n i f o l d for t h e
proper specifications).
(4) Perform cylinder compression test:
(a) Check engine o i l level a n d add o i l , i f neces-
sary.
(b) D r i v e the vehicle u n t i l engine reaches nor-
m a l operating temperature.
(c) Select a route free f r o m traffic and other
forms o f congestion, observe a l l traffic laws a n d
b r i s k l y accelerate t h r o u g h the gears several times.
The h i g h e r engine speed may help clean out valve
seat deposits w h i c h can prevent accurate compres-
sion readings.
CAUTION: Do not overspeed the engine.
(d) Remove a l l spark plugs from engine. A s
spark plugs are being removed, check electrodes for
abnormal f i r i n g indicators - fouled, hot, oily, etc.
Record cylinder number of spark p l u g for future
reference.
(e) Disconnect coil w i r e f r o m distributor and se-
cure t o good ground to prevent a spark from start-
i n g a fire.
(f) Be sure t h r o t t l e blades are fully open d u r i n g
the compression check.
(g) Insert compression gage adaptor into t h e
No. 1 spark p l u g hole. C r a n k engine u n t i l m a x i -
m u m pressure is reached on gauge. Record t h i s
pressure as No. 1 cylinder pressure.
(h) Repeat Step 4 g for a l l r e m a i n i n g cylinders.
(i) Compression should not be less t h a n 689
kPa (100 psi) and not v a r y more t h a n 172 kPa (25
psi) from cylinder to cylinder.
(j) I f one or more cylinders have abnormally
low compression pressures, repeat steps 4a t h r o u g h
4h.
(k) I f the same cylinder or cylinders repeat a n
abnormally low reading on the second compression
 • ENGINE 9-5

test, i t could indicate t h e existence o f a problem i n

the cylinder i n question.
T h e r e c o m m e n d e d compression pressures
are t o be used o n l y as a guide t o diagnosing
engine problems. A n engine s h o u l d N O T be
disassembled t o d e t e r m i n e t h e cause o f l o w
compression unless some m a l f u n c t i o n i s
present.
(5) Clean or replace s p a r k plugs as necessary and
adjust gap. See Group 8 D , I g n i t i o n System for gap
adjustment and torque.
(6) Test resistance o f spark p l u g cables. Refer t o
Group 8D, I g n i t i o n System.
(7) Inspect the p r i m a r y w i r e . Test coil output volt-
age, p r i m a r y and secondary resistance. Replace parts
as necessary. Refer t o Group 8D, I g n i t i o n System and
make necessary adjustment.
(8) Reset i g n i t i o n t i m i n g to specifications (see Spec- Fig. 1 Cylinder Bore Cross-Hatch Pattern
ification Label on engine compartment hood).
a l i g h t h o n i n g o i l available f r o m major o i l d i s t r i b u -
(9) Perform a combustion analysis.
tors. Do n o t use e n g i n e o r t r a n s m i s s i o n o i l , m i n -
(10) Test fuel p u m p for pressure and vacuum. Refer
eral spirits o r kerosene.
to Group 14, F u e l System for the proper specifica-
(3) H o n i n g should be done b y moving the hone u p
tions.
and down fast enough t o get a cross-hatch p a t t e r n .
(11) Inspect m a n i f o l d heat control valve i n the en-
W h e n hone m a r k s i n t e r s e c t a t 50° to 60°, t h e cross-
gine exhaust m a n i f o l d for proper operation (see
hatch angle is most satisfactory for proper seating o f
Group 0, L u b r i c a t i o n a n d Maintenance for the proper rings (Fig. 1).
procedure). A p p l y M a n i f o l d H e a t C o n t r o l Valve Sol- (4) A controlled hone motor speed between 200 and
vent t o the b u s h i n g and shaft. 300 r p m is necessary to obtain the proper cross-hatch
(12) Inspect a i r f i l t e r element (see Group 0, L u b r i - angle. T h e n u m b e r o f u p a n d down strokes per
cation and Maintenance for t h e proper procedure). m i n u t e can be regulated to get the desired 50° to 60°
(13) Inspect crankcase v e n t i l a t i o n system (see angle. Faster up and down strokes increase t h e cross-
Group 0, L u b r i c a t i o n a n d Maintenance for the proper hatch angle.
procedure). (5) A f t e r h o n i n g , i t is necessary t h a t the block be
(14) For emission controls see Group 25, Emission cleaned again t o remove a l l traces of abrasives.
Controls System for service procedures.
(15) Inspect and adjust accessory b e l t drives (refer CAUTION: Be sure all abrasives are removed from
to Group 7, Cooling System for t h e proper adjust- engine parts after honing. It is recommended that a
ments). solution of soap and water be used with a brush
(16) Road test vehicle as a f i n a l test. and the parts thoroughly dried. The bore can be
considered clean when it can be wiped clean with a
HONING CYLINDER BORES white cloth remains clean. Oil the bores after clean-
ing to prevent rusting.
Before honing, stuff p l e n t y o f clean shop towels u n -
der t h e bores and over t h e crankshaft t o keep abra-
sive m a t e r i a l s f r o m e n t e r i n g the crankshaft area. MEASURING WITH PLASTIGAGE
(1) Used carefully, the cylinder bore sizing hone C- Engine crankshaft bearing clearances can be deter-
823 equipped w i t h 220 g r i t stones, i s t h e best tool for m i n e d by use of Plastigage or equivalent. The follow-
t h i s job. I n a d d i t i o n t o deglazing, i t w i l l reduce taper i n g is t h e recommended procedures for t h e use o f
and out-of-round as w e l l as r e m o v i n g l i g h t scuffing, Plastigage:
scoring or scratches. U s u a l l y a few strokes w i l l clean (1) Remove o i l f i l m from surface to be checked.
up a bore and m a i n t a i n t h e required l i m i t s . Plastigage is soluble i n o i l .
(2) Deglazing of the c y l i n d e r walls m a y be done us- (2) T h e t o t a l clearance of the m a i n bearings can
i n g a cylinder surfacing hone, Tool C-3501, equipped only be determined b y removing the weight o f t h e
w i t h 280 g r i t stones (C-3501-3810) i f the cylinder crankshaft. T h i s can be accomplished by either o f
bore is s t r a i g h t a n d r o u n d . 20-60 strokes, depending two methods:
on t h e bore condition, w i l l be sufficient t o provide a P R E F E R R E D M E T H O D - S h i m m i n g t h e bear-
satisfactory surface. U s i n g h o n i n g o i l C-3501-3880 or ings adjacent to the bearing to be checked i n order t o
9 - 6 ENGINE
BEARING CAP
BEARING
SHELL
PLASTIC-GAGE
i m
m
HI
MM
mill
J8909-59
Fig. 2 Placement of Plastigage in Bearing Shell
remove t h e clearance between upper bearing shell
and t h e crankshaft. T h i s c a n be accomplished b y
placing a m i n i m u m o f 0.254 m m (0.010 inch) s h i m
between t h e bearing shell and t h e bearing cap o n the
adjacent bearings a n d t i g h t e n i n g t h e bolts t o 14-20
N»m (10-15 ft. lbs.) torque.
• W h e n checking N o . 1 m a i n bearing; s h i m # 2
m a i n bearing.
• W h e n checking N o . 2 m a i n bearing; s h i m # 1 &
# 3 m a i n bearing.
• W h e n checking N o . 3 m a i n bearing; s h i m # 2 &
# 4 m a i n bearing.
• W h e n checking N o . 4 m a i n bearing; s h i m # 3 &
# 5 m a i n bearing.
• W h e n checking N o . 5 m a i n bearing; s h i m # 4
m a i n bearing.
• W h e n checking N o . 4 m a i n bearing; s h i m N o . 3
m a i n b e a r i n g (3.9 E n g i n e only).
A l l s h i m s m u s t b e r e m o v e d before r e a s s e m -
bling engine.
A L T E R N A T I V E M E T H O D - T h e weight o f t h e
crankshaft i s supported b y a j a c k under t h e counter-
weight adjacent t o t h e b e a r i n g being checked.
(3) Place a piece o f Plastigage across t h e entire
w i d t h o f t h e bearing shell i n t h e cap approximately
6.35 m m (1/4 inch) off center a n d away from t h e o i l
holes ( F i g . 2). I n a d d i t i o n , suspect areas c a n be
checked b y placing t h e Plastigage i n t h e suspect
area. T i g h t e n the b e a r i n g cap bolts o f the bearing be-
i n g checked t o 115 N»m (85 f t . lbs.) torque.
The checking of connecting r o d clearances does not
require s h i m m i n g o f t h e crankshaft. However, before
assembling t h e r o d cap w i t h Plastigage i n place, t h e
PLASTIC-GAGE
J8909-60
Fig. 3 Clearance Measurement
crankshaft m u s t be t u r n e d u n t i l t h e connecting r o d
to be checked starts m o v i n g t o w a r d t h e top o f t h e en-
gine. O n l y t h e n should t h e cap be assembled a n d
tightened t o 6 1 N»m (45 f t . lbs.) torque. Do n o t rotate
t h e crankshaft w h i l e assembling t h e cap or t h e Plas-
tigage m a y be smeared, g i v i n g inaccurate results.
(4) Remove t h e bearing cap and compare t h e w i d t h
of the flattened Plastigage w i t h t h e metric scale pro-
vided on t h e package (Fig. 3). Locate t h e band closest
to t h e same w i d t h , t h i s band shows t h e a m o u n t o f
clearance i n thousandths o f a m i l l i m e t e r . Differences
i n readings between t h e ends indicate t h e a m o u n t o f
taper present. Record a l l readings t a k e n . Refer t o
Engine Specifications i n t h i s section. P l a s t i g a g e
generally i s accompanied b y t w o scales. O n e
s c a l e i s i n i n c h e s , the other i s a m e t r i c s c a l e .
(5) Plastigage i s available i n a v a r i e t y o f clearance
ranges. T h e 0.025-0.076 m m (0.001-0.003 inch) i s
usually t h e most appropriate for checking engine
bearing clearances.
REPAIR OF DAMAGED OR WORN THREADS
Damaged o r w o r n threads can be repaired. Essen-
t i a l l y , t h i s repair consists of d r i l l i n g o u t w o r n or
damaged threads, t a p p i n g t h e hole w i t h a special
H e l i - C o i l Tap, (or equivalent), a n d i n s t a l l i n g a n i n -
sert i n t o t h e tapped hole. This brings t h e hole back
to i t s o r i g i n a l t h r e a d size.
CAUTION: Be sure that the tapped holes maintain
the original centerline.
Heli-Coil tools a n d inserts are readily available
from automotive parts jobbers.
 • ENGINE 9-7

ENGINE DIAGNOSIS
INDEX
Page Page
Checking Engine Oil Pressure 9 Service Diagnosis - Mechanical 7
General Information 7 Service Diagnosis - Performance 8
Inspection For Engine Oil Leaks 9

GENERAL INFORMATION Refer t o t h e Service Diagnosis—Mechanical chart

and t h e Service Diagnosis—Performance char t for
Engine diagnosis is helpful i n d e t e r m i n i n g t h e possible causes a n d corrections o f malfunctions. Refer
causes of malfunctions not detected and remedied by to Group 14, F u e l System for the fuel system diagno-
routine tune-ups. sis.
These malfunctions may be classified as either me-
chanical (e.g., a strange noise), or performance (e.g.,
engine idles r o u g h and stalls).

SERVICE DIAGNOSIS - MECHANICAL

CONDITION POSSIBLE CAUSES CORRECTION

NOISY VALVES • High and low oil level in crankcase • Check for correct oil level. Refer to Group
0, Lubrication and Maintenance.
• Thin or diluted oil • Change oil. Refer to Group 0, Lubrication
and Maintenance.
• Low oil pressure • Check engine oil level.
• Dirt in lash adjusters • Clean hydraulic lash adjusters.
• Worn rocker arms • Inspect oil supply to rocker arms.
• Worn lash adjusters • Install new hydraulic lash adjusters.
• Worn valve guides • Ream and install new valves with oversize
stems.
• Excessive runout of valve seats or valve • Grind valve seats and valves.
faces

CONNECTING ROD NOISE • Insufficient oil supply
• Low oil pressure
• Thin or diluted oil
• Excessive bearing clearance
• Connecting rod journal out-of-round
• Misaligned connecting rods
MAIN BEARING NOISE • Insufficient oil supply
• Low oil pressure
• Thin or diluted oil
• Excessive bearing clearance
• Excessive end play
• Crankshaft journal out-of-round worn
• Loose flywheel or torque converter
OIL PRESSURE DROP • Low oil level
• Low oil pressure
• Clogged oil filter
• Worn parts in oil pump
• Thin or diluted oil
• Excessive bearing clearance
• Oil pump relief valve stuck
• Oil pump suction tube loose, bent or
cracked
OIL LEAKS • Misaligned or deteriorated gaskets
• Loose fastner, broken or porous metal part • Tighten, repair or replace the part.
• Check engine oil level. Refer to Group 0,
Lubrication and Maintenance.
• Check engine oil level. Inspect oil pump
relief valve and spring.
• Change oil to correct viscosity.
• Measure bearings for correct clearance.
• Replace crankshaft or grind journals.
• Replace bent connecting rods.
• Check engine oil level. Refer to Group 0,
Lubrication and Maintenance.
• Check engine oil level. Inspect oil pump
relief valve and spring.
• Change oil to correct viscosity.
• Measure bearings for correct clearance.
• Check No. 3 main bearing for wear on
flanges.
• Replace crankshaft or grind journals.
• Tighten to correct torque.
•Check engine oil level.
•Check sending unit.
•Install new oil filter
•Replace worn parts or pump.
•Change oil to correct viscosity.
•Measure bearings for correct clearance.
•Remove valve and inspect, clean and
install.
• Remove oil pan and install new tube, if
necessary.
• Replace the gasket.
J9009-122
9 - 8 ENGINE
SERVICE DIAGNOSIS - PERFORMANCE
CONDITION POSSIBLE CAUSES
ENGINE WILL NOT START • Weak battery
• Corroded or loose battery connections
• Faulty starter
• Moisture on ignition wires and distributor
cap
• Faulty ignition cables
• Faulty coil or control unit
• Incorrect spark plug gap
• Incorrect ignition timing
• Dirt or water in fuel line
• Faulty fuel pump
ENGINE STALLS OR • Idle speed set too low
ROUGH IDLE • Leak in intake manifold
• Worn or burned distributor rotor
• Incorrect ignition wiring
• Faulty coil
• EGR valve leaking
ENGINE LOSS OF POWER • Incorrect ignition timing
• Worn or burned distributor rotor
• Worn distributor shaft
• Dirty or incorrectly gapped spark plugs
• Dirt or water in fuel line or filter
• Faulty fuel pump
• Incorrect valve timing
• Blown cylinder head gasket
• Low compression
• Burned, warped or pitted valves
• Plugged or restricted exhaust system
• Faulty ignition cables
• Faulty coil
ENGINE MISSES ON • Dirty, or gap too wide in spark plugs
ACCELERATION
• Incorrect ignition timing
• Burned, warped or pitted valves
• Faulty coil
ENGINE MISSES AT HIGH • Dirty or gap set too wide in spark plug
SPEED
• Worn distributor shaft
• Worn or burned distributor rotor
• Faulty coil
• Incorrect ignition timing
• Dirty injector in throttle body
• Dirt or water in fuel line or filter
•
CORRECTION
• Charge or replace, as necessary. Refer to
Group 8A, Battery/Starting/Charging
System Diagnosis.
• Clean and tighten battery connections.
Apply a coat of light mineral grease to
terminals.
• Refer to Group 8B, Battery/Starter Service.
• Wipe wires and cap clean and dry.
• Replace any cracked or shorted cables.
• Test and replace, if necessary. Refer to
Group 8D Ignition System.
t
• Set gap. Refer to Group 8D, Ignition
System.
• Refer to Group 8D, Ignition System.
• Clean lines.
• Install new fuel pump. Refer to Group 14,
Fuel System.
• Refer to Group 14, Fuel System.
• inspect intake manifold gasket and
replace, if necessary. Refer to Group 11,
Exhaust System and Intake Manifold.
• Install new rotor.
• Install correct wiring.
• Test and replace, if necessary. Refer to
Group 8D, Ignition System.
• Test and replace, if necessary. Refer to
Group 25, Emissions.
• Refer to Group 8D, Ignition System.
• Install new rotor.
• Remove and repair distributor. Refer to
Group 8D, Ignition System.
• Clean plugs and set gap. Refer to Group
8D, Ignition System.
• Clean lines and replace filter. Refer to
Group 14, Fuel System.
• Install new pump.
• Refer to Valve Timing in this group.
• Instal new cylinder head gasket.
• Test compression of each cylinder.
• Install new valves.
• Install new parts, as necessary.
• Replace any cracked or shorted cables.
• Test and replace, as necessary.
• Clean spark plugs and set gap. Refer to
Group 8D, Ignition System.
• Refer to Group 8D, Ignition System.
• Install new valves.
• Test and replace, if necessary. Refer to
Group 8D, Ignition System.
• Clean spark plugs and set gap. Refer to
Group 8D, Ignition System.
• Remove and repair distributor. Refer to
Group 8D, Ignition System.
• Install new distributor rotor.
• Test and replace, if necessary. Refer to
Group 8D, Ignition System.
• Refer to Group 8D, Ignition System.
• Refer to Group 14, Fuel System.
• Clean lines and replace filter. Refer to
Group 14, Fuel System.
J9009-95
 • ENGINE
SERVICE DIAGNOSIS - PERFORMANCE (CONT.)
CONDITION POSSIBLE CAUSES
OIL PUMPING AT • Worn, scuffed or broken rings
RINGS—SPARK PLUGS • Carbon in oil ring slot
FOULING • Rings fitted too tight in grooves
• Leaking intake gasket
• Worn valve guides
• Leaking valve guide seals
INSPECTION FOR ENGINE OIL LEAKS
I f an o i l leak source is not r e a d i l y identifiable, the
following steps should be followed:
(1) A t t a c h a n a i r hose w i t h pressure gauge a n d
regulator to the dipstick tube.
(2) Disconnect the breather cap t o a i r cleaner hose
at the breather cap end. Cap or p l u g breather cap
nipple.
(3) Remove the P C V valve f r o m the cylinder head
cover. Cap or p l u g the PCV valve grommet.
(4) After the engine is sealed, set t h e a i r pressure
regulator N O H I G H E R t h a n 27 k P a (4 psi).
(5) U s i n g a l i q u i d soap solution or preferable a
stethoscope, inspect a l l suspected o i l leak areas. I f an
o i l leak area is detected, repair per the service man-
u a l instructions.
(6) I f no leaks are detected, t u r n off t h e a i r supply
and remove t h e a i r hose and a l l plugs. I n s t a l l t h e
PCV valve and breather cap hose. See step 7 and
check for higher pressure leaks o c c u r r i n g d u r i n g nor-
m a l engine operation.
(7) Clean the o i l off the suspect o i l leak area using
a suitable solvent. D r i v e t h e vehicle a t various
speeds approximately 24 k m (15 miles). Check t h e
engine for signs of a n o i l leak. I f a n o i l leak i s found,
repair per the service m a n u a l i n s t r u c t i o n s .
9•9
CORRECTION
• Hone cylinder bores and install new rings.
• Install new rings.
• Remove the rings. Check grooves. If groove is
not proper width, replace piston.
• Replace gasket and tighten to the proper
specifications.
• Ream guides and replace valves with oversize
valves and seals.
• Replace seals.
J9009-121
(8) I f the leakage occurs a t the crankshaft rear o i l
seal:
(a) Raise the vehicle.
(b) Remove torque converter or clutch housing
cover and inspect rear of block for evidence of o i l .
A circular spray p a t t e r n generally indicates seal
leakage. Where leakage tends t o r u n s t r a i g h t
down, possible causes are a porous block and the
rear cam and galley plugs. See Group 9, Engines
(Rear M a i n B e a r i n g O i l Seals), for the proper seal
(and retainer) i n s t a l l a t i o n .
(c) I f no leaks are detected w h i l e the crankcase
is pressurized 27 kPa (4 psi), very slowly t u r n the
crankshaft and watch for leakage. I f a leak is de-
tected w h i l e t u r n i n g t h e crankshaft, i t s possible
the crankshaft seal surface is damaged i n the seal
area, m i n o r nicks or scratches can be polished out
w i t h emery cloth. See Group 9, Engines (Rear
M a i n B e a r i n g O i l Seals), for the proper seal (and
retainer) i n s t a l l a t i o n .
CHECKING ENGINE OIL PRESSURE
(1) Remove o i l pressure sending u n i t w i t h Tool C-
4597).
(2) I n s t a l l o i l pressure l i n e a n d gauge (Tool C-
3292). S t a r t engine and record pressure. Refer to en-
gine specification (engine lubrication) for proper
pressures.
 3.9L ENGINE S E R V I C E PROCEDURES
INDEX
Page Page
Camshaft (Engine Removed From Vehicle) 22 Oil Filter 32
Camshaft Bearings (Engine Removed Oil Line Plug Inspection 32
From Vehicle) 23 Oil Pan . 29
Connecting Rods 26 Oil Pump 30
Crankshaft Identification 27 Oil Pump Inspection Limits For
Crankshaft Main Bearings 27 Replacement—3.9L 37
Crankshaft Main Journals 27 Oversize And Undersize Engine Component
Cylinder Block . .. . 24 Markings—3.9L 37
Cylinder Heads 13 Pistons, Pins and Rings 25
Distributor Drive Shaft Bushing 23 Rear Main Bearing Oil Seals 28
Engine Assembly 11 Rocker Arms And Shaft Assembly 12
Engine Core Oil And Cam Plugs . . . . . . . . . . . . . 25 Timing Chain Cover External Oil Seal 21
Engine Front Mounts (Insulators) 10 Timing Chain Cover, Oil Seal And Chain 20
Engine Rear Mount (Insulator) 10 Torque Specifications—3.9L . 38
Engine Specifications—3.9L 33 Valve Timing 19
Hydraulic Tappets 18 Valves And Valve Springs 15

ENGINE FRONT MOUNTS (INSULATORS)

REMOVAL
(1) Raise hood and position f a n t o assure clearance
for radiator top t a n k and hose.
(2) I n s t a l l engine l i f t i n g f i x t u r e (Tool C-3487-A).
(3) Raise vehicle o n hoist.
(4) Remove bolts and nuts f r o m brackets and insu-
lators (Fig. 1).
(5) Raise engine w i t h l i f t i n g f i x t u r e only far
enough t o remove insulators.

INSTALLATION
(1) W i t h engine raised S L I G H T L Y , i n s t a l l insula-
tors on frame crossmember. I n s t a l l bolt and washer
assemblies (Fig. 1).
(2) Lower engine w i t h l i f t i n g f i x t u r e w h i l e g u i d i n g
insulator studs into bracket.
(3) I n s t a l l insulator t o bracket n u t a n d washer.
T i g h t e n t h e attaching nuts to 102 N - m (75 f t . lbs.)
torque and t h e bolts t o 4 1 N»m (30 f t . lbs.) torque
(Fig. 1).
(4) Lower the vehicle. flfrT SIDE) RR09B143
(5) Remove l i f t i n g f i x t u r e .
Fig. 1 Engine Front Mounts
ENGINE REAR MOUNT (INSULATOR) (5) Raise rear of transmission enough to provide i n -
sulator to crossmember clearance. Remove the i n s u -
lator.
REMOVAL
(1) Raise the vehicle on a hoist. INSTALLATION
(2) Position transmission j a c k a n d raise rear of (1) I n s t a l l insulator i n transmission rear support
transmission and engine S L I G H T L Y . bracket. I n s t a l l through-bolt.
(3) Remove rear mount (insulator) through-bolt and (2) W i t h insulator secured i n a L E V E L position
n u t (Fig. 2). (relative to f i n a l attachment to transmission rear
(4) Remove t h e bolts a t t a c h i n g t h e insulator to support bracket) t i g h t e n through-bolt n u t to 68 N*m
frame crossmember bracket (Fig. 2). (50 ft. lbs.) torque.
 (5) Remove radiator and heater hoses. Remove the
radiator (see Group 7, Cooling System for the proper
procedure).
(6) Set fan shroud aside.
(7) Discharge the a i r conditioner, i f equipped (refer
to Group 24, H e a t i n g and A i r C o n d i t i o n i n g for ser-
vice procedures).
(8) Remove a i r conditioning hoses
(9) Remove the v a c u u m lines.
(10) Remove the d i s t r i b u t o r cap and w i r i n g .
(11) Remove the t h r o t t l e body, fuel lines and l i n k -
age.
(12) Remove the starter w i r e s and o i l pressure
wire.
(13) Disconnect the power steering hoses, i f
equipped.
(14) Remove starter motor, alternator, charcoal
canister and horns.
(15) Raise and support the vehicle on a hoist.
(16) Disconnect exhaust pipe a t manifold.
(17) M a n u a l T r a n s m i s s i o n
See Group 2 1 , Transmissions for t h e M a n u a l
Transmission Removal procedure.
(18) A u t o m a t i c T r a n s m i s s i o n
(a) Remove bell housing bolts and inspection
Fig. 2 Rear Engine Support plate.
(3) U s i n g the transmission jack, lower t h e rear (b) A t t a c h a C clamp on f r o n t bottom of trans-
mission torque converter h o u s i n g to prevent torque
m o u n t (insulator) onto the crossmember bracket.
converter from coming out.
(4) T i g h t e n the flange nuts to 4 1 N - m (30 f t . lbs.)
(c) Remove torque converter drive plate bolts.
torque.
M a r k converter and drive plate to aid i n assembly.
(5) Remove the transmission jack.
(d) Support the transmission.
(6) Lower the vehicle.
(e) Lower the vehicle.
(19) I n s t a l l engine l i f t i n g f i x t u r e . A t t a c h a chain
ENGINE ASSEMBLY hoist to f i x t u r e eyebolt.
(20) Remove engine front m o u n t bolts (Fig. 1).
CHECK OPERATION OF EXHAUST VALVE (21) Remove engine from engine compartment and
ROTATORS i n s t a l l on engine repair stand.
Before an engine is disassembled for valve g r i n d i n g (22) Disconnect the torque converter drive plate
or major repair work, the performance of the exhaust from the engine crankshaft.
valve rotators should be checked.
(1) W i t h engine i n the vehicle, remove cylinder INSTALLATION
head covers. (1) Position the torque converter drive plate onto
(2) Observe exhaust valve r o t a t i o n w i t h t h e engine the crankshaft. T i g h t e n the bolts to 75 N-m (55 ft.
r u n n i n g at 2000 and 3000 r p m . The valve should ro- lbs.) torque.
tate a t u n i f o r m and constant speeds (direction of ro- (2) Remove engine from the r e p a i r stand and posi-
t a t i o n is not i m p o r t a n t ) . There is generally a large t i o n i t i n t o the engine compartment.
difference i n r o t a t i o n speeds between 1000 a n d 3000 (3) I n s t a l l the engine front m o u n t bolts. T i g h t e n
rpm. the bolts to 4 1 N-m (30 ft. lbs.) torque.
(3) Rotators w h i c h do not appear to rotate should (4) Remove engine l i f t i n g f i x t u r e .
be replaced. (5) M a n u a l T r a n s m i s s i o n
See Group 2 1 , Transmissions for the M a n u a l
REMOVAL Transmission I n s t a l l a t i o n procedure.
(1) Scribe hood hinge outlines on hood and remove (6) A u t o m a t i c T r a n s m i s s i o n
t h e hood. (a) Raise and support t h e vehicle.
(2) Remove the battery. (b) A l i g n the torque converter plate to the
(3) D r a i n cooling system. torque converter. I n s t a l l and t i g h t e n the bolts to 31
(4) Remove the a i r cleaner. N-m (270 i n . lbs.) torque.
 (c) I n s t a l l bell housing bolts. T i g h t e n the b e l l RIGHT
housing bolts to 41 N-m (30 ft. lbs.) torque.
(d) Remove the C clamp.
(e) I n s t a l l the inspection plate.
(f) Remove the transmission support.
(7) Position t h e exhaust pipe to t h e manifold.
T i g h t e n the nuts to 33 N-m (24 ft. lbs.) torque.
(8) Lower the vehicle.
(9) I n s t a l l t h e starter motor, alternator, charcoal
canister and horns.
(10) Remove t h e starter wires a n d o i l pressure
wire.
(11) I n s t a l l t h r o t t l e body, fuel lines and linkage. RELIEVED FOR ROTATOR
CLEARANCE
(12) Connect the vacuum lines.
(13) I n s t a l l the distributor cap and w i r i n g .
(14) I n s t a l l the radiator (see Group 7, Cooling Sys-
tems). Connect the radiator hoses and heater hoses.
(15) I n s t a l l fan shroud i n position.
(16) F i l l the cooling system (see Group 7, Cooling
System for the proper procedures).
(17) I n s t a l l the battery.
(18) A t t a c h the air cleaner to the t h r o t t l e body.
(19) Connect t h e power steering hoses, i f so
equipped. INTAKE ROCKER ARM EXHAUST ROCKER ARM
(20) I n s t a l l a i r conditioning equipment and charge 8909-71
a i r conditioning. Refer to Group 24, H e a t i n g and A i r
Fig. 1 Intake and Exhaust Rocker Arm Identification
Conditioning for proper service.
(21) W a r m engine and adjust.
(22) I n s t a l l hood and line up w i t h the scribe m a r k s .
(23) Road test vehicle.

ROCKER ARMS AND SHAFT ASSEMBLY

REMOVAL
(1) Disconnect spark p l u g wires b y p u l l i n g on t h e
boot s t r a i g h t out i n line w i t h plug.
(2) Disconnect closed v e n t i l a t i o n system and evap-
oration control system from cylinder head cover.
(3) Remove cylinder head cover and gasket.
(4) Remove four rocker shaft bolts and retainers. Fig. 2 Rocker Arm Location—Left Bank
(5) Remove rocker arms and shaft assembly. CAUTION: THE ROCKER ARM SHAFT SHOULD BE
(6) I f rocker a r m assemblies are disassembled for TORQUED DOWN SLOWLY, STARTING WITH THE
cleaning or replacement, refer to F i g . 1 for rocker CENTERMOST BOLTS. ALLOW 20 MINUTES TAP-
a r m identification, and Fig. 2 for positioning on t h e PET BLEED DOWN TIME AFTER INSTALLATION OF
shaft. THE ROCKER SHAFTS BEFORE ENGINE OPERA-
(7) The exhaust rocker a r m must have r e l i e f for TION.
clearance (Fig. 1).
(2) Clean cylinder head cover gasket surface. I n -
INSTALLATION
spect cover for distortion a n d straighten, i f necessary.
(1) I n s t a l l rocker a r m and shaft assemblies w i t h
(3) Clean head r a i l , i f necessary. I n s t a l l cylinder
N O T C H (Fig. 3) on end of rocker shaft p o i n t i n g to
centerline of engine and t o w a r d front (left bank) and head cover and t i g h t e n to 9 N-m (80 i n . lbs.) torque.
to the rear (right bank). Make sure t o i n s t a l l t h e (4) I n s t a l l closed crankcase v e n t i l a t i o n system and
long stamped steel retainers i n the n u m b e r t w o and evaporation control system.
four positions. Tighten t h e bolts to 23 N - m (200 i n .
lbs.) torque (Fig. 3).
 SHORT STAMPED INSTALLATION
RETAINERS (1) Clean a l l surfaces o f cylinder block and cylinder
heads.
(2) Inspect a l l surfaces w i t h a straightedge i f there
is any reason to suspect leakage. I f out of flatness ex-
ceeds 0.00075 mm/mm (0.00075 inch/inch) times t h e
span l e n g t h i n inches i n any direction, either replace
LONG STAMPED "NOTCH"
RETAINERS
head or l i g h t l y machine t h e head surface.
(END OF ROCKER SHAFT) RP123 F O R E X A M P L E — I f a 305 m m (12 i n c h ) s p a n i s
0.102 m m (0.004 inch) out o f flat, a l l o w a b l e i s 305
Fig. 3 Rocker Arm Retainers and NOTCH Location X 0.00075 (12 X 0.00075) e q u a l s 0.23 m m (0.009
CYLINDER HEADS i n c h ) . T h i s a m o u n t o f o u t o f flat i s a c c e p t a b l e .
(3) The cylinder head surface f i n i s h should be 1.78-
T h e alloy cast i r o n cylinder heads shown i n (Fig. 4) 4.57 microns (70-180 microinches).
are h e l d i n place b y eight bolts. The spark p l u g s are (4) I n s t a l l new gaskets o n cylinder block.
located i n peak o f the wedge between t h e valves. (5) Remove cylinder heads from h o l d i n g fixtures
and place heads o n engine.
REMOVAL (6) O n 6 cylinder engines bolt t h r e a d sealer is not
(1) D r a i n cooling system. required. S t a r t i n g a t top center, t i g h t e n a l l cylinder
(2) Disconnect battery ground cable. head bolts t o 68 N-m (50 ft. lbs.) torque i n sequence
(3) Remove alternator, t h r o t t l e body, a i r cleaner (Fig. 5). Repeat procedure, t i g h t e n a l l cylinder head
a n d fuel line. bolts to 143 N-m (105 f t . lbs.) torque. Repeat proce-
(4) Disconnect accelerator linkage. dure t o confirm t h a t a l l bolts are a t 143 N-m (105 f t .
lbs.) torque.
INTAKE SPARK
VALVES PLUGS
OIL FEED
HOLE

COOLAN
EXHAUST VALVES
PASSAGE RP121
Fig. 4 Cylinder Head Assembly
(5) Remove d i s t r i b u t o r cap and wires.
(6) Disconnect coil wires, heat indicator sending
u n i t w i r e , heater hoses and bypass hose.
(7) Remove closed v e n t i l a t i o n system, evaporation
control system and cylinder head covers.
(8) Remove i n t a k e manifold, and t h r o t t l e body as
a n assembly.
(9) Remove exhaust manifolds.
(10) Remove rocker a r m and shaft assemblies. Re-
move push rods and identify to ensure i n s t a l l a t i o n i n
o r i g i n a l locations.
(11) Remove t h e head bolts f r o m each cylinder
head and remove cylinder heads.
(12) Place cylinder heads i n h o l d i n g f i x t u r e Tool C-
3626. Remove spark plugs.
/ RP122
Fig. 5 Cylinder Head Bolt Tightening Sequence
(7) Inspect push rods a n d replace w o r n or bent
rods.
(8) I n s t a l l push rods, rocker a r m and shaft assem-
blies w i t h t h e N O T C H o n t h e end o f rocker shaft
p o i n t i n g to centerline o f engine and t o w a r d front (left
bank) and to the rear ( r i g h t bank). T h e notch is a l -
ways to left as facing cylinder head. M a k e sure t o i n -
s t a l l the long stamped steel retainers i n the n u m b e r
two and four positions. T i g h t e n the bolts t o 23 N - m
(200 i n . lbs.) torque (Fig. 6).
(9) Coat i n t a k e manifold side gaskets l i g h t l y w i t h
sealer. R I G H T and L E F T side gaskets are required.
Cutouts a t top front of each gasket ( L T for left side
and R T for r i g h t side) identifies each gasket position
(Fig. 6).
(10) I n s t a l l side gaskets t o cylinder head.
 (16) I n s t a l l t h e twelve a t t a c h i n g bolts (Finger
T i g h t ) . T i g h t e n t h e bolts t o 34 N - m (25 ft. lbs.)
torque i n t h e t i g h t e n i n g sequence shown i n (Fig. 8).
T i g h t e n t h e same bolts t o 54 N - m (40 ft. lbs.) torque
i n sequence shown (Fig. 8).

RP124

Fig. 6 Intake Manifold Side Gaskets (Left Side

Shown)
(11) Clean cylinder block front and rear gasket sur-
faces u s i n g a suitable solvent (Fig. 7). RP126
(12) A p p l y a t h i n , u n i f o r m coating o f a q u i c k d r y
cement to t h e i n t a k e manifold front and r e a r gaskets Fig. 8 Intake Manifold Bolt Tightening Sequence
and cylinder block gasket surface. W h e n i n s t a l l i n g (17) I n s t a l l exhaust manifolds a n d t i g h t e n bolts t o
gaskets, t h e center hole i n t h e gasket M U S T engage 27 N-m (20 f t . lbs.) torque and t i g h t e n t h e n u t s to 20
dowels i n block. E n d holes i n seals M U S T be locked N-m (15 f t . lbs.) torque.
i n t o tangs of head gasket (Fig. 7). (18) Adjust spark plugs to specifications (see Group
SIDE GASKET 1/4" DIAMETER OF 8D, I g n i t i o n System). I n s t a l l the plugs a n d t i g h t e n t o
RUBBER SEALER 4 1 N - m (30 f t . lbs.) torque.
ONTO EACH OF
(19) I n s t a l l coil wires, heat indicator sending u n i t
MANIFOLD TO
CYLINDER HEAD w i r e , heater hoses and bypass hose.
GASKET CORNERS (20) I n s t a l l t h r o t t l e linkage a n d adjust, as neces-
sary.
(21) I n s t a l l distributor cap and wires.
(22) I n s t a l l fuel lines, a l t e r n a t o r a n d drive belt.
T i g h t e n alternator m o u n t i n g bolt t o 4 1 N - m (30 f t .
lbs.) torque a n d adjusting strap bolt t o 23 N - m (200
CEMENT CYLINDER i n . lbs.) torque. See Group 7, Cooling System for ad-
BLOCK SURFACE AND j u s t i n g t h e belt tension.
BOTH SIDES OF (23) I n s t a l l collared studs i n cylinder head. T i g h t e n
INTAKE MANIFOLD CYLINDER
END GASKETS to 13 N - m (115 i n . lbs.) torque. Inspect studs to be
HEAD GASKET RP125 certain t h a t collar has bottomed o n cylinder head. I f
not, remove stud and clean and t a p s t u d hole.
Fig. 7 Intake Manifold Sealing
(24) Place new cylinder head cover gaskets i n posi-
(13) Carefully i n s t a l l the front a n d rear i n t a k e t i o n a n d i n s t a l l cylinder head covers. T i g h t e n t o 9
manifold gaskets. N-m (80 i n . lbs.) torque.
(14) Place a drop (approximately 1/4 i n c h diameter) (25) I n s t a l l closed crankcase v e n t i l a t i o n system a n d
of rubber sealer, or equivalent, onto each of t h e evaporation control system.
F O U R m a n i f o l d to cylinder head gasket corners. (26) F i l l cooling system (see Group 7, Cooling Sys-
(15) Carefully lower intake manifold i n t o position t e m for proper procedure).
on the cylinder block and cylinder heads. A f t e r i n - (27) Connect t h e battery negative cable.
take m a n i f o l d is i n place, inspect to m a k e sure seals
are i n place.
 VALVES AND VALVE SPRINGS
The valves are arranged i n l i n e a n d inclined 18°.
The rocker shaft support a n d t h e valve guides are
cast i n t e g r a l w i t h the heads.
(a) I n s t a l l sleeve Tool C-3973 over valve stem
a n d i n s t a l l valve ( F i g . 11). T h e special sleeve
places t h e valve a t the correct height for checking
w i t h a d i a l indicator.

REMOVAL
(1) W i t h cylinder head removed, compress valve
springs using Tool C-3422-A (Fig. 9).
(2) Remove valve r e t a i n i n g locks, valve spring re-
tainers, valve stem cup seals and valve springs.
(3) Before r e m o v i n g valves, remove any burrs f r o m
valve stem lock grooves t o prevent damage t o t h e
valve guides. Identify valves t o ensure i n s t a l l a t i o n i n
o r i g i n a l location.

Fig. 11 Positioning Valve with Tool C-3973

(b) A t t a c h d i a l indicator Tool C-3339 to c y l i n -
der head and set i t a t r i g h t angle of valve stem be-
i n g measured (Fig. 12).

Fig. 9 Compress Valve Springs with Tool C-3422A

VALVE INSPECTION
Clean valves t h o r o u g h l y a n d discard burned,
warped and cracked valves.
Measure valve stems for wear. N e w stem diameters
should measure (Fig. 10):

Intake . . . 9.449 to 9.474 mm Fig. 12 Measuring Valve Guide Wear

(0.372 to 0.373 inch)
(c) Move valve to and from the indicator. T h e
. . 9.423 to 9.449 mm t o t a l d i a l indicator r e a d i n g should not exceed 0.432
(0.371 to 0.372 inch) m m (0.017 inch). Ream t h e guides for valves w i t h
oversize stems i f dial indicator reading is excessive
If wear exceeds 0.051 mm or i f the stems are scuffed or scored.
(0.002 inch), replace valve Service valves w i t h oversize stems are available
(Fig. 13).
J9009-109
Slowly t u r n reamer b y h a n d and clean guide thor-
oughly before i n s t a l l i n g n e w valve.
Fig. 10 Valve Stem Diameters
Remove carbon and v a r n i s h deposits f r o m inside o f CAUTION: DO NOT attempt to ream the valve
valve guides w i t h a reliable guide cleaner. guides from standard directly to 0.762 mm (0.030
inch). Use step procedure of 0.127, 0.381 and 0.762
Measure valve stem guide clearance as follows:
mm (0.005, 0.015 and 0.030 inch) so the valve
guides may be reamed true in relation to the valve
seat.
 VALVE SEATS
Reamer Reamer Valve Guide
Tool No. Oversize Size
CAUTION: DO NOT unshroud valves during valve
C-3433 0.127 mm 9.63-9.65 mm
(0.005 inch) (0.379-0.380 inch) seat refacing (Fig. 16).

C-3430 0.381 mm 9.88-9.91 mm

(0.015 inch) (0.389-0.390 inch)

C-3427 0.762 mm 10.26-10.29 mm

(0.030 inch) (0.404-0.405 inch)

J9009-100

Fig. 13 Reamer Sizes

REFACING VALVES AND VALVE SEATS
The i n t a k e and exhaust valves have a 44-1/2° t o
45° face angle. The valve seats have a 45° t o 45-1/2°
face angle (Fig. 14).
D

Fig. 16 Refacing Valve Seats

(1) W h e n refacing valve seats, i t is i m p o r t a n t t h a t
the correct size valve guide pilot be used for reseat-
i n g stones. A t r u e and complete surface m u s t be ob-
tained.
(2) Measure t h e concentricity of valve seat u s i n g
A-SEAT WIDTH (INTAKE 1/16 (1.587 mm) TO 3/32 (2.381 mm) INCH
EXHAUST: (.O8CK10O INCH) - (2-15 mm) d i a l indicator No. 13725. Total runout should not ex-
B-FACE ANGLE (INTAKE & EXHAUST: 4 4 ^ - 4 5 ° ) ceed 0.051 m m (0.002 inch) t o t a l indicator reading.
C-SEAT ANGLE (INTAKE & EXHAUST: 45°-45M°) (3) Inspect the valve seat w i t h Prussian blue t o de-
D-CONTACT SURFACE
PU605 t e r m i n e where t h e valve contacts t h e seat. To do
t h i s , coat valve seat L I G H T L Y w i t h Prussian blue
Fig. 14 Valve Face and Seat Angles t h e n set valve i n place. Rotate the valve w i t h l i g h t
pressure. I f the blue is transferred to t h e center o f
VALVES
valve face, contact is satisfactory. I f the blue is t r a n s -
Inspect t h e r e m a i n i n g m a r g i n after the valves are
ferred t o the top edge o f valve face, lower valve seat
refaced (Fig. 15). Valves w i t h less t h a n 1.190 m m (3/
w i t h a 15° stone. I f the blue is transferred t o b o t t o m
64 inch) m a r g i n should be discarded.
edge o f valve face raise valve seat w i t h a 60° stone.
(4) W h e n 'seat is properly positioned t h e w i d t h o f
i n t a k e seats should be 1.587 to 2.381 m m (1/16 t o 3/
INTAKE EXHAUST 32 inch). The w i d t h of t h e exhaust seats should be
VALVE VALVE 2.00-2.50 m m (0.080-0.100 inch).
FACE'
TESTING VALVE SPRINGS
(1) Whenever valves have been removed for inspec-
t i o n , reconditioning or replacement, valve springs
•STEM*
should be tested. A s a n example t h e compression
l e n g t h o f the spring t o be tested is 1-5/16 i n c h . T u r n
table o f Tool C-647 u n t i l surface is i n l i n e w i t h t h e
VALVE SPRING 1-5/16 i n c h m a r k on the threaded stud a n d the zero
RETAINER LOCK m a r k to the front (Fig. 17). Place spring over stud on
GROOVES
the table and l i f t compressing lever to set tone de-
vice. P u l l on torque wrench u n t i l p i n g is heard. T a k e
RP129 reading o n torque wrench a t this i n s t a n t . M u l t i p l y
t h i s reading by two. This w i l l give the s p r i n g load a t
Fig. 15 Intake and Exhaust Valves test l e n g t h . Fractional measurements are indicated
on the table for finer adjustments. Refer t o specifica-

RF259
Fig. 17 Testing Valve Spring for Compressed
Length with Tool C-647
tions t o o b t a i n specified height a n d allowable ten-
sions. Discard t h e springs t h a t do n o t meet
specifications.
(2) Inspect each valve spring for squareness w i t h a
steel square a n d surface plate, test springs from both
ends (Fig. 18). I f t h e s p r i n g is more t h a n 1.984 m m
(5/64 inch) out-of-square, i n s t a l l a new spring.
~~ VALVE SPRING
SQUARE
RF180
Fig. 18 Checking Valve Spring for Squareness
INSTALLATION
CAUTION: Installing the wrong exhaust valve spring
in engines with positive rotators can cause severe
engine damage. Refer to specifications for proper
identification.
(1) Coat valve stems w i t h l u b r i c a t i o n o i l and insert
t h e m i n cylinder head.
(2) I f valves or seats are reground, check valve
stem height w i t h Tool C-3968 (Fig. 19). I f valve is
too long, g r i n d off the t i p u n t i l l e n g t h is w i t h i n l i m -
its. E n g i n e i s e q u i p p e d w i t h e x h a u s t v a l v e r o t a -
tors, d o n o t g r i n d exhaust valve stem t i p .
TOOL
Fig. 19 Measuring Valve Stem Length with Tool
C-396B
(3) I n s t a l l new seals on a l l valve stems a n d over
valve guides ( F i g . 20). I n s t a l l valve springs a n d
valve retainers.
RETAINER
SPRING
INTAKE VALVE
RH150A
Fig. 20 Installing Valve, Cup Seal, Spring and
Retainer
(4) Compress valve springs w i t h Tool C-3422-A, i n -
s t a l l locks and release tool. I f valves and/or seats are
reground, measure t h e installed height of springs,
make sure measurement is t a k e n from bottom of
spring seat i n cylinder head t o t h e bottom surface of
spring retainer ( i f spacers a r e installed, measure
f r o m t h e top o f spacer). I f h e i g h t is greater t h a n
42.86 m m (1-11/16 inches), i n s t a l l a 1.587 m m (1/16
inch) spacer i n head counterbore t o b r i n g s p r i n g
h e i g h t back to n o r m a l 41.27 t o 42.86 m m (1-5/8 t o 1-
11/16 inch). Exhaust valve springs w i t h positive ro-
tators should have a length o f 36.8-38.1 m m (1.45-
1.51 inch) w h e n t h e valve is closed.
REPLACE VALVE STEM SHIELDS OR VALVE
SPRINGS (CYLINDER HEAD NOT REMOVED)
(1) Set engine basic t i m i n g to T D C and remove A i r
Cleaner.
(2) Remove cylinder head covers and spark plugs.
(3) Remove coil w i r e from d i s t r i b u t o r and secure to
good ground to prevent engine f r o m s t a r t i n g .
(4) U s i n g suitable socket and flex handle at crank-
shaft pulley r e t a i n i n g bolt, t u r n engine so the # 1
piston is at Top Dead Center on the compression
stroke.
(5) Remove rocker arms w i t h rocker shaft and i n -
s t a l l a d u m m y shaft. The rocker arms should not be
disturbed and left on shaft.
(6) W i t h a i r hose attached to adapter tool C-3907
installed i n # 1 spark p l u g hole, apply 620.5 to 689
k P a (90 to 100 psi) a i r pressure.
(7) U s i n g Tool C-3906 or C-4228 compress valve
s p r i n g and remove retainer valve locks and valve
spring.
(8) I n s t a l l seals on the exhaust valve stem and po-
s i t i o n down against valve guides. Fig. 1 Roller Tappets Aligning Yoke and Retainer
(9) The i n t a k e valve stem seals should be pushed
f i r m l y and squarely over the valve guide using the engine reaches n o r m a l operating temperature. A l l o w
valve stem as a guide. DO N O T FORCE seal against 5 m i n u t e s to stabilize o i l level, check dipstick.
top of guide. W h e n i n s t a l l i n g the valve retainer
OIL LEVEL TOO HIGH
locks, compress the s p r i n g only enough to i n s t a l l the
I f o i l level is above the F U L L m a r k on dipstick, i t
locks.
is possible for the connecting rods to dip i n t o t h e o i l
(10) Follow the same procedure on the r e m a i n i n g 5
w h i l e engine is r u n n i n g and create foam. Foam i n o i l
cylinders using the f i r i n g sequence 1-6-5-4-3-2. M a k e
pan w o u l d be fed to t h e h y d r a u l i c tappets by t h e o i l
sure piston i n cylinder is at T D C on the valve spring
p u m p causing t h e m to lose l e n g t h and allow valves
t h a t is being removed.
to seat n o i s i l y .
(11) Remove adapter Tool 3907.
(12) Remove d u m m y shaft a n d i n s t a l l rocker shaft OIL LEVEL TOO LOW
w i t h rocker arms. Low o i l level m a y allow o i l p u m p to take i n a i r
(13) I n s t a l l covers and coil w i r e to distributor. w h i c h w h e n fed to t h e tappets, causes t h e m to lose
(14) I n s t a l l air cleaner. l e n g t h a n d allows valves to seat noisily. A n y leaks
(15) Road test vehicle. on i n t a k e side of o i l p u m p t h r o u g h w h i c h a i r can be
d r a w n w i l l create t h e same tappet action. Check t h e
HYDRAULIC TAPPETS
l u b r i c a t i o n system f r o m the i n t a k e strainer to t h e
V a l v e t r a i n modifications include roller tappet as- p u m p cover, i n c l u d i n g the r e l i e f valve retainer cap.
semblies, a l i g n i n g yokes and yoke retainers. W h e n tappet noise is due to aeration, i t may be i n -
Roller tappet a l i g n m e n t is m a i n t a i n e d by machined t e r m i t t e n t or constant, and u s u a l l y more t h a n one
flats on tappet body being f i t t e d ( i n pairs)into six tappet w i l l be noisy. W h e n o i l level and leaks have
a l i g n i n g yokes. The yokes are secured by an align- been corrected, engine should be operated at fast idle
m e n t yoke retainer (Fig. 1). for sufficient t i m e to allow a l l of the air inside of t h e
Before disassembling any p a r t of the engine to cor- tappets to be bled out.
rect tappet noise, read the o i l pressure at the gauge
(install a reliable gauge at pressure sending u n i t ) . TAPPET NOISE DIAGNOSIS
The pressure should be between 207 to 552 kPa (30 (1) To determine source of tappet noise,operate en-
and 80 psi) at 2000 R.P.M. I f vehicle has no o i l pres- gine at idle w i t h cylinder head covers removed.
sure gauge, check t h e oil level i n the o i l pan. (2) Feel each valve s p r i n g or rocker a r m to detect
The oil level i n t h e pan should never be above the noisy tappet. The noisy tappet w i l l cause the affected
F U L L m a r k on dipstick, or below the A D D O I L
spring and/or rocker a r m to v i b r a t e or feel r o u g h i n
m a r k . E i t h e r of these two conditions could be respon-
operation.
sible for noisy tappets. Check t h e o i l level after the
 W o r n valve guides or cocked s p r i n g s are some- (3) I f plunger shows signs o f scoring or wear a n d
times mistaken for noisy tappets. If such is the valve is p i t t e d , or i f valve seat o n end o f plunger i n -
case, noise may be dampened b y applying side dicates a n y condition t h a t w o u l d prevent valve from
t h r u s t o n the valve spring. I f n o i s e i s not appre- seating, i n s t a l l a n e w tappet assembly.
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 the noise is in (4) Assemble tappets (Fig. 2).
the tappet. I n s p e c t t h e r o c k e r a r m p u s h rod
PLUNGER PLUNGER
sockets a n d p u s h r o d e n d s for w e a r . SPRING RETAINER
CHECK
(3) Valve tappet noise ranges from l i g h t noise t o a BALL SPRING CLIP
heavy click. A l i g h t noise is usually caused b y exces-
sive leak down a r o u n d t h e u n i t plunger w h i c h w i l l
necessitate replacing t h e tappet, o r b y t h e plunger ROLLER
TAPPET
p a r t i a l l y s t i c k i n g i n t h e tappet body cylinder. A
BODY
heavy click is caused either b y a tappet check valve CHECK VALVE PLUNGER
not seating, or b y foreign particles becoming wedged SPRING CAP RK637
between t h e p l u n g e r a n d t h e tappet body, causing
the plunger t o stick i n t h e down position. T h i s heavy Fig. 2 Hydraulic Tappet Assembly
click w i l l be accompanied b y excessive clearance be- INSTALLATION
tween the valve stem a n d rocker a r m as valve closes. (1) L u b r i c a t e tappets.
I n either case, tappet assembly should be removed (2) I n s t a l l tappets i n t h e i r o r i g i n a l positions.
for inspection and cleaning. (3) W i t h roller tappets, i n s t a l l a l i g n i n g yokes w i t h
A R R O W t o w a r d camshaft (Fig. 1).
REMOVAL
(4) W i t h roller tappets, i n s t a l l yoke retainer a n d
(1) Remove valve cover a n d rocker assembly a n d
t i g h t e n bolts t o 23 N m (200 i n . lbs.) torque and i n -
#

push rods a n d i d e n t i f y push rods t o ensure i n s t a l l a -

s t a l l i n t a k e manifold (Fig. 1).
t i o n i n o r i g i n a l location.
(5) I n s t a l l push rods i n o r i g i n a l positions.
(2) Remove i n t a k e m a n i f o l d , yoke retainer a n d
(6) I n s t a l l rocker a r m and shaft assembly.
a l i g n i n g yokes (Fig. 1).
(7) I n s t a l l valve cover.
(3) Slide Tool C-4129 t h r o u g h opening i n cylinder
(8) S t a r t and operate engine. W a r m u p to n o r j m a l
head and seat tool f i r m l y i n t h e head o f tappet.
(4) P u l l tappet out o f bore w i t h a t w i s t i n g m o t i o n . operating temperature.
I f a l l tappets are t o be removed, identify tappets t o
CAUTION: To prevent damage to valve mechanism,
ensure i n s t a l l a t i o n i n o r i g i n a l location.
engine must not be run above fast idle until all hy-
(5) I f the tappet or bore i n cylinder block is scored,
draulic tappets have filled with oil and have become
scuffed, or shows signs o f s t i c k i n g , r e a m the bore to
quiet.
next oversize and replace w i t h oversize tappet.

CAUTION: 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
work on one tappet at a time to avoid mixing of
parts.Mixed parts are not compatible. Do not disas-
semble a tappet on a dirty work bench.
DISASSEMBLY
(1) Pry out plunger r e t a i n e r s p r i n g clip.
(2) Clean v a r n i s h deposits f r o m inside o f tappet
body above plunger cap.
(3) I n v e r t tappet body a n d remove plunger cap,
plunger, check valve, check valve spring, check valve
retainer a n d plunger spring. Check valve could be
flat or ball.
CLEANING AND ASSEMBLY
(1) Clean a l l tappet parts i n a solvent t h a t w i l l re-
move a l l v a r n i s h and carbon.
(2) Replace tappets t h a t are u n f i t for f u r t h e r ser-
vice w i t h new assemblies.
VALVE TIMING
(1) T u r n crankshaft u n t i l t h e # 6 exhaust valve is
closing a n d # 6 i n t a k e valve is opening.
(2) I n s e r t a 6.350 m m (1/4 inch) spacer between
rocker a r m pad and stem t i p o f # 1 i n t a k e valve. A l -
low s p r i n g load to bleed tappet down g i v i n g i n effect
a solid tappet.
(3) I n s t a l l a d i a l indicator so plunger contacts valve
spring r e t a i n e r as nearly perpendicular as possible.
Zero t h e indicator.
(4) Rotate t h e crankshaft clockwise (normal r u n -
n i n g direction) u n t i l t h e valve has lifted 0.254 m m
(0.010 inch).
CAUTION: Do not turn crankshaft any further clock-
wise as valve spring might bottom and result in se-
rious damage.
 (5) The t i m i n g o f t h e crankshaft pulley should now
read f r o m 10° before top dead center t o 2° after top
dead center. Remove spacer. I f reading is not w i t h i n
specified l i m i t s :
(a) Check sprocket index marks.
(b) Inspect t i m i n g chain for wear.
(c) Check accuracy o f DC m a r k on t i m i n g i n d i -
cator.

TIMING CHAIN COVER, OIL SEAL AND CHAIN

COVER REMOVAL
(1) D r a i n cooling system.
(2) Refer to Group 7, Cooling System for procedure
to remove w a t e r p u m p .
Fig. 4 Measuring Timing Chain Wear and Stretch
(3) Remove power steering pump. (4) I n s t a l l a new t i m i n g chain, i f its movement ex-
(4) Remove p u l l e y f r o m v i b r a t i o n damper and bolt ceeds 3.175mm (1/8 inch).
and washer securing v i b r a t i o n damper on crankshaft. (5) I f c h a i n is not satisfactory, remove camshaft
(5) I n s t a l l bar f r o m Tool (C-3688) and screw from sprocket a t t a c h i n g cup washer, and remove t i m i n g
Tool (C-3732A) a n d p u l l v i b r a t i o n damper from end c h a i n w i t h crankshaft and camshaft sprockets.
of crankshaft (Fig. 3). (6) Place both camshaft sprocket and crankshaft
(6) Remove fuel lines. sprocket o n the bench w i t h t i m i n g m a r k s o n exact
(7) Loosen o i l p a n bolts a n d remove the front bolt i m a g i n a r y center line t h r o u g h both camshaft a n d
at each side. crankshaft bores.
(8) Remove c h a i n case cover and gasket u s i n g ex- (7) Place t i m i n g chain around b o t h sprockets.
treme c a u t i o n t o avoid damaging o i l pan gasket. (8) T u r n crankshaft and camshaft t o l i n e u p w i t h
keyway location i n crankshaft sprocket and i n cam-
shaft sprocket.
(9) L i f t sprockets and chain (keep sprockets t i g h t
against t h e chain i n position as described).
(10) Slide both sprockets evenly over t h e i r respec-
t i v e shafts and use a s t r a i g h t edge to check a l i g n -
m e n t o f t i m i n g m a r k s (Fig. 5).
(11) I n s t a l l t h e cup washer, and camshaft bolt.
T i g h t e n t h e bolt t o 47 N n n (35 ft. lbs.) torque.
(12) Check camshaft for O.OSlto 0.0152 m m (0.002
to 0.006 inch) end play w i t h a new t h r u s t plate a n d
up t o 0.254 m m (0.010 inch) end play w i t h a used
t h r u s t plate. I f not w i t h i n these l i m i t s i n s t a l l a new
Fig. 3 Removing Vibration Damper Assembly
t h r u s t plate.
MEASURING TIMING CHAIN FOR STRETCH
(1) Place a scale next to t i m i n g chain so t h a t any
movement o f c h a i n m a y be measured.
(2) Place a torque wrench and socket over camshaft
sprocket a t t a c h i n g b o l t and apply torque i n the direc-
t i o n of crankshaft r o t a t i o n t o take up slack; 4 1 N n n
(30 ft. lbs.) ( w i t h cylinder head installed) or 20 N n n
(15 ft. lbs.) (cylinder heads removed). W i t h a torque
applied t o t h e camshaft sprocket bolt, crankshaft
should not be p e r m i t t e d to move. I t may be necessary
to block crankshaft t o prevent rotation.
(3) H o l d i n g a scale w i t h dimensional reading even
w i t h edge of a chain l i n k , apply torque i n the reverse
direction 14 N n n (30 ft. lbs.) ( w i t h cylinder heads i n -
stalled) or 20 N n n (15 f t . lbs.) (cylinder heads re- Fig. 5 Alignment of Timing Marks
moved) and note a m o u n t of chain movement (Fig. 4).
 TIMING CHAIN COVER EXTERNAL OIL SEAL
REMOVAL
(1) Disconnect battery.
(2) Loosen and remove belts from crankshaft p u l -
ley.
(3) Remove radiator shroud retainer bolts and set
shroud back over engine.
(4) Remove fan and shroud f r o m engine.
(5) Remove crankshaft pulley and v i b r a t i o n damper
bolt and washer from end of crankshaft.
(6) I n s t a l l b a r f r o m tool (C-3688) and screw from
tool (C-3732A) and p u l l v i b r a t i o n damper from end o f
crankshaft (Fig. 3).
(7) U s i n g a suitable tool behind the lips of the o i l
seal p r y outward, being careful n o t t o damage t h e
crankshaft seal surface o f cover (Fig. 6).
Fig. 6 Removing Oil Seal
INSTALLATION
(1) I n s t a l l new seal b y i n s t a l l i n g the threaded shaft
p a r t o f tool (C-4251) into t h e threads o f the crank-
shaft.
(2) Place seal i n t o opening w i t h seal s p r i n g towards
the inside of the engine.
(3) Place t h e i n s t a l l i n g adapter C-4251-3 w i t h t h e
t h r u s t bearing and n u t on the shaft. T i g h t e n the n u t
u n t i l tool is flush w i t h t h e t i m i n g chain cover (Fig.
7).
Fig. 7 Installing Oil Seal
(4) I n s t a l l v i b r a t i o n damper u s i n g tool C-3688 (Fig.
8).
(5) I n s t a l l retainer bolt and washer and t i g h t e n the
bolt to 183 N«m (135 f t . lbs.) torque.
(6) I n s t a l l pulley on v i b r a t i o n damper a n d t i g h t e n
the bolt to 23 N*m (200 i n . lbs.) torque.
(7) Set radiator shroud back over engine a n d i n -
s t a l l fan and belts.
(8) I n s t a l l radiator shroud t o radiator.
(9) Connect battery.
COVER INSTALLATION
(1) Be sure m a t i n g surfaces o f chain case cover a n d
cylinder block are clean and free from b u r r s .
(2) U s i n g a new cover gasket, carefully i n s t a l l
chain case cover to avoid damaging o i l pan gasket. A
3.175 m m (1/8 inch) diameter bead of R T V sealer, or
equivalent is recommended on t h e o i l pan gasket. D o
not tighten bolts at this time.
(3) Lubricate seal l i p w i t h l u b r i p l a t e , or equivalent.
Position damper h u b slot i n crankshaft. D a m p e r w i l l
act as a pilot for the crankshaft seal.
(4) Place i n s t a l l i n g tool, p a r t o f Puller set Tool C-
3688 i n position a n d press v i b r a t i o n damper on
crankshaft (Fig. 8).
Fig. 8 Installing Vibration Damper with Tool C-3688
(5) Tighten chain case cover bolts to 4 1 N«m (30 f t .
lbs.) torque. Then t i g h t e n o i l p a n bolts t o 23 N»m
(200 i n . lbs.) torque.
(6) I n s t a l l v i b r a t i o n damper retainer bolt w i t h
washer and t i g h t e n to 183 N n n (135 ft. lbs.) torque.
(7) Position pulley on v i b r a t i o n damper a n d attach
w i t h bolts and lockwashers. T i g h t e n bolts t o 23 N»m
(200 i n . lbs.) torque.
(8) I n s t a l l fuel lines.
(9) I n s t a l l water pump and housing assembly u s i n g
new gaskets. Tighten bolts to 4 1 N n n (30 f t . lbs.)
torque.
(10) I n s t a l l power steering p u m p .
(11) I n s t a l l fan and belt, hoses and close drains.
(12) I n s t a l l radiator shroud.
(13) F i l l cooling system (see Group 7, Cooling Sys-
t e m for the proper procedure).
CAMSHAFT (ENGINE REMOVED FROM VEHICLE)
REMOVAL
The camshaft has a n i n t e g r a l o i l p u m p and distrib-
u t o r drive gear (Fig. 9).
DOUBLE ROLLER CHAIN
SPROCKET
Fig. 9 Camshaft and Dual Sprocket Assembly
(1) Remove i n t a k e manifold.
(2) Remove t h e cylinder head covers.
(3) Remove the t i m i n g case cover and t i m i n g chain.
(4) Remove rocker a r m and shaft assemblies.
(5) Remove push rods a n d tappets; identify each
p a r t so i t can be installed i n t h e o r i g i n a l location.
(6) Remove distributor a n d l i f t o u t t h e o i l p u m p
and d i s t r i b u t o r drive shaft.
(7) Remove camshaft t h r u s t plate; note location o f
oil t a b (Fig. 10).
Fig. 10 Timing Chain Oil Tab Installation
(8) I n s t a l l a long bolt into front of camshaft to fa-
cilitate removal of the camshaft. Remove camshaft,
being careful not to damage cam b e a r i n g w i t h t h e
cam lobes.
To reduce i n t e r n a l leakage a n d help m a i n t a i n
higher o i l pressure a t idle, c u p plugs have been
pressed i n t o t h e o i l galleries b e h i n d t h e cam-
s h a f t t h r u s t p l a t e ( F i g . 11).
Fig. 11 Location of Cup Plugs in Oil Galleries
INSTALLATION
(1) Lubricate camshaft lobes and camshaft bearing
journals and insert t h e camshaft to w i t h i n 5 1 m m (2
inches) of its f i n a l position i n cylinder block.
W h e n e v e r a n e n g i n e h a s b e e n r e b u i l t and/or a
n e w c a m s h a f t and/or n e w t a p p e t s h a v e b e e n i n -
stalled, a d d one p i n t o f M O P A R Crankcase Con-
ditioner, o r equivalent t o engine o i l t o a i d i n
break-in. T h e o i l m i x t u r e should be left i n en-
g i n e f o r a m i n i m u m o f 805 k m (500 m i l e s ) , a n d
drained a t the next n o r m a l o i l change.
(2) I n s t a l l Tool C-3509 w i t h tongue back o f distrib-
utor drive gear (Fig. 12).
Fig. 12 Camshaft Holding Tool C-3509 (Installed
Position)
(3) H o l d tool i n position w i t h a d i s t r i b u t o r lock-
plate bolt. This tool w i l l r e s t r i c t camshaft from being
pushed i n too far and prevent k n o c k i n g out the welch
 p l u g i n rear o f cylinder block. T o o l s h o u l d r e m a i n
installed u n t i l t h e camshaft a n d crankshaft
s p r o c k e t s a n d timing c h a i n h a v e b e e n i n s t a l l e d .
(4) I n s t a l l camshaft t h r u s t plate and c h a i n o i l tab,
w i t h three bolts (Fig. 10). M a k e s u r e t a n g e n t e r s
l o w e r r i g h t h o l e i n t h r u s t p l a t e . T i g h t e n bolts to
24 N r m (210 i n . lbs.) torque. Top edge o f t a b should
be flat against t h r u s t plate i n order t o catch o i l for
chain lubrication.
(5) Place b o t h camshaft sprocket a n d crankshaft
sprocket o n t h e bench w i t h t i m i n g m a r k s o n exact
i m a g i n a r y center line t h r o u g h both camshaft a n d
crankshaft bores.
Fig. 14 Removal/Installation Camshaft Bearings
(6) Place t i m i n g chain around both sprockets. (Tool C-3132A)
(7) T u r n crankshaft and camshaft t o l i n e u p w i t h
keyway location i n crankshaft sprocket a n d i n cam-
INSTALLATION
(1) I n s t a l l new camshaft bearings w i t h Tool C-
shaft sprocket.
3132-A b y s l i d i n g t h e n e w camshaft bearing shell
(8) L i f t sprockets and chain (keep sprockets t i g h t
over proper adapter.
against t h e c h a i n i n position as described).
(2) Position rear bearing i n the tool. I n s t a l l horse-
(9) Slide b o t h sprockets evenly over t h e i r respective
shoe lock a n d by reversing removal procedure, care-
shafts and use a straight edge t o check a l i g n m e n t of
f u l l y drive bearing shell i n t o place.
t i m i n g m a r k s (Fig. 13).
(3) I n s t a l l r e m a i n i n g bearings i n t h e same manner.
Bearings m u s t be carefully aligned t o b r i n g o i l holes
i n t o f u l l register w i t h o i l passages f r o m t h e m a i n
bearing. Also, No. 2 bearing must index w i t h the o i l
passage t o the left cylinder head and No. 3 b e a r i n g
m u s t index w i t h the o i l passage to t h e r i g h t cylinder
head. I f t h e camshaft b e a r i n g shell o i l holes are n o t
i n exact alignment, remove a n d i n s t a l l t h e m correct-
ly. I n s t a l l a new core hole p l u g a t t h e rear o f cam-
shaft. 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 .

DISTRIBUTOR DRIVE SHAFT BUSHING

Fig. 13 Alignment of Timing Marks REMOVAL

(1) I n s e r t Tool C-3052 i n t o old b u s h i n g and t h r e a d
(10) I n s t a l l t h e cup washer, a n d camshaft bolt.
down u n t i l a t i g h t fit is obtained (Fig. 15).
T i g h t e n bolt t o 47 N-m (35 ft. lbs.) torque.
(2) H o l d p u l l e r screw a n d t i g h t e n p u l l e r n u t u n t i l
(11) Measure camshaft end play. Refer t o Specifica-
b u s h i n g i s removed.
tions for proper clearance. I f not w i t h i n l i m i t s i n s t a l l
a new t h r u s t plate.
(12) Each tappet reused must be i n s t a l l e d i n t h e
same position from w h i c h i t was removed. Tappets
m u s t have a definite crown. W h e n c a m s h a f t i s r e -
placed, a l l o f the tappets must be replaced.

CAMSHAFT BEARINGS (ENGINE REMOVED FROM

VEHICLE)

REMOVAL
(1) W i t h engine completely disassembled, d r i v e out
rear cam b e a r i n g core hole p l u g .
(2) I n s t a l l proper size adapters a n d horse shoe Fig. 15 Removal Distributor Driveshaft Bushing
washers (part o f Tool C-3132-A) a t back o f each bear- (Tool C-3052)
i n g shell. D r i v e out bearing shells (Fig. 14).
9 - 24 3.9L ENGINE •
INSTALLATION
(1) Slide new bushing over b u r n i s h i n g end o f Tool
C-3053 a n d insert the tool a n d b u s h i n g i n t o the bore.
(2) D r i v e bushing a n d tool i n t o position, using a
h a m m e r (Fig. 16).

Fig. 18 Position of Installed Distributor Drive Gear

RH164
INSTALLATION (DISTRIBUTOR)
Fig. 16 Installing Distributor Driveshaft Bushing (1) H o l d t h e d i s t r i b u t o r over t h e m o u n t i n g pad on
(Tool C-3053) cylinder block.
(2) T u r n rotor u n t i l i t points to approximate loca-
(3) A s t h e burnisher is p u l l e d t h r o u g h t h e b u s h i n g
t i o n o f No. 1 tower t e r m i n a l i n d i s t r i b u t o r cap (Fig.
by t i g h t e n i n g t h e p u l l e r n u t , t h e bushing is ex-
19).
panded t i g h t i n block a n d burnished to correct size,
(3) Place distributor O-Ring i n position.
(Fig. 17). D o n o t r e a m t h i s b u s h i n g .
(4) Lower t h e d i s t r i b u t o r a n d engage t h e shaft i n
the slot of distributor drive shaft gear.
BUSHING
3.9L SIX CYLINDER ENGINE
DISTRIBUTOR - CLOCKWISE ROTATION
FIRING ORDER- 1 - 6 - 5 - 4 - 3 - 2
LEFT BANK

RIGHT BANK
Fig. 17 Burnishing Distributor Driveshaft Bushing
RP135
DISTRIBUTOR TIMING
Before i n s t a l l i n g the d i s t r i b u t o r and o i l p u m p drive Fig. 19 Distributor with Rotor Positioned Under No.
shaft, t i m e engine as follows: 1 Tower of Cap
(1) Rotate crankshaft u n t i l No. 1 cylinder is a t top CYLINDER BLOCK
dead center on t h e firing stroke.
(2) W h e n i n t h i s position, t h e t i m i n g m a r k on v i -
PISTON REMOVAL
b r a t i o n damper should be under " O " on t h e t i m i n g
(1) Remove top ridge of cylinder bores w i t h are l i -
indicator.
able ridge reamer before removing pistons f r o m cyl-
(3) Coat shaft a n d drive gear w i t h engine o i l . I n -
inder block. B e s u r e t o k e e p t o p s o f p i s t o n s
s t a l l t h e shaft so t h a t after gear spirals i n t o place. I t
covered d u r i n g this operation. Pistons a n d con-
w i l l index w i t h t h e o i l p u m p shaft, so slot i n top of
necting rods must be removed f r o m t o p o f cylin-
drive gear w i l l be aligned i n a direction (forward) to-
der block. When removing piston and
wards left front i n t a k e m a n i f o l d a t t a c h i n g bolt hole
connecting r o d assemblies f r o m t h e engine, r o -
(Fig. 18).
t a t e c r a n k s h a f t so t h a t e a c h c o n n e c t i n g r o d i s
centered i n cylinder bore.
 (2) Inspect connecting rods and connecting rod caps
for cylinder i d e n t i f i c a t i o n . Identify t h e m , i f neces-
sary.
(3) Remove connecting r o d cap. I n s t a l l connecting
rod bolt guide set on connecting rod bolts. Push each
piston a n d r o d assembly o u t o f cylinder bore. B e
careful not t o n i c k crankshaft journals.
(4) A f t e r r e m o v a l , i n s t a l l bearing cap o n t h e m a t -
i n g rod.
CLEANING AND INSPECTION
(1) Clean c y l i n d e r block thoroughly and check a l l
core hole plugs for evidence of leaking.
(2) I f n e w core plugs a r e installed, see "Engine
Core O i l a n d C a m Plugs".
(3) E x a m i n e block for cracks or fractures.
CYLINDER BORE INSPECTION
The cylinder w a l l s should be checked f o r o u t of-
r o u n d a n d taper w i t h Tool C-119. I f t h e cylinder
bores show more t h a n 0.127 m m (0.005 inch) out-of-
r o u n d , or a taper of more t h a n 0.254 m m (0.010
inch), or i f t h e cylinder walls are badly scuffed or
scored, the c y l i n d e r block should be bored and honed,
and new pistons a n d r i n g s fitted. Whatever type o f
b o r i n g equipment i s used, boring and h o n i n g opera-
t i o n should be closely coordinated w i t h the fitting o f
pistons and r i n g s i n order t h a t specified clearances
may be m a i n t a i n e d .
INSTALLATION
Thoroughly clean inside of cup p l u g hole i n c y l i n -
der block or head. Be sure t o remove o l d sealer.
L i g h t l y coat inside o f cup p l u g hole w i t h Loctite S t u d
N ' B e a r i n g M o u n t , or equivalent. M a k e c e r t a i n t h e
new p l u g is cleaned o f a l l o i l or grease. U s i n g proper
drive p l u g , drive p l u g into hole so t h a t t h e sharp
edge o f t h e p l u g is a t least 0.5 m m (0.02 inch) inside
t h e lead-in chamfer.
I t i s not necessary to w a i t for c u r i n g of the sealant.
The cooling system can be filled a n d t h e vehicle
placed i n service immediately.
PISTONS, PINS AND RINGS
The pistons are cam ground so t h a t the diameter a t
the p i n boss is less t h a n i t s diameter across t h e
t h r u s t face. This allows for expansion under n o r m a l
operating conditions. Under operating temperatures,
expansion forces t h e p i n bosses away f r o m each
other, thus, causing t h e piston t o assume a more
nearly r o u n d shape. I t is i m p o r t a n t t h a t pistons be
checked for taper and e l l i p t i c a l shape before they are
fitted i n t o the cylinder bore (Fig. 2).
3.886-3.891

ENGINE CORE OIL AND CAM PLUGS

REMOVAL
U s i n g a b l u n t tool such as a d r i f t or a screwdriver
and a hammer, s t r i k e t h e bottom edge o f the cup THE DIAMETER (D)
p l u g . W i t h t h e cup p l u g rotated, grasp firmly w i t h ELLIPTICAL SHAPE OF THE PISTON SHOULD BE .000 TO .0006
pliers or other suitable too l a n d remove p l u g (Fig. 1). SKIRT SHOULD BE .010 (.254mm) TO (.0152mm) IN.
.012 (.304mm) IN. LESS AT DIAMETER LARGER THAN (C)
(A) THAN ACROSS THE THRUST
CAUTION: Do not drive cup plug into the casting as
FACES AT DIAMETER (B) 8909-57
restricted cooling can result and cause serious en-
gine problems. Fig. 2 Piston Measurements
CYLINDER / / FINISHED PISTONS
BLOCK — A l l pistons are machined t o t h e same w e i g h t i n
/ grams, regardless of oversize, to m a i n t a i n piston bal-
/ -
ance. F o r cylinder bores w h i c h have been honed or
SECOND bored new pistons are furnished w i t h fitted pins,
fc§£^ y REMOVE PLUG
available i n standard and oversize—0.508 m m (0.020
WITH PLIERS
inch).
FIRST
STRIKE HERE FITTING PISTONS
WITH HAMMER
Piston and cylinder w a l l must be clean and dry.
Specified clearance between the piston and the c y l i n -
DRIFT der w a l l is 0.0127 to 0.0381 m m (0.0005 t o 0.0015
RN297 inch).
Piston diameter should be measured a t the top o f
Fig. 1 Core Hole Plug Removal s k i r t 90° to piston p i n axis. Cylinder bores should be
measured halfway down the cylinder bore and trans-
verse t o t h e engine crankshaft center l i n e .
Pistons a n d c y l i n d e r bores s h o u l d b e mea-
s u r e d a t n o r m a l r o o m t e m p e r a t u r e , 21°C (70°F).
PISTON PINS
The p i s t o n p i n rotates i n t h e piston only, a n d is re-
t a i n e d b y t h e press interference f i t o f the piston p i n
i n t h e connecting rod.
FITTING RINGS
(1) Measure piston r i n g gap about t w o inches f r o m
bottom o f cylinder bore i n w h i c h i t is t o befitted ( A n
i n v e r t e d piston can be used to push the r i n g s down t o
insure p o s i t i o n i n g r i n g s squarely i n the cylinder bore
before measuring).
(2) I n s e r t feeler stock i n t h e gap. T h e r i n g gap
should be between 0.254 and 0.508 m m (0.010 and
0.020 inch) for compression rings and 0.381 t o 1.575
m m (0.015 t o 0.062 inch) for o i l r i n g steel r a i l s i n
standard size bores (for new service r i n g s ) . M a x i m u m
gap i n 0.127 m m (0.005 inch) O/S bores should be
0.907 m m (0.036 inch) for compression r i n g s a n d
1.778 m m (0.070 inch) for o i l r i n g steel r a i l s .
(3) Measure side clearance between piston r i n g and
r i n g l a n d (Fig. 3). Clearance should be 0.038 t o 0.076
m m (0.0015 t o 0.003 inch) for t h e top compression
r i n g a n d t h e intermediate r i n g . Steel r a i l service o i l
r i n g should be free i n groove, b u t should not exceed
0.127 m m (0.005 inch) side clearance.
point, a stamped letter " O " , a n oval depression or t h e
w o r d top) i s t o the top o f the piston.
CONNECTING RODS
INSTALLATION PISTON AND CONNECTING
ROD ASSEMBLY
(1) Before i n s t a l l i n g pistons, a n d connecting r o d as-
semblies i n t o the bore, be sure t h a t compression r i n g
gaps are staggered so t h a t n e i t h e r is i n l i n e w i t h o i l
r i n g r a i l gap.
(2) Before i n s t a l l i n g t h e r i n g compressor, m a k e
sure t h e o i l r i n g expander ends are b u t t e d and t h e
r a i l gaps located properly (Fig. 4).
(3) Immerse the piston head a n d r i n g s i n clean en-
gine o i l . Slide the r i n g compressor (Tool C-385) over
the piston and t i g h t e n w i t h the special wrench ( p a r t
of Tool C-385). B e s u r e p o s i t i o n o f r i n g s does n o t
change d u r i n g this operation.
(4) I n s t a l l connecting r o d b o l t protectors on r o d
bolts, t h e l o n g protector should be i n s t a l l e d o n t h e
numbered side of the connecting rod.
(5) Rotate crankshaft so t h a t t h e connecting r o d
j o u r n a l is o n the center o f t h e c y l i n d e r bore. I n s e r t
rod a n d piston i n t o cylinder bore a n d guide rod over
the c r a n k s h a f t j o u r n a l .

PISTON RING FEELER GAUGE

TOP VIEW OF BLOCK

A-EXPANDER GAPS B-RAIL GAPS
IF YOU HAVE FOLLOWED THE
INSTRUCTIONS, THE RING WILL BE
IN THIS POSITION ON THE PISTON.
TOP RAIL GAP-
RH166"

Fig. 3 Measuring Piston Ring Side Clearance

(4) O n the 3.9L engine, the keys o n the spacer ex-
pander m u s t be inserted into the hole i n the o i l r i n g BOTTOM
groove over the piston p i n front boss (Fig. 4). RAIL GAP

(5) A r r a n g e o i l r i n g r a i l gaps on inboard side o f

piston (Top of F i g . 4). ENDS
BUTTING
(6) I n s t a l l compression rings i n middle a n d top
grooves u s i n g R i n g Installer Tool C-4184. Be sure RP137
the compression r i n g identification m a r k (a d r i l l
Fig. 4 Proper Oil Ring Installation
 (6) T a p t h e piston down i n cylinder bore, u s i n g a Undersize Journal Identification Stamp
h a m m e r handle. A t t h e same t i m e , guide connecting
rod i n t o position o n crankshaft j o u r n a l . .001 inch (Rod) Rl-R2-R3-Etc.
.010 inch (Rod) RX
(7) T h e notch or groove o n t o p o f piston m u s t be .001 inch (Main) M1-M2-M3 or M4
p o i n t i n g t o w a r d front o f engine. The larger chamfer .010 inch (Main) MX
of the connecting r o d bore m u s t be installed t o w a r d STEEL STAMP IDENTIFICATION EXAMPLE
R (ROD) AND/OR M (MAIN) FOLLOWED R2 M4
crankshaft j o u r n a l fillet. BY THE ROD OR MAIN NUMBER OR R3
(8) I n s t a l l r o d caps. I n s t a l l n u t s on cleaned a n d
oiled rod bolts and t i g h t e n n u t s t o 6 1 N n n (45ft.lbs.)
torque.

INSTALLATION OF CONNECTING ROD

BEARINGS
F i t a l l rods o n one b a n k u n t i l completed. D O N O T
alternate f r o m one b a n k t o another, because w h e n
t h e rods are assembled to pistons correctly, t h e y are
not interchangeable from one b a n k t o another.
The b e a r i n g caps are n o t interchangeable a n d
should be m a r k e d a t removal t o ensure correct as-
sembly.
Each b e a r i n g cap has a s m a l l " V " groove across the
p a r t i n g face. W h e n i n s t a l l i n g t h e lower bearing
shell, make certain t h a t the " V " groove i n t h e shell
is i n l i n e w i t h t h e " V " groove i n t h e cap. T h i s pro-
vides l u b r i c a t i o n o f t h e cylinder w a l l i n the opposite
bank.
The bearing shells m u s t be installed so t h a t t h e
tangs are i n t h e machined grooves i n t h e rods and
caps.
L i m i t s o f taper or out-of-round o n any crankshaft
j o u r n a l s should be h e l d t o 0.025 m m (0.001 inch).
Bearings are available i n 0.025 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) a n d 0.305 m m (0.012 inch) under-
size. I n s t a l l t h e b e a r i n g s i n p a i r s . D o n o t u s e a
new bearing half w i t h a n o l d bearing half. D o
n o t file t h e r o d s o r b e a r i n g caps.
CRANKSHAFT IDENTIFICATION
A crankshaft w h i c h has one or more connecting rod
or m a i n b e a r i n g j o u r n a l s undersize w i l l be stamped
w i t h 1/4 i n c h letters near t h e notch of t h e No. 6
crankshaft counterweight (Fig. 5).
R X indicates A L L r o d j o u r n a l s are (0.010 inch) u n -
dersize; M X indicates A L L m a i n journals are 0.254
m m (0.010 inch) undersize.
CRANKSHAFT MAIN JOURNALS
The crankshaft j o u r n a l s should be checked for ex-
cessive wear, taper a n d scoring. L i m i t s of taper or
out-of-round on a n y crankshaft journals should be
h e l d to 0.025 m m (0.001 inch). Journal g r i n d i n g
should not exceed 0.305 m m (0.012 inch) under t h e
standard j o u r n a l diameter. D O N O T g r i n d t h r u s t
faces o f No. 3 m a i n bearing. D O N O T nick c r a n k p i n
Fig. 5 Location of Crankshaft Identification on No. 6
Counterweight
or b e a r i n g fillets. A f t e r g r i n d i n g , remove r o u g h edges
f r o m c r a n k s h a f t o i l holes and clean out a l l o i l pas-
sages.
CAUTION: After any journal grind, it is important
that the final paper or cloth polish be in the same
direction as the engine rotates.
CRANKSHAFT MAIN BEARINGS
B e a r i n g caps are n o t interchangeable a n d should
be m a r k e d a t removal to insure correct assembly.
Upper a n d lower bearing halves a r e N O T inter-
changeable. Lower m a i n bearing halves o f No. 1 and
No. 3 are interchangeable.
Upper a n d lower No. 2 bearing halves are flange to
carry t h e crankshaft t h r u s t loads a n d are N O T inter-
changeable w i t h any other bearing halves i n t h e en-
gine ( F i g . 6). A l l bearing capbolts removed d u r i n g
service procedures are t o be cleaned and oiled before
r e i n s t a l l a t i o n . B e a r i n g shells are available i n stan-
dard a n d t h e f o l l o w i n g undersizes: 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 i n s t a l l a n undersize bearing t h a t w i l l reduce
clearance below specifications.
REMOVAL
(1) Remove o i l p a n and identify b e a r i n g caps before
removal.
(2) Remove b e a r i n g caps one a t a t i m e . Remove up-
per h a l f o f b e a r i n g b y i n s e r t i n g Tool C-3059 i n t o the
o i l hole o f crankshaft (Fig. 7).
(3) S l o w l y rotate crankshaft clockwise, forcing out
upper h a l f o f b e a r i n g shell.
S - 28 3.9L ENGINE
Fig. 7 Removing/Installing Upper Main Bearing with
Tool C-3059
INSTALLATION
O n l y one m a i n b e a r i n g s h o u l d be selectively
fitted w h i l e a l l other m a i n b e a r i n g c a p s a r e
properly tightened.
When i n s t a l l i n g a new upper bearing shell, s l i g h t l y
chamfer the sharp edges from the p l a i n side.
(1) Start bearing i n place, and insert Tool C-3059
into o i l hole of crankshaft (Fig. 7).
(2) Slowly rotate crankshaft counterclockwise slid-
i n g the bearing i n t o position. Remove Tool C-3059.
REAR MAIN BEARING OIL SEALS
The service seal is a two piece, fitted, "Rope Type."
The upper rope seal h a l f can be installed w i t h crank-
shaft removed or i n vehicle w i t h crankshaft i n -
stalled. Lower rope seal h a l f is required i n s t a l l a t i o n
when upper seal is installed.
UPPER ROPE SEAL SERVICE (CRANKSHAFT
REMOVED)
(1) I n s t a l l a new rear bearing o i l seal i n the c y l i n -
der block so t h a t b o t h ends protrude.
(2) U s i n g Tool C-3511, tap seal down into position
u n t i l tool is seated i n bearing bore (Fig. 8).
•
Fig. 8 Installing Upper/Lower Oil Seal with Tool
C-3511
(3) H o l d tool i n t h i s position and cut off t h e p o r t i o n
of seal t h a t extends below the block (or cap) on b o t h
sides (Fig. 9).
Fig. 9 Trimming Upper/Lower Oil Seal
UPPER ROPE SEAL (IN
VEHICLE-CRANKSHAFT INSTALLED)
(1) Remove defective upper seal and i n s t a l l new
one u s i n g O i l Seal Remover and Installer Tool K D -
492, or equivalent (which includes complete instruc-
tions a n d is available from most auto supply stores).
(2) Carefully, t r i m the upper seal after i n s t a l l a t i o n
to e l i m i n a t e frayed ends.
LOWER ROPE SEAL
(1) I n s t a l l a new seal i n bearing cap so t h a t both
ends p r o t r u d e .
(2) U s i n g Tool C-3511, tap seal down i n t o position
u n t i l tool is seated i n bearing bore.
(3) H o l d tool i n t h i s position and cut off t h e p o r t i o n
of the seal t h a t extends above the cap on b o t h sides.
(4) I n s t a l l cap seals into slots i n bearing cap (Fig.
10). I f t h i s is not done, o i l leakage w i l l occur. L i g h t l y
oil seals w i t h engine oil.
 E N D SEALS
Fig. 10 Rear Main Bearing Cap
(5) Assemble bearing cap to cylinder block. I n s t a l l
cleaned a n d oiled cap bolts a n d t i g h t e n to 115 N n n
(85 ft. lbs.) torque.
(6) I n s t a l l o i l pump. A d d sealer a t bearing cap to
block j o i n t (Fig. 11) t o provide o i l p a n end sealing.
I n s t a l l o i l pan.
Fig. 11 Oil Pan End Seal at Rear Bearing
OIL PAN
REMOVAL
(1) Disconnect b a t t e r y ground cable.
(2) Remove engine o i l dipstick.
(3) Remove t h e engine cover a n d a i r cleaner assem-
bly.
(4) Remove the engine controller (S.M.E.C.).
(5) Raise vehicle on a hoist.
(6) Remove t h e r i g h t a n d left transmission support
braces.
(7) Loosen t h e exhaust pipe support bracket.
(8) Remove t h e starter motor.
(9) Remove t h e transmission dust shield.
(10) D r a i n t h e engine o i l .
(11) Remove the 0 sensor a n d a i r injection tube.
2 insulator bolts.
(12) Remove the exhaust pipe.
(13) Remove the r i g h t engine m o u n t n u t . Loosen
(DO N O T R E M O V E ) t h e left engine m o u n t n u t .
(14) Support t h e r i g h t side of t h e engine w i t h a n
adjustable j a c k stand.
(15) Remove t h e r e a r engine support (transmission)
insulator bolts.
(16) Position a transmission j a c k under t h e t r a n s -
mission.
(17) Raise t h e transmission and engine jacks as r e -
quired to allow for t h e o i l p a n removal.
(18) Remove t h e o i l p a n bolts a n d remove t h e o i l
pan.
CLEANING AND INSPECTION
(1) Clean o i l p a n i n solvent a n d wipe d r y w i t h a
clean cloth. Clean a l l gasket m a t e r i a l from m o u n t i n g
surfaces of p a n a n d block.
(2) Inspect o i l d r a i n p l u g and p l u g hole for stripped
or damaged threads a n d repairs necessary. I n s t a l l a
new d r a i n p l u g gasket. T i g h t e n d r a i n p l u g to 27 N n n
(20 f t . lbs.) torque.
(3) Inspect o i l p a n m o u n t i n g flange for bends or
distortion. S t r a i g h t e n flange, i f necessary.
(4) Clean o i l screen a n d pipe thoroughly i n clean
solvent. Inspect condition of screen.
INSTALLATION
(1) Place a drop of R T V a t chain case cover to block
p a r t i n g line.
(2) U s i n g a new p a n gasket set, add drop of R T V
sealer a t corners of rubber a n d cork (Fig. 12).
(3) I n s t a l l p a n a n d t i g h t e n bolts to 23 N* (200 i n .
lbs.) torque.
Fig. 12 Oil Pan Gaskets and Seal Installation
(4) Lower t h e transmission and engine jacks.
(5) I n s t a l l t h e rear engine support (transmission)
(6) Remove t h e transmission a n d engine jacks.
(7) I n s t a l l t h e r i g h t engine mount n u t and t i g h t e n
the left and r i g h t engine mount nuts.
 (8) I n s t a l l exhaust cross over pipe. T i g h t e n t h e INNER ROTOR DISTRIBUTOR DRIVESHAFT
n u t s t o 33 N n n (24 ft. lbs.) torque.
(9) I n s t a l l the 0 sensor a n d a i r injection tube.
2

(10) I n s t a l l the t r a n s m i s s i o n dust shields.

(11) I n s t a l l the s t a r t e r motor.
(12) T i g h t e n the exhaust pipe support bracket.
(13) I n s t a l l the r i g h t and left transmission support
braces.
(14) Lower the vehicle.
(15) I n s t a l l the engine controller (S.M.E.C.).
(16) I n s t a l l the a i r cleaner assembly.
RY10B
(17) Position the engine cover i n place and t i g h t e n
t h e a t t a c h i n g bolts a n d latches.
Fig. 14 Oil Pump
(18) I n s t a l l o i l dipstick.
(19) Connect the b a t t e r y ground cable. INSPECTION AND REPAIR
(20) F i l l t h e crankcase w i t h clean o i l t o proper (1) Clean a l l parts thoroughly. M a t i n g surface o f
level. the o i l pump cover should be smooth. Replace p u m p
assembly i f cover is scratched or grooved.
OIL PUMP (2) L a y a s t r a i g h t edge across the p u m p cover sur-
face (Fig. 15). I f a 0.038 m m (0.0015 inch) feeler
I t is necessary t o remove t h e o i l pan, and remove gauge can be inserted between cover and s t r a i g h t -
the o i l p u m p from r e a r m a i n bearing cap t o service edge, p u m p assembly should be replaced.
the o i l pump.

DISASSEMBLY
(1) To remove the r e l i e f valve, proceed as follows:
(a) Remove cotter p i n , d r i l l a 3.175 m m (1/8
inch) hole i n t o the r e l i e f valve retainer cap and i n -
sert a self-threading sheet m e t a l screw i n t o cap.
(b) Clamp screw i n t o a vise and w h i l e support-
i n g o i l pump, remove cap b y tapping p u m p body
u s i n g a soft h a m m e r . Discard retainer cap and re-
move s p r i n g and r e l i e f valve (Fig. 13).

Fig. 15 Checking Oil Pump Cover Flatness

(3) Measure thickness and diameter o f outer rotor.
I f outer rotor thickness measures 20.9 m m (0.825
inch) or less or i f the diameter is 62.7 m m (2.469
inches) or less, replace outer rotor (Fig. 16).

Fig. 13 Oil Pressure Relief Valve

(2) Remove o i l p u m p cover bolts and lock]washers,
and l i f t off cover.
(3) Remove pump r o t o r and shaft, and l i f t out outer
rotor.
(4) Wash a l l parts i n a suitable solvent and inspect
carefully for damage or wear (Fig. 14). Fig. 16 Measuring Outer Rotor Thickness
 Fig. 17 Measuring Inner Rotor Thickness Fig. 19 Measuring Clearance Between Rotors
(4) I f inner rotor measures 20.9 m m (0.825 inch) or
less, replace i n n e r rotor and shaft assembly (Fig. 17).
(5) Slide outer rotor i n t o p u m p body, press to one
side w i t h fingers and measure clearance between ro-
tor and p u m p body (Fig. 18). I f measurements is
0.356 m m (0.014 inch) or more, replace o i l p u m p as-
sembly.

Fig. 20 Measuring Clearance Over Rotors

Fig. 18 Measuring Outer Rotor Clearance in

Housing
(6) I n s t a l l i n n e r rotor and shaft i n t o p u m p body. I f
clearance between inner and outer rotors is 0.203
m m (0.008 inch) or more, replace shaft and b o t h ro-
tors (Fig. 19).
(7) Place a straight edge across the face of the RN98
pump, between bolt holes. I f a feeler gauge of 0.102
m m (0.004 inch) or more can be inserted between ro-
Fig. 21 Proper Installation of Retainer Cap
tors and the s t r a i g h t edge, replace p u m p assembly
(Fig. 20). OIL PUMP ASSEMBLY AND INSTALLATION
(8) Inspect o i l pressure r e l i e f valve plunger for (1) Assemble pump, u s i n g new parts as required.
scoring and free operation i n i t s bore. S m a l l m a r k s (2) Tighten cover bolts to 11 N n n (95 i n . lbs.)
may be removed w i t h 400-grit wet or d r y sandpaper. torque.
(9) The r e l i e f valve spring has a free l e n g t h of ap- (3) Prime oil pump before i n s t a l l a t i o n by filling ro-
proximately 49.5 m m (1.95 inches) a n d should test t o r cavity w i t h engine o i l .
between 19.5 and 20.5 pounds w h e n compressed to 34 (4) I n s t a l l o i l pump. D u r i n g i n s t a l l a t i o n slowly ro-
m m (1-11/32 inch). Replace s p r i n g t h a t fails to meet t a t e pump body to ensure driveshaft-to-pump rotor
specifications (Fig. 21). shaft engagement. H o l d the o i l p u m p base flush
(10) I f oil pressure is low and p u m p is w i t h i n spec-
ifications, inspect for w o r n engine bearings or other
reasons for o i l pressure loss.
against m a t i n g surface o n N o . 4 m a i n b e a r i n g cap.
F i n g e r t i g h t e n pump a t t a c h i n g bolts. T i g h t e n attach-
i n g bolts t o 4 1 N n n (30 ft. lbs.) torque.

OIL LINE PLUG INSPECTION

The o i l l i n e p l u g is located i n t h e v e r t i c a l passage
i n t h e block between t h e O i l - T o - F i l t e r a n d Oil-From-
F i l t e r passages (Fig. 22). E r r a t i c , l o w or n o o i l pres-
sure could occur, i f the p l u g i s n o t i n s t a l l e d correctly
or i s missing.
(1) Remove o i l pressure sending u n i t f r o m back o f
block.
(2) I n s e r t a 3.175 m m (1/8 inch) finish w i r e or
equivalent i n t o passage.
Fig. 23 Removing Oil Filter with Tool C-4065
(3) P l u g should be 190.0 t o 195.2 m m (7-1/2 t o 7-
11/16 inches) from machined surface o f block, a n d (6) Use Stud W B e a r i n g m o u n t adhesive on outside
54.0 t o 57.7 m m (2-1/8 t o 2-5/16 inches) f r o m bottom diameter o f p l u g t o ensure retention o f position. As-
of t h e block (Fig. 22). semble engine a n d check o i l pressure.
(4) I f p l u g i s too h i g h , use a suitable f l a t dowel
d r i f t t o position properly. OIL FILTER
(5) I f p l u g is off position. Remove o i l p a n and No. 4 W h e n s e r v i c i n g the o i l filter, a v o i d deforming
m a i n b e a r i n g cap. Use suitable f l a t dowel t o remove the filter C A N b y i n s t a l l i n g the tool b a n d s t r a p
plug.

OIL FLOWS TO ONLY ONE BRACKET ON

ROCKER SHAFT EACH HEAD. BRACKET IS SECOND FROM
REAR ON RIGHT HEAD. BRACKET IS
SECOND FROM FRONT ON LEFT HEAD

TO MAIN BEARINGS
ROCKER SHAFT
PASSAGE

OIL GALLERY

OIL SUPPLY
FROM HOLLOW ROCKER SHAFT BRACKET
PUSH ROD VIEW B

OIL PASSAGE FOR OIL PASSAGE TO

PRESSURE INDICATOR LIGHT CYLINDER HEAD
OIL GALLERY

RIGHT OIL GALLERY

TAPPET
PASSAGE
TO CAMSHAFT
REAR BEARING

OIL FROM FILTER

PLUG TO SYSTEM

OIL TO FILTER
CRANKSHAFT FEED FROM OIL GALLERY TO # 2 MAIN
BEARING AND PASSAGE TO HEAD MAIN
FROM OIL PUMP
VIEW D 8909-77
VIEWC

Fig. 22 Engine Lubrication System

a g a i n s t t h e can-to-base l o c k s e a m . T h e l o c k (3) Lubricate gasket of new filter w i t h clean engine
s e a m ( j o i n i n g t h e c a n t o t h e base) i s r e i n f o r c e d oil.
b y the base plate. (4) I n s t a l l and t i g h t e n filter t o 20 N-m (15 f t . lbs.)
(1) U s i n g Tool C-4065, unscrew filter from base torque, or 3/4 to 1 t u r n s after gasket contacts base.
and discard (Fig. 23). Use filter wrench, i f necessary.
(2) Wipe base clean, t h e n inspect gasket contact (5) S t a r t engine and check f o r leaks.
surface.
ENGINE SPECIFICATIONS—3JL

Type 90°V
Number of C y l i n d e r s . . . . . . . . . . . . . . . . . . . . . . . . 6
Bore ........................... 3.91"
Stroke . . . . .......... 3.31"
Piston Displacement 238 cu. in.—(3.9L)
Compression ratio 9.0 to 1
Minimum Compression Pressure See "Engine
Performance" in Standard Service Procedures 100 psi
Maximum Variation between Cylinders (any
one engine) — 25 %
Firing Order 1-6-5-4-3-2
Basic Timing Refer to Emission Control Information
Label on Vehicle
CYLINDER NUMBER (front to rear)
Left Bank 1- 3-5
Right Bank 2- 4-6
CYLINDER BLOCK
Cylinder Bore (standard) 3.910"—3.912"
Cylinder Bore Out-of-Round
(Maximum allowable before reconditioning) .005"
Cylinder Bore Taper
(Maximum allowable before reconditioning) .010"
Reconditioning Working Limits
(for taper and out-of-round) .001"
Maximum Allowable Oversize (cylinder bore) . .040"
Tappet Bore Diameter .9051"—.9059"
Distributor Lower Drive Shaft Bushing
(press fit in block) .0005"—.014"
Shaft to Bushing Clearance .0007"— .0027"
PISTONS
Type Material . Alloy Tin Coated
Land Clearance (Diametrical) . . . . . . . . . . .019"— .024"
Clearance at Top of Skirt .0005"— .0015"
Weight (Std. through .040" oversize) 594.6 ± 2 gms.
Piston Length (overall) 3.40"
Ring Groove Depth
No. 1 .205"
No. 2 .205"
No. 3 .194"
Pistons for Service Standard and .020"
Oversize

PISTON PINS
Type Press Fit in Rod
Diameter .9841"— .9843"
Length 2.990"—3.020"
Clearance in Piston (Light Thumb
P u s h ® 70° F . ) . . . . . . — . . . . .0000"— .0005"
End Play . . . . None
Clearance in Rod .0007"— .0014"
(Interference)

Pins for Service Standard .003"

and .008" oversize

J9009-102
9 - 34 3.9L ENGINE •
ENGINE SPECIFICATIONS—3JL (CONT.)

PISTON RINGS
Number of Rings per Piston 3
Compression... — — 2
Oil 1
Oil Ring Type 3-piece
steel rail
chrome-face
Ring Width
Compression .. .0770"— .0780"
Oil—Steel rails .0252" Max
Ring Gap
Compression .010"—.020"
Oil—Steel rails .015"— .055"
Ring Side Clearance
Compression .0015"— .0030"
Oil—Steel rails .0002"— .005"
Service Rings
Ring Gap
Compression .010"—.020"
Oil (Steel rails) .010"— .062"
Ring Side Clearance
Compression — .0015"— .004"
Oil (Steel rails) .0002"— .005"

CONNECTING RODS
Length (Center to Center) 6.121"
Weight (less bearing shells) 726 Grams
Side Clearance (two rods) .006"— .014"
Piston Pin Bore Diameter .9819"— .9834"

CONNECTING ROD BEARINGS

Type Tri-Metal
Diameter and Width 2.126" x .842"
Clearance Desired .0005"— .0022"
Maximum Allowable • .0022"
Bearings for Service Std., .001", .002",
.010", .012"

CRANKSHAFT
Type Counter-Balanced
Bearings Aluminum Lead
Thrust Taken By No. 2 Main Bearing
End Play .002"— .007"
Maximum Allowable .010"
Diametral Clearance Desired # 1 - .0005"—.0015"
Maximum Diametral Clearance Allowed # 1 — .0015"
Diametral Clearance Desired # 2 , 3, and 4 — .0005"— .0020"
Diametral Clearance Allowed # 2 , 3, and 4 .0025"
Finish at Rear Oil Seal Surface. Diagonal Knurling

MAIN BEARING JOURNALS

Diameter 2.4995"—2.5005"
Maximum Allowable Out-of-Round and/or Taper .001"
Bearings for Service Available in
Standard and the following undersizes .001", .002", .003",
.010", .012"

CONNECTING ROD JOURNALS

Diameter 2.124"—2.125"
Maximum Allowable Out-of-Round and/or Taper .001"

J9009-103
 3.9L ENGINE 9 - 35

ENGINE SPECIFICATIONS—3.9L (CONT.)

CAMSHAFT
Drive Chain
Bearings Steel Backed Babbitt
Number 4
Diametral Clearance . .001"—.003"
Maximum Allowable before Reconditioning . .005"
Thrust Taken By Thrust Plate
End Play .002"— .010"
Maximum Allowable .010"
CAMSHAFT JOURNALS
Diameter
No. 1 1.998"—1.999"
No. 2 1.967"—1.968"
No. 3 1.951"—1.952"
No. 4 1.5605"—1.5615"
CAMSHAFT BEARINGS
Diameter
No. 1 2.000"—2.001"
No. 2 1.984"—1.985"
No. 3 1.953"—1.954"
No. 4 1.5625"—1.5635"
VALVE TIMING
Intake Opens (BTC) 10°
Intake Closes (ABC) 50°
Exhaust Opens (BBC) •. 52°
Exhaust Closes (ATC) 16°
Valve Overlap 26°
Intake Valve Duration 240°
Exhaust Valve Duration 248°
TIMING CHAIN
Number of Links 68
Pitch .375"
Width .875"
TAPPETS
Type Hydraulic Roller
Body Diameter .9035"—.9040"
Clearance in Block .0011"— .0024"
Service Tappets Available Std., .001", .008", .030"
Dry Lash .060"—.210"
CYLINDER HEAD
Valve Seat Run-Out (Maximum) .003"
Intake Valve Seat Angle 45°—45-1/2°
Seat Width (finish) .065"—.085"
Exhaust Valve Seat Angle 45°—45-1/2°
Seat Width (finish) .080"—.100"
Cylinder Head Gasket (Thickness compressed) .033"
VALVE GUIDES
Type Cast in Head
Guide Bore Diameter .374"— .375" Std.
VALVES—(INTAKE)
Head Diameter 1.780"
Length (overall) 4.962"—4.987"
Stem Diameter (Standard) .372"—.373"
Stem to Guide Clearance .001"—.003"
Maximum Allowable by rocking method — .017"
Face Angle 44-l/2°-45°
Valve for Service (oversize stem diam.) Std., .005", .015", .030 "
Lift (Zero lash) .373"

J9009-104
 ENGINE SPECIFICATIONS—3.9L (CONT.)

VALVES—(EXHAUST)
Head Diameter 1.517"
Length overall Without Rotators 4.969"—5.005"
Length overall With Rotators 4.977"—5.012"
Stem Diameter (Standard) .371—.372"
Stem to Guide Clearance .002"—.004"
Maximum Allowable by rocking method .017"
Face Angle 44-l/2°-45°
Valves for Service (oversize stem diam.) Std., .005", .015", .030"
Lift (Zero Lash) .400"

ENGINE VALVE SPRINGS

LOCATION/IDENTIFICATION Intake Exhaust
(With Rotator)
Number 6 6
Color Blue White
Free Length (Approx.) 2.00" 1.81"
Wire Diameter .192" .185"
Number of coils 6.4 5.8
Load when compressed to 78-88 lbs. 80-90 lbs.
(valve closed) @ 1-11/16" @ 1-13/64"
Load when compressed to 170-184 lbs. 180-194 lbs.
(valve open) @ 1-5/16" @ 1-1/16"
Maximum allowable out of plumb 1/16" 1/16"
Valve spring installed height
(spring seat to retainer) 1-5/8"—1-11/16" 1-29/64"—1-33/64"
Use 1/16" spacer to reduce spacing height
when over specifications

ENGINE LUBRICATION
Pump Type Rotary,
Full Pressure
Capacity (qts.) U.S 4 (with or without Oil Filter)
Pump Drive Camshaft
Minimum Pressure, Engine Fully warmed up
*Curb Idle 6 psi
3000 RPM 30 to 80 psi
Oil Filter Bypass Valve Setting 9 to 15 psi
Oil Pressure Switch Minimum Actuating Pressure 5 to 7 psi
Oil Filter Type Full Flow
*lf pressure is "0" at curb idle, do not run engine at 3000 RPM.
J9009-105
 3.9L ENGINE 9 - 37

OIL PUMP INSPECTION LIMITS FOR REPLACEMENT—3.9L

Oil Pump Cover Out Of Flat -0015 inch or more

Outer Rotor Thickness .825 inch or less
Outer Rotor Diameter 2.469 inch or less
Inner Rotor Thickness .825 inch or less
Clearance Over Rotors—Outer .004 inch or more
Inner .004 inch or more
Outer Rotor Clearance -014 inch or more
Tip Clearance Between Rotors -008 inch or more

J9009-106

OVERSIZE AND UNDERSIZE ENGINE COMPONENT MARKINGS—3.9L

Condition Identification Location of Identification

. 0 0 1 " U/S Crankshaft R or M Steel stamped (near notch)
M-2-3 etc. (Indicating on number six
No. 2 & 3 main bearing crankshaft counterweight
journal)
and/or
R-l-4 etc. (Indicating
No. 1 & 4 connecting rod
journal)
. 0 1 0 " U/S Crankshaft RX or MX Steel stamped (near notch)
MX (Indicates .010" U/S on number six
all main journals) crankshaft counterweight
and/or
RX (Indicating .010" U/S
all rod journals)
. 0 2 0 " O/S Cylinder A Following engine serial number
Bores
. 0 0 8 " O/S Tappets • 3/8" diamond shaped stamp
Top pad—Front of engine and
flat ground on outside surface
of each O/S tappet bore.
. 0 0 5 " O/S Valve Stems X Milled pad adjacent to two
3/8" tapped holes on each end
of cylinder head.

J9009-107
9 - 38 3.9L ENGINE

TORQUE SPECIFICATIONS—3JL

Torque * Newton
Thread Size Foot-Pounds Metres
Alternating Adjusting Strap Bolt 5/16"—18 200 in.-lbs. (23)
Alternator Adjusting Strap Mounting Bolt 3/8"—16 30 (41)
Alternator Bracket B o l t . . . . . . . . . . . . . . . — .— 3/8"—16 30 (41)
Alternator Mounting Pivot Nut 3/8"—16 30 (41)
Camshaft Sprocket Lockbolt 7/16"—14 50 (68)
Camshaft Thrust Plate 5/16"—18 210 in.-lbs. (24)
Chain Case Cover Bolt 3/8"—16 35 (47)
Clutch Housing Bolt — 3/8"—16 30 (41)
7/16"—14 50 (68)
Connecting Rod Nut 3/8"—24 45 (61)
Crankshaft Bolt (Vibration Damper) 3/4"_16 135 (181)
Cylinder Head Bolt 1/2"—13 105 (143)
Cylinder Head Covers—Nut l/4"_20 80 in.-lbs. (9)
Stud l/4"_20 115 in.-lbs. (13)
Distributor Clamp Bolt 5/16"—18 200 in.-lbs. (23)
Engine Front Mount Insulator to Frame Bracket ( 4 x 2 ) . 50 (68)
Engine Front Mount Insulator to Engine Adaptor (4 x 2) 30 (41)
Engine Rear Mount Insulator to Crossjnember ( 4 x 2 ) . . 30 (41)
Engine Rear Mount Insulator to Extension Bracket 75 (102)
Engine Rear Mount Bracket to Extension (4 x 2) 50 (68)
Exhaust Manifold Screw 5/16"—18 20 (27)
Nut 5/16"—24 15 (20)
Exhaust Pipe Flange Nut 7/16"—14 24 (33)
Fan Blade Attaching Bolts — 5/16"—18 200 in.-lbs. (23)
Flex Plate to Converter 5/16"—24 270 in.-lbs. (31)
Flex Plate to Crankshaft 7/16"—20 55 (75)
Flywheel to Crankshaft . 7/16"—20 55 (75)
Intake Manifold Bolt 3/8"—16 45 (61)
Main Bearing Cap Bolt 1/2"—13 85 (115)
Oil Pan Drain Plug 1/2"—20 20 (27)
Oil Pan Screw 5/16"—18 200 in.-lbs. (23)
Oil Pump Cover Bolt l/4"_20 95 in.-lbs. (11)
Oil Pump Attaching Bolt 3/8"—16 30 (41)
Oil Filter Attaching Stud 3/4"—16 50 (61)
Oil Pressure Gauge Sending Unit 1/8" NPTF 60in.-lbs. (7)
Rocker Shaft Bracket Bolt 5/16"—18 200 in.-lbs. (23)
Spark Plug — 14mm 30 (41)
Starter Mounting Bolt 7/16"—14 50 (68)
Temperature Gauge Sending Unit 1/8" NPTF 60 in.-lbs. (7)
Vibration Damper Screw to Crankshaft 3/4"—16 100 (136)
Water Pump to (Chain Case Cover) Bolt 3/8"—16 30 (41)
A/C Compressor Bracket to Water Pump Bolt 3/8"—16 30 (41)
A/C Compressor to Bracket Nut 7/16"—14 50 (68)
A/C Compressor Support Bolts . 3/8"—16 30 (41)
*AII Critical Fastners should be clean and lightly oiled.
J9009-108
 5.2L/5.9L ENGINE 9 - 39

5.2L/5.9L ENGINE S E R V I C E PROCEDURES

INDEX
Page Page
Balance Of V8 Engine Damper, Crankshaft And Engine Specifications—5.2L/5.9L . 64
Torque Converter . . . . . . . . . . . . . . . . . . . . . . . 55 Hydraulic Tappets 47
Camshaft (Engine Removed From Vehicle) 51 Oil Filter 62
Camshaft Bearings (Engine Removed From Oil Line Plug . 61
Vehicle) . . . . . . . . . . . . . . 52 Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Connecting Rods 56 Oil Pump . 60
Oil Pump Inspection Limits For Replacement—
Crankshaft Identification 55 5.2L/5.9L 69
Crankshaft Main Bearings 57 Oversize And Undersize Engine Component
Crankshaft Main Journals 57 Markings-5.2L/5.9L 69
Cylinder Block . 54 Pistons, Pins And Rings 54
Cylinder Heads 42 Rear Main Bearing Oil Seals 57
Distributor drive Shaft Bushing . 52 Rocker Arms And Shaft Assembly 41
Engine Assembly 40 Timing Chain Cover External Oil Seal 50
Engine Core Oil And Cam Plugs 54 Timing Chain Cover, Oil Seal And Chain . . . . . . . 49
Engine Front Mounts 39 Torque Specifications—5.2L/5.9L 70
Engine Rear Mounts—4-WD . . . . . . . . . . . . . . . . . 40 Valve Timing 48
Engine Rear Support—2-WD . . . . . . . . . . . . . . . . 39 Valves And Valve Springs 44

ENGINE FRONT MOUNTS

REMOVAL
(1) Raise hood and position fan t o assure clearance
for radiator top t a n k and hose.
(2) I n s t a l l engine l i f t i n g f i x t u r e Tool C-3487-A,
USE FRONT HOLES
w i t h adapter rods DD-2179.
FOR INSULATOR MTG. NUT
(3) Raise vehicle on hoist. 2-WHEEL DRIVE WASHER
(4) Remove n u t s from brackets a n d insulators (Fig. BRACKET'
1). TIGHTENING TORQUE INSULATOR'
(5) Raise engine w i t h l i f t i n g fixture only far <§> 75 FT. LBS. (102 N-m) LEFT^ipj
enough t o remove insulators. <B> 65 FT. LBS. (88 N.m) 4-WHEEL DRIVE
FRAME SHOWN
30 FT. LBS. (41 N-m) INSULATOR
INSTALLATION
(1) W i t h engine raised s l i g h t l y , i n s t a l l insulators BRACKET
(FRONT ENG
and brackets. SUPPORT)
(2) Lower engine w i t h l i f t i n g f i x t u r e w h i l e g u i d i n g
insulator studs i n t o a t t a c h i n g holes i n crossmember
and brackets.
(3) T i g h t e n a t t a c h i n g n u t s a n d bolts to specified
torques (Fig. 1).
(4) Lower t h e vehicle.
(5) Remove l i f t i n g f i x t u r e .
LEFT SIDE
ENGINE REAR SUPPORT—2-WD 2-WHEEL
RR09B145
DRIVE

REMOVAL Fig. 1 Engine Front Mounts

(1) Raise t h e vehicle on a hoist.
(4) Remove insulator from bottom face of transmis-
(2) Position a transmission j a c k under the trans-
sion extension housing (sport u t i l i t y ) or from t h e
mission and raise rear o f transmission and engine
crossmember bracket (Fig. 2).
SLIGHTLY.
(3) Remove rear m o u n t through-bolt from frame
crossmember or bracket (Fig. 2).
9 - 40 5.2L/5.9L ENGINE •
TRANSMISSION
EXTENSION
SKID PLATE
ATTACHING BOLTS

SPACER

PU873

Fig. 3 Skid Plate

TRANSFER CASE
ASSEMBLY
CROSSMEMBER
(SPORT UTILITY)

CROSSMEMBER
BRACKET TRANSMISSION
BRACKET
SURFACES MARKED A-B MUST
A B E HELD PARALLEL TO SURFACE
C WHEN OOUT 6 IS TORQUE BOLT

TIGHTENING TORQUE
WASHER
50 FT. LBS. (68 N.m)
SLEEVE
<|> 30 FT. LBS. (41 N.m)
INSULATOR

CROSSMEMBER
RR09B146 (EXCEPT SPORT UTILITY)

Fig. 2 Engine Supports—Rear

eg)-*—WASHER
INSTALLATION
(1) I n s t a l l i n s u l a t o r on transmission extension
7" RAIL *PLATE TAB
housing. T i g h t e n t h e bolts to 68 N-m (50 f t . lbs.) TO RIGHT REAR RK 716
torque.
(2) I n s t a l l t h r o u g h - b o l t t h r o u g h crossmember and Fig. 4 Engine Mounts—Rear
mount (sport u t i l i t y ) or t h r o u g h bracket and mount ENGINE ASSEMBLY
(Fig. 2). T i g h t e n these bolts t o 68 N n n (50 f t . lbs.)
torque.
(3) Remove the transmission j a c k . CHECKING OPERATION OF EXHAUST VALVE
(4) Lower the vehicle. ROTATORS
Before a n engine is disassembled for valve g r i n d i n g
ENGINE REAR MOUNTS—4-WD or major r e p a i r w o r k , the performance of the exhaust
valve rotators should be checked.
(1) W i t h engine i n t h e vehicle, remove c y l i n d e r
REMOVAL
head covers.
(1) Raise the vehicle on a hoist.
(2) Observe exhaust valve rotation w i t h the engine
(2) Remove t h e s k i d plate ( i f equipped) from the
r u n n i n g a t 2000 and 3000 R P M . The valve should ro-
rear crossmember a n d transmission crossmember
tate a t u n i f o r m and constant speeds, (direction o f ro-
(Fig. 3). t a t i o n is n o t important). There. is generally a large
(3) Position transmission j a c k under transmission difference i n rotation speeds between 1000 a n d 3000
and raise rear o f transmission a n d engine RPM.
SLIGHTLY.
(3) Rotators w h i c h do not appear to function prop-
(4) Remove m o u n t i n g bolts a n d insulators (Fig. 4).
erly should be replaced.
INSTALLATION
REMOVAL
(1) I n s t a l l insulators and m o u n t i n g bolts (Fig. 4).
(1) Scribe hood hinge outlines on hood and remove
(2) I n s t a l l the skid plate (Fig. 3). the hood.
(3) Lower the vehicle. (2) Remove the battery.
 • 5.2L/5.9L ENGINE
(3) D r a i n cooling system.
(4) Remove t h e a i r cleaner.
(5) Remove radiator a n d heater hoses. Remove t h e
radiator (see Group 7, Cooling System for t h e proper
procedure).
(6) Set f a n shroud aside.
(7) Discharge t h e a i r conditioner, i f equipped (refer
to Group 24, H e a t i n g a n d A i r C o n d i t i o n i n g for ser-
vice procedures).
(8) Remove a i r conditioning hoses
(9) Remove t h e v a c u u m lines.
(10) Remove t h e d i s t r i b u t o r cap and w i r i n g .
(11) Remove t h e t h r o t t l e body, fuel lines and l i n k -
age.
(12) Remove t h e starter wires a n d o i l pressure
wire.
(13) Disconnect t h e power steering hoses, i f
equipped.
(14) Remove s t a r t e r motor, alternator, charcoal
canister and horns.
(15) Raise and support t h e vehicle on a hoist.
(16) Disconnect exhaust pipe a t manifold.
(17) M a n u a l T r a n s m i s s i o n
See Group 2 1 , Transmissions for t h e M a n u a l
Transmission Removal procedure.
(18) A u t o m a t i c T r a n s m i s s i o n
(a) Remove b e l l housing bolts a n d inspection
plate.
(b) A t t a c h a C clamp on front bottom o f trans-
mission torque converter housing to prevent torque
converter from coming out.
(c) Remove torque converter drive plate bolts.
M a r k converter a n d drive plate to a i d i n assembly.
(d) Support t h e transmission.
(e) Lower t h e vehicle.
(19) I n s t a l l engine l i f t i n g f i x t u r e . A t t a c h a chain
hoist t o f i x t u r e eyebolt.
(20) Remove engine f r o n t m o u n t bolts (Fig. 1).
(21) Remove engine f r o m engine compartment and
i n s t a l l on engine r e p a i r stand.
(22) Disconnect t h e torque converter drive plate
f r o m t h e engine crankshaft.
INSTALLATION
(1) Position t h e torque converter drive plate onto
t h e crankshaft. T i g h t e n t h e bolts to 75 N - m (55 f t .
lbs.) torque.
(2) Remove engine f r o m t h e repair stand and posi-
t i o n i t into t h e engine compartment.
(3) I n s t a l l t h e engine f r o n t m o u n t bolts. Tighten
t h e bolts to 4 1 N - m (30 f t . lbs.) torque.
(4) Remove engine l i f t i n g f i x t u r e .
(5) M a n u a l T r a n s m i s s i o n
See Group 2 1 , Transmissions for t h e M a n u a l
Transmission I n s t a l l a t i o n procedure.
(6) A u t o m a t i c T r a n s m i s s i o n
(a) Raise and support t h e vehicle.
9 - 41
(b) A l i g n t h e torque converter plate to the
torque converter. I n s t a l l a n d t i g h t e n the bolts to 31
N-m (270 i n . lbs.) torque.
(c) I n s t a l l b e l l housing bolts. T i g h t e n t h e bell
housing bolts t o 4 1 N - m (30 ft. lbs.) torque.
(d) Remove t h e C clamp.
(e) I n s t a l l t h e inspection plate.
(f) Remove t h e transmission support.
(7) Position t h e exhaust pipe t o t h e manifold.
T i g h t e n t h e n u t s t o 33 N - m (24 ft. lbs.) torque.
(8) Lower t h e vehicle.
(9) I n s t a l l t h e starter motor, alternator, charcoal
canister a n d horns.
(10) Remove t h e starter wires a n d o i l pressure
wire.
(11) I n s t a l l t h r o t t l e body, fuel lines and linkage.
(12) Connect t h e v a c u u m lines.
(13) I n s t a l l t h e d i s t r i b u t o r cap and w i r i n g .
(14) I n s t a l l t h e radiator (see Group 7, Cooling Sys-
tems). Connect t h e radiator hoses and heater hoses.
(15) I n s t a l l f a n shroud i n position.
(16) F i l l t h e cooling system (see Group 7, Cooling
System for t h e proper procedures).
(17) I n s t a l l t h e battery.
(18) A t t a c h t h e a i r cleaner t o t h e t h r o t t l e body.
(19) Connect t h e power steering hoses, i f so
equipped.
(20) I n s t a l l a i r conditioning equipment and charge
a i r conditioning. Refer to Group 24, H e a t i n g and A i r
Conditioning for proper service.
(21) W a r m engine and adjust.
(22) I n s t a l l hood a n d line u p w i t h the scribe marks.
(23) Road test vehicle.
ROCKER ARMS AND SHAFT ASSEMBLY
REMOVAL
(1) Disconnect spark p l u g wires b y p u l l i n g on the
boot s t r a i g h t o u t i n l i n e w i t h p l u g .
(2) Disconnect closed v e n t i l a t i o n system and evap-
oration control system from cylinder head cover.
(3) Remove cylinder head cover and gasket.
(4) Remove five rocker shaft bolts and retainers.
(5) Remove rocker arms and shaft assembly.
(6) I f rocker a r m assemblies are disassembled for
cleaning or replacement, refer t o (Fig. 1) for rocker
a r m identification, and (Fig. 2) for positioning on the
shaft.
(7) O n engines w i t h exhaust valve rotators, ex-
haust rocker a r m m u s t have r e l i e f for clearance (Fig.
1).
INSTALLATION
(1) I n s t a l l rocker a r m a n d shaft assemblies w i t h
N O T C H on end of rocker shaft p o i n t i n g to center line
of engine a n d t o w a r d front o f engine on the left bank
and to the rear on r i g h t bank, m a k i n g sure to install
9 - 42 5.2L/5.9L ENGINE •
(5) M a k e sure t h a t the load spreader washers are
so positioned t h a t t h e y w i l l f i t free w h e n the cover
a t t a c h i n g bolts are t i g h t e n e d as specified.
(6) I f a n y interference is noticed between the load-
spreader washer a n d t h e cover, remove bolt a n d
washer. Position the washer t o e l i m i n a t e the inter-
ference. I n s t a l l b o l t a n d t i g h t e n as specified.
(7) I n s t a l l closed crankcase v e n t i l a t i o n system and
evaporation control system.

CYLINDER HEADS
The a l l o y cast i r o n cylinder heads shown i n (Fig. 3)
RELIEVED FOR ROTATOR
CLEARANCE
are h e l d i n place b y 10 bolts. T h e spark plugs are lo-
cated i n peak o f the wedge between the valves.

REMOVAL
(1) D r a i n cooling system a n d disconnect battery
ground cable.
(2) Remove alternator, a i r cleaner and fuel line.
(3) Disconnect accelerator l i n k a g e .
(4) Remove v a c u u m control hose f r o m t h r o t t l e
body.
(5) Remove d i s t r i b u t o r cap a n d wires.
(6) Disconnect coil wires, heat indicator sending
INTAKE ROCKER ARM EXHAUST ROCKER ARM
8909-71 u n i t w i r e , heater hoses and bypass hose.
(7) Remove closed v e n t i l a t i o n system, evaporation
Fig. 11ntake and Exhaust Rocker Arm Identification control system and cylinder head covers.
(8) Remove i n t a k e manifold, i g n i t i o n coil and t h r o t -
t l e body as a n assembly.
(9) Remove exhaust manifolds.
(10) Remove rocker a r m and shaft assemblies. Re-
move p u s h rods and identify t o insure installation i n
o r i g i n a l locations.
(11) Remove the 10 head bolts f r o m each cylinder
head and remove cylinder heads.
(12) Place cylinder heads i n h o l d i n g f i x t u r e Tool C-
3626. Remove spark plugs.

Fig. 2 Proper Rocker Arm Location on Shaft

the long stamped steel retainers i n the number two
and four positions, t i g h t e n to 23 N*m (200 i n . lbs.)
torque (Fig. 2).

CAUTION: The rocker arm shaft should be torqued

down slowly, starting with the centermost bolts. Al-
low 20 minutes tappet bleed down time after instal-
lation of the rocker shafts before engine operation.

(2) Clean cylinder head cover gasket surface. I n -

spect cover for distortion and straighten i f necessary.
(3) Clean head r a i l i f necessary. I n s t a l l cylinder
Fig. 3 Cylinder Head Assembly (Typical)
head cover and t i g h t e n to 11 N»m (95 i n . lbs.) torque.
(4) Whenever the cylinder head cover gasket flange INSTALLATION
has been reworked, i t m a y be necessary to i n s t a l l (1) Clean a l l surfaces of cylinder block and cylinder
load spreader washers. heads.
(2) Inspect a l l surfaces w i t h a straightedge i f there
is any reason to suspect leakage. I f out of flatness ex-
ceeds 0.00075 mm/mm (0.00075 inch/inch) times t h e
span length i n inches i n any direction, either replace
head or l i g h t l y machine t h e head surface.
F O R E X A M P L E — I f a 305 m m (12 i n c h ) s p a n i s
0.102 m m (0.004 i n c h ) o u t o f flat, a l l o w a b l e i s 305
X 0.00075 (12 X 0.00075) e q u a l s 0.23 m m (0.009
inch). This a m o u n t o f o u t of f l a t i s acceptable.
(3) The cylinder head surface f i n i s h should be 1.78-
4.57 microns (70-180 microinches).
(4) I n s t a l l new gaskets o n cylinder block.
(5) Remove cylinder heads from h o l d i n g f i x t u r e s
and place heads on engine.
(6) Thread sealer is not required. S t a r t i n g a t t o p
center, t i g h t e n a l l cylinder head bolts t o 68 N * m (50
ft. lbs.) torque i n sequence (Fig. 4). Repeat procedure,
t i g h t e n a l l cylinder head bolts t o 143 N - m (105 ft.
lbs.) torque. Repeat procedure t o c o n f i r m t h a t a l l
bolts are at 143 N-m (105 ft. lbs.) torque.
Fig. 5 Engine Intake Manifold Side Gaskets (Left
Side Shown)—5.2L
gaskets, the center hole i n t h e gasket M U S T engage
dowels i n block. E n d holes i n seals M U S T be locked
i n t o tangs of head gasket (Fig. 6). A l l o w t o d r y 4 to 5
minutes or u n t i l tack free.

Fig. 4 Cylinder Head Bolt Tightening Sequence

(7) Inspect push rods a n d replace w o r n or bent
rods.
(8) I n s t a l l push rods, rocker a r m a n d shaft assem-
blies w i t h t h e N O T C H on t h e e n d o f rocker shaft
p o i n t i n g to centerline of engine a n d t o w a r d front (left
bank) and to the rear ( r i g h t bank). T h e notch is a l -
ways to left as facing cylinder head. M a k e sure t o i n -
s t a l l t h e long stamped steel retainers i n t h e n u m b e r
t w o and four positions. T i g h t e n the bolts t o 23 N - m
(200 i n . lbs.) torque.
Fig. 6 Intake Manifold Sealing
(9) Coat i n t a k e manifold side gaskets l i g h t l y w i t h
sealer. R I G H T and L E F T side gaskets are r e q u i r e d . (13) Carefully i n s t a l l t h e front a n d rear i n t a k e
Cutouts a t top front of each gasket ( L T for left side manifold gaskets.
and R T for r i g h t side) identifies each gasket position (14) Place drop (approximately 1/4" diameter) o f
(Fig. 5). rubber sealer R T V onto each of the four manifold t o
(10) I n s t a l l side gaskets t o cylinder head. cylinder head gasket corners.
(11) Clean cylinder block f r o n t a n d rear gasket sur- (15) Carefully lower i n t a k e manifold i n t o position
faces using a suitable solvent (Fig. 6). on t h e cylinder block and cylinder heads. After i n -
(12) Apply a t h i n , u n i f o r m coating o f a q u i c k d r y take manifold is i n place, inspect to make sure seals
cement to the i n t a k e manifold f r o n t a n d rear gaskets are i n place.
and cylinder block gasket surface. W h e n i n s t a l l i n g
9 - 44 5.2L/5.9L ENGINE
(16) I n s t a l l t h e twelve a t t a c h i n g bolts Finger
T i g h t . T i g h t e n the bolts t o 34 N-m (25 ft. lbs.) torque
i n the t i g h t e n i n g sequence shown i n (Fig. 7). T i g h t e n
the same bolts to 54 N - m (40 f t . lbs.) i n sequence
shown (Fig. 7). Check t h a t a l l bolts are a t 5 4 N - m
(40 f t . lbs.) torque.
•
REMOVAL
(1) W i t h cylinder head removed, compress valve
springs u s i n g Tool C-3422-A (Fig. 8).
(2) Remove valve r e t a i n i n g locks, valve spring re-
tainers, valve stem cup seals and valve springs.
(3) Before r e m o v i n g valves, remove any b u r r s from
valve stem lock grooves t o prevent damage t o t h e
valve guides. Identify valves t o insure i n s t a l l a t i o n i n
o r i g i n a l location.

Fig. 7 Intake Manifold Screw Tightening Sequence

(17) I n s t a l l exhaust manifolds a n d t i g h t e n bolts to
27 N-m (20 ft. lbs.) torque and t i g h t e n the n u t s t o 20 Fig. 8 Compressing Valve Springs with Tool C-
N n n (15 f t . lbs.) torque. 3422A
(18) A d j u s t spark plugs t o specifications (see Group
VALVE INSPECTION
8D, I g n i t i o n System). I n s t a l l the plugs and t i g h t e n to
Clean valves t h o r o u g h l y a n d discard burned,
4 1 N-m (30 ft. lbs.) torque.
warped and cracked valves.
(19) I n s t a l l coil wires, heat indicator sending u n i t Measure valve stems for wear. N e w stem diameters
w i r e , heater hoses and bypass hose. should measure (Fig. 9):
(20) I n s t a l l vacuum control hose to t h e t h r o t t l e
body.
(21) I n s t a l l t h r o t t l e linkage a n d adjust, as neces- Intake . . . 9.449 to 9.474 mm
sary. (0.372 to 0.373 inch)
(22) I n s t a l l d i s t r i b u t o r cap and wires.
Exhaust . . 9.423 to 9.449 mm
(23) I n s t a l l fuel lines, a l t e r n a t o r a n d drive belt.
(0.371 to 0.372 inch)
T i g h t e n alternator m o u n t i n g bolt t o 4 1 N n n (30 f t .
lbs.) torque and adjusting strap bolt t o 23 N - m (200
i n . lbs.) torque (see Group 7, Cooling Section o n ad- If wear exceeds 0.051 mm
(0.002 inch), replace valve
j u s t i n g belt tension).
(24) Place new cylinder head cover gaskets i n posi- J9009-109
t i o n and i n s t a l l cylinder head covers. T i g h t e n t o 11
N-m (95 i n . lbs.) torque using load spreader fasten- Fig. 9 Valve Stem Diameters
ers.
(25) I n s t a l l closed crankcase v e n t i l a t i o n system and Remove carbon and v a r n i s h deposits from inside of
evaporation control system. valve guides w i t h a reliable guide cleaner.
Measure valve stem guide clearance as follows:
(26) F i l l cooling system.
(27) I n s t a l l battery ground cable. (a) I n s t a l l sleeve Tool C-3973 over valve stem
(Fig. 10) a n d i n s t a l l valve. The special sleeve
VALVES AND VALVE SPRINGS places the valve a t the correct h e i g h t for checking
w i t h a d i a l indicator.
The valves are arranged i n l i n e i n t h e cylinder (b) A t t a c h d i a l indicator Tool C-3339 to cylin-
heads and inclined 18 degrees. T h e rocker shaft sup- der head and set i t a t r i g h t angle of valve stem be-
port and t h e valve guides are cast i n t e g r a l w i t h the ing measured (Fig. 11).
heads.
 5.2L/5.9L ENGINE 9 - 45

Slowly t u r n reamer b y h a n d a n d clean guide t h o r -

oughly before i n s t a l l i n g n e w valve. D O N O T a t -
tempt t o ream t h e valve guides f r o m s t a n d a r d
d i r e c t l y t o 0 . 7 6 2 m m (0.030 i n c h ) . U s e s t e p p r o c e -
d u r e o f 0.127 m m 0.381 m m a n d 0.762 m m (0.005
f

i n c h , 0.015 i n c h a n d 0.030 i n c h ) so t h e v a l v e
guides m a y be reamed true i n relation t o t h e
v a l v e seat.

REFACING VALVES AND VALVE SEATS

The i n t a k e and exhaust valve seats a n d valve faces
have a 45° angle. The valve face a n d valve seat a n -
gles are shown i n (Fig. 13).

Fig. 10 Positioning Valve with Tool C-3973

VALVE /

A-SEAT WIDTH (INTAKE 1/16 (1.587 mm) TO 3/32 (2.381 mm) INCH
EXHAUST: (.08O-.1OO INCH) - (2-23 mm)
B-FACE ANGLE (INTAKE & EXHAUST: 44^°-45°)
C-SEAT ANGLE (INTAKE & EXHAUST: 45°-45M ) e

D-CONTACT SURFACE
PU605

Fig. 13 Valve Face and Seat Angles

VALVES
Inspect the r e m a i n i n g m a r g i n after t h e valves are
refaced. Valves w i t h less t h a n 1.190 m m (3/64 inch)
Fig. 11 Measuring Valve Guide Wear
m a r g i n should be discarded (Fig. 14).
(c) Move valve to and f r o m t h e indicator. T h e
t o t a l d i a l i n d i c a t o r reading should n o t exceed 0.432
JL
m m (0.017 inch). Ream t h e guides for valves w i t h INTAKE EXHAUST
oversize stems i f d i a l indicator r e a d i n g is excessive VALVE VALVE
or i f t h e stems are scuffed or scored.
Service valves w i t h oversize stems are available i n
0.127 m m (0.005 inch), 0.381 m m (0.015 inch) a n d
0.762 m m (0.030 inch) inch oversize. Reamers to ac-
commodate t h e oversize valve stem are as follows
(Fig. 12):

Reamer Reamer Valve Guide

Tool No. Oversize Size
C-3433 0.127 mm 9.63-9.65 mm
(0.005 inch) (0.379-0.380 inch)

C-3430 0.381 mm 9.88-9.91 mm

(0.015 inch) (0.389-0.390 inch) PU606
C-3427 0.762 mm 10.26-10.29 mm
(0.030 inch) (0.404-0.405 inch) Fig. 14 Intake and Exhaust Valves (Typical)

J9009-100

Fig. 12 Reamer Sizes

 VALVE SEATS ments are indicated o n t h e table for f i n e r adjust-
ments. Refer t o specifications t o o b t a i n specified
CAUTION: The 5.2L engine cylinder head combus- h e i g h t a n d allowable tensions. Discard t h e springs
tion chambers have been modified by valve shroud- t h a t do not meet specifications.
ing. DO NOT UNSHROUD VALVES DURING VALVE
SEAT REFACING (Fig. 15).

REFACING STONE f
MUST NOT CUT
VALVE SHROUD

RF259

Fig. 15 Refacing 5.2L Engine Valve Seats Fig. 16 Testing Valve Spring with Tool C-647

(1) When refacing valve seats, i t is i m p o r t a n t t h a t (2) Inspect each valve s p r i n g for squareness w i t h a
t h e correct size valve guide p i l o t be used for reseat- steel square and surface plate, test springs f r o m both
i n g stones. A true and complete surface m u s t be ob- ends (Fig. 17).
tained. (3) I f the s p r i n g is more t h a n 1.984 m m (5/16 inch)
(2) Measure the concentricity of valve seat using out o f square, i n s t a l l a new spring.
d i a l indicator No. 13725. Total r u n o u t should not ex-
ceed 0.051 m m (0.002 inch) (total indicator reading). ~ VALVE SPRING
(3) Inspect the valve seat w i t h Prussian blue to de-
t e r m i n e where the valve contacts t h e seat. To do
t h i s , coat valve seat L I G H T L Y w i t h Prussian blue
t h e n set valve i n place. Rotate t h e valve w i t h l i g h t
pressure. I f the blue is transferred to t h e center of
valve face, contact is satisfactory. I f the blue is trans-
ferred to top edge of valve face, lower valve seat w i t h
a 15° stone. I f the blue is transferred to bottom edge
of valve face raise valve seat w i t h a 60° stone.
(4) When seat is properly positioned t h e w i d t h of SQUARE
i n t a k e seats should be 1.587 to 2.381 m m (1/16 to 3/
32 inches). The w i d t h of the exhaust seats should be
2.0 t o 2.5 m m (5/64 to 3/32 inches).
RF180
TESTING VALVE SPRINGS
Fig. 17 Checking Valve Spring for Squareness
(1) Whenever valves have been removed for inspec-
t i o n , reconditioning or replacement, valve springs INSTALLATION
should be tested. As a n example t h e compression Installing the wrong exhaust valve spring i n
l e n g t h of the spring to be tested is 1-5/16 inches. engines w i t h positive rotors c a n c a u s e severe e n -
T u r n table of Tool C-647 (Fig. 16) u n t i l surface is i n gine damage. R e f e r to specifications for p r o p e r
l i n e w i t h the 1-5/16 i n c h m a r k o n the threaded stud identification.
and t h e zero m a r k to t h e front. Place s p r i n g over (1) Coat valve stems w i t h l u b r i c a t i o n o i l and insert
stud on t h e table and l i f t compressing lever to set t h e m i n cylinder head.
tone device. P u l l on torque wrench u n t i l p i n g is (2) I f valves or seats are reground, check valve
heard. Take reading on torque wrench a t t h i s i n - stem height w i t h Tool C-3968 (Fig. 18). I f valve is
stant. M u l t i p l y this reading by two. This w i l l give
t h e spring load at test length. F r a c t i o n a l measure-
 • 5.2L/5.9L ENGINE
Fig. 18 Measuring Valve Stem Length with Tool
C-3968
too long, g r i n d off t i p u n t i l l e n g t h is w i t h i n l i m i t s . I f
engine is e q u i p p e d w i t h rotators, d o n o t g r i n d
v a l v e s t e m tip.
(3) I n s t a l l n e w cup seals on a l l valve stems a n d
over valve guides (Fig. 19). I n s t a l l valve springs a n d
valve retainers.
(4) Compress valve springs w i t h Tool C-3422-A, i n -
s t a l l locks a n d release tool. I f valves and/or seats are
reground, measure t h e installed height o f springs,
m a k e sure measurement is t a k e n f r o m bottom o f
s p r i n g seat i n cylinder head to t h e bottom surface o f
spring r e t a i n e r ( i f spacers are installed, measure
f r o m t h e t o p o f spacer). I f height is greater t h a n
42.86 m m (1-11/16 inches), i n s t a l l a 1.587 m m (1/16
inch) spacer i n head counterbore to b r i n g s p r i n g
h e i g h t back t o n o r m a l 41.27 t o 42.86 m m (1-5/8 t o
1-11/16 inches) E x h a u s t valve springs w i t h positive
rotators should have a l e n g t h o f 36.8-38.1 m m (1.45-
1.51 inch) w h e n t h e valve is closed.
Fig. 19 Installing Valve, Cup Seal, Spring,
Retainer
9 - 47
REPLACING VALVE STEM SHIELDS OR VALVE
SPRINGS, CYLINDER HEAD NOT REMOVED
(1) Set engine basic t i m i n g to T D C and remove A i r
Cleaner.
(2) Remove cylinder head covers and spark plugs.
(3) Remove coil w i r e from d i s t r i b u t o r and secure t o
good g r o u n d to prevent engine f r o m s t a r t i n g .
(4) U s i n g suitable socket and flex handle a t crank-
shaft p u l l e y r e t a i n i n g bolt, t u r n engine so the n u m -
ber 1 piston is a t Top Dead Center on t h e
compression stroke.
(5) Remove rocker arms w i t h rocker shaft and i n -
s t a l l a d u m m y shaft. (The rocker arms should not be
disturbed and left on shaft).
(6) W i t h a i r hose attached to adapter Tool C-3907
installed i n number 1 spark p l u g hole, apply 620 t o
689 k P a (90 to 100 psi) a i r pressure. M a k e sure pis-
t o n i n cylinder is a t TDC on the valve spring t h a t is
being removed.
(7) U s i n g Tool C-3906 or C-4228 compress valve
spring a n d remove retainer valve locks a n d valve
spring.
(8) I n s t a l l cup shields on t h e exhaust valve stem
and position down against valve guides.
(9) T h e i n t a k e valve stem seals should be pushed
f i r m l y and squarely over the valve guide using t h e
valve stem as a guide. DO N O T Force seal against
top o f guide. W h e n i n s t a l l i n g t h e valve r e t a i n e r
locks, compress the spring only enough t o i n s t a l l t h e
locks.
(10) Follow the same procedure on the r e m a i n i n g 7
cylinders using the f i r i n g sequence 1-8-4-3-6-5-7-2.
(11) Remove adapter Tool 3907.
(12) Remove d u m m y shaft and i n s t a l l rocker shaft
w i t h rocker arms.
(13) I n s t a l l covers and coil w i r e to distributor.
(14) I n s t a l l a i r cleaner.
(15) Road test vehicle.
HYDRAULIC TAPPETS
PRELIMINARY STEP TO CHECKING THE
HYDRAULIC TAPPETS
Before disassembling any part o f the engine to cor-
rect tappet noise, read the oil pressure a t the gauge
( I n s t a l l a reliable gauge at pressure sending u n i t i f
vehicle has no o i l pressure gauge) and check o i l level
i n the o i l pan. The pressure should be between 207 t o
552 k P a (30 and 80 psi) a t 3000 r p m .
The o i l level i n the pan should never be above t h e
F U L L m a r k on the dipstick, or below the A D D O I L
m a r k . E i t h e r of these two conditions could be respon-
sible for noisy tappets.
and
OIL LEVEL TOO HIGH
I f o i l level is above the F U L L m a r k on dipstick, i t
is possible for the connecting rods to dip i n t o the o i l
9 - 48 5.2L/5.9L ENGINE
w h i l e engine is r u n n i n g and create foam. Foam i n o i l
p a n w o u l d be fed t o t h e hydraulic tappets b y the o i l
p u m p causing t h e m t o lose l e n g t h and allow valves
to seat n o i s i l y .
OIL LEVEL TOO LOW
Low o i l level may allow pump to take i n a i r w h i c h
w h e n fed t o t h e tappets, cause t h e m to lose length
and allows valves t o seat noisily. A n y leaks o n i n -
t a k e side o f o i l p u m p t h r o u g h w h i c h a i r can be
d r a w n w i l l create the same tappet action. W h e n tap-
pet noise is due t o aeration, i t may be i n t e r m i t t e n t or
constant, a n d u s u a l l y more t h a n one tappet w i l l be
noisy. W h e n o i l level and leaks have been corrected,
engine should be operated a t fast idle for sufficient
t i m e t o a l l o w a l l o f t h e a i r inside o f the tappets to be
bled out.
TAPPET NOISE DIAGNOSIS
(1) To determine source of tappet noise, operate en-
gine a t idle w i t h cylinder head covers removed.
(2) Feel each valve spring or rocker a r m to detect
noisy tappet. The noisy tappet w i l l cause the affected
s p r i n g and/or rocker a r m to vibrate or feel r o u g h i n
operation.
W o r n v a l v e guides o r c o c k e d springs a r e some
times m i s t a k e n for n o i s y tappets. I f s u c h i s the
case, 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
t h r u s t o n the v a l v e spring. I f noise i s not appre-
c i a b l y r e d u c e d , i t c a n be a s s u m e d the noise i s i n
the tappet. I n s p e c t the r o c k e r a r m p u s h r o d
s o c k e t s a n d p u s h r o d ends for wear.
(3) V a l v e tappet noise ranges from l i g h t noise to a
heavy click. A l i g h t noise is usually caused by exces-
sive leak-down around the u n i t plunger w h i c h w i l l
necessitate replacing t h e tappet, or by t h e plunger
p a r t i a l l y s t i c k i n g i n t h e tappet body cylinder. A
heavy click is caused either b y a tappet check valve
not seating, or by foreign particles becoming wedged
between t h e plunger a n d t h e tappet body, causing
the p l u n g e r t o stick i n the down position. T h i s heavy
click w i l l be accompanied by excessive clearance be-
tween t h e valve stem and rocker a r m as valve closes.
I n e i t h e r case, tappet assembly should be removed
for inspection and cleaning.
REMOVAL
(1) Remove the a i r cleaner.
(2) Remove valve cover a n d rocker assembly and
push rods a n d identify push rods to insure installa-
t i o n i n o r i g i n a l location.
(3) W i t h roller tappets, remove i n t a k e manifold,
yoke r e t a i n e r and a l i g n i n g yoke.
(4) Slide Tool C-4129 t h r o u g h opening i n cylinder
head and seat tool f i r m l y i n the head of tappet.
(5) P u l l tappet out of bore w i t h a t w i s t i n g motion.
I f a l l tappets are t o be removed, identify tappets to
insure i n s t a l l a t i o n i n o r i g i n a l location.
•
CAUTION: 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
work on one tappet at a time to avoid mixing of
parts. Mixed parts are not compatible. Oo not disas-
semble a tappet on a dirty work bench.
DISASSEMBLY
(1) P r y out plunger retainer s p r i n g clip.
(2) Clean v a r n i s h deposits f r o m inside o f tappet
body above plunger cap.
(3) I n v e r t tappet body a n d remove plunger cap,
plunger, f l a t or b a l l check valve, check valve s p r i n g ,
check valve r e t a i n e r and plunger spring.
CLEANING AND ASSEMBLY
(1) Clean a l l tappet parts i n a solvent t h a t w i l l re-
move a l l v a r n i s h a n d carbon.
(2) Replace tappets t h a t are u n f i t for f u r t h e r ser-
vice w i t h n e w assemblies.
(3) I f plunger shows signs of scoring or wear a n d
v a l v e is p i t t e d , or i f valve seat on end o f plunger i n -
dicates a n y condition t h a t w o u l d prevent valve f r o m
seating, i n s t a l l a n e w tappet assembly.
(4) Assemble tappets (Fig. 1).
"FLAT" TAPPET CHECK PLUNGER
TAPPET BODY SPRING PLUNGER CAP RR09B139
Fig. 1 Hydraulic Tappet Assemblies
INSTALLATION
(1) L u b r i c a t e tappets.
(2) I n s t a l l tappets and push rods i n t h e i r o r i g i n a l
positions.
(3) I n s t a l l rocker a r m and shaft assembly.
(4) I n s t a l l vent cover.
(5) I n s t a l l d i s t r i b u t o r , start engine and reset t i m -
ing.
CAUTION: To prevent damage to valve mechanism,
engine must not be run above fast idle until all hy-
draulic tappets have filled with oil and have become
quiet.
VALVE TIMING
(1) T u r n crankshaft u n t i l the No. 6 exhaust valve
is closing and No. 6 i n t a k e valve is opening.
 • 5.2L/5.9L ENGINE
(2) Insert a 6.350 m m (1/4 inch) spacer between
rocker a r m pad a n d stem t i p of No. 1 i n t a k e valve.
A l l o w s p r i n g load t o bleed tappet down g i v i n g i n ef-
fect a solid tappet.
(3) I n s t a l l a d i a l i n d i c a t o r so plunger contacts valve
spring retainer as n e a r l y perpendicular as possible.
Zero the indicator.
(4) Rotate the crankshaft clockwise (normal r u n -
n i n g direction) u n t i l t h e valve has lifted 0.254 m m
(0.010 inch) for 5.2L engines, 0.863 m m (0.034 inch)
for 5.9L engine.
CAUTION: Do not turn crankshaft any further clock-
wise as valve spring might bottom and result in se-
rious damage.
The t i m i n g of t h e crankshaft pulley should now
read from 10° before top dead center to 2° top dead
center. Remove spacer.
(5) I f reading is n o t w i t h i n specified l i m i t s :
(a) Check sprocket index m a r k s .
(b) Inspect t i m i n g chain for wear.
(c) Check accuracy of DC m a r k on t i m i n g i n d i -
cator.
TIMING CHAIN COVER, OIL SEAL AND CHAIN
COVER REMOVAL
(1) D r a i n cooling system.
(2) Refer to Group 7, Cooling System for procedure
to remove water p u m p .
(3) Remove power steering pump.
(4) Remove p u l l e y f r o m v i b r a t i o n damper and bolt
and washer securing v i b r a t i o n damper on crankshaft.
(5) I n s t a l l bar f r o m Tool (C-3688) and screw from
Tool (C-3732A) and p u l l v i b r a t i o n damper from end
of crankshaft (Fig. 2).
(6) Remove fuel lines.
(7) Loosen o i l p a n bolts and remove the front bolt
a t each side.
(8) Remove chain case cover and gasket u s i n g ex-
treme caution t o avoid damaging o i l pan gasket.
Fig. 2 Removing Vibration Damper with Tool C-3688
9 - 49
MEASURING TIMING CHAIN FOR STRETCH
(1) Place a scale next to the t i m i n g chain so t h a t
any movement o f t h e chain may be measured.
(2) Place a torque wrench and socket over camshaft
sprocket a t t a c h i n g bolt and apply torque i n direction
of crankshaft r o t a t i o n t o take up slack; 4 1 N n n (30
ft. lbs.) w i t h (cylinder head installed) or 20 N»m (15
ft. lbs.) (cylinder heads removed). W i t h a torque ap-
plied t o t h e camshaft sprocket bolt, crankshaft
should n o t be p e r m i t t e d to move. I t may be necessary
to block t h e crankshaft t o prevent r o t a t i o n .
(3) H o l d i n g a scale w i t h dimensional reading even
w i t h t h e edge o f a c h a i n l i n k , apply torque i n the re-
verse d i r e c t i o n 14 N*m (30 f t . lbs.) ( w i t h cylinder
heads installed) or 20 N»m (15 f t . lbs.) (cylinder
heads removed) and note amount o f chain movement
(Fig. 3).
Fig. 3 Measuring Timing Chain Wear and Stretch
(4) I n s t a l l a new t i m i n g chain, i f its movement ex-
ceeds 3.175 m m (1/8 inch).
(5) I f c h a i n is not satisfactory, remove camshaft
sprocket a t t a c h i n g cup washer, and remove t i m i n g
chain w i t h crankshaft and camshaft sprockets.
(6) Place both camshaft sprocket and crankshaft
sprocket o n t h e bench w i t h t i m i n g marks o n exact
i m a g i n a r y center l i n e t h r o u g h b o t h camshaft and
crankshaft bores.
(7) Place t i m i n g c h a i n around both sprockets.
(8) T u r n crankshaft and camshaft t o line up w i t h
keyway location i n crankshaft sprocket and i n cam-
shaft sprocket.
(9) L i f t sprockets and chain (keep sprockets t i g h t
against t h e chain i n position as described).
(10) Slide both sprockets evenly over t h e i r respec-
t i v e shafts and use a straightedge to check alignment
of t i m i n g m a r k s (Fig. 4).
(11) I n s t a l l t h e cup washer, and camshaft bolt.
T i g h t e n b o l t t o 47 N-m (35 ft. lbs.).
(12) Check camshaft for 0.051 to 0.0152 m m (0.002
to 0.006 inch) end play w i t h a new t h r u s t plate and
g - 50 5.2L/5.9L ENGINE •
(3) Place the i n s t a l l i n g adapter C-4251-3 w i t h t h e
t h r u s t bearing and n u t on the shaft. T i g h t e n n u t u n -
t i l t o o l i s flush w i t h the t i m i n g chain cover (Fig. 6).

Fig. 4 Alignment of Timing Marks

up t o 0.254 m m (0.010 inch) end play w i t h a used
t h r u s t plate. I f not w i t h i n these l i m i t s i n s t a l l a new
t h r u s t plate. Fig. 6 Installing Oil Seal

TIMING CHAIN COVER EXTERNAL OIL SEAL (4) I n s t a l l v i b r a t i o n damper using Tool C-3688
(Fig. 7).
(5) I n s t a l l retainer bolt and washer and torque t o
REMOVAL 183 N - m (135 f t . lbs.) torque.
(1) Disconnect battery.
(6) I n s t a l l pulley on v i b r a t i o n damper and torque
(2) Loosen and remove belts f r o m crankshaft p u l -
to 23 N n n (200 i n . lbs.) torque.
ley.
(7) Set radiator shroud back over engine and i n -
(3) Remove r a d i a t o r shroud retainer screws and set
s t a l l f a n and belts.
shroud back over engine.
(8) I n s t a l l radiator shroud t o radiator.
(4) Remove fan and shroud from engine.
(9) Connect battery.
(5) Remove crankshaft p u l l e y and v i b r a t i o n damper
belt and washer f r o m end o f crankshaft.
(6) I n s t a l l bar f r o m Tool (C-3688) and screw from
Tool (C-3732A) and p u l l v i b r a t i o n damper from end
of crankshaft (Fig. 2).
(7) U s i n g a suitable tool behind t h e lips of the o i l
seal pry o u t w a r d , being careful not t o damage the
crankshaft seal surface of cover (Fig. 5).

Fig. 7 Installing Vibration Damper with Tool C-3688

COVER INSTALLATION
(1) Be sure m a t i n g surfaces of chain case cover and
cylinder block are clean and free from burrs.
(2) U s i n g a new cover gasket, carefully i n s t a l l
c h a i n case cover to avoid damaging o i l pan gasket. A
3.175 m m ( l / 8 t h inch) diameter bead of R T V sealer
Fig. 5 Removing Oil Seal is recommended on t h e o i l pan gasket. D O N O T
t i g h t e n bolts a t t h i s time.
INSTALLATION
(1) I n s t a l l new seal by i n s t a l l i n g t h e threaded shaft (3) Lubricate seal lip w i t h lubriplate, position v i -
b r a t i o n damper hub slot on crankshaft. Damper w i l l
p a r t of Tool (C-4251) into the threads o f the crank-
act as a p i l o t for the crankshaft seal.
shaft.
(4) Place i n s t a l l i n g tool, p a r t of Puller set Tool C-
(2) Place seal i n t o opening w i t h seal spring towards
3688 i n position and press vibration damper on
the inside of the engine.
crankshaft (Fig. 7).
 • 5.2L/5.9L ENGINE 9 - 51

(5) T i g h t e n c h a i n case cover bolts t o 4 1 N n n (30 f t .

lbs.) torque first, t h e n t i g h t e n o i l pan bolts to 23 N n n
(200 i n . lbs.) torque.
(6) I n s t a l l v i b r a t i o n damper retainer bolt w i t h
washer and t i g h t e n t o 183 N - m (135 ft. lbs.) torque.
(7) Position p u l l e y on v i b r a t i o n damper and attach
w i t h bolts a n d lockwashers. T i g h t e n to 23 N-m (200
i n . lbs.) torque.
(8) I n s t a l l fuel lines.
(9) I n s t a l l w a t e r p u m p and housing assembly using
new gaskets. T i g h t e n bolts to 4 1 N - m (30 f t . lbs.)
torque.
(10) I n s t a l l power steering pump.
(11) I n s t a l l f a n a n d belt, hoses and close drains.
(12) I n s t a l l r a d i a t o r shroud.
(13) F i l l cooling system.
RH157
CAMSHAFT (ENGINE REMOVED FROM VEHICLE)
The camshaft has a n i n t e g r a l o i l pump and distrib- Fig. 9 Location of Cup Plugs in Oil Galleries
u t o r drive gear, as shown i n (Fig. 8). Remove i n t a k e
manifold, cylinder head covers, t i m i n g case cover and
t i m i n g chain.

CUP WASHER

OIL PUMP AND

DISTRIBUTOR DRIVE
GEAR INTEGRAL
WITH CAMSHAFT
CAMSHAFT SPROCKET 8909-78

Fig. 8 Camshaft and Sprocket Assembly RH159\

REMOVAL
(1) Remove rocker a r m a n d shaft assemblies.
(2) Remove push rods a n d tappets; identify so each
p a r t w i l l be replaced i n i t s o r i g i n a l location.
(3) Remove d i s t r i b u t o r a n d l i f t out t h e o i l pump
and d i s t r i b u t o r drive shaft.
(4) Remove camshaft t h r u s t plate, note location of
o i l tab.
(5) I n s t a l l a long bolt i n t o f r o n t of camshaft to fa-
cilitate removal o f t h e camshaft; remove camshaft,
being careful not t o damage cam bearings w i t h t h e
cam lobes.
(6) To reduce i n t e r n a l leakage and help m a i n t a i n
higher o i l pressure a t idle, cup plugs have been
pressed i n t o o i l galleries b e h i n d the camshaft t h r u s t
plate (Fig. 9).
INSTALLATION
(1) Lubricate camshaft lobes and camshaft bearing
j o u r n a l s and insert t h e camshaft to w i t h i n 2 inches
of i t s final position i n cylinder block.
(2) I n s t a l l Tool C-3509 w i t h tongue back of distrib-
u t o r drive gear (Fig. 10).
Fig. 10 Camshaft Holding Tool C-3509 in Installed
Position
(3) H o l d tool i n position w i t h d i s t r i b u t o r lock plate
bolt. This tool w i l l restrict camshaft f r o m being
pushed i n too far a n d prevent k n o c k i n g out t h e welch
p l u g i n rear o f cylinder block. Tool should r e m a i n i n -
stalled u n t i l t h e camshaft and crankshaft sprockets
and t i m i n g chain have been installed.
(4) I n s t a l l camshaft t h r u s t plate and c h a i n o i l tab,
w i t h three bolts as shown i n (Fig. 11). M a k e sure
t a n g enters lower r i g h t hole i n t h r u s t plate. T i g h t e n
to 24 N - m (210 i n . lbs.) torque. Top edge o f t a b
should be flat against t h r u s t plate i n order t o catch
o i l for chain l u b r i c a t i o n .
(5) Place b o t h camshaft sprocket a n d crankshaft
sprocket on t h e bench w i t h t i m i n g m a r k s o n exact
i m a g i n a r y center line t h r o u g h both camshaft a n d
crankshaft bores.
(6) Place t i m i n g chain around both sprockets.
(7) T u r n crankshaft and camshaft to l i n e u p w i t h
keyway location i n crankshaft sprocket and i n cam-
shaft sprocket.
9 - 52 5.2L/5.9L ENGINE
Fig. 11 Timing Chain Oil Tab Installation
(8) L i f t sprockets and chain (keep sprockets t i g h t
against the c h a i n i n position as described).
(9) Slide both sprockets evenly over t h e i r respective
shafts and use a straightedge to check a l i g n m e n t o f
t i m i n g marks (Fig. 12).
(10) I n s t a l l t h e cup washer, a n d camshaft bolt.
T i g h t e n bolt t o 47 N * m (35 ft. lbs.) torque.
(11) Measure camshaft end play. Refer to Specifica-
tions for proper clearance. I f not w i t h i n l i m i t s new
t h r u s t plate.
(12) Each tappet reused m u s t be installed i n t h e
same position from w h i c h i t was removed. Tappets
m u s t have a definite crown. When camshaft is r e
placed, a l l of the tappets m u s t be replaced.
Fig. 12 Alignment of Timing Marks
•
CAMSHAFT BEARINGS (ENGINE REMOVED FROM
VEHICLE)
REMOVAL
(1) W i t h engine completely disassembled, drive out
rear cam b e a r i n g core hole p l u g .
(2) I n s t a l l proper size adapters a n d horseshoe
washers (part o f Tool C-3132-A) a t back o f each bear-
i n g s h e l l t o be removed and drive o u t bearing shells
(Fig. 13).
Fig. 13 Removal and Installation of Camshaft
Bearings with Tool C-3132A
INSTALLATION
(1) I n s t a l l n e w camshaft bearings w i t h Tool C-
3132-A b y s l i d i n g t h e n e w camshaft b e a r i n g shell
over proper adapter.
(2) Position rear bearing i n the tool. I n s t a l l horse-
shoe lock and b y reversing removal procedure, care-
f u l l y d r i v e b e a r i n g shell i n t o place.
(3) I n s t a l l r e m a i n i n g bearings i n the same manner.
Bearings m u s t be carefully aligned t o b r i n g o i l holes
into f u l l register w i t h o i l passages f r o m t h e m a i n
bearing. Also, n u m b e r two bearing m u s t index w i t h
the o i l passage t o the left cylinder head and n u m b e r
four b e a r i n g m u s t index w i t h the o i l passage t o the
r i g h t cylinder head. I f the camshaft bearing shell o i l
holes are not i n exact alignment, remove and i n s t a l l
t h e m correctly. I n s t a l l a new core hole p l u g a t t h e
rear o f camshaft. Be sure t h i s p l u g does not leak.
DISTRIBUTOR DRIVE SHAFT BUSHING
REMOVAL
(1) I n s e r t Tool C-3052 i n t o old b u s h i n g and t h r e a d
down u n t i l a t i g h t fit is obtained (Fig. 14).
(2) H o l d p u l l e r screw and t i g h t e n p u l l e r n u t u n t i l
b u s h i n g is removed.
INSTALLATION
(1) Slide new b u s h i n g over b u r n i s h i n g end o f Tool
C-3053 and i n s e r t the tool and b u s h i n g i n t o the bore.
(2) D r i v e b u s h i n g and tool i n t o position, u s i n g a
h a m m e r (Fig. 15).
 • 5.2L/5.9L ENGINE 9 - 53

(2) When i n t h i s position, t h e t i m i n g m a r k on v i -

b r a t i o n damper should be u n d e r " 0 " on the t i m i n g i n -
dicator.
(3) Coat shaft and drive gear w i t h engine oil. I n -
s t a l l the shaft so t h a t after gear spirals into place, i t
w i l l index w i t h the oil p u m p shaft, so slot i n top of
drive gear w i l l point i n a direction parallel to t h e
centerline of the crankshaft (Fig. 17).
\ i
I DISTRIBUTOR DRIVE

Fig. 14 Removing Distributor Drive Shaft Bushing

with Tool C-3052

PU192B

Fig. 17 Position or Installed Distributor Drive Gear

RH164 INSTALLATION OF DISTRIBUTOR
(1) H o l d the d i s t r i b u t o r over the m o u n t i n g pad on
Fig. 15 Installing Distributor Drive Shaft Bushing cylinder block w i t h vacuum chamber p o i n t i n g toward
with Tool C-3053 r i g h t front o f engine.
(3) A s the burnisher is pulled t h r o u g h t h e bushing (2) T u r n rotor u n t i l i t points forward and to ap-
b y t i g h t e n i n g t h e puller n u t , t h e b u s h i n g is ex- proximate location of No. 1 tower t e r m i n a l i n distrib-
panded t i g h t i n block and burnished t o correct size u t o r cap (Fig. 18).
(Fig. 16). D O N O T R E A M T H I S B U S H I N G . (3) Place d i s t r i b u t o r " O " r i n g i n position.
(4) Lower the d i s t r i b u t o r a n d engage t h e shaft i n
the slot of d i s t r i b u t o r drive shaft gear.
BUSHING

LEFT BANK
® 9

DISTRIBUTOR ROTOR
(RIGHT ROTATION)

FRONT OF r - \
ENGINE " - V

RIGHT BANK
© © (5 ©
Fig. 16 Burnishing Distributor Drive Shaft Bushing
RN855
DISTRIBUTOR TIMING
Fig. 18 Distributor with Rotor Positioned Under No.
Before i n s t a l l i n g the d i s t r i b u t o r and o i l p u m p drive 1 Tower of Cap
shaft, time engine as follows:
(1) Rotate crankshaft u n t i l No. 1 cylinder is a t top
dead center on the f i r i n g stroke.
9 - 54 5.2L/5.9L ENGINE •
CYLINDER BLOCK

PISTON REMOVAL
(1) Remove top ridge of cylinder bores w i t h a r e l i -
able ridge reamer before r e m o v i n g pistons f r o m cyl-
inder block. Be sure t o keep tops o f pistons covered
d u r i n g t h i s operation. Pistons a n d connecting rods
must be removed f r o m top o f cylinder block. W h e n
removing piston and connecting r o d assemblies from
the engine, rotate crankshaft so t h a t each connecting
rod is centered i n cylinder bore.
(2) Inspect connecting rods a n d connecting rod caps
for cylinder identification. I d e n t i f y t h e m i f necessary.
(3) Remove connecting r o d cap. I n s t a l l connecting Fig. 1 Core Hole Plug
rod bolt guide set on connecting r o d bolts. Push each
INSTALLATION
piston a n d r o d assembly o u t o f cylinder bore. Be
Thoroughly clean inside o f cup p l u g hole i n c y l i n -
careful not to nick crankshaft j o u r n a l s .
der block or head. Be sure t o remove o l d sealer.
(4) After removal, i n s t a l l b e a r i n g cap on the mat-
L i g h t l y coat inside o f cup p l u g hole w i t h Loctite S t u d
i n g rod. N ' B e a r i n g M o u n t or equivalent. M a k e certain t h e
new p l u g is cleaned of a l l o i l or grease. U s i n g proper
CLEANING AND INSPECTION
drive p l u g , drive p l u g i n t o hole so t h a t t h e sharp
(1) Clean cylinder block t h o r o u g h l y a n d check a l l
edge o f the p l u g is a t least 0.50 m m (0.020 inch) i n -
core hole plugs for evidence o f l e a k i n g .
side the lead-in chamfer.
(2) I f new core plugs are i n s t a l l e d , coat edges of
I t is not necessary t o w a i t for c u r i n g of the sealant.
p l u g and core hole w i t h M O P A R Gasket M a k e r or The cooling system can be filled a n d t h e vehicle
equivalent. Drive t h e core p l u g i n so t h a t t h e r i m placed i n service i m m e d i a t e l y .
lies at least 0.397 m m (1/64 inch) below the lead-in
chamfer. PISTONS, PINS AND RINGS
(3) E x a m i n e block for cracks or fractures.
The pistons are cam g r o u n d so t h a t the diameter a t
CYLINDER BORE INSPECTION the p i n boss is less t h a n i t s diameter across t h e
The cylinder walls should be checked for out- t h r u s t face. This allows for expansion under n o r m a l
of-bound and taper w i t h Tool C-119. I f the cylinder operating conditions. U n d e r operating temperatures,
bores show more t h a n 0.127 m m (0.005 inch) out-of- expansion forces t h e p i n bosses away from each
round, or a taper of more t h a n 0.254 m m (0.010 inch) other, t h u s , causing t h e piston t o assume a more
or i f the cylinder w a l l s are badly scuffed or scored, nearly r o u n d shape. I t is i m p o r t a n t t h a t pistons be
the cylinder block should be bored a n d honed, a n d checked for taper and e l l i p t i c a l shape before they are
fitted i n t o t h e cylinder bore (Figs. 2 and 3).
new pistons and rings fitted. Whatever type of boring
equipment is used, boring a n d h o n i n g operation
should be closely coordinated w i t h t h e fitting o f pis-
tons and rings i n order t h a t specified clearances may
be m a i n t a i n e d .

ENGINE CORE OIL AND CAM PLUGS

REMOVAL
U s i n g a b l u n t tool such as a d r i f t or a screwdriver
and a hammer, s t r i k e t h e b o t t o m edge o f the cup
p l u g (Fig. 1). W i t h the cup p l u g r o t a t e d , grasp firmly
w i t h pliers or other suitable tool a n d remove p l u g SHAPE OF THE PISTON SKIRT .000 TO .0006 INCH (.0152 mm)
(Fig. 1). SHOULD BE .010 TO .012 IN. LARGER THAN (C)
(.254 TO .304 mm) LESS AT DIAMETER
(A) THAN ACROSS THE THRUST
CAUTION: Do not drive cup plug into the casting as FACES AT DIAMETER (B) 8909-62
restricted cooling can result and cause serious en-
gine problems. Fig. 2 Piston Measurements—5.2L Engine
 • 5.2L/5.9L ENGINE 9 - 55

3.969 T O 3.974- 0.907 m m (0.036 inch) for compression r i n g s a n d

1.778 m m (0.070 inch) for o i l r i n g steel rails.
(3) Measure side clearance between piston r i n g and
r i n g l a n d (Fig. 4). Clearance should be 0.038 t o 0.076
m m (0.0015 t o 0.003 inch) for t h e t o p compression
r i n g and t h e intermediate r i n g . Steel r a i l service o i l
r i n g should be free i n groove, b u t should not exceed
0.127 m m (0.005 inch) side clearance.

THE ELLIPTICAL SHAPE OF THE DIAMETER (D) SHOULD BE PISTON RING FEELER GAUGE
PISTON SKIRT SHOULD BE .011 .0000 TO .0005 (.0152 mm)
(.279 mm) TO .013 (.330 mm) IN. IN. LARGER THAN (C)
LESS AT DIAMETER (A) THAN
ACROSS THE THRUST FACES AT
DIAMETER (B) RR09B140

Fig. 3 Piston Measurements—5.9L Engine

FINISHED PISTONS
A l l pistons are machined t o t h e same w e i g h t i n
grams, regardless o f oversize, t o m a i n t a i n p i s t o n b a l -
ance. F o r cylinder bores w h i c h have been honed or
bored new pistons are furnished w i t h f i t t e d pins,
available i n standard a n d t h e f o l l o w i n g oversize:
0.508 m m (0.020 inch).
FITTING PISTONS
Piston and cylinder w a l l m u s t be clean a n d dry.
Specified clearance between the piston and t h e c y l i n -
der w a l l is 0.0127 t o 0.0381 m m (0.0005 t o 0.0015
inch).
Piston diameter should be measured a t t h e top o f
s k i r t 90° t o piston p i n axis. Cylinder bores should be
measured halfway down the cylinder bore a n d trans-
verse to the engine crankshaft center line.
Pistons a n d cylinder bores should be measured a t
n o r m a l room temperature, 21°C (70°F).
PISTON PINS
O n both t h e 5.2L and 5.9L engines, the p i s t o n p i n
rotates i n t h e piston only, and i s r e t a i n e d b y t h e
press interference f i t of the piston p i n i n t h e connect-
i n g rod.
FITTING RINGS
(1) Measure piston r i n g gap about t w o inches f r o m
b o t t o m of cylinder bore i n w h i c h i t is t o be f i t t e d . ( A n
i n v e r t e d piston can be used to push the r i n g s d o w n t o
i n s u r e p o s i t i o n i n g r i n g s squarely i n t h e c y l i n d e r bore
before measuring).
(2) Insert feeler stock i n t h e gap. T h e r i n g gap
should be between 0.254 and 0.508 m m (0.010 a n d
0.020 inch) for compression rings a n d 0.381 t o 1.575
m m (0.015 t o 0.062 inch) for o i l r i n g steel r a i l s i n
standard size bores (for new service rings). M a x i m u m
gap i n 0.127 m m (0.005 inch) O/S bores s h o u l d be
Fig. 4 Measuring Piston Ring Side Clearance
(4) O n both the 5.2L and 5.9L engines, the keys on
the spacer expander m u s t be inserted i n t o the hole i n
the o i l r i n g groove over t h e piston p i n front boss
(Fig. 5).
(5) A r r a n g e o i l r i n g r a i l gaps on inboard side of
piston as shown a t top o f (Fig. 5).
(6) I n s t a l l compression r i n g s i n m i d d l e a n d top
grooves; use R i n g I n s t a l l e r Tool C-3586 for 5.2L en-
gines, and Tool C-3562 for 5.9L engines or C-4184 for
both engines. Be sure the identification m a r k (a d r i l l
point, stamped letter O, oval depression or w o r d top)
on each compression r i n g is t o the top o f the piston
when r i n g is installed.
CRANKSHAFT IDENTIFICATION
A crankshaft w h i c h has one or more connecting rod
or m a i n bearing j o u r n a l s undersize w i l l be stamped
w i t h 1/4" letters on t h e m i l l e d f l a t o n t h e N o . 8
crankshaft counterweight on 5.2L crankshafts a n d on
the No. 3 crankshaft counterweight o f t h e 5.9L
crankshafts (Fig. 6).
R X indicates A L L r o d j o u r n a l s are 0.254 m m
(0.010 inch) undersize; M X indicates A L L m a i n jour-
nals are 0.254 m m (0.010 inch) undersize.
BALANCE OF V8 ENGINE DAMPER, CRANKSHAFT
AND TORQUE CONVERTER
The 5.9L engines have external crankshaft bal-
ance. E x t e r n a l balance is identified b y the off-center
weight cast i n t h e v i b r a t i o n damper h u b a n d t h e
9 - 56 5.2L/5.9L ENGINE •
t i o n a d a m p e r o r torque c o n v e r t e r b e i n g r e -
placed s h o u l d l o o k t h e same w i t h respect t o
h a v i n g o r n o t h a v i n g off-center w e i g h t s .
W h e n a crankshaft i s replaced, a l l m a i n a n d con-
necting r o d bearings should be replaced w i t h n e w
bearings. Therefore, selective f i t t i n g o f t h e bearings
is not r e q u i r e d when a c r a n k s h a f t a n d bearings are
replaced.

CONNECTING RODS

INSTALLING PISTON AND CONNECTING ROD

ASSEMBLY
(1) Before i n s t a l l i n g pistons, a n d connecting rod as-
semblies i n t o the bore, be sure t h a t compression r i n g
TOP VIEW OF BLOCK
gaps are staggered so t h a t n e i t h e r is i n l i n e w i t h o i l
A-EXPANDER GAPS B-RAIL GAPS
r i n g r a i l gap.
IF YOU HAVE FOLLOWED THE INSTRUCTIONS, (2) Before i n s t a l l i n g t h e r i n g compressor, make
THE RING WILL BE IN THIS POSITION ON THE sure t h e o i l r i n g expander ends a r e b u t t e d a n d t h e
PISTON. r a i l gaps located as shown i n (Fig. 5).
TOP RAIL G A P - r * 3 " - (3) Immerse the piston head a n d r i n g s i n clean en-
=0.62:
gine o i l , slide the r i n g compressor, Tool C-385, over
the p i s t o n and t i g h t e n w i t h t h e special w r e n c h (part
of Tool C-385). Be sure position o f r i n g s does n o t
change d u r i n g this operation.
BOTTOM
RAIL GAP (4) I n s t a l l connecting r o d b o l t protectors on r o d
bolts, t h e long protector should be i n s t a l l e d o n t h e
numbered side of the connecting r o d .
(5) Rotate crankshaft so t h a t t h e connecting r o d
ENDS
RN96 j o u r n a l is o n the center o f the c y l i n d e r bore. Insert
rod a n d piston into cylinder bore a n d guide r o d over
Fig. 5 Proper Oil Ring Installation the crankshaft j o u r n a l .
larger balance weights welded on t h e torque con- (6) T a p the piston d o w n i n c y l i n d e r bore, u s i n g a
verter. B o t h of these items w i l l be present o n a h a m m e r handle. A t the same t i m e , guide connecting
crankshaft w i t h external balance. rod i n t o position on crankshaft j o u r n a l .
Therefore, w h e n replacing the damper, c r a n k (7) T h e notch or groove o n t o p o f piston m u s t be
shaft, o r t o r q u e converter o n a n y V 8 engine i t is p o i n t i n g t o w a r d front o f engine a n d t h e larger cham-
i m p o r t a n t t o use c o r r e c t p a r t n u m b e r s . I n a d d i - fer of t h e connecting r o d bore m u s t be i n s t a l l e d t o -
w a r d crankshaft j o u r n a l f i l l e t .
Undersize Journal Identification Stamp (8) I n s t a l l rod caps, t i g h t e n n u t s t o 6 1 N»m (45 f t .
0.025 mm (0.001 inch) (Rod) R1-R2-R3 or R4 lbs.) torque.
0.254 mm (0.010 inch) (Rod) RX
0.025 mm (0.001 inch) (Main) M1-M2-M3-M4 or M5
0.254 mm (0.010 inch) (Main) AAX INSTALLATION OF CONNECTING ROD
BEARINGS
F i t a l l rods on one b a n k u n t i l completed. Do not a l -
(ROD)
5.2L ENGINE ternate f r o m one b a n k t o another, because w h e n the
(MAIN)
5.9L ENGINE rods are assembled t o pistons correctly, they are not
interchangeable from one b a n k t o another.
The bearing caps are n o t interchangeable a n d
should be marked a t r e m o v a l t o i n s u r e correct as-
sembly.
Each bearing cap has a s m a l l V groove across the
J9009-129 p a r t i n g face. When i n s t a l l i n g t h e lower bearing
shell, m a k e certain t h a t t h e V groove i n t h e shell is
Fig. 6 Location of Crankshaft Identification on No. 8 i n l i n e w i t h the V groove i n t h e cap. This provides
Counterweight l u b r i c a t i o n of the cylinder w a l l i n t h e opposite bank.
 • : 5.2L/5.9L ENGINE 9 - 57

The bearing shells m u s t be installed so t h a t t h e

tangs are i n the machined grooves i n the rods a n d
caps.
L i m i t s o f taper o r out-of-round o n any crankshaft
j o u r n a l s should be h e l d to 0.025 m m (0.001 inch).
Bearings are available i n 0.025 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) a n d 0.305 m m (0.012 inch) under-
size. I n s t a l l the bearings i n pairs. Do not use a new
b e a r i n g h a l f w i t h a n old bearing half. Do not file t h e
rods o r bearing caps.

CRANKSHAFT MAIN JOURNALS

The crankshaft j o u r n a l s should be checked for ex-
cessive wear, taper and scoring. L i m i t s of taper or
out-of-round o n a n y crankshaft j o u r n a l s should be
Fig. 7 Main Bearing Identification
h e l d t o 0.025 m m (0.001 inch). J o u r n a l g r i n d i n g
should not exceed 0.305 m m (0.012 inch) under t h e (2) Remove b e a r i n g caps one a t a t i m e . Remove up-
standard j o u r n a l diameter. D O N O T g r i n d t h r u s t per h a l f o f b e a r i n g b y i n s e r t i n g Tool C-3059 (Fig. 8)
faces o f N u m b e r 3 m a i n bearing. D O N O T n i c k i n t o the o i l hole of crankshaft.
c r a n k p i n or bearing fillets. After g r i n d i n g , remove (3) Slowly rotate crankshaft clockwise, forcing out
r o u g h edges from crankshaft o i l holes and clean out upper h a l f of b e a r i n g shell.
a l l o i l passages.

CAUTION: With the nodular cast iron crankshafts

used in all 5.2L and 5.9L engines it is important that
the final paper or cloth polish after any journal
grind be in the same direction as normal rotation in
the engine.

CRANKSHAFT MAIN BEARINGS

B e a r i n g caps are not interchangeable and should
be m a r k e d a t removal to insure correct assembly.
Upper a n d lower b e a r i n g halves are N O T i n t e r -
changeable on the 5.2L engine. Lower m a i n bearing
halves of 2 and 4 are interchangeable. Upper m a i n
b e a r i n g halves o f 2 and 4 are interchangeable. O n
t h e 5.9L engine 1, 2 and 4 upper and lower bearings
are grooved and are interchangeable on h i g h perfor-
mance only. Standard 5.9L engine uses p l a i n lower
m a i n bearings, (except No. 5).
Upper a n d lower N u m b e r 3 bearing halves are
have flanges to carry the crankshaft t h r u s t loads a n d
are N O T interchangeable w i t h a n y other b e a r i n g
halves i n the engine (Fig. 7). A l l bearing cap bolts
removed d u r i n g service procedures are t o be cleaned
a n d oiled before i n s t a l l a t i o n . B e a r i n g shells are
available i n standard 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 i n s t a l l an undersize bearing
t h a t w i l l reduce clearance below specifications.
REMOVAL
(1) Remove o i l p a n and identify bearing cap before
removal.
Fig. 8 Removing and Installing Upper Main Bearing
with Tool C-3059
INSTALLATION
O n l y one m a i n b e a r i n g should be selectively fitted
w h i l e a l l other m a i n bearing caps are properly t i g h t -
ened.
W h e n i n s t a l l i n g a new upper b e a r i n g shell, s l i g h t l y
chamfer the sharp edges from the p l a i n side.
(1) S t a r t b e a r i n g i n place, and i n s e r t Tool C-3059
i n t o o i l hole o f crankshaft (Fig. 8).
(2) Slowly rotate crankshaft counter-clockwise slid-
i n g the b e a r i n g i n t o position. Remove Tool C-3059.
REAR MAIN BEARING OIL SEALS
The 5.2L engine service seal is a t w o piece, fitted,
R O P E T Y P E . T h e upper rope seal h a l f can be i n -
stalled w i t h crankshaft removed or i n vehicle w i t h
 9 - 58 5.2L/5.9L ENGINE •
crankshaft installed. Lower rope seal h a l f is r e q u i r e d
i n s t a l l a t i o n w h e n upper seal is installed.
The 5.9L engine service seals are o f s p l i t R U B B E R
T Y P E composition. T h e upper seal (half) can be i n -
stalled w i t h o u t removing t h e crankshaft. T h e seal
m u s t be used as a complete upper and lower set.

5.2L ENGINE SEAL SERVICE

UPPER ROPE SEAL (IN VEHICLE-CRANKSHAFT INSTALLED)

(1) Remove defective upper seal a n d i n s t a l l n e w
one u s i n g O i l Seal Remover and I n s t a l l e r Tool K D -
492 or equivalent (which includes complete i n s t r u c -
tions a n d is available from most auto supply stores).
(2) Carefully, t r i m the upper seal after i n s t a l l a t i o n
to e l i m i n a t e frayed ends.

UPPER ROPE SEAL (CRANKSHAFT REMOVED)

(1) I n s t a l l a new rear bearing o i l seal i n t h e c y l i n -
der block so t h a t both ends protrude.
(2) U s i n g Tool C-3511, tap seal down i n t o position
u n t i l tool is seated i n bearing bore (Fig. 9).

Fig. 11 Rear Main Bearing Cap (5.2L Engine)

(6) I n s t a l l o i l pump. A d d sealer a t b e a r i n g cap t o
block j o i n t (Fig. 12) to provide o i l p a n end sealing.
Install oil pan.

Fig. 9 Installing Upper/Lower Oil Seal with Tool

C-3511
(3) H o l d tool i n t h i s position and cut off t h e p o r t i o n
of seal t h a t extends below the block (or cap) o n b o t h
sides (Fig. 10).

LOWER ROPE SEAL (CRANKSHAFT REMOVED)

(1) I n s t a l l a new seal i n bearing cap so t h a t b o t h
ends protrude.
(2) U s i n g Tool C-3511, tap seal down i n t o position
u n t i l tool is seated i n bearing bore.
(3) H o l d tool i n t h i s position and cut off t h e p o r t i o n
of t h e seal t h a t extends above the cap o n b o t h sides.
(4) I n s t a l l cap seals i n t o slots i n b e a r i n g cap (Fig.
11). I f t h i s is not done, o i l leakage w i l l occur. L i g h t l y
oil seals w i t h engine o i l . Fig. 12 Oil Pan End Seal at Rear Bearing
(5) Assemble bearing cap to cylinder block. I n s t a l l
cleaned and oiled cap bolts and torque t o 115 N * m
(85 ft. lbs.) torque.
 • 5 2L/5.9L ENGINE 9 - 59

5.9L ENGINE SEAL SERVICE (2) Raise vehicle. D r a i n engine o i l , remove exhaust
cross over pipe and remove left engine to t r a n s m i s -
REMOVING SEALS sion s t r u t .
Rubber Type-Lower. Remove o i l seal b y p u s h i n g (3) Remove o i l p a n bolts a n d remove o i l p a n .
the end w i t h a s m a l l screwdriver.
Rubber Type-Upper. Remove upper seal b y press- CLEANING AND INSPECTION
i n g w i t h a s m a l l screwdriver o n t h e end o f t h e seal (1) Clean o i l p a n i n solvent and wipe d r y w i t h a
being careful n o t t o damage t h e crankshaft (Fig. 13). clean cloth. Clean a l l gasket m a t e r i a l from m o u n t i n g
surfaces o f p a n a n d block.
INSTALLING SEALS (2) Inspect o i l d r a i n p l u g and p l u g hole for stripped
or damaged threads and repair as necessary. I n s t a l l
a new d r a i n p l u g gasket. T i g h t e n p l u g to 27 N»m (20
ft. lbs.) torque.
(3) Inspect o i l p a n m o u n t i n g flange for bends or
distortion. Straighten flange, i f necessary.
(4) Clean o i l screen a n d pipe thoroughly i n clean
solvent. Inspect condition o f screen.

INSTALLATION
(1) U s i n g a new p a n gasket, add drop o f R T V
sealer a t corners of rubber a n d cork (Fig. 15). Be
sure notches on side gaskets are installed as shown
Fig. 13 Removing Composition (Rubber Type) Seal
i n F i g . 15 (5.9L engines).
CAUTION: Always wipe crankshaft surface clean, (2) I n s t a l l p a n and t i g h t e n bolts to 23 N r m (200 i n .
then oil lightly before installing a new seal. lbs.) torque.
(3) I n s t a l l engine to transmission strut.
(1) L i g h t l y o i l lips of crankshaft seals.
(4) I n s t a l l exhaust cross over pipe. T i g h t e n t o 33
(2) Rotate h a l f seal i n t o cylinder block w i t h p a i n t N«m (24 f t . lbs.) torque.
stripe t o w a r d rear. Be careful n o t t o shave or c u t
(5) Lower vehicle and i n s t a l l o i l dipstick.
outer surface o f seal.
(6) Connect battery ground cable.
(3) Place t h e other h a l f seal i n bearing cap w i t h
(7) F i l l crankcase w i t h o i l t o proper level.
p a i n t stripe t o w a r d rear.
(4) A p p l y R T V sealer adjacent t o rubber seal (Fig.
14). Assemble b e a r i n g cap t o block immediately after
applying sealer. I n s t a l l cleaned a n d oiled bolts.
T i g h t e n t h e bolts t o 115 N - m (85 f t . lbs.) torque.
ADD SEALER

RH170

Fig. 14 Rear Main Bearing Cap (5.9L Engine)

OIL PAN

REMOVAL Fig. 15 Oil Pan Gaskets and Rear Seal Installation

(1) Disconnect b a t t e r y g r o u n d cable; remove engine
o i l dipstick.
9 - 60 5.2L/5.9L ENGINE •
OIL PUMP INSPECTION AND REPAIR
(1) Clean a l l parts thoroughly. M a t i n g surface o f
I t i s necessary t o remove the o i l pan, and remove the o i l pump cover should be smooth. Replace p u m p
t h e o i l p u m p f r o m rear m a i n bearing cap to service assembly i f cover is scratched or grooved.
the oil pump. (2) L a y a straightedge across the p u m p cover sur-
face (Fig. 18). I f a 0.038 m m (0.0015 inch) feeler
DISASSEMBLY
gauge can be inserted between cover and s t r a i g h t -
(1) To remove the r e l i e f valve, proceed as follows:
edge, p u m p assembly should be replaced.
(a) Remove cotter p i n , d r i l l a 3.175 m m (1/8
inch) hole i n t o the r e l i e f valve retainer cap and i n -
sert a self-threading sheet m e t a l screw into cap.
(b) C l a m p screw i n t o a vise and w h i l e support-
i n g o i l p u m p , remove cap b y t a p p i n g pump body
u s i n g a soft hammer. Discard retainer cap and re-
move s p r i n g and r e l i e f valve (Fig. 16).

Fig. 18 Checking Oil Pump Cover Flatness

(3) Measure thickness a n d diameter o f O U T E R ro-
tor. I f outer rotor thickness measures 20.9 m m (0.825
inch) or less, (Fig. 19), or the diameter is 62.7 m m
(2.469 inches) or less, replace outer rotor.

Fig. 16 Oil Pressure Relief Valve (Disassembled)

(2) Remove o i l pump cover bolts and lockwashers,
and l i f t o f f cover.
(3) Discard o i l seal r i n g .
(4) Remove pump rotor and shaft, and l i f t out outer
rotor.
(5) Wash a l l parts i n a suitable solvent and inspect
carefully for damage or wear (Fig. 17).
INNER ROTOR DISTRIBUTOR DRIVESHAFT

Fig. 19 Measuring Outer Rotor Thickness

(4) I f I N N E R rotor measures 20.9 m m (0.825 inch)
or less replace i n n e r rotor and shaft assembly (Fig.
20).
(5) Slide outer rotor i n t o pump body w i t h large
chamfered edge installed i n w a r d i n t o p u m p body
(Fig. 21), press t o one side w i t h fingers and measure
clearance between rotor and pump body (Fig. 21). I f
measurement is 0.356 m m (0.014 inch) or more, re-
place o i l pump assembly.
(6) I n s t a l l i n n e r rotor and shaft i n t o p u m p body. I f
Fig. 17 Oil Pump
clearance between inner and outer rotors (Fig. 22) is
0.203 m m (0.008 inch) or more, replace shaft a n d
both rotors.
 • 5.2L/5.9L ENGINE 9 - 61

Fig. 23 Measuring Clearance Over Rotors

Fig. 20 Measuring Inner Rotor Thickness t w e e n 19.5 a n d 20.5 pounds w h e n compressed t o 34.0
m m (1-11/32 inches). Replace spring t h a t fails t o
meet specifications ( F i g . 24).
(10) I f o i l pressure i s low a n d pump is w i t h i n spec-
ifications, inspect f o r w o r n engine bearings or other
reasons for o i l pressure loss.

Fig. 21 Measuring Outer Rotor Clearance in

Housing

RN98

OUTER
ROTOR Fig. 24 Proper Installation of Retainer Cap

OIL LINE PLUG

The o i l l i n e p l u g i s located i n the vertical passage
INNER,
ROTOR i n t h e block between the Oil-To-Filter and O i l - F r o m -
F i l t e r passages (Fig. 25). Improper i n s t a l l a t i o n or ab-
sence could cause erratic, low or no o i l pressure.

RH179
Fig. 22 Measuring Clearance Between Rotors
(7) Place a straightedge across t h e face of t h e
pump, between bolt holes. I f a feeler gauge of 0.004
i n c h (0.102 m m ) or more can be inserted between ro-
tors a n d t h e straightedge, replace p u m p assembly
(Fig. 23).
(8) Inspect o i l pressure r e l i e f valve plunger for
scoring a n d free operation i n i t s bore. S m a l l marks
m a y be removed w i t h 400-grit w e t or d r y sandpaper.
(9) The r e l i e f valve spring has a free l e n g t h of ap-
p r o x i m a t e l y 49.0 m m (1.95 inch) and should test be-
INSPECTION
(1) Remove o i l pressure sending u n i t from back o f
block.
(2) I n s e r t a 3.175 m m (1/8 inch) w i r e or equivalent
i n t o passage.
(3) P l u g should be 190.0 t o 195.2 m m (7-1/2 t o 7-
11/16 inches) f r o m machined surface of block ( F i g .
25).
(4) I f p l u g i s off location. Remove o i l pan a n d No. 5
m a i n b e a r i n g cap. Use suitable flat dowel to remove
p l u g and position p l u g properly. P l u g should be 54.0
to 57.7 m m (2-1/8 t o 2-5/16 inches) from b o t t o m o f
t h e block. Coat outside diameter of p l u g w i t h M O -
 9 - 62 5.2L/5.9L ENGINE •
OIL FLOWS TO ONLY ONE BRACKET ON
EACH HEAD. BRACKET IS SECOND FROM
REAR ON RIGHT HEAD. BRACKET IS
SECOND FROM FRONT ON LEFT HEAD

TO AAAIN TO CAMSHAFT
ROCKER SHAFT BEARINGS BEARINGS
OIL PASSAGE
OIL
SUPPLY
FROM HOLLOW
PUSH ROD ROCKER SHAFT
BRACKET

PASSAGE TO
OIL PASSAGE FOR OIL CYLINDER HEAD
PRESSURE INDICATOR LIGHT

RIGHT OIL GALLERY

PASSAGE
CAMSHAFT
REAR BEARING
OIL PUMP
OIL FROM FILTER
OIL INTAKE
TO CONNECTING
TO SYSTEM
ROD BEARINGS
OIL TO FILTER FEED FROM OIL GALLERY TO
#2 MAIN BEARING AND
CRANKSHAFT PASSAGE TO HEAD MAIN
FROM OIL PUMP 8909-79

Fig. 25 Engine Lubrication System

PAR (stud and bearing m o u n t adhesive) or equiva-
lent to assure retention o f position.
OIL FILLER CAP AND
(5) Assemble engine and check o i l pressure. GROMMET
EXTENSION

OIL PUMP ASSEMBLY AND INSTALLATION

(1) Assemble pump, using new parts as required.
(2) I n s t a l l n e w o i l seal rings between cover and
pump body. T i g h t e n cover bolts t o 11 N»m (95 i n .
lbs.) torque.
(3) P r i m e o i l p u m p before i n s t a l l a t i o n b y f i l l i n g ro-
tor cavity w i t h engine o i l .
(4) I n s t a l l o i l pump. D u r i n g i n s t a l l a t i o n slowly ro-
tate pump body t o ensure driveshaft-to-pump rotor
shaft engagement and t h a t p u m p i s f u l l y seated be-
OIL DIPSTICK AND TUBE
fore i n s t a l l i n g fasteners. T i g h t e n attaching bolts t o "SPIN-ON" OIL FILTER
41 N-m (30 f t . lbs.) torque. THROW-AWAY TYPE RN849

OIL FILTER Fig. 26 Oil Filter, Dipstick and Oil Filter

The o i l f i l t e r should be replaced to coincide w i t h
every second o i l change.
(1) U s i n g Tool C-4065, unscrew f i l t e r from base
and discard (Figs. 26 and 27).
• 5.2L/5.9L ENGINE 9 - 63

(2) Wipe base clean, t h e n inspect gasket contact

surface.
(3) Lubricate gasket o f new filter w i t h clean engine
oil.
(4) I n s t a l l and t i g h t e n filter t o 20 N-m (15ft.lbs.)
torque, or, 3/4 to 1 t u r n s after gasket contacts base.
Use filter wrench, i f necessary.
(5) Start engine a n d check for leaks.

Fig. 27 Removing Oil Filter with Tool C-4065

9 - 64 5.2L/5.9L ENGINE •
ENGINE SPECIFICATIONS—5.2L/5.9L

CYLINDER HEAD
0.0762 mm 0.003 inch
45°-45W»
Intake Valve Seat Width (Finish) 1.651-2.159 mm 0.065-0.085 inch
45°-45W
Exhaust Valve Seat Width (Finish) 2.032-2.540 mm 0.080-0.100 inch
0.8382 mm 0.033 inch

VALVE GUIDES
Cast in the Cylinder Head
. . . 9.500-9.525 mm 0.374-0.375 inch

VALVES (INTAKE)
45.212 mm 1.780 inch
(5.9L) . 47.752 mm 1.880 inch
Length Overall (5.2L) 126.03-126.67 mm 4.962-4.987 inch
(5.9L) 126.21-126.85 mm 4.969-4.994 inch
9.449-9.474 mm 0.372-0.373 inch
. 0.0254-0.0762 mm 0.001-0.003 inch
0.4318 mm 0.017 inch
44Vfe°-45°
Lift (Zero Lash) (5.2L) 9.474 mm 0.373 inch
(5.9L) 10.414 mm 0.410 inch
Standard
0.127 mm 0.005 inch
0.381 mm 0.0015 inch
0.762 mm 0.030 inch

VALVES (EXHAUST)
1.517 inch
(5.9L) 1.617 inch
Length (Overall)
. . . . . . . . 126.21-127.13 mm 4.969-5.005 inch
126.42-127.30 mm 4.977-5.012 inch
(5.9L) . 126.44-127.30 mm 4.978-5.012 inch
9.423-9.449 mm 0.371-0.372 inch
0.0508-0.1016 mm 0.002-0.004 inch
0.017 inch
44Vfe°-45°
0.400 inch
(5.9L) 0.410 inch
Standard
0.127 mm 0.005 inch
0.381 mm 0.0015 inch
0.762 mm 0.030 inch

VALVE TIMING
10° (5.2L) 18° (5.9L)
50° (5.2L) 54" (5.9L)
52° (5.2L) 57° (5.9L)
16° (5.2L) 15° (5.9L)
26° (5.2L) 33° (5.9L)
240° (5.2L) 252° (5.9L)
. 248° (5.2L) 252° (5.9L)

J9009-125
• 5.2L/5.9L ENGINE 9-65

ENGINE SPECIFICATIONS-5.2L/5.9L (CONT.)

VALVE SPRINGS

8 Springs
Blue
(Exhaust with Rotators - 5.2L) White
(Exhaust with Rotators - 5.9L) Yellow
50.80 mm 2.00 inch
(Exhaust) 45.97 mm 1.81 inch
4.877 mm 0.192 inch
(Exhaust with Rotators - 5.2L) 4.699 mm 0.185 inch
(Exhaust with Rotators - 5.9L) 4.877 mm 0.192 inch
6.4 coils
(Exhaust with Rotators - 5.2L) 5.8 coils
(Exhaust with Rotators - 5.9L) 5.6 coils
Load When Compressed (Intake) 347-391 N 78-88 lbs.
(Valve Closed) @ 42.86 mm @ 1-11/16 inch
(Exhaust) 356-400 N 80-90 lbs.
@ 37.70 mm @1-31/64 inch
756-818 N 170-184 lbs.
(Valve Open) @ 33.34 mm @ 1-5/16 inch
(5.2L - Exhaust) 801-863 N 180-194 lbs.
@ 27.38 mm @ 1-5/64 inch
(5.9L - Exhaust) 805-876 N 181-197 lbs.
@ 26.99 mm @ 1-1/16 inch
Max. Allowable Out-of-Plumb 1.588 mm 1/16 inch
Valve Spring Installed (Intake) 41.275-42.86 mm 1-5/8 1-11/16 inch
36.909-38.497 mm 1-29/64 1-33/64 inch

Use a 1/16 inch spacer to reduce spacing height when over specifications

TIMING CHAIN

68 links
Pitch 9.525 mm 0.375 inch
Width 15.875 mm 0.625 inch

TAPPETS

Type . • • Hydraulic
22.949-22.962 mm 0.9035-0.904 inch
0.0279-0.0610 mm 0.0011-0.0024 inch
1.524-5.334 mm 0.060-0.210 inch
Push Rod Length (5.2L) 172.57-173.08 mm 6.794-6.814 inch
(5.9L) 190.63-191.14 mm 7.505-7.525 inch
Standard Standard
0.0254 mm 0.001 inch
0.2032 mm 0.008 inch
0.7620 mm 0.030 inch

J9009-126
9 - 66 5.2L/5.9L ENGINE •
ENGINE SPECIFICATI0NS-5.2L/5.9L (CONT.)

CAMSHAFT
Chain
Steel Backed Babbitt
5
. . . . . . . . . . 0.0254-0.0762 mm 0.001-0.003 inch
0.127 mm 0.005 inch
Thrust Plate
0.0508-0.254 mm 0.002-0.010 inch
0.254 mm 0.010 inch

CAMSHAFT JOURNALS
50.749-50.775 mm 1.998-1.999 inch
50.343-50.368 mm 1.982-1.983 inch
. 49.962-49.987 mm 1.967-1.968 inch
49.555-49.581 mm 1.951-1.952 inch
39.637-39.662 mm 1.5605-1.5615 inch

CAMSHAFT BEARINGS
50.800-50.825 mm 2.000-2.001 inch
50.394-50.419 mm 1.984-1.985 inch
50.013-50.038 mm 1.969-1.970 inch
49.606-49.632 mm 1.953-1.954 inch
39.688-39.713 mm 1.5625-1.5635 inch

CYLINDER BLOCK
99.31-99.36 mm 3.910-3.912 inch
(5.9L) 101.60-101.65 mm 4.000-4.002 inch
Cylinder Bore Out-of-Round
0.005 inch
Cylinder Bore Taper
0.010 inch
0.025 mm 0.001 inch
0.040 inch
22.99-23.01 mm 0.9051-0.9059 inch
Distributor Lower Drive Shaft
0.0005-0.014 inch
0.0007-0.0027 inch

CONNECTING RODS
6.121 inch

(5.9L). . . . . . . . . . .
0.006-0.014 inch
24.966-24.978 mm 0.9829-0.9834 inch

CONNECTING ROD JOURNALS

53.950-53.975 mm 2.124-2.125 inch
0.001 inch

J9009-127
• 5.2L/5.9L ENGINE 9 - 67

ENGINE SPECIFICATI0NS-5.2L/5.9L (CONT.)

CONNECTING ROD BEARINGS

Type (5.2L) . . . . . . . . . . . . Tin-Aluminum

(5.9L) . " . Tri-Metal
54.000 mm 2.126 inch
Width 21.387 mm 0.842 inch
0.0127-0.0559 mm 0.0005-0.0022 inch
0.0559 mm 0.0022 inch
(5.9L) 0.0635 mm 0.0025 inch
Standard Standard
0.0254 mm 0.001 inch
0.0508 mm 0.002 inch
0.2540 mm 0.010 inch
0.3048 mm 0.012 inch

CRANKSHAFT

Type (5.2U Fully Counter-Balanced

(5-9L) Fully Externally-Balanced
Bearings (5.2L) Steel Backed Babbitt
#3 Thrust Aluminum
<5.9L) Steel Backed Lead Aluminum
#5 Babbitt
#3 Main Bearing
End Play (5.2L) 0.051-0.178 mm 0.002-0.007 inch
(5.9L) 0.051-0.229 mm 0.002-0.009 inch
0.254 mm 0.010 inch
0.0127-0.0381 mm 0.0005-0.0015 inch
0.0381 mm 0.0015 inch
0.0127-0.0508 mm 0.0005-0.0020 inch
0.0635 mm 0.0025 inch
Diagonal Knurling

MAIN BEARING JOURNALS

63.487-63.513 mm 2.4995-2.5005 inch

(5.9L) 71.361-71.387 mm 2.8095-2.8105 inch
0.0254 mm 0.001 inch
Standard Standard
0.0254 mm 0.001 inch
0.0508 mm 0.002 inch
0.0762 mm 0.003 inch
0.2540 mm 0.010 inch
0.3048 mm 0.012 inch

ENGINE LUBRICATION

Rotary Full Pressure

Camshaft
41.4 kPa 6 psi
207-552 kPa 30-80 psi
48.3-62.1 kPa 7-9 psi

•CAUTION: If pressure is 0 at curb idle, DO NOT run engine at 3000 rpm.

J9009-128
9 - 68 5.2L/5.9L ENGINE •
ENGINE SPECIFICATIONS —5.2L/5.9L (CONT.)

PISTONS
Alloy Tin Coated
0.483-0.610 mm 0.019-0.024 inch
(5.9L) . . 0.508-0.660 mm 0.020-0.026 inch
Clearance at Top of Skirt 0.013-0.038 mm 0.0005-0.0015 inch
Weight (5.2L) 594.6 ± 2 grams
(5.9L) 584.0 ± 2 grams
Piston length (Overall) (5.2L) 86.36 mm 3.40 inch
(5.9L) 81.03 mm 3.19 inch
Ring Groove Depth (5.2L)
No. 1 . . . . 5.207 mm 0.205 inch
No. 2 5.207 mm 0.205 inch
No. 3 . . . . 4.928 mm 0.194 inch
Ring Groove Depth (5.9L)
No. 1 5.334 mm 0.210 inch
No. 2 5.334 mm 0.210 inch
No. 3 . 5.055 mm 0.199 inch
, , Standard
0.508 mm 0.020 inch

PISTON PINS
Type Press Fit in Rod
24.996-25.001 mm 0.9841-0.9843 inch
75.946-76.708 mm 2.990-3.020 inch
0.0000-0.0127 mm 0.0000-0.0005 inch
(Light Thumb Push (5.9L) 0.0064-0.0191 mm 0.00025-0.00075 inch
. , None
0.0178-0.0356 mm 0.0007-0.0014 inch
Interference
. . Standard
0.076 & 0.203 mm 0.003 & 0.008 inch

PISTON RINGS
3
2
1
. . 3-piece steel rail chrome-face
Ring Width
1.9558-1.9812 mm 0.077-0.078 inch
0.640 mm Max. 0.0252 inch Max.
Ring Gap
0.254-0.508 mm 0.010-0.020 inch
0.381 -1.397 mm 0.015-0.055 inch
Ring Side Clearance
0.038-0.076 mm 0.0015-0.003 inch
0.005-0.127 mm 0.0002-0.005 inch
Ring Gap - Service Rings
0.254-1.508 mm 0.010-0.020 inch
0.254-1.575 mm 0.010-0.062 inch
(5.9L) . 0.381 -1.575 mm 0.015-0.062 inch
Ring Side Clearance
0.038-0.102 mm 0.0015-0.004 inch
0.005-0.127 mm 0.0002-0.005 inch

J9009-131
 OIL PUMP INSPECTION LIMITS FOR REPLACEMENT—5.2L/5.9L

Oil Pump Cover Out Of Flat.. .0015 inch or more

Outer Rotor Thickness . . .825 inch or less
Outer Rotor Diameter 2.469 inch or less
Inner Rotor Thickness .825 inch or less
Clearance Over Rotors—Outer .004 inch or more
Inner .004 inch or more
Outer Rotor Clearance .014 inch or more
Tip Clearance Between Rotors .008 inch or more

J9009-106

OVERSIZE AND UNDERSIZE ENGINE COMPONENT MARKINGS-5.2L/5.9L

CONDITION IDENTIFICATION LOCATION OF IDENTIFICATION

0.025 mm (0.001 inch) RorM Milled flat on number eight crankshaft

U/S Crankshaft M-2-3 etc. (Indicating No. 2 & 3 main counterweight on 5.2L cranks. On 5.9L cranks it
bearing journal) is on the number three counterweight.
and/or
R-l -4 etc. (Indicating No. 1 & 4 connecting
rod journal)

0.254 mm (0.010 inch) RXor MX Milled flat on number eight crankshaft

U/S Crankshaft MX (Indicates 0.254 mm (0.010 inch) U/S all counterweight on 5.2L cranks. On 5.9L cranks it
main journals) is on the number three counterweight.
and/or
RX (Indicating 0.254 mm (0.010 inch) U/S all rod
journals)

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.

J9009-130
9 - 70 5.2L/5.9L ENGINE •
TORQUE SPECIFICATIONS-5.2L/5.9L

COMPONENT TORQUE

41 Nnn 30 ft, lbs.

68 N-m 50 ft. lbs.
41 Nnn 30 ft. lbs.
23 Nnn (200 in. lbs.)
41 Nnn 30 ft. lbs.
41 Nnn 30 ft. lbs.
41 Nnn 30 ft. lbs.

68 N-m 50 ft. lbs.

24 Nnn (210 in. lbs.)
47 Nnn 35 ft. lbs.
Clutch Housing 3/8" Bolts 41 Nnn 30 ft. lbs.
7/16" Bolts 68 Nnn 50 ft. lbs.

61 Nnn 45 ft. lbs.

136 Nnn 100 ft. lbs.
143 Nnn 105 ft. lbs.
9 Nnn (80 in. lbs.)

23 Nnn (200 in. lbs.)

102 Nnn 75 ft. lbs.

88 Nnn 65 ft. lbs.
68 Nnn 50 ft. lbs.
68 N-m 50 ft. lbs.
102 Nnn 75 ft. lbs.
27 Nnn 20 ft. lbs.
20 Nnn 15 ft. lbs.
33 Nnn 24 ft. lbs.

23 Nnn (200 in. lbs.)

31 Nnn (270 in. lbs.)
75 Nnn 55 ft. lbs.
75 Nnn 55 ft. lbs.

54 Nnn 40 ft. lbs.

115 Nnn 85 ft. lbs.

27 Nnn 20 ft. lbs.

23 Nnn (200 in. lbs.)
11 Nnn (95 in. lbs.)
41 Nnn 30 ft. lbs.
68 Nnn 50 ft. lbs.
7 Nnn (60 in. lbs.)

23 Nnn (200 in. lbs.)

41 Nnn 30 ft. lbs.

68 Nnn 50 ft. lbs.

7 N-m (60 in. lbs.)

41 Nnn 30 ft. lbs.

J9009-124
 • EXHAUST SYSTEM AND INTAKE MANIFOLD
EXHAUST SYSTEM AND INTAKE MANIFOLD
CONTENTS
Page
EXHAUST DIAGNOSIS . .
GENERAL INFORMATION
G E N E R A L INFORMATION
Page
Catalytic Converter
Exhaust G a s Recirculation ( E G R ) .
Exhaust System
EXHAUST SYSTEM
The basic exhaust system consists of exhaust m a n -
ifolds, exhaust pipe, catalytic converter(s), extension
pipe, heat shields, muffler a n d tailpipe (Fig. 1).
A l l engines have a thermostatic controlled heat
valve i n the exhaust m a n i f o l d for faster w a r m u p and
improved d r i v e a b i l i t y after cold start.
The exhaust manifolds are equipped w i t h b a l l
flange outlets t o assure a t i g h t seal and s t r a i n free
connections. T h e exhaust system must be properly
aligned to prevent stress, leakage and body contact.
I f the system contacts any body panel, i t may am-
plify objectionable noises o r i g i n a t i n g from the engine
or body.
W h e n inspecting a n exhaust system, c r i t i c a l l y i n -
spect for cracked or loose j o i n t s , stripped screw or
bolt threads, corrosion damage and w o r n , cracked or
broken hangers. Replace a l l components t h a t are
badly corroded or damaged. D O N O T attempt t o re-
pair.
W h e n replacement is required, use o r i g i n a l equip-
m e n t parts (or t h e i r equivalent) to assure proper
a l i g n m e n t a n d t o provide acceptable exhaust noise
levels.
CAUTION: Avoid application of rust prevention
compounds or undercoating materials to exhaust
system floor pan heat shields. Light overspray near
the edges is permitted. Application of coating will
result in excessive floor pan temperatures and ob-
jectionable fumes.
CATALYTIC CONVERTER
The stainless steel catalytic converter body is de-
signed to last t h e life o f the vehicle. Excessive heat
can result i n b u l g i n g or other distortion, b u t exces-
sive heat w i l l not be the f a u l t of t h e converter. A fuel
system, a i r injection system or i g n i t i o n system m a l -
11-1
Page
3 SERVICE PROCEDURES ... 3
1
INDEX
Page
1 Heat Shields . ..1
1 Manifold Heat Control Valve . .. 2
1
function t h a t p e r m i t s u n b u r n e d fuel t o enter the con-
verter w i l l usually cause overheating. I f a converter
is heat-damaged, correct the cause o f the damage a t
the same t i m e t h e converter is replaced. Also, inspect
a l l other components of the exhaust system for heat
damage.
Unleaded gasoline m u s t be used t o avoid contami-
n a t i n g the catalyst core.
HEAT SHIELDS
Heat shields are needed to protect both the vehicle
and the environment from the h i g h temperatures de-
veloped i n the v i c i n i t y of the catalytic converter. The
combustion reaction facilitated by t h e catalyst re-
leases additional heat i n the exhaust system. U n d e r
severe operating conditions, t h e temperature i n -
creases i n t h e area o f the reactor. Such conditions
can exist when the engine misfires or otherwise does
not operate a t peak efficiency. D O N O T remove
spark p l u g wires f r o m plugs or b y any other means
short out cylinders. F a i l u r e o f the catalytic converter
can qccur due t o a temperature increase caused b y
u n b u r n e d fuel passing t h r o u g h the converter.
Do not allow the engine to operate a t fast idle for
extended periods (over five minutes). This condition
may result i n excessive temperatures i n the exhaust
system and on the floor p a n .
EXHAUST GAS RECIRCULATION (EGR)
To assist i n t h e control of oxides of nitrogen (NOx)
i n engine exhaust, a l l engines are equipped w i t h a n
exhaust gas r e c i r c u l a t i o n system. The use of exhaust
gas to d i l u t e i n c o m i n g air/fuel m i x t u r e s lowers peak
flame temperatures d u r i n g combustion, thus l i m i t i n g
the formation of NOx.
Exhaust gases are t a k e n from openings i n the ex-
haust gas crossover passage i n the i n t a k e manifold.
Refer to Group 25, Emission Control Systems of t h i s
 11-2 EXHAUST SYSTEM AND INTAKE MANIFOLD •
EXHAUST
PIPE

HEAVY DUTY
TRUCK

J9011-41

Fig. 1 Exhaust Systems (Typical)

m a n u a l for a complete description, diagnosis and ser-
vice procedures on the exhaust gas recirculation sys-
t e m and components.
MANIFOLD HEAT CONTROL VALVE
A manifold heat control valve is located i n t h e
r i g h t exhaust manifold. The thermostatic controlled
valve directs heated exhaust gases to the heat cham-
ber i n the i n t a k e m a n i f o l d beneath the t h r o t t l e body.
This helps vaporize t h e fuel m i x t u r e d u r i n g the en-
gine w a r m - u p period. When the valve is closed, t h e
exhaust gases are directed to t h e heat chamber
t h r o u g h t h e r i g h t side of the exhaust crossover pas-
sage. A f t e r c i r c u l a t i n g t h r o u g h t h e heat chamber,
the gases are r e t u r n e d to t h e exhaust manifold
t h r o u g h t h e left side o f the passage.
 EXHAUST SYSTEM AND INTAKE MANIFOLD 11-3

E X H A U S T DIAGNOSIS
CONDITION POSSIBLE CAUSE CORRECTION

EXCESSIVE EXHAUST (a) Leaks at pipe joints. (a) Tighten clamps at leaking joints.
NOISE (b) Burned or blown out muffler. (b) Replace muffler assembly.
(c) Burned or rusted out exhaust pipe. (c) Replace exhaust pipe.
(d) Exhaust pipe leaking at manifold flange. (d) On all engines, tighten bail joint connection
attaching bolt nuts to 33 N*m (24 ft. lbs.)
alternate tightening.
(e) Exhaust manifold cracked or broken. (e) Replace manifold.
(f) Leak between manifold and cylinder head. (f) Tighten manifold to cylinder head stud nuts
or bolts to specifications.
(g) Restriction in muffler or tail pipe. (g) Remove restriction, if possible, or replace
as necessary.

LEAKING EXHAUST GASES (a) Leaks at pipe joints. (a) Tighten U-bolts at leaking joints to
17 N-m (150 in. lbs.)
(b) Damaged or improperly installed gaskets. (b) Replace gaskets as necessary.

ENGINE HARD TO WARM (a) Heat control valve frozen in the open (a) Free up manifold heat control valve using a
UP OR WILL NOT RETURN position. suitable solvent.
TO NORMAL IDLE (b) Blocked crossover passage in intake (b) Remove restriction or replace intake manifold.
manifold.

HEAT CONTROL VALVE (a) Thermostat broken. (a) Replace thermostat.

NOISY (b) Broken, weak or missing anti-rattle spring. (b) Replace spring.

J9011-33

SERVICE PROCEDURES
INDEX
Page Page
Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . 12 Manifold Heat Control Valve . 13
Exhaust Pipe, Mufflers, Converters and Tailpipe . . . 3 Torque Specifications 14
Intake Manifold 10

EXHAUST PIPE, MUFFLERS, CONVERTERS AND n a l equipment parts (or t h e i r equivalent) be used to
TAILPIPE assure proper a l i g n m e n t w i t h other parts i n the sys-
t e m and provide acceptable exhaust noise levels.

REMOVAL (GENERAL) INSTALLATION (GENERAL)

(1) Raise vehicle on hoist a n d apply p e n e t r a t i n g o i l
to clamp bolts and nuts of component being removed.
(2) Remove clamps and supports f r o m exhaust sys-
t e m to p e r m i t a l i g n m e n t of p a r t s d u r i n g assembly.
(3) Clean ends of pipes and/or muffler to assure
m a t i n g of a l l parts. Discard b r o k e n or w o r n insula-
tors, rusted clamps, supports a n d a t t a c h i n g parts.
W h e n replacement is r e q u i r e d on any component o f
the exhaust system, i t is most i m p o r t a n t t h a t o r i g i -
(1) Assemble pipes, muffler, supports and clamps
loosely to p e r m i t proper alignment of a l l parts.
(2) B e g i n n i n g a t f r o n t of system, a l i g n and clamp
each component t o m a i n t a i n position a n d proper
clearance w i t h underbody parts.
(3) O n models u s i n g ball-type connections, alter-
n a t e l y t i g h t e n bolts t o assure flanges are even and
parallel.
(4) T i g h t e n a l l clamps and supports to the proper
torques (Figs. 1 t h r u 6).
11 - 4 EXHAUST SYSTEM AND INTAKE MANIFOLD

STRUT-TRANSMISSION
C A S E T O BLOCK

TIGHTENING TORQUE
20 FT. LBS. (27 N»m)

m 125
200
IN. LBS.
IN. LBS.
(13
(23
N»m)
N«m)
m 32 FT. LBS. (44 N«m)

Fig. 1 Single Exhaust System—Light Duty Trucks (Not Sport Utility)

 EXHAUST SYSTEM AND INTAKE MANIFOLD 11-5

FRAME
FRAME CROSSMEMBER
SIDE RAIL TAPPING SCREW
SUPPORT
BRACE

BOLT
NUT
<3> SUPPORT
(MUFFLER)
BRACKET SUPPORT
MUFFLER BOLT-
MUFFLER

TAIL PIPE TAIL PIPE

CLAMP (ARROW N) K^Ww
(131", 135", 159" W H E E L B A S E V * ^
4

ARRQWY UPPER FLOOR

(115* WHEELBASE) PAN HEAT SHIELD

SCREW
FRAME
SIDE RAIL

TAIL PIPE
TAIL PIPE
SUPPORT
SHIELD
CLAMP ASSEMBLY ATTACHING
BRACKET

TAIL PIPE
EXTENSION

ARROW Z

MUFFLER

TIGHTENING TORQUE TAIL PIPE

S 20 FT. LBS. (27 N*m)
m 125 IN. LBS. (13 N*m)
m 200 IN. LBS. (23 N*m)
m 32 FT. LBS. (44 N « m )

CLAMP
TAIL PIPE
(FRONT)
ARROW P
(135". 159" WHEELBASE) U-NUT J9011-43

Fig. 2 Single Exhaust System—Light Duty Trucks (Not Sport Utility)

11-6 EXHAUST SYSTEM AND INTAKE MANIFOLD

CATALYTIC
CONVERTERS FLOOR PAN HEAT SHIELD
(4 WHEEL DRIVE)

RETAINER

FRONT
SUSPENSION
CROSSMEMBER
TIGHTENING TORQUE
.50 ± .19
TYPICAL 19 FT. LBS. (26 N « m )
200 FT. LBS. (23 N*m)
BRAKE
LINE ® 125 IN. LBS. (14 N « m )

m 250 IN. LBS. (28 H*m)

32 FT. LBS. (42 N*m)
® 40 FT. LBS. (54 N » m )

TYPICAL SLIP JOINT

(MUST BE FULLY ENGAGED)
BRAKE
LINE
SHIELD
(2 WHEEL DRIVE)
J9011-44

Fig. 3 Dual Exhaust System—Heavy Duty Trucks

 EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 7

SCREW & WASHER

/\
B

BRACE

BRACE

SCREW &
WASHER
MANUAL TRANS. AUTO TRANS.
VIEW IN DIRECTION VIEW IN DIRECTION
OF ARROW T OF ARROW V
FRAME
FRAME

\
SCREW & 131 WHEELBASE
WASHER 135 WHEELBASE
BRACKET
135 WHEELBASE

131 WHEELBASE
INSULATORS BRACKET

SHOULDER
INSULATORS
MUFFLER SCREW

<3>
PIPE(S)
SHOULDER
MUFFLER SCREW
PIPE
159" WHEELBASE 131 & 135 WHEELBASE
VIEW IN DIRECTION VIEW IN DIRECTION
OF ARROW Y OF ARROW X

FRAME

FRAME

SCREWS &
WASHER
TIGHTENING TORQUE
19 FT. LBS. (26 N»m)
200 IN. LBS. (23 N»m)
CONVERTER 125 IN. LBS; (14 N«m)
PIPE(S) 250 IN. LBS. (28 N«m)
32 FT. LBS. (42 N*m)
40 FT. LBS. (54 N«m)

INSULATORS
SHOULDER
SCREW

VIEW IN DIRECTION VIEW IN DIRECTION

OF ARROW W OF ARROW Z J9011-45

Fig. 4 Dual Exhaust System—Heavy Duty Trucks

11-8 EXHAUST SYSTEM AND INTAKE MANIFOLD •

VIEW IN DIRECTION
OF ARROW D J9011-46

Fig. 5 Sport Utility Exhaust System

 EXHAUST SYSTEM AND INTAKE MANIFOLD 11-9

TO MUFFLER TO MUFFLER
TO ENGINE

TIGHTENING TORQUE
24 FT. LB. (33 N » m )
125 IN. LB. (14 N « m )
200 IN. LB. (23 N*m)
30 FT. LB. (41 N « m )
50 FT. LB. (68 N*m)
95 IN. LB. (10 N « m )
40 IN. LB. (5 N*m)
90 IN. LB. (10 N » m )
65 IN. LB. (7 N » m )
32 FT. LB. (43 N*m)
TO FRONT
MUFFLER
VIEWC
VIEW A VIEW A VIEW B EXHAUST PIPE &
5.2L/5.9L ENG. 5.2L/5.9L ENGINES WITH EXHAUST PIPE FRT. & MUFFLER CLAMP
AAAN. TRANS. CATALYTIC CONVERTER EXHAUST PIPE REAR (TYPICAL)

NUT SUPPORT

SCREW

FRAME (REFERENCE)

VIEWC VIEW D

SPACER
FRONT FRONT
HEAT SCREW
HEAT
SHIELD SHIELD

CROSSMEMEBER
SKID PLATE SCREW SCREW CONED WASHER USED
WITH CATALYST
CATALYTIC
CONVERTER UPPER UPPER HEAT SHIELD UPPER HEAT SHIELD
LOWER HEAT SHIELD HEAT SHIELD WITH 6 IN. RAIL WITH 7 IN. RAIL
AD8 (4 x 4) AD4 (4 x 2) AD8 (4 x 4) AD8 (4 x 4) J9011-47

Fig. 6 Sport Utility Exhaust System

11 - 10 EXHAUST SYSTEM AND INTAKE MANIFOLD •
INTAKE MANIFOLD CAUTION: Intake manifold SIDE gaskets are identi-
fied with cutouts (RT for RIGHT side and LT for
LEFT side) (Figs. 8 and 9). They MUST be installed
REMOVAL
as designated to provide proper coolant flow
(1) Disconnect the battery negative cable. through the water cooled intake manifold.
(2) D r a i n t h e cooling system (refer t o Group 7,
Cooling System for t h e proper procedures).
(3) Remove the alternator, a i r cleaner a n d fuel
lines ( i n t a k e and r e t u r n ) .
(4) Disconnect t h e accelerator l i n k a g e a n d i f so
equipped, t h e speed control and transmission k i c k -
down cables.
(5) Remove the r e t u r n spring.
(6) Remove the d i s t r i b u t o r cap and wires.
(7) Disconnect the coil wires, heat i n d i c a t o r send-
i n g u n i t w i r e , heater hoses and bypass hose.
(8) Remove the closed crankcase v e n t i l a t i o n and
evaporation control systems.
(9) Remove the r i g h t cylinder head cover.
(10) Remove i n t a k e manifold bolts.
(11) L i f t the i n t a k e manifold and t h r o t t l e body out
of the engine compartment as a n assembly.
(12) Remove the t h r o t t l e body bolts a n d l i f t t h e
t h r o t t l e body off the i n t a k e manifold (Fig. 7). Discard
the t h r o t t l e body gasket. Fig. 8 Intake Manifold Side Gaskets (3.9L Left Side
Shown)
BOLTS

J9011-31

Fig. 7 Throttle Body Assembly

CLEANING AND INSPECTION
Clean manifold i n solvent and blow d r y w i t h com-
pressed a i r .
Inspect manifold for cracks. Fig. 9 Intake Manifold Side Gaskets (5.2L Left Side
Inspect m a t i n g surfaces of manifold f o r flatness Shown)
w i t h a straightedge. (2) Place a drop (approximately 1/4 i n c h diameter)
Inspect exhaust crossover passages t h r o u g h m a n i - of Rubber Sealer (RTV) into each of t h e four block to
fold. I f passages are coated w i t h hard, b l a c k carbon, cylinder head corners.
they should be scraped clean and sandblasted t o re- (3) A p p l y a t h i n , u n i f o r m coating of a q u i c k dry ce-
move t h e carbon deposits. ment t o the i n t a k e manifold f r o n t and rear gaskets
and cylinder block gasket surface.
INSTALLATION (4) A l l o w to dry 4 to 5 m i n u t e s or u n t i l tack-free to
(1) U s i n g a new gasket, i n s t a l l the t h r o t t l e body the touch.
onto t h e intake manifold. T i g h t e n t h e bolts t o 20 (5) Carefully i n s t a l l the front and rear i n t a k e man-
N T H (175 i n . lbs.) torque. ifold gaskets. When i n s t a l l i n g gaskets, t h e center
 • EXHAUST SYSTEM AND INTAKE MANIFOLD
hole i n the gasket M U S T engage dowels i n the block.
E n d holes i n seals M U S T be locked into tangs o f
head gasket (Figs. 10 a n d 11).
Fig. 10 Intake Manifold END Sealing—3.9L
Fig. 11 Intake Manifold END Sealing-5.2U5.9L
Engines
(6) Carefully lower i n t a k e m a n i f o l d i n t o position on
the cylinder block and cylinder heads. After i n t a k e
manifold is i n place, inspect t o make sure seals are
i n place.
(7) I n s t a l l t h e a l l a t t a c h i n g cap bolts (finger t i g h t ) .
T i g h t e n the cap bolts to 34 N*m (25 ft. lbs.) torque i n
the t i g h t e n i n g sequence shown i n Fig. 12 or 13. T h e n
t i g h t e n the cap bolts to 54 N»m (40 ft. lbs.) torque i n
the sequence shown i n F i g . 12 or 13.
(8) I n s t a l l closed crankcase v e n t i l a t i o n and evapo-
r a t i o n control systems.
(9) I n s t a l l coil wires, heat indicator sending u n i t
w i r e , heater hoses and bypass hose.
(10) I n s t a l l d i s t r i b u t o r cap a n d wires.
11-11
Fig. 12 Intake Manifold Bolt Tightening
Engine Sequence—3.9L
Fig. 13 Intake Manifold Bolt Tightening
Sequence—5.2L/5.9L
(11) Hook up the r e t u r n spring.
(12) Connect t h e accelerator linkage a n d i f so
equipped, the speed control and transmission k i c k -
down cables.
(13) I n s t a l l the fuel lines (intake and r e t u r n ) .
(14) I n s t a l l the alternator and drive belt. T i g h t e n
a l t e r n a t o r m o u n t i n g bolt to 4 1 N*m (30 f t . lbs.)
torque. Tighten the adjusting strap bolt t o 23 N»m
(200 i n . lbs.) torque. See Group 7, Cooling System for
the proper adjusting o f belt tension.
(15) I n s t a l l the a i r cleaner.
(16) I n s t a l l the r i g h t cylinder head cover.
(17) F i l l cooling system (refer to Group 7, Cooling
System for the proper procedure).
(18) Connect the battery negative cable.
11-12 EXHAUST SYSTEM AND INTAKE MANIFOLD •
EXHAUST MANIFOLD (3) Raise a n d support the vehicle.
(4) Assemble t h e exhaust pipe t o t h e exhaust m a n -
ifold a n d secure w i t h bolts, n u t s a n d washers.
REMOVAL T i g h t e n these n u t s to 33 N » m (24 ft. lbs.) torque.
(1) Disconnect the battery negative cable.
(5) Lower t h e vehicle.
(2) Raise a n d support the vehicle.
(6) Connect t h e battery negative cable.
(3) Remove t h e bolts a n d n u t s attaching t h e ex-
h a u s t pipe t o the exhaust manifold.
(4) Lower t h e vehicle.
(5) Remove bolts, n u t s and washers attaching m a n -
ifold to cylinder head.
(6) Remove m a n i f o l d from t h e cylinder head.

CLEANING AND INSPECTION

Clean m a t i n g surfaces on cylinder head and m a n i -
fold. Wash w i t h solvent a n d blow d r y w i t h com-
pressed air.
Inspect m a n i f o l d for cracks.
Inspect m a t i n g surfaces of manifold for flatness 8911-15
w i t h a s t r a i g h t edge. Gasket surfaces m u s t be f l a t
w i t h i n 0.2 m m per 300 m m (0.008 inch per foot). Fig. 14 Exhaust Manifold installation (Right Manifold
O n t h e R i g h t H a n d manifold, test manifold heat Shown)—3.9L
control valve for free operation. I f necessary, apply a
CONICAL WASHERS^
suitable m a n i f o l d heat control valve solvent to b o t h SQ^
ends of t h e valve shaft. Be sure t h e manifold is
C O O L and solvent is allowed to soak a few m i n u t e s
to dissolve deposits. Then, w o r k valve back and f o r t h
u n t i l i t t u r n s freely. Be sure studs are f u l l y seated.

INSTALLATION

CAUTION: If the studs came out with the nuts

when removing the exhaust manifold, install new
studs. Apply sealer on the coarse thread ends. Wa-
ter leaks may develop at the studs if this precaution Fig. 15 Exhaust Manifold Installation (5.2L Engine
is not taken. Shown)

(1) Position the exhaust manifolds on the two studs

located on t h e cylinder head. I n s t a l l conical washers
and nuts on these studs (Fig. 14 and 15).
(2) I n s t a l l two bolts and conical washers a t the i n -
ner ends o f the exhaust manifold outboard arms. I n -
s t a l l two bolts W I T H O U T washers on the center a r m
of exhaust manifold (Figs. 14 and 15). S t a r t i n g a t t h e
center a r m and w o r k i n g outward, t i g h t e n the bolts t o
27 N * m (20 f t . lbs.) torque and the stud nuts to 20
N T H (15 f t . lbs.) torque.
• EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 13

MANIFOLD HEAT CONTROL VALVE (FIG. 16) INSTALLATION

(1) Press cup seals i n (cupped ends facing outward)
u n t i l seals extend i n t o manifold 2.54 m m (0.100 inch)
REMOVAL
on each side.
(1) Remove the r i g h t exhaust manifold.
(2) Press i n bushings flush w i t h outer edge o f ex-
(2) Position the valve plate and g r i n d off t h e spot
h a u s t manifold.
welds from valve plate a n d shaft.
(3) L i n e r e a m bushings and seals t o 7.8163-7.8994
(3) Remove the a n t i - r a t t l e spring.
m m (0.3095-0.3110 inch) diameter. D o n o t u s e 7.9
(4) Remove counterweight and shaft assembly.
m m (5/16 i n c h ) r e a m e r . Test for free f i t of shaft i n
(5) Press out the bushings and seals from t h e ex-
bushings and seals.
haust m a n i f o l d .
(4) I n s t a l l valve stop i n slot o n counterweight so
(6) Inspect the vent holes and clean out, i f neces-
looped ends face o u t w a r d , away from t h e counter-
sary.
w e i g h t shaft hole (Fig. 16).
(5) Position thermostat so the center end or t a b is
p o i n t i n g to t h e left a n d the hook or outer end points
down. I n s t a l l thermostat o n the counterweight.
(6) A t 32.00 m m (1.24 inch), m a r k one end o f shaft
w i t h a suitable dye. Press counterweight o n t h e
m a r k e d end o f the shaft u n t i l flush w i t h shaft end.
(7) W i t h t h e counterweight end of the shaft facing
you, w r a p t h e thermostatic spring 140° i n a counter-
clockwise direction. I n s t a l l t h e shaft assembly
t h r o u g h outer bushing, seal and valve plate w i t h the
center strap facing t h e flange end o f the manifold.
A t t a c h hook end of thermostatic spring t o stop p i n .
(8) Position t h e counterweight end of the shaft a t
t h e 32.00 m m (1.24 inch) m a r k . W i t h the valve plate
centered between t h e seals a n d t h e valve plate
closed, arc w e l d valve plate to shaft w i t h a stainless
steel r o d . A r c welding ground m u s t be made a t coun-
terweight.
(9) Test for free operation. I n s t a l l a n t i - r a t t l e
spring.
(10) I n s t a l l exhaust manifold. T i g h t e n the bolts t o
27 N * m (20 f t . lbs.) a n d the nuts to 20 N*m (15 f t .
lbs.) torque.
(11) I n s t a l l t h e exhaust pipe t o manifold. T i g h t e n
t h e n u t s to 33 N»m (24 ft. lbs.) torque.

Fig. 16 Manifold Heat Control Valve

11-14 EXHAUST SYSTEM AND INTAKE MANIFOLD •

TORQUE SPECIFICATIONS

COMPONENT TORQUE

23 Nfn (200 in. lbs.)

41 N*m(30ft. lbs.)

41 Nfn(30ft. lbs.)

27 Nfn (20 ft. lbs.)

20NTTI (15 ft. lbs.)

41 Nfn (30 ft. lbs.)

33 N«m (24 ft. lbs.)

15 N«m (125 in. lbs.)

34 N-m (25 ft. lbs.)

54 Nfn (40 ft. lbs.)

41 N*m (30 ft. lbs.)

23 Nfn (200 in. lbs.)

23 Nfn (200 in. lbs.)

23 Nnn (200 in. lbs.)

20 N-m (175 in. lbs.)

J9011-34
 • GROUP
FRAME STRUCTURES
CONTENTS
Page
INSPECTION PROCEDURES 6 SPECIFICATIONS
SERVICE PROCEDURES 11
GENERAL INFORMATION
The m a i n function o f the t r u c k frame is t o provide
support for a l l chassis components, body m o u n t i n g
and t o carry the payload w h i l e keeping deflections a t
a tolerable level.
The frame is a complex s t r u c t u r a l mechanism
w h i c h reacts to applied loads a n d road inputs b y
bending a n d t w i s t i n g . T h e m a i n bending members
are t h e siderails. Resistance t o frame t w i s t is pro-
vided b y crossmembers w h i c h are r i g i d l y attached to
t h e siderails w i t h either r i v e t s or bolts t o f o r m t h e
so-called "ladder t y p e " frame (Figs. 1 t h r u 4).
FRAME SIDERAIL MATERIAL
Carbon steel w i t h a m i n i m u m y i e l d s t r e n g t h o f
32000 psi is used to fabricate t h e l i g h t a n d t h e me-
d i u m d u t y t r u c k frame siderails.
Since the y i e l d s t r e n g t h for t h e same steel can vary
considerably i t has been Dodge's practice t o specify
t h e m i n i m u m y i e l d s t r e n g t h . T h u s t h e 32000 psi
m i n i m u m frame has i n r e a l i t y a range o f 32000 to
44000 psi w i t h a t y p i c a l average value o f 38000 psi.
For severe applications, h i g h s t r e n g t h steel frame
siderail reinforcements o f the same steel are used.
FRAME LOAD-CARRYING CAPACITY
Since by f a r the most i m p o r t a n t factor o f frame ac-
t i o n is i t s flexing, i t is customary t o compare t h e
frames b y t h e i r "Resisting B e n d i n g M o m e n t "
(R.R.M.), t e r m denoting t h e m a x i m u m bending t h e
siderails can safely w i t h s t a n d .
13 - 1
Page
12
TIGHTENING REFERENCE . . . . . . . . . . . . . . . . 12
The resisting bending moment can be used for
quick comparison o f frames h a v i n g different r a i l con-
figuration and materials.
The Resisting B e n d i n g Moment consists of t w o
terms: Section Modulus and M a t e r i a l Y i e l d Strength.
(Section Modulus x Y i e l d Strength = R.B.M.)
The greater the section modulus and the higher the
yield strength, t h e stronger t h e siderails.
The t e r m Section Modulus pertains to the cross-sec-
tion of the siderail a n d is determined b y r a i l depth,
flange w i d t h , and m a t e r i a l thickness.
Y i e l d s t r e n g t h is a measurement i n psi o f stress a t
which a m a t e r i a l exhibits a specified permanent de-
formation.
FRAME TYPE
L i g h t D u t y T r u c k a n d Sport U t i l i t y frames are o f a
ladder type w i t h drop center section channel siderail
and crossmembers. Crossmembers are riveted or
bolted to t h e frame. Body support a n d suspension
m o u n t i n g brackets are riveted to siderails. (See Figs.
6, 7, and 8 for i n c h dimensions.)
A D 1 - A D 4 frames are designed to accommodate i n -
dependent f r o n t suspension w i t h t h e suspension
crossmember as a p a r t o f the frame assembly as are
engine front m o u n t i n g brackets w h i c h are welded to
the suspension crossmember a n d riveted to t h e
siderail.
AD5-AD8 (four-wheel-drive vehicles) frames are
basically t h e same, except front suspension cross-
member is replaced w i t h a smaller engine support
crossmember.
 00
RIVETS
1

39

C/)
HI
ZD
O
•H

m
oo

CROSSMEMBER
(FUEL TANK SUPPORTS)
FRONT
SPRING BRACKET

Fig. 1-AD8 Frame Structure with Body Mount and Spring Hanger Brackets
BRACKET — ENGINE
FRONT SUPPORT

30
>

00
"H
30
C
o
•H
CZ
30
m
oo

CROSSMEMBERS 00
(FUEL TANK SUPPORTS)
RN895 1
00

Fig. 2—AD4 Frame Structure with Body Mount and Suspension Brackets
 MID FRAME CROSSMEMBER
(EXTRA) (159"-165" W.B.)

ENGINE/SUSPENSION FRONT
SUPPORT CROSSMEMBER
ALL FASTENERS ARE
RIVETS EXCEPT A S NOTED PU892C

Fig. 3—AD1, 2 and 3 Frame Structure

Fig. 4—ADS, 6 and 7 Frame Structure
13 - 6 FRAME STRUCTURES
INSPECTION PROCEDURES
Page
Dimensions . 8
General Information
GENERAL INFORMATION
I m p r o p e r frame a l i g n m e n t is u s u a l l y a r e s u l t o f a n
accident o r vehicle being operated w i t h excessive
loads or w i t h loads n o t positioned i n a reasonably
d i s t r i b u t e d manner.
A distorted frame w i l l affect f r o n t wheel o r rear
axle a l i g n m e n t and cause excessive wear, mechanical
failures i n power t r a i n , w i n d o w glass cracks a n d door
opening problems. Vehicle performance, h a n d l i n g
a n d ride q u a l i t y can be i m p a i r e d .
INSPECTION
Before proceeding w i t h frame a l i g n m e n t checks, i n -
spect a l l frame parts for visible damage such as
cracks, t w i s t s , bends, or other excessive deforma-
tions. Also, riveted, bolted, or welded connections,
looseness o r missing parts.
A l l damaged areas m u s t be repaired or parts r e -
placed as necessary.
HORIZONTAL OR DIAGONAL
D e t e r m i n e frame deviation f r o m being square b y
t h e f o l l o w i n g procedure:
(1) Select several points along one siderail, prefer-
ably a t crossmember locations.
(2) Transfer these w i t h a p l u m b bob to floor, paper
sheets can be fastened to floor a t these points for bet-
t e r acuracy.
(3) Locate corresponding points on other siderail
and transfer t h e m i n t h e same m a n n e r to t h e floor.
(4) Move t r u c k away a n d measure between a l l
points diagonally a n d p a r a l l e l to siderails, corre-
sponding measurements should n o t differ b y more
t h a n 1/4 inch.
* ^ — ,
Fig. 5—Alignment
•
INDEX
Page
Inspection 6
6 Measurements 7
(5) Take measurement across a t f r o n t a n d rear
m a r k s and b y d i v i d i n g distances i n half, indicate t h e
two points o n floor.
(6) Stretch a chalk-line between points 1 a n d 2 i n
F i g . 5 and snap s t r i n g .
(7) Check to see how close centerline is t o diagonal
intersection points A , B , C, D , E, a n d F i n F i g . 5.
(8) M a r k i n g s on floor w i l l now give a n i n d i c a t i o n o f
frame distortion i n p l a i n view.
(9) A n y point on one s i d e r a i l should be w i t h i n 1/8
i n c h ahead or behind corresponding p o i n t on opposite
side.
(10) Frame bow sideways should n o t exceed 1/8
i n c h per 100 inch l e n g t h o f frame.
(11) Overall w i d t h o f frame should n o t v a r y more
t h a n 1/8 inch.
(12) Repeat steps (1) t h r o u g h (11) after s t r a i g h t e n -
i n g frame.
VERTICAL OR SIDEVIEW
Determine t w i s t o f frame a n d degree o f siderails
not being p a r a l l e l t o one another as follows:
V e r t i c a l dimensions are measured f r o m a level
floor to corresponding points o n left a n d r i g h t
siderails. Dimensions should t h e n be plotted to scale
vertical and horizontal on a sheet o f paper and points
connected for each sidemember separately. G r a p h
w i l l show t h e relative position of t h e sidemembers.
Points on siderail or for horizontal check are se-
lected a t rear frame crossmembers a n d a n y one o f
these points on one sidemember should be m a x i m u m
1/8 inch above or below corresponding p o i n t o n other
siderail.
RN888
Markings
• FRAME STRUCTURES 13-7

MEASUREMENTS (1) Place vehicle o n level floor.

(2) I f vehicle is loaded, m a k e sure payload does not
O b t a i n measurements for frame a l i g n m e n t checks exceed specified l i m i t and t h e load i s d i s t r i b u t e d as
w i t h t h e body on vehicle. Figures 6, 7, and 8 as iden- evenly as possible. F o r better accuracy o f measure-
tified, indicate dimensions i n chosen areas t o deter- ments, a l l payload should be removed.
mine frame alignment. T h e procedures are (3) Check tires for recommended a i r pressure and
recommended as follows: adjust as necessary.
 INSIDE OF METAL
TO OUTSIDE OF METAL

37.68

5.55

30
>

l- INSIDE OF METAL CO
—I
30
REAR OVERHANG CZ
CENTERLINE OF FRONT WHEELS .750 DIAMETER G A U G E HOLE
SEE SPECIFICATIONS' o
-H
30
m
CO

mm CO
.1
Fig. 7— Frame Dimensions (ADl, 2 and 3) CO
 WHEELBASE

CENTERLINE OF REAR WHEELS

I SEE SPECIFICATIONS
CENTERLINE OF FRONT WHEELS

mm I

Fig. 8—Frame Dimensions (ADS, 6 and 7) •

 • FRAME STRUCTURES
SERVICE PROCEDURES
INDEX
Page
General Information 11
GENERAL INFORMATION
Frames w h i c h are bent o r t w i s t e d can be s t r a i g h t -
ened, i f necessary, b y heat application. T h e tempera-
t u r e is t o be kept under 1050°F (a d u l l r e d glow) as
excessive heat w i l l i m p a i r t h e strength o f the mate-
r i a l , r e s u l t i n g i n a weakened frame.
This heat method i s permissible o n L i g h t a n d M e -
d i u m d u t y frames only. Damaged frame r a i l s , cross-
members a n d brackets c a n be repaired b y
s t r a i g h t e n i n g or replacing.
Welded connections between r a i l s a n d crossmem-
bers are n o t recommended.
STRAIGHTENING
S t r a i g h t e n i n g should be l i m i t e d t o parts n o t se-
verely damaged. N e w bolts or rivets for a t t a c h i n g the
parts should be o f same specifications as o r i g i n a l
bolts or rivets.
REPLACEMENT
Replacement is recommended as the o r i g i n a l shape
of the p a r t m a y not be easily recognizable. Also, i m -
properly straightened frame components w i l l have
h a r m f u l effects on a l i g n m e n t .
REPAIRING
DRILLING
No holes should be d r i l l e d i n siderail flanges as
t h i s w i l l reduce frame s t r e n g t h . Holes d r i l l e d i n
siderail v e r t i c a l web m u s t be 1-1/2 inches m i n i m u m
from top and bottom flanges.
New holes should be located a distance away f r o m
existing holes, as n o t to reduce cross section o f
siderails i n a n y one v e r t i c a l section b y more t h a n
30%.
13 - 11
Page
Repairing 11
WELDING
W e l d i n g o f siderails a n d crossmembers should be
done, preferably, w i t h electric welding equipment as
i t retains heat i n a s m a l l area l i m i t i n g the change- of
hardness o f m e t a l .
A damaged frame member is to be closely inspected
for cracks. I t is possible t h a t cracks w i l l appear as a
result o f s t r a i g h t e n i n g o f a member. I n either case,
crack or cracks are t o be repaired as follows:
(1) Stop-drill a t t h e end p o i n t of the crack w i t h 1/8
inch d r i l l .
(2) V-groove crack t o allow good weld penetration.
(3) Weld u p t h e crack.
(4) G r i n d surface smooth i f reinforcement is to be
used.
USE OF FASTENERS
Bolts or rivets can be used i n r e p a i r i n g frames or
adding reinforcement. W h e n i t is more practical t o
substitute a bolt for a r i v e t , use next larger size bolt
to prevent bolt from w o r k i n g loose. Ream holes i f
necessary.
Coned washers a r e preferred to split lock type.
Generally Grade 5 bolts w i l l suffice i n repair w o r k .
Grade 3 bolts should be avoided. Proper torque i s
mandatory to provide adequate locking and preclude
loosening o f fasteners. Refer to t h e Specifications
chart for bolt grades a n d torques.
REINFORCING
Reinforcement can be made from channel, angle or
flat stock of common carbon steel and approximately
equal i n thickness t o t h e p a r t to be repaired. I t is not
possible to recommend proper reinforcement for a l l
repairs. A reinforcement should provide a n adequate
section i n cracked area a n d have sufficient overlap
w i t h t h e o r i g i n a l p a r t and be properly attached.
Reinforcing channel should have flanges shorter
t h a n sidemember flanges t o preclude welding along
edge of r a i l flange. Otherwise, l o n g i t u d i n a l welds are
quite acceptable. Complete transverse welds are to be
avoided.
13-12 FRAME STRUCTURES •
SPECIFICATIONS

Values of the section modulus, yield strength and

R.B.M. are shown for each siderail in the following
tables.

LIGHT DUTY MODELS

Wheel Siderail Section Section Rear

Model Base Depth Flange Gage Modulus R.B.M.* Overhand
CONVENTIONAL Inch
CAB Inch (cm) Inch (cm) Inch (cm) Inch (cm) Inch (cm) Pounds (kg) Inch (cm)
AD1 115 (292) 6.06 (15) 2.27 (6) .156 (.396) 2.86 (7.26) 91520 (41513) 38.25 (97.15)
AD1 131 (332) 6.06 (15) 2.27 (6) .156 (.396) 2.86 (7.26) 91520 (41513) 42.25 (107.31)
AD2 131 (332) 6.17 (16) 2.32 (6) .210 (.533) 3.88 (9.86) 124160 (56319) 42.25 (107.31)
AD3 131 (332) 7.20 (18) 2.73 (7) .194 (.493) 5.02 (12.75) 160640 (72866) 42.25 (107.31)
AD3 135 (342) 7.20 (18) 2.73 (7) .194 (.493) 5.02 (12.75) 160640 (72866) 42.25 (107.31)
AD3 159 (404) 7.31 (18) 2.79 (7) .250 (.635) 6.56 (16.66) 160640 (72866) 48.25 (122.55)
AD5 115 (292) 6.12 (18) 2.30 (6) .188 (.477) 3.43 (8.71) 109760 (49787) 38.25 (97.15)
AD5, 6 131 (332) 6.17.(18) 2.32 (6) .210 (.533) 3.88 (9.86) 124160 (56319) 42.25 (107.31)
AD7 135 (318) 7.20 (18) 2.73 (7) .194 (.493) 5.02 (12.75) 160640 (72866) 48.25 (122.55)
CLUB CAB
AD1 133 (338) 7.16 (18) 2.72 (7) .176 (.447) 4.57 (11.60) 146240 (66334) 38.25 (97.15)
AD1-2 149 (378) 7.20 (18) 2.73 (7) .194 (.493) 5.02 (12.75) 160640 (72866) 42.25 (107.31)
AD5-6 149 (378) 7.23 (18) 2.75 (7) .210 (.533) 5.47 (13.87) 175040 (79398) 42.25 (107.31)
SPORT UTILITY
AD4 106 (269) 6.06 (15) 2.27 (6) .156 (.396) 2.86 (7.26) 91520 (41513) 38.25 (97.15)
AD8 106 (269) 6.06 (15) 2.27 (6) .156 (.396) 2.86 (7.26) 91520 (41513) 38.25 (97.15)
* Resisting Bending Moment based on 32000 psi minimum yield strength of siderail steel.

TIGHTENING R E F E R E N C E

Torque in Ft.-Lbs. (Nnn)

Bolt Size Grade 5 Grade 8

3/8 X 16 20-40 (27-54) 30-50 (41-68)
3/8 X 24 25-45 (34-61) 30-60 (41-81)
7/16 X 14 35-65 (47-88) 50-80 (68-108)
7/16 X 20 40-70 (54-95) 60-90 (81-122)
1/2 X 13 55-95 (75-129) 80-120 (108-163)
1/2 X 20 65-105 (88-142) 85-135 (115-183)
9/16 X 12 80-130 (108-166) 110-160 (149-217)
9/16 X 18 90-140 (122-190) 125-175 (169-237)
 FUEL SYSTEM
CONTENTS
Page
ACCELERATOR PEDAL AND THROTTLE
CABLE .15
DUAL POINT FUEL INJECTION 17
FUEL DELIVERY SYSTEM ...3
GENERAL INFORMATION
T h r o u g h o u t t h i s group, references m a y be made t o
a p a r t i c u l a r vehicle by letter or n u m b e r designation.
A c h a r t showing the breakdown o f these designations
is included i n the I n t r o d u c t i o n Section a t the front o f
t h i s service m a n u a l .
The Fuel System consists of t h e fuel t a n k , fuel
p u m p , fuel filter, t h r o t t l e body, fuel lines a n d vac-
u u m lines.
The F u e l D e l i v e r y S y s t e m consists o f t h e fuel
p u m p , fuel pressure regulator, fuel f i l t e r , fuel tubes,
fuel hoses, and fuel injectors.
The F u e l T a n k A s s e m b l y consists o f t h e fuel
t a n k , filler tube, a fuel gauge sending u n i t assembly
a n d a pressure-vacuum f i l l e r cap.
Also, to be considered p a r t o f t h e fuel system is the
E v a p o r a t i o n C o n t r o l S y s t e m , w h i c h is designed to
reduce t h e emission of fuel vapor i n t o t h e atmo-
sphere.
The description a n d function o f t h e Evaporation
Control System is found i n Group 25 o f t h i s m a n u a l .
FUEL REQUIREMENTS
Y o u r vehicle was designed a n d developed for opti-
m u m operating performance a n d efficiency u s i n g
h i g h q u a l i t y unleaded gasoline.
I n order t o r e t a i n t h e o p t i m u m performance quali-
ties and enjoy trouble-free operation o f y o u r vehicle,
i t i s recommended t h a t only gasolines f r o m reputable
dealers be used.
Use unleaded gasolines h a v i n g a m i n i m u m octane
r a t i n g of 87, (R + M ) 12.
Should your vehicle develop spark knock (ping),
purchase your fuel from another source. Vehicles
m a y respond differently to gasolines h a v i n g the same
octane r a t i n g . Occasional trace knock a t l o w engine
speeds is n o t h a r m f u l . However, continued knock a t
h i g h speeds can damage y o u r engine a n d should be
reported to your dealer i m m e d i a t e l y . Engine damage
as a result o f prolonged operation of a vehicle w i t h
continuous h i g h speed knock m a y not be covered b y
t h e new vehicle w a r r a n t y .
I n addition to u s i n g unleaded gasoline w i t h t h e
proper octane r a t i n g , gasolines t h a t contain deter-
Page
FUEL TANKS 9
GENERAL DIAGNOSIS 31
SERVICE PROCEDURES 47
gents and anti-corrosion additives are recommended.
The use of gasoline c o n t a i n i n g these additives help
improve fuel economy, reduce emissions a n d m a i n -
t a i n vehicle performance.
Low q u a l i t y fuel can cause problems such as h a r d
s t a r t i n g , stalling, a n d d r i v e a b i l i t y deterioration. I f
problems of this type are experienced, i t is recom-
mended t h a t another b r a n d o f gasoline be used prior
to considering service for t h e vehicle.
The exhaust emission system o f your vehicle is de-
signed to meet a l l emission regulations w h i l e a t t h e
same t i m e providing excellent fuel economy. Catalyst
systems require t h a t only unleaded gasoline be used.
Use of leaded fuel w i l l not o n l y destroy t h e effective-
ness of the catalytic converter used t o reduce exhaust
emissions, b u t w i l l also m a k e p a r t of the fuel control
system inoperative a n d lead t o h i g h fuel consump-
tion.
A l l vehicles have w a r n i n g labels on the i n s t r u m e n t
panel and adjacent to t h e fuel filler cap o r door t h a t
state U N L E A D E D F U E L O N L Y . These vehicles
also have fuel f i l l e r tubes designed to accept only the
unleaded gasoline dispensing nozzle. Damage result-
i n g from the use of leaded gasoline m a y n o t be cov-
ered by the new vehicle w a r r a n t y .
GASOLINES CONTAINING ALCOHOL
Y o u r vehicle was designed a n d developed for opti-
m u m operating performance a n d efficiency u s i n g gas-
oline. Some fuel suppliers sell gasoline/alcohol blends
as motor vehicle fuel. The type and a m o u n t o f alco-
h o l used i n the blend is i m p o r t a n t . M a n y states re-
quire t h a t the service s t a t i o n pumps dispensing
gasoline containing alcohol be properly labeled w i t h
the type and amount of alcohol present. I f y o u r state
does not have t h i s requirement, we recommend t h a t
you ask t h e gasoline s t a t i o n operator i f t h e i r fuel
contains alcohol and i f so, w h a t type and amount.
The following t w o types o f alcohols are generally
used i n gasoline blends:
E T H A N O L ( E t h y l or G r a i n Alcohol) is used as a
m i x t u r e of 10 percent e t h a n o l a n d 90 percent u n -
leaded gasoline and identified as "ethanol enhanced",
"contains ethanol", or "gasohol". Gasoline blended
14 - 2 FUEL SYSTEM
w i t h ethanol, may be used in your vehicle. Note that
these blends, due to their generally higher volatility,
m a y adversely affect the starting, driveability and
fuel efficiency of your vehicle. I f problems are expe-
rienced with ethanol/gasoline blends, it is recom-
mended that the vehicle be operated on gasoline.
M E T H A N O L (Methyl or Wood Alcohol) is used i n
a variety of concentrations blended with unleaded
gasoline. Y o u may encounter fuels containing three
percent or more methanol along with other alcohols,
called cosolvents.
D o not u s e gasolines c o n t a i n i n g methanol.
U s e of methanol/gasoline blends may result in
starting and driveability deterioration and damage to
critical fuel system components.
F u e l system damage and vehicle performance prob-
lems, resulting from the use of gasolines containing
•
methanol, are not the responsibility of Chrysler Mo-
tors and may not be covered by the new vehicle war-
ranty.
GASOLINES CONTAINING MTBE
Fuels that are a mixture of unleaded gasoline and
up to 15 percent M T B E (Methyl Tertiary B u t y l
Ether) may be used i n your vehicle.
MATERIALS ADDED TO FUEL
Indiscriminate use of fuel system cleaning agents
should be avoided. Many of these materials intended
for gum and varnish removal may contain active sol-
vents or similar ingredients that can be harmful to
gasket and diaphragm materials used i n fuel system
component parts.
 FUEL DELIVERY SYSTEM

INDEX
Page Page

Fuel Filter 6 Fuel Pump Module 4

Fuel Hoses and Clamps 7 Fuel Pump Pressure Test 3
Fuel Pump 3 Fuel System Pressure Release Procedure 3

FUEL PUMP FUEL SYSTEM PRESSURE RELEASE PROCEDURE

The fuel p u m p used i n t h i s system has a perma-
nent magnet electric motor. The p u m p i s p a r t o f the
fuel pump module located i n t h e f u e l t a n k a n d i m -
mersed i n t h e fuel ( F i g . 1). T h e fuel i s d r a w n i n
t h r o u g h a filter and pushed t h r o u g h t h e electric mo-
tor t o t h e outlet. The p u m p contains a check valve,
located near t h e p u m p outlet, r e s t r i c t i n g fuel move-
m e n t i n either direction t o m a i n t a i n fuel supply l i n e
pressure when t h e p u m p is n o t operational. Voltage
to operate t h e p u m p i s supplied t h r o u g h t h e A u t o
Shutdown Relay.
WARNING: THE TBI FUEL SYSTEM IS UNDER A
CONSTANT PRESSURE OF APPROXIMATELY 100
KPA (14.5 PSI). BEFORE SERVICING THE FUEL
PUMP, FUEL LINES, FUEL FILTER, THROTTLE
BODY OR FUEL INJECTOR, THE FUEL SYSTEM
PRESSURE MUST BE RELEASED.
(1) Loosen fuel f i l l e r cap t o release fuel t a n k pres-
sure.
(2) Disconnect injector w i r i n g harness from engine
harness.
(3) Connect a j u m p e r w i r e to ground t e r m i n a l
N u m b e r 1 o f t h e injector harness ( F i g . 2) to engine
ground.
(4) Connect a j u m p e r w i r e t o t h e positive t e r m i n a l
N u m b e r 2 o f the injector harness (Fig. 2) and touch
the battery positive post for no longer t h a n 5 sec-
onds. T h i s releases system pressure.
(5) Remove j u m p e r wires.
(6) Continue fuel system service.
TERMINAL #1

Perform fuel system pressure release procedure be-

fore servicing t h e fuel p u m p .
TERMINAL #2 8914-123
PRESSURE RELIEF/
_ _ _ _ _ ROLLOVER VALVE
Fig. 2 Injector Harness Connector
ELECTRICAL FUEL PUMP PRESSURE TEST
TERMINAL

WARNING: THE TBI FUEL SYSTEM IS UNDER A

CONSTANT PRESSURE OF APPROXIMATELY 100
KPA (14.5 PSI). BEFORE PERFORMING THE FUEL
PUMP PRESSURE TEST THE FUEL SYSTEM PRES-
SURE MUST BE RELEASED.

(1) F u e l system pressure m u s t be released prior t o

servicing a fuel system hose or component. Perform
FUEL GAUGE fuel system pressure release.
SENDING UNIT
(2) Disconnect t h e 5/16 diameter fuel supply hose
f r o m t h e engine fuel line assembly. Use care w h e n
FUEL r e m o v i n g t h e fuel hose t o prevent damage to t h e
RESERVOIR hose or t h e fuel line. Replace hose i f damaged. Con-
nect fuel system pressure tester C-4799A between
fuel supply hose and engine fuel l i n e assembly.
RR14G218 (3) U s i n g diagnostic tester, w i t h t h e key i n t h e
" R u n " position, use Actuate O u t p u t s Test " A u t o
Fig. 1 Fuel Pump Shutdown Relay", this w i l l activate t h e fuel pump
 and pressurize t h e system. I f t h e gauge reads 100
K p a ± 7 K p a (14.5 p s i ± 1 psi), pressure i s correct
and f u r t h e r testing i s n o t r e q u i r e d . R e i n s t a l l fuel
hose u s i n g a new o r i g i n a l equipment type clamp, a n d
t i g h t e n to 1 N»m (10 in-lbs.) torque. I f pressure is not
correct, record t h e pressure a n d continue w i t h test
procedure.
(4) I f fuel pressure i s below specifications, i n s t a l l
tester i n the fuel supply line, between the fuel t a n k
and fuel filter a t the rear of vehicle.
(5) Repeat test. I f pressure is 5 psi higher t h a n pre-
v i o u s l y recorded pressure, replace fuel filter. I f no
change is observed, gently squeeze r e t u r n hose. I f
pressure increases, replace pressure regulator. I f no
change is observed, problem is either a plugged
p u m p filter (sock) or defective fuel pump.
(6) I f pressure is above specifications, remove t h e
fuel r e t u r n l i n e hose from t h e chassis line a t fuel
t a n k and connect a 3 foot piece o f fuel hose t o the re-
t u r n line. P u t t h e other end i n t o a n approved gaso- Fig. 3 Top View of Fuel Pump Module
l i n e container ( m i n i m u m 2 g a l l o n size) so t h a t a l l REMOVAL
r e t u r n fuel w i l l flow i n t o container. Repeat test. I f
pressure is now correct, check i n - t a n k r e t u r n hose for WARNING: THE TBI FUEL SYSTEM IS UNDER A
k i n k i n g . Replace fuel p u m p assembly i f i n - t a n k res- CONSTANT PRESSURE OF APPROXIMATELY 100
e r v o i r check valve or aspirator j e t is obstructed. (This KPA (14.5 PSI). BEFORE SERVICING THE FUEL
test should be performed w h e n fuel t a n k is 1/2 f u l l or PUMP MODULE THE FUEL SYSTEM PRESSURE
greater.) MUST BE RELEASED.
(7) I f pressure is s t i l l above specifications, remove
fuel r e t u r n hose from t h r o t t l e body. Connect a substi- (1) D r a i n t h e fuel t a n k . Refer t o " D r a i n i n g F u e l
t u t e hose t o the t h r o t t l e body r e t u r n nipple a n d place T a n k " i n t h i s group.
other end o f hose i n clean container. Repeat test. I f (2) Remove fuel t a n k . Refer to " F u e l T a n k s " i n t h i s
pressure is now correct, check f o r restricted fuel re- group.
t u r n line. I f no change is observed, replace fuel pres- ( 3 ) W h i l e holding t h e fuel p u m p module down, re-
sure regulator. move the h o l d i n g clamp (Fig. 4 )
(4) Release t h e module. I t w i l l s p r i n g u p from i t s
MECHANICAL MALFUNCTIONS
position.
Mechanical malfunctions are more difficult t o diag-
(5) Remove module f r o m fuel t a n k .
nose w i t h t h i s system. The Single Board E n g i n e Con-
t r o l l e r (SBEC) has been programmed t o compensate
for some mechanical malfunctions such as incorrect
cam t i m i n g o r vacuum leaks. I f engine performance
problems are encountered, and n o f a u l t codes are dis-
played, t h e problem m a y be mechanical r a t h e r t h a n
electronic.

FUEL PUMP MODULE

The fuel pump module is i n s t a l l e d i n the top of the
fuel t a n k (Fig. 3 ) . I t contains t h e fuel p u m p , fuel
p u m p reservoir, i n - t a n k fuel filter, pressure relief/
rollover valve, electrical connector for the fuel pump
gauge sending u n i t , fuel filler vent, fuel supply and
r e t u r n tube connections, and t h e fuel d r a i n tube nip-
ple.

Fig. 4 Fuel Pump Module Removal/Installation

 • FUEL SYSTEM 14 - i

DISASSEMBLY MOUNTING
(1) Remove sending u n i t a t t a c h i n g screws from LUGS
m o u n t i n g bracket located on t h e d r a i n tube (Fig. 5).
FUEL RESERVIOR

FUEL GAUGE RESERVOIR

SENDING

RR14G174
FASTNERS

Fig. 7 Removing Fuel Line Coil from Reservoir

FUEL UNE FUEL RETURN FUEL RETURN CHECK

COIL ASSEMBLY HOSE VALVE
FUEL
FLOAT

FUEL DRAIN TUBE

RR14G172

Fig. 5 Fuel Gauge Sending Unit Service

(2) Disconnect electrical wires from sending unit
(Fig. 6) Remove sending u n i t .
FUEL GAUGE OUNTING
WIRES LUGS
RR14G177

Fig. 8 Fuel Pump and Reservoir Assembly

(5) Release t h e p u m p m o u n t i n g bracket f r o m t h e
reservoir using t h u m b and fore fingers. Press t h e
bracket w i t h both t h u m b s t o w a r d t h e center o f t h e
reservoir (Figs. 9 and 10).

FUEL PUMP
MOUNTING BRACKET

RR14G173

Fig. 6 Fuel Gauge Sending Unit Wiring Terminals

(3) Remove the d r a i n tube from t h e m o u n t i n g l u g
at t h e b o t t o m of the reservoir (Fig. 7).
(4) Remove the lower-most coil o f the d r a i n tube
out o f t h e m o u n t i n g lugs on top o f the reservoir (Fig.
8). Care should be t a k e n to avoid unsnapping t h e r e -
t u r n l i n e check valve cover f r o m t h e bottom o f t h e RR14G175
reservoir. I f t h i s cap comes free, snap back into place
(Fig. 8). Fig. 9 Fuel Pump Mount Bracket
 14 - 6 FUEL SYSTEM
Fig. 10 Removal and Installation of Fuel Pump
(6) Remove and r e t a i n pump m o u n t i n g bracket and
rubber collar from hose. C u t hose clamp on t h e sup-
p l y line t o t h e pump. Discard clamp. Remove pump/
filter assembly from hose (Fig. 11).
Fig. 11 Servicing Fuel Pump
(7) I f p u m p is operational but the filter requires re-
placement, gently " w a l k " a broad blade screwdriver
around t h e filter m o u n t i n g ferrule to remove filter
(Fig. 12). Care should be taken to avoid damage to
the p u m p i n l e t . I f p u m p is not operational, discard
entire assembly. Do n o t reuse filter.
ASSEMBLY
(1) Press new filter onto pump. (A new p u m p is
provided w i t h new filter.)
(2) Use a n e w clamp t o attach the pump to t h e sup-
p l y hose. Use Tool C-4124 to crimp clamp.
(3) Reposition pump m o u n t i n g bracket a n d rubber
collar o n supply hose between the bulge i n t h e hose
and t h e p u m p . (Fig. 11).
(4) Position the pump i n the reservoir so t h a t t h e
filter aligns w i t h the cavity i n the reservoir (Fig. 10).
•
Fig. 12 Servicing Fuel Filter
(5) Snap p u m p bracket/collar i n t o t h e reservoir
(Fig. 9).
(6) Position coil tube onto reservoir so t h a t t h e
d r a i n tube aligns w i t h m o u n t i n g lugs o n reservoir.
(Fig. 7).
(7) Snap lower-most coil i n t o m o u n t i n g lugs o n top
of the reservoir.
(8) Snap t h e d r a i n tube i n t o t h e lugs on t h e bottom
of the reservoir.
(9) Connect electrical wires to n e w sending u n i t
(Fig. 6).
(10) A l i g n index t a b on new level u n i t w i t h index
hole on m o u n t i n g bracket.
(11) A t t a c h n e w level u n i t to m o u n t i n g bracket
w i t h screws. ( F i g . 5).
(12) I n s t a l l reassembled u n i t i n t o fuel t a n k .
INSTALLATION
(1) W i p e seal area of t a n k clean.
(2) I n s t a l l a new O-ring seal on t h e p u m p .
(3) A l i g n fuel pump module w i t h r e t a i n i n g bracket
on bottom o f fuel t a n k (Fig. 13). The fuel p u m p mod-
ule m a y have a slight interference fit w i t h t h e
bracket.
(4) Push t h e module down and i n s t a l l t h e r e t a i n i n g
clamp. T i g h t e n clamp to 4.5 N»m (40 i n . lbs.) torque.
(5) I n s t a l l fuel t a n k . Refer to " F u e l T a n k s "
FUEL FILTER
REMOVAL
WARNING: THE TBI FUEL SYSTEM IS UNDER A
CONSTANT PRESSURE OF APPROXIMATELY 100
KPA (14.5 PSI). BEFORE SERVICING THE FUEL FIL-
TER THE FUEL SYSTEM PRESSURE MUST BE RE-
LEASED.
(1) Perform F u e l System Pressure Release proce-
dure.

Fig. 13 Fuel Pump Module Retaining Bracket
(2) Disconnect battery negative cable f r o m battery.
(3) Remove f i l t e r r e t a i n i n g screw and remove filter
assembly f r o m m o u n t i n g plate (Fig. 14).
(4) Loosen outlet hose clamp on filter a n d i n l e t
hose clamp o n rear fuel tube (Fig. 14).
(5) W r a p a shop towel around hoses t o absorb fuel.
Remove hoses a t filter and fuel tube. Discard clamps.
FUEL FILTER
ASSEMBLY
FUEL SUPPLY AND
RETURN HOSE ASSEMBLY
Fig. 14 Fuel Filter
INSTALLATION
(1) I n s t a l l i n l e t hose on fuel tube and t i g h t e n new
clamp to 1 N n n (10 i n . lbs.) torque.
(2) I n s t a l l o u t l e t hose on filter outlet f i t t i n g a n d
t i g h t e n new clamp to 1 N*m (10 i n . lbs.) torque.
(3) Position filter assembly on m o u n t i n g plate a n d
t i g h t e n m o u n t i n g screw to 8 N n n (75 i n . lbs.) torque.
FUEL HOSES AND CLAMPS
WARNING: THE TBI FUEL SYSTEM IS UNDER A
CONSTANT PRESSURE OF APPROXIMATELY 100
KPA (14.5 PSI). BEFORE SERVICING FUEL SYSTEM
HOSES OR LINES THE FUEL SYSTEM PRESSURE
MUST B E RELEASED.
Inspect a l l hose connections. Ensure t h e y are se-
cure a n d n o t leaking. Hoses should be replaced i m -
mediately i f there is a n y evidence o f degradation
t h a t could result i n f a i l u r e .
A v o i d contact w i t h clamps or other components
t h a t cause abrasions or scuffing. Ensure t h a t t h e
rubber hoses are properly routed to prevent p i n c h i n g
and to avoid heat sources.
The hoses used on fuel injected vehicles are o f spe-
cial construction due t o t h e possibility o f contami-
nated fuel i n t h i s system. I f i t is necessary t o replace
these hoses, only hoses m a r k e d EFM/EFI m a y be
used.
The hose clamps used on fuel injected vehicles are
of a special rolled edge construction to prevent t h e
edge of t h e clamp c u t t i n g i n t o t h e hose. O n l y these
rolled edge type clamps m a y be used i n t h i s system,
a l l other types of clamps may cut into t h e hoses a n d
FUEL TUBES cause h i g h pressure fuel leaks.
TO ENGINE Use n e w o r i g i n a l equipment type hose clamps,
t i g h t e n hose clamps to 1 N n n (10 i n . lbs.) torque.
QUICK-CONNECT FUEL TUBE FITTINGS
Quick-connect fuel tube f i t t i n g s a t t h e ends o f the
chassis fuel lines (Fig. 15). The f i t t i n g consists of O-
r i n g s a n d a plastic release collar to disconnect t h e
fitting f r o m t h e fuel tube.
QUICK-CONNECT
FITTING
RR14G220
J9014-187
Fig. 15 Quick-Connect Fitting
 A t t h e end o f the fuel tube nipple is a raised shoul-
der. W h e n t h e fuel tube i s installed i n t o the quick-
connect f i t t i n g t h e shoulder i s locked i n place b y
tangs inside t h e f i t t i n g (Fig. 16). After t h e tube i s i n -
stalled i n t o t h e fitting, Verify t h a t connection i s se-
cure b y firmly p u l l i n g back o n fuel tube (Fig. 17).
The tube should be locked i n place.
RELEASE
QUICK CONNECT COLLAR
FITTING SHOULDER QUICK-CONNECT
FITTING J9014-189

Fig. 17 Assembled Quick-Connect Fitting

PULL COLLAR
BACK

RELEASE
NIPPLE
COLLAR J9014-188

Fig. 16 Quick-Connect Fitting Assembly

SLIDE TUBE
To disconnect t h e fitting from t h e fuel tube, p u l l OUT OF
the release collar back i n t o t h e fitting a n d slide t h e FITTING
f i t t i n g off o f the fuel tube ( F i g . 18). J9014-190

Fig. 18 Quick-Connect Fitting Disassembly

 FUEL TANKS
INDEX
Page
Fuel Gauge Sending Unit 14
Fuel Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Fuel System Pressure Release Procedure 10
Fuel Tank Pressure Relief/Rollover Valve 14
Fuel Tank Skid Plate . . . . . . ........ 10
GENERAL INFORMATION
Chrysler Motors b u i l t vehicles pass a f u l l 360° r o l l -
over w i t h o u t fuel leakage. To accomplish t h i s , fuel
and vapor flow controls are required for a l l fuel t a n k
connections.
A l l models are equipped w i t h a rollover valve
mounted i n t h e t o p o f t h e fuel t a n k . O n vehicles
equipped w i t h a r e t u r n l i n e from t h e fuel pump to
the fuel t a n k a one-way check valve is used to pro-
vide the r e q u i r e d protection. I n a d d i t i o n t o the valve,
improved flow control is used i n t h e fuel pump to
control flow w h e n t h e pump is subjected to t h e
higher t h a n n o r m a l pressure w h i c h can occur d u r i n g
rollover. A fuel f i l l e r cap w i t h a higher pressure set-
t i n g is used for the same reason on vehicles w i t h side
fill.
A n evaporation control system is used to reduce
the emissions o f fuel vapors i n t o t h e atmosphere by
evaporation a n d reduce t h e u n b u r n e d hydrocarbons
emitted by t h e vehicle engine. W h e n fuel evaporates
f r o m t h e fuel t a n k , t h e vapors pass t h r o u g h vent
hoses or tubes t o a charcoal canister where they are
t e m p o r a r i l y h e l d u n t i l t h e y can be d r a w n i n t o the i n -
t a k e m a n i f o l d w h e n t h e engine is r u n n i n g .
Inspect a l l hose connections such as clamps a n d
couplings to m a k e sure they are secure and no leaks
are present. Hoses should be replaced immediately i f
there is any evidence o f degradation t h a t could result
i n failure.
A v o i d contact w i t h clamps or other components
t h a t cause abrasions or scuffing. Ensure t h a t t h e
rubber hoses a r e properly routed t o prevent p i n c h i n g
and to avoid heat sources.
The hoses used o n fuel injected vehicles are of a
special construction due to the higher fuel pressures
involved i n t h i s system. I f i t is necessary t o replace
these hoses, o n l y hoses m a r k e d E F M / E F I m a y be
used.
Page
Fuel Tanks 10
Heat Shields 10
General Information 9
No-Lead Fuel Tank Filler Tube 9
Pressure-Vacuum Filler Cap . . . . . . . . . . . . . . . . . . 9
The hose clamps used o n fuel injected vehicles are
of a special r o l l e d edge construction to prevent t h e
edge of the clamp c u t t i n g i n t o the hose. O n l y these
rolled edge type clamps may be used on t h i s system,
a l l other types o f clamps may cut i n t o the hoses and
cause h i g h pressure fuel leaks.
NO-LEAD FUEL TANK FILLER TUBE
A l l catalyst equipped vehicles have a special fuel
t a n k f i l l e r tube. The fuel filler opening is smaller i n
diameter t h a n those used for non-catalyst vehicles t o
p e r m i t e n t r y o f only the smaller no-lead fuel nozzles.
I n addition a deflector, w h i c h is opened by t h e no-
lead fuel nozzle, deters the a d d i t i o n of fuel b y means
other t h a n t h e proper nozzle.
The fuel filler tube on these models is equipped
w i t h a one way b a l l check valve designed to prevent
fuel back splash w h i c h m a y occur w h i l e f i l l i n g t h e
tank.
A label is attached to the i n s t r u m e n t panel under
the fuel gauge t h a t reads " U N L E A D E D FUEL
O N L Y " as a reminder to the driver. A s i m i l a r label
is located near the fuel t a n k filler.
PRESSURE-VACUUM FILLER CAP
The loss o f any fuel or vapor out of the f i l l e r neck
is prevented b y t h e use of a pressure-vacuum filler
cap. Relief valves inside the cap w i l l release o n l y u n -
der significant pressure of 6.58 to 8.44 k P a (1.95 to
2.5 psi). T h e vacuum release for a l l gas caps i s be-
tween .97 a n d 2.0 k P a (.14 a n d .29 psi). T h i s cap
m u s t be replaced by a s i m i l a r u n i t i f replacement is
necessary, i n order for t h e system to r e m a i n effec-
tive.
CAUTION: Remove filler cap prior to removing or
repairing fuel lines to relieve tank pressure.
14-10 FUEL SYSTEM •

FUEL TANK CAPACITIES (2) Disconnect injector w i r i n g harness from engine

harness.
TANK: LITERS GALLONS (3) Connect a j u m p e r w i r e to ground t e r m i n a l
N u m b e r 1 o f t h e injector harness (Fig. 2) t o engine
Standard 83.0 22
ground.
Optional 114 30
120.9 34
(4) Connect a j u m p e r w i r e t o the positive t e r m i n a l
Ramcharger
N u m b e r 2 o f the injector harness ( F i g . 2) a n d touch
Nominal refill capacities are shown. A variation may be observed t h e battery positive post for no longer t h a n 5 sec-
from vehicle to vehicle due to manufacturing tolerances and refill
onds. T h i s releases system pressure.
procedures.
(5) Remove j u m p e r wires.
J9014-182 (6) Continue fuel system service.
FUEL TANK SKID PLATE
FUEL TANKS
A protective m e t a l s k i d plate is available for t h e
Ramcharger 34 gallon fuel t a n k (Fig. 1). The plate is DRAINING FUEL TANK
mounted t o the frame r a i l s a n d to brackets attached (1) Remove fuel f i l l e r cap t o release fuel t a n k pres-
to the crossmembers. sure.
FRAME RAIL (2) P e r f o r m F u e l System Pressure Release proce-

Fig. 2 Injector Harness Connectors

SKID PLATE
RN869
Fig. 1 Fuel Tank Skid Plate
HEAT SHIELDS
The sheet metal heat shields must be removed
when servicing the fuel t a n k , fuel lines or vapor vent
line. I t is very i m p o r t a n t t h a t these heat shields be
reinstalled after service to protect t h e lines and t a n k
from t h e heat of the exhaust system. See Group 11 i n
this m a n u a l for proper i n s t a l l a t i o n .
FUEL SYSTEM PRESSURE RELEASE PROCEDURE
The fuel system is under a constant pressure of ap-
proximately 100 k P a (15 psi). Before servicing t h e
fuel t a n k t h e fuel pressure m u s t be released as fol-
lows:
(1) Loosen fuel f i l l e r cap to release fuel t a n k pres-
sure.
dure as described i n t h i s group.
(3) Raise vehicle o n hoist.
(4) D r a i n fuel i n t o a portable holding t a n k or a
properly labeled "gasoline" safety container.
• I f t h e fuel p u m p operates, fuel can be drained
t h r o u g h t h e fuel supply hose.
• I f the p u m p does n o t operate, b u t t h e fuel level i n
the fuel t a n k is below t h e fuel filler hose, fuel can be
siphoned t h r o u g h t h e fuel f i l l e r hose. The hose w i l l
have to be disconnected from t h e f i l l e r neck.
• I f the fuel t a n k is f u l l and the fuel pump does n o t
operate, d r a i n fuel from f i l l e r neck. Support fuel t a n k
w i t h a transmission jack. Loosen fuel t a n k m o u n t i n g
straps w i t h t h e passenger side fuel strap loosened
s l i g h t l y more t h a n d r i v e r side strap. Lower t h e t a n k
s l i g h t l y . Loosen t h e f i l l e r neck to f i l l e r hose clamp.
Slide clamp back o n hose. W r a p shop towels around
fuel f i l l e r hose to absorb any spilled fuel. Disconnect
f i l l e r hose from f i l l e r neck. D r a i n fuel t a n k t h r o u g h
f i l l e r hose.
REMOVAL-MID-FRAME MOUNTED TANKS FUEL FILTER
PRESSURE RELIEF/
(1) D r a i n fuel t a n k . Refer t o D r a i n i n g F u e l T a n k i n ROLLOVER VALVE FUEL TUBES
t h i s group.
FUEL TANK
(2) Disconnect b a t t e r y negative cable. ASSEMBLY
(3) Remove fuel t a n k filler cap before disconnecting
any fuel or v e n t lines. T h e t a n k could be under a
s l i g h t pressure.
(4) Pump a l l fuel from fuel t a n k i n t o a n approved
portable h o l d i n g t a n k . I f t h i s equipment is n o t avail-
able, disconnect t h e fuel l i n e and d r a i n t a n k d r y i n t o
a properly identified "Gasoline" safety container.
(5) Raise vehicle o n hoist a n d disconnect a l l vent
hoses and filler hose (Fig. 3 a n d 4).
(6) Place a transmission j a c k under t h e center o f
the fuel t a n k a n d apply s l i g h t pressure. J9014-191

WARNING: WRAP SHOP TOWELS AROUND HOSES
TO CATCH ANY GASOLINE SPILLAGE.
(7) Remove fuel t a n k m o u n t i n g strap n u t s a t t h e
crossmembers ( F i g . 5). Lower fuel t a n k enough to
p e r m i t fuel gauge w i r e a n d fuel tubes to be discon-
nected from t h e fuel pump module a t t h e top of t h e
fuel t a n k . To remove fuel tubes squeeze locking tabs
on connector a n d p u l l tube back (Fig. 6).
(8) Lower fuel t a n k .
Fig. 3 Fuel Hose Connections to Fuel Tank—Mid-
Frame Mounted Fuel Tanks
INSTALLATION-MID-FRAME MOUNTED
TANKS
(1) Place fuel t a n k on top of transmission jack and
raise h i g h enough t o connect t h e fuel tubes and
gauge w i r e to t h e fuel pump module on the top of the
tank.
(2) Raise t a n k i n t o position under crossmembers
and connect t h e t w o end m o u n t i n g straps. Remove
transmission jack. T i g h t e n a l l straps f i r m l y . Do not
over t i g h t e n r e t a i n i n g strap n u t s .
(3) Connect vent hoses.

"U" NUT (4)

SCREW
(20 INCH-POUNDS)

SCREW
(20 INCH-
POUNDS)

CLAMP
CLAMP (20 INCH-POUNDS)
(2)
VIEW IN DIRECTION
OF ARROW Z RB1362A

Fig. 4 Fuel Filler Neck and Vent Hose Connections—Mid-Frame Mounted Fuel Tanks
14-12 FUEL SYSTEM •
USED WITH
TIGHTENING TORQUE REAR
7-INCH RAIL
A 30 FT LBS (41 N-m) STRAP

B TIGHTEN TO SECURE TANK

C 100 IN LBS (11 N-m)

|%-~NUT<J> <J>
VIEW IN CIRCLE Z
(30 GAL. TANK) J9014-183

Fig. 5 Mid-Frame Mounted Fuel Tank Removal/Installation

REMOVAL-RAMCHARGER MODELS
FUEL LINE T O PUAAP A S S E M B L Y C O N N E C T O R (1) D r a i n fuel t a n k . Refer to D r a i n i n g Fuel T a n k i n
t h i s section.
(2) Disconnect battery ground cable.
(3) Remove fuel t a n k f i l l e r cap to release fuel t a n k
PRESS HERE T O RELEASE
pressure.
(4) P u m p a l l fuel from fuel t a n k into a n approved
portable h o l d i n g t a n k . I f t h i s equipment is n o t avail-
able, disconnect the fuel line and d r a i n t a n k d r y into
a properly identified "Gasoline" safety container. Re-
fer to " D r a i n i n g Fuel T a n k " .
(5) Raise vehicle on hoist.
(6) Place transmission jack under center of t a n k
and apply slight pressure. Disconnect t h e t a n k
m o u n t i n g straps " J " bolts a n d remove r e t a i n i n g
FUEL P U M P M O D U L E RR14G182
straps ( F i g . 7).
Fig. 6 Fuel Tube to Fuel Pump Module Connection (7) Lower t a n k on transmission jack far enough to
p e r m i t access to the fuel tubes and fuel gauge send-
(4) Connect fuel line i f i t was disconnected to d r a i n
i n g u n i t electrical connection a t t h e fuel pump mod-
tank. Recap d r a i n tube.
ule on top of the t a n k ( F i g . 8).
( 5 ) Refill fuel t a n k a n d inspect a l l hoses a n d lines
(8) To remove fuel tubes squeeze locking tabs on
for leaks. Connect battery cable.
connector and p u l l tube back (Fig. 6). Disconnect fuel
 NUT (2)
ASSEMBLY "U" NUT (4)
(200 INCH-POUNDS)
FUEL
TANK FILLER
TUBE

HOSE

FUEL TANK
CLAMP FILLER

TIGHTEN NUT TO
. END OF THREAD CLAMP
FUEL TANK FUEL TANK ON STUD CLAMP
M
^U!^ G
ASSEMBLY VIEW A* _
J9014-186
STRAPS STRAP ADJUSTAAENT J9014-184
Fig. 7 Ramcharger Fuel Tank Removal/Installation Fig. 9 Fuel Filler Tube and Vent Tube to Filler Neck
Connections
FUEL TUBES
(5) Remove jack.
(6) Connect filler tube and a l l vent hoses. I n s t a l l
new hose clamps a n d t i g h t e n securely.
(7) Connect fuel l i n e i f disconnected to d r a i n t a n k .
FUEL TANK
Recap d r a i n tube.
(8) Refill fuel t a n k a n d inspect a l l hoses and lines
for leaks.
(9) Reconnect battery ground cable.
FUEL RESERVOIR
The fuel reservoir (Fig. 10) is attached to t h e lower
end of the fuel p u m p module. The purpose of the res-
PRESSURE RELIEF/
ROLLOVER VALVE

ELECTRICAL
VENT TERMINAL
HOSE

TO FILLER
NECK J9014-I85
Fig. 8 Fuel Tube Connections—Ramcharger
gauge sending u n i t electrical connector from fuel
p u m p module. Remove ground strap.
(9) Remove fuel filler tube hose a n d fill v e n t hose
from t a n k (Fig. 8 a n d F i g . 9). FUEL GAUGE
(10) Lower fuel t a n k . SENDING UNIT

INSTALLATION
(1) Position t a n k on transmission jack. FUEL
(2) Raise t a n k h i g h enough t o connect t h e fuel RESERVOIR
tubes and gauge sending u n i t electrical connector to
t h e fuel pump module a t t h e top o f the t a n k .
RR14G218
(3) Raise t a n k i n t o position.
(4) I n s t a l l t a n k m o u n t i n g straps. Connect " J " bolts Fig. 10 Fuel Pump Module
a n d t i g h t e n the nuts as shown i n F i g . 8.
ervoir is to provide fuel a t t h e p u m p i n t a k e d u r i n g
a l l d r i v i n g conditions, especially those w h e n low fuel
levels are present. The fuel r e t u r n l i n e directs fuel
i n t o the reservoir.
FUEL GAUGE SENDING UNIT
The fuel gauge sending u n i t is attached t o t h e fuel
p u m p module (Fig. 11). The fuel p u m p module m u s t
be removed t o service t h e fuel gauge sending u n i t .
Fig. 11 Fuel Gauge Sending Unit
REMOVAL
(1) Remove fuel gauge sending u n i t fasteners from
m o u n t i n g bracket on d r a i n tube (Fig. 11).
(2) Disconnect electrical wires from level u n i t (Fig.
12).
Fig. 12 Servicing Fuel Gauge Sending Unit
(3) Reverse above procedure for i n s t a l l a t i o n .
FUEL TANK PRESSURE RELIEF/ROLLOVER VALVE
The fuel t a n k s o f a l l vehicles are equipped w i t h a
pressure relief/rollover v a l v e . T h e d u a l function
valves relieve f u e l t a n k pressure a n d prevent fuel
flow t h r o u g h t h e fuel t a n k v e n t hoses i n t h e event of
vehicle rollover. A l l vehicles pass a f u l l 360° rollover
w i t h o u t fuel leakage.
The pressure relief/rollover valve ( F i g . 13) is
mounted a t t h e t o p o f the f u e l p u m p module.
PRESSURE RELIEF/ROLLOVER VALVE SCREWDRIVER
Fig. 13 Servicing Pressure Relief/Rollover Valve
REMOVAL
(1) Remove fuel t a n k refer t o " F u e l T a n k s " section
i n t h i s group.
(2) Wedge t h e blade o f a s t r a i g h t screwdriver be-
tween t h e rubber grommet a n d t h e fuel t a n k where
the support r i b i s located ( F i g . 13). D o n o t w e d g e
between the valve a n d t h e grommet o r damage
to the valve m a y result u p o n removal.
(3) Use a second screwdriver as a support to p r y
the valve and grommet assembly from t h e t a n k .
(4) To remove t h e grommet from t h e valve, place
the valve u p r i g h t on a f l a t surface and push down on
the grommet peeling i t down off the valve.
INSTALLATION
(1) I n s t a l l t h e rubber g r o m m e t i n t h e fuel t a n k a n d
w o r k i t around t h e curled l i p .
(2) Lubricate t h e grommet w i t h P o w e r S t e e r i n g
F l u i d a n d push t h e valve d o w n w a r d i n t o the grom-
met. T w i s t valve u n t i l properly positioned.
(3) I n s t a l l fuel t a n k . Refer t o " F u e l T a n k Installa-
tion".
 • FUEL SYSTEM 14-15

A C C E L E R A T O R PEDAL AND T H R O T T L E C A B L E

INDEX
Page Page
Accelerator Pedal ....... 15 Throttle Cable .. 15
General Information 15

GENERAL INFORMATION THROTTLE CABLE

A l l models have two torsion r e t u r n springs on t h e
t h r o t t l e body, and a n accelerator pedal r e t u r n spring
(extension spring) w h i c h gives positive t h r o t t l e re-
t u r n a n d lower t h r o t t l e pedal efforts w h i l e meeting
safety requirements.
ACCELERATOR PEDAL
CAUTION: Be careful not to damage or kink throttle
or speed control core wire during installation or re-
moval of accelerator pedal or cables.
REMOVAL
F r o m inside the vehicle, h o l d up the pedal and re-
move t h e cable retainer a n d t h r o t t l e cable from t h e
upper end o f the pedal shaft (Fig. 1).
CAUTION: Be careful not to damage or kink throttle
or speed control core wire during installation or re-
moval of accelerator pedal or cables.
REMOVAL
(1) F r o m inside t h e vehicle, remove the cable hous-
i n g retainer clip and core w i r e cable retainer (Fig. 1).
(2) Remove the core w i r e f r o m the pedal shaft.
(3) F r o m the engine compartment, p u l l the housing
end-fitting o u t o f the dash panel grommet (Fig. 1).
The grommet should r e m a i n i n the dash panel hole.
(4) Remove t h e cable slug f r o m t h e t h r o t t l e body
cam. Separate the cable m o u n t i n g bracket w i t h wide-
j a w pliers by compressing the e n d - f i t t i n g tabs (Fig. 2
or 3).

THROTTLE RETURN
RETAINER CUP THROTTLE CABLE SPRING
RETAINER
GROMMET

THROTTLE CABLE
ASSEMBLY

THROTTLE
ACCELERATOR PEDAL CABLE
ASSEMBLY
NUT (2)

TRANSMISSION
RR14G223 KICKDOWN ROD
DASH PANEL (UPPER)

Fig. 1 Accelerator Pedal Removal or Installation BELL CRANK

W o r k i n g from t h e engine compartment, remove

nuts f r o m pedal shaft a n d bracket assembly studs.
Remove assembly f r o m vehicle.

INSTALLATION
Position assembly on dash panel and i n s t a l l r e t a i n - TRANSMISSION
KICKDOWN ROD
i n g n u t s , t i g h t e n t o specifications. F r o m inside t h e
(LOWER)
vehicle, h o l d up t h e pedal and i n s t a l l t h e t h r o t t l e ca-
ble and cable retainer i n t h e upper end o f the pedal J9014-192
shaft.
Fig. 2 Throttle Cable Attachment—3.9L Engine
14 - 18 FUEL SYSTEM •
INSTALLATION THROTTLE BODY THROTTLE CABLE BRACKET
(1) I n s t a l l the cable housing i n t o t h e cable m o u n t -
i n g bracket on the t h r o t t l e body and attach the cable
s l u g w i t h t h e r e t a i n i n g clip onto t h e t h r o t t l e body
cam.
(2) I n s t a l l the r e m a i n i n g cable housing e n d - f i t t i n g
i n t o t h e dash panel grommet and attach the housing
r e t a i n e r clip from inside the vehicle.
(3) I n s t a l l the b a l l end o f the cable t h r o u g h t h e
hole i n t h e pedal shaft and i n s t a l l t h e plastic cable
retainer.

OF ARROW X RR14G164

Fig. 3 Throttle Cable Attachment—5.2L and 5.9L

Engine
 • FUEL SYSTEM
DUAL POINT F U E L I N J E C T I O N
Page
A/C S w i t c h - S B E C Input 19
Air Conditioning Clutch R e l a y - S B E C Output . . . . 22
Air Switching Solenoid—SBEC Output . . . . . . . . . 22
Alternator—SBEC Output 23
Auto Shutdown (ASD) R e l a y — S B E C Output . . . . . 23
Battery Voltage—SBEC Input . . . . . . . . . . . . . . . . 19
Brake Light Switch—SBEC Input . . . . . . . . . 19
Canister Purge Solenoid—SBEC Output . . . . . . . . 23
Check Engine L a m p — S B E C Output . . . . . . . 23
Coolant TemperatureSensor—SBEC Input . . . . . . 19
E G R Solenoid—SBEC Output 23
EMR L a m p — S B E C Output 23
Engine S p e e d — S B E C Input 19
Fuel Injectors—SBEC Output . . . . . . . . . . . . . . . . 24
Fuel Pressure Regulator 30
Fuel P u m p — S B E C Output . . . 24
General Information ". . . 17
GENERAL INFORMATION
The D u a l - P o i n t Electronic F u e l Injection System
(Fig. 1) is a computer regulated system t h a t provides
a precise air/fuel r a t i o for a l l d r i v i n g conditions. F u e l
is supplied t o the engine t h r o u g h two fuel injectors
i n the t h r o t t l e body.
A t the center of the system is t h e Single Board E n -
gine Controller (SBEC). The SBEC is a pre-
programmed, d i g i t a l computer t h a t regulates i g n i t i o n
t i m i n g , a i r - f u e l r a t i o , emission control devices, charg-
i n g system, speed control and idle speed. The SBEC
can adapt i t s p r o g r a m m i n g to meet changing operat-
i n g conditions.
Various sensors provide the inputs necessary for
t h e SBEC t o correctly regulate fuel flow at the injec-
tor. These include t h e M a n i f o l d Absolute Pressure
sensor, T h r o t t l e Position sensor, Oxygen Sensor,
Coolant Temperature sensor, and Vehicle Distance
sensor. I n a d d i t i o n t o the sensors, c e r t a i n switches
and relays provide i m p o r t a n t inputs. These include
t h e Neutral-Safety S w i t c h a n d A i r Conditioning
C l u t c h Relay.
A l l i n p u t s t o t h e Single Board Engine Controller
are converted i n t o signals. A i r - f u e l r a t i o , i g n i t i o n
t i m i n g and other controlled outputs are adjusted
based on these i n p u t s . The SBEC adjust the air-fuel
r a t i o by c h a n g i n g injector pulse w i d t h . Injector pulse
w i d t h is t h e period o f t i m e t h a t a n injector is ener-
gized by t h e SBEC.
The fuel injection system is a "Speed-Density" sys-
t e m . I n t h i s type of system engine R P M a n d manifold
absolute pressure are the p r i m a r y computer inputs
t h a t determine fuel injector pulse w i d t h . The SBEC
m a i n t a i n s desired air/fuel (14.7 t o 1) r a t i o by deter-
m i n i n g mass a i r flow and adjusts fuel injector pulse
w i d t h to o b t a i n the correct mass fuel flow.
14 - 17
Page
Idle Contact S w i t c h - S B E C Input . . . . . . . . . . . . . 20
Idle Speed Control (ISC) A c t u a t o r - S B E C Output . 24
Ignition C o i l - S B E C Output . . . . . . . . . . . . . . . . . . 24
Lock-Up Torque Convertor Solenoids—SBEC
Outputs 25
Manifold Absolute Pressure (MAP) S e n s o r — S B E C
Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Modes of Operation 25
Overdrive S o l e n o i d - S B E C Outputs . . . . . . . . . . . 24
Oxygen Sensor ( 0 S e n s o r ) - S B E C Input . . . . . .
2 20
Single Board Engine Controller (SBEC) 17
Throttle Body 27
Throttle Body Temperature S e n s o r — S B E C Input
(5.2L and 5.9L Engines) 21
Throttle Position Sensor ( T P S ) - S B E C Input . . . . 21
Transmission Gear Selection—SBEC Input 22
Vehicle Distance (Speed) S e n s o r - S B E C Input . . . 22
The combination of engine R P M and t h r o t t l e angle
( t h r o t t l e position i n p u t ) indicates engine a i r flow.
The M A P sensor i n p u t indicates a i r density. T h e
product of engine air flow and a i r density is mass a i r
flow. The product o f fuel pressure and injector pulse
w i d t h i s mass fuel flow.
SYSTEM DIAGNOSIS
The Single Board Module Engine Controller
(SBEC) tests m a n y of i t s o w n i n p u t and o u t p u t cir-
cuits. I f a f a u l t is found i n a major system, t h i s i n -
f o r m a t i o n is stored i n memory. I n f o r m a t i o n about
t h i s f a u l t can be displayed to a technician by means
of t h e i n s t r u m e n t panel Check Engine l a m p or b y
connecting the Diagnostic Readout Box I I ( D R B I I )
and reading descriptions o f any faults w h i c h have
been stored i n memory. Refer to the Service Diagnos-
tic Tester and accompanying manuals. The Service
Diagnostic Tester plugs i n t o a diagnostic connector
inside the engine compartment.
SINGLE BOARD ENGINE CONTROLLER (SBEC)
The Single Board Engine Controller ( S B E C - F i g .
2) is a d i g i t a l computer c o n t a i n i n g a microprocessor.
I t receives i n p u t signals f r o m various switches a n d
sensors. Based on these inputs, the SBEC regulates
various engine and vehicle operations t h r o u g h differ-
ent system components t h a t are referred to as " S B E C
Outputs".
The SBEC controls fuel injector pulse w i d t h (air-
fuel r a t i o ) based on inputs received from sensors t h a t
react to exhaust gas oxygen content, coolant temper-
ature, m a n i f o l d absolute pressure, battery voltage,
engine speed, t h r o t t l e position, t h r o t t l e body temper-
ature (5.2L and 5.9L engines) battery voltage, a n d
i n p u t s from switches t h a t are triggered b y a i r condi
14-18 FUEL SYSTEM •
BOARD SINGLE
ENGINE
CONTROLLER DIAGNOSTIC
(SBEC) TOOL

CHECK ENGINE
THROTTLE LAMP
POSITION NEUTRAL LOCK-UP TORQUE CONVERTER
SENSOR SAFETY SWITCH SOLENOID
DISTANCE
SENSOR

A C CUTOUT AUTO SHUT- PART THROTTLE

RELAY DOWN RELAY UNLOCK RELAY
COOLANT THROTTLE
§ TEMPERATURE MANIFOLD BODY
1
r

HEATED SENSOR TEMPERATURE

ABSOLUTE
OXYGEN SENSOR SENSOR
PRESSURE
SENSOR 5.2LAND5.9L
IDLE SPEED CONTROL ENGINES
(ISC) ACTUATOR ONLY
EGR, AIR SWITCHING AND
IGNITION CANISTER PURGE SOLENOIDS
R
mr| UP
E C E
A/C ELECTRONIC
CYCLING CLUTCH
SWITCH
DISTRIBUTOR
IGNITION COIL

A/C LOW IN-TANK PUMP

PRESSURE CUTOFF FUEL ALTERNATOR
SWITCH INJECTORS

SHIFT
INDICATOR
LAMP J9014-170

Fig. 1 Dual-Point Injection Components

LEFT R P M (the d i s t r i b u t o r pick-up), manifold absolute
FENDER pressure, coolant temperature, t h r o t t l e position,
transmission gear selection (automatic transmission),
vehicle speed, and the idle contact switch. These sen-
sors are considered "SBEC I n p u t s "
The SBEC adjusts idle speed based on i n p u t s i t r e -
ceives from sensors t h a t react to: t h r o t t l e position,
60 WAY ELECTRICAL vehicle speed, transmission gear selection, coolant
CONNECTOR temperature and from i n p u t s i t receives f r o m t h e a i r
conditioning clutch switch, brake l i g h t switch, a n d
idle contact switch.
Based on inputs t h a t i t receives, t h e SBEC also
SINGLE BOARD controls i g n i t i o n coil d w e l l and evaporative canister
ENGINE CONTROLLER
(SBEC)
purge operation. The SBEC also adjusts t h e a l t e r n a -
J908D-56 t o r charge rate t h r o u g h control of the alternator field
and provides speed control operation.
Fig. 2 Single Board Engine Controller (SBEC) SBEC Inputs:
A i r Conditioning Switch
t i o n i n g selection, transmission gear selection (auto-
B a t t e r y Voltage
m a t i c transmissions only), and speed control. These
B r a k e L i g h t Switch
sensors and switches are considered "SBEC I n p u t s " .
Coolant Temperature Sensor
The SBEC adjusts i g n i t i o n t i m i n g based upon i n -
Engine Speed (Distributor Pick-up)
puts i t receives from sensors t h a t react to: engine
Idle contact switch
• M a n i f o l d Absolute Pressure ( M A P ) Sensor BATTERY VOLTAGE—SBEC INPUT
• N e u t r a l Safety S w i t c h
• Oxygen Sensor The SBEC monitors t h e battery voltage i n p u t t o
determine fuel injector pulse w i d t h a n d a l t e r n a t o r
• T h r o t t l e Position Sensor
field control.
• T h r o t t l e Body Temperature Sensor (5.2L a n d 5.9L
I f battery voltage is low the SBEC w i l l increase i n -
engines)
jector pulse w i d t h (period of t i m e t h a t t h e injector i s
• Vehicle Distance Sensor
energized) t o compensate for t h e reduced flow
SBEC Outputs
t h r o u g h t h e injector caused b y t h e lowered voltage.
• A/C C l u t c h Relay
• A i r S w i t c h i n g Solenoid BRAKE LIGHT SWITCH-SBEC INPUT
• Alternator
• A u t o S h u t d o w n (ASD) Relay W h e n t h e brake l i g h t switch is activated, t h e
• Canister Purge Solenoid SBEC receives a n i n p u t i n d i c a t i n g t h a t t h e brakes
• Check E n g i n e L a m p are being applied. After receiving t h i s i n p u t t h e
• Diagnostic Connector SBEC m a i n t a i n s idle speed t o a scheduled R P M
• E G R Solenoid t h r o u g h control o f the Idle Speed C o n t r o l A c t u a t o r .
• E M R Lamp
• F u e l Injectors
COOLANT TEMPERATURE SENSOR-SBEC INPUT
• Idle Speed C o n t r o l (ISC) Actuator The Coolant Temperature Sensor i s i n s t a l l e d n e x t
• Ignition Coil to the thermostat housing i n the i n t a k e m a n i f o l d w a -
• Overdrive a n d Lock-up Torque Converter Sole- ter jacket passage and provides a n i n p u t voltage t o
noids the SBEC (Fig. 3). A s coolant temperature varies t h e
• Shift I n d i c a t o r L a m p Coolant Temperature Sensors resistance changes r e -
The A u t o m a t i c S h u t D o w n (ASD) relay i s mounted s u l t i n g i n a different i n p u t voltage t o t h e SBEC.
externally, b u t is switched o n and off b y t h e SBEC. W h e n t h e engine is cold, t h e SBEC w i l l demand
The relay provides voltage for t h e electric fuel pump, s l i g h t l y richer air-fuel m i x t u r e s a n d h i g h e r idle
fuel injector, i g n i t i o n coil a n d exhaust gas oxygen speeds u n t i l n o r m a l operating temperatures are
sensor heater element. T h e SBEC monitors t h e dis- reached.
t r i b u t o r pick-up s i g n a l t o determine engine speed
a n d compute injector synchronization. I f t h e SBEC
does n o t receive a d i s t r i b u t o r signal w h e n t h e i g n i -
t i o n switch i s i n t h e " R U N " position, i t w i l l n o t en-
ergize t h e A S D relay, stopping t h e b a t t e r y voltage
supply t o t h e fuel injector, fuel pump, i g n i t i o n coil,
a n d oxygen sensor heater element.
The SBEC contains a voltage converter w h i c h con-
verts b a t t e r y voltage to a regulated 8.0 volts t o
power t h e d i s t r i b u t o r pick-up. T h e SBEC also pro-
vides a five (5) v o l t supply for t h e M a n i f o l d Absolute
Pressure ( M A P ) sensor and T h r o t t l e Position Sensor
(TPS).

A/C SWITCH-SBEC INPUT

W h e n t h e A/C s w i t c h is i n t h e O N position, t h e
SBEC receives a n i n p u t i n d i c a t i n g t h a t t h e a i r con-
d i t i o n i n g h a s been selected. A f t e r receiving t h i s i n -
p u t the SBEC activates the A/C compressor clutch b y
g r o u n d i n g t h e A/C c l u t c h relay, and m a i n t a i n s idle
speed to a scheduled R P M t h r o u g h control o f the Idle
Speed C o n t r o l A c t u a t o r .
The SBEC w i l l de-energize t h e A/C clutch relay i f
i t receives i n p u t f r o m either t h e A/C l o w pressure
s w i t c h i n d i c a t i n g a l o w refrigerant level, o r from t h e
electric c l u t c h cycling s w i t c h i n g i n d i c a t i n g evapora-
t o r freezing.
Fig. 3 Coolant Temperature Sensor
ENGINE SPEED-SBEC INPUT
The engine speed i n p u t is supplied to t h e SBEC b y
the d i s t r i b u t o r pick-up. The d i s t r i b u t o r pick-up i s a
H a l l Effect device (Fig. 4).
A shutter (sometimes referred to as a n i n t e r r u p t e r )
is attached to t h e distributor shaft. T h e s h u t t e r con-
tains one blade per engine cylinder (six blades for
the 3.9L engine or eight blades for the 5.2L and 5.9L
engines). A switch plate is mounted to the d i s t r i b u t o r
housing above t h e shutter. The switch plate contains
the d i s t r i b u t o r pick-up (a H a l l Effect device a n d
14 - 20 FUEL SYSTEM •
magnet) t h r o u g h w h i c h the shutter blades rotate. A s MANIFOLD ABSOLUTE PRESSURE (MAP)
the s h u t t e r blades pass t h r o u g h the pick-up, t h e y i n - SENSOR-SBEC INPUT
t e r r u p t t h e magnetic field. The H a l l effect device i n
the p i c k - u p senses t h e change i n t h e magnetic field The M A P sensor reacts t o absolute pressure i n t h e
and switches on and off (creating pulses), generating i n t a k e m a n i f o l d and provides a n i n p u t voltage t o t h e
the i n p u t signal t o t h e SBEC. The SBEC calculates Single B o a r d Engine Controller (SBEC). A s engine
engine speed t h r o u g h t h e number of pulses gener- load changes manifold pressure varies, causing t h e
ated. M A P sensors resistance t o change. T h e change i n
M A P sensor resistance results i n a different i n p u t
CAP voltage t o t h e SBEC. T h e i n p u t voltage level supplies
the SBEC w i t h i n f o r m a t i o n r e l a t i n g t o a m b i e n t baro-
metric pressure d u r i n g engine start-up (cranking)
and t o engine load w h i l e the engine is r u n n i n g . T h e
ROTOR
SBEC uses t h i s i n p u t along w i t h i n p u t s f r o m other
SWITCH PLATE sensors t o adjust air-fuel m i x t u r e .
HALL
EFFECT The M A P sensor is mounted o n t h e t h r o t t l e body
SWITCH (Fig. 6) a n d is connected t o the t h r o t t l e body w i t h a
SHUTTER v a c u u m hose and to the SBEC electrically.
BLADE
SHUTTER MAP
BLADE SENSOR TO VACUUM
SOURCE
3-WAY ELECTRICAL
CONNECTOR

HOUSING

SHAFT J9014-142

Fig. 4 Distributor Pick-Up—Typical

IDLE CONTACT SWITCH-SBEC INPUT
8914-96
The idle contact switch is i n t e g r a l w i t h t h e idle
speed (ISC) actuator and provides a n i n p u t signal to Fig. 6 Manifold Absolute Pressure (MAP) Sensor
Location
the SBEC ( F i g . 5). T h i s i n p u t enables t h e SBEC to
increase or decrease t h e throttle stop angle (by ex- OXYGEN SENSOR (0 SENSOR)-SBEC INPUT
2

t e n d i n g or r e t r a c t i n g the ISC actuator) i n response to

engine operating conditions. The 0 sensor is located i n t h e exhaust down pipe
2

on 3.9L engines (Fig. 7) and o n 5.2L a n d 5.9L e n -

ISC
gines above the left exhaust m a n i f o l d outlet (Fig. 8).
MOTOR
The 0 sensor provides a n i n p u t voltage t o the Single
2

Board Engine Controller (SBEC) r e l a t i n g the oxygen

content of the exhaust gas. The SBEC uses t h i s i n -
f o r m a t i o n t o fine t u n e the air-fuel r a t i o b y a d j u s t i n g
injector pulse w i d t h .
IDLE
CONTACT
The 0 sensor produces voltages f r o m 0 to 1 v o l t ,
2

SWITCH depending upon t h e oxygen content of t h e exhaust

gas i n the exhaust manifold. W h e n a large a m o u n t o f
oxygen is present (caused by a l e a n air-fuel m i x t u r e ) ,
the sensor produces a l o w voltage. W h e n there is a
lesser a m o u n t present (rich air-fuel m i x t u r e ) i t pro-
duces a higher voltage. B y m o n i t o r i n g t h e oxygen
content a n d converting i t to electrical voltage, t h e
GROUND J9014-159 sensor acts as a rich-lean switch.
The oxygen sensor is equipped w i t h a h e a t i n g ele-
Fig. 5 Idle Contact Switch m e n t t h a t keeps the sensor a t proper operating tern-
perature d u r i n g a l l operating modes. M a i n t a i n i n g
correct sensor temperature a t a l l times allows t h e
system t o enter i n t o closed loop operation sooner.
I n "Closed Loop" operation t h e SBEC monitors the
0 sensor i n p u t (along w i t h other inputs) a n d adjusts
2

t h e injector pulse w i d t h accordingly. D u r i n g "Open

Loop" operation t h e SBEC ignores t h e 0 sensor i n -
2

p u t a n d adjusts injector pulse w i d t h t o a prepro-

grammed value (based o n other sensor inputs).

J9014473

Fig. 9 Throttle Body Temperature Sensor

Fig. 7 Heated Oxygen Sensor Location—3.9L
Engine
4-WAY HEATED 0 SENSOR
2 HEATED Oj SENSOR
THROTTLE POSITION SENSOR (TPS)-SBEC
INPUT
The T h r o t t l e Position Sensor (TPS) is mounted o n
the t h r o t t l e body below t h e M A P sensor a n d con-
nected t o the t h r o t t l e blade shaft (Fig. 10). T h e TPS
is a variable resistor t h a t provides t h e Single Board
Engine Controller (SBEC) w i t h a n i n p u t signal (volt-
age) t h a t represents t h r o t t l e blade position. A s t h e
position o f the t h r o t t l e blade changes, the resistance
of the TPS changes.
The SBEC supplies approximately 5 volts t o t h e
TPS. T h e TPS o u t p u t voltage ( i n p u t signal t o t h e
SBEC) represents t h e t h r o t t l e blade position. T h e
SBEC receives a n i n p u t signal voltage from t h e TPS
v a r y i n g i n a n approximate range o f from 1 v o l t a t
m i n i m u m t h r o t t l e opening (idle) t o 4 volts a t wide
open t h r o t t l e . A l o n g w i t h i n p u t s f r o m other sensors,
the SBEC uses t h e T P S i n p u t t o determine c u r r e n t
engine operating conditions a n d adjust fuel injector
pulse w i d t h a n d i g n i t i o n t i m i n g .

MAP SENSOR

Fig. 8 Heated Oxygen Sensor Location—5.2L and

5.9L Engines
THROTTLE BODY TEMPERATURE SENSOR-SBEC
INPUT (5.2L and 5.9L Engines)
Vehicles equipped w i t h a 5.2L o r 5.9L engine have
a t h r o t t l e body temperature sensor. T h e sensor (Fig.
9) monitors t h r o t t l e body temperature w h i c h is the
same as fuel temperature. I t is m o u n t e d i n the throt-
SENSOR (TPS) J9014-157
t l e body. This sensor provides i n f o r m a t i o n o n fuel
temperature w h i c h allows the SBEC t o enrichen t h e Fig. 10 Throttle Position Sensor
a i r fuel m i x t u r e for a h o t restart condition.
14 - 22 FUEL SYSTEM •
TRANSMISSION GEAR SELECTION-SBEC INPUT
The n e u t r a l safety switch (Fig. 11) is located on the
transmission housing a n d provides a n i n p u t t o t h e
SBEC t h a t indicates the automatic transmission is i n
Park, N e u t r a l or a drive gear selection. T h i s i n p u t is
used to determine idle speed (varying w i t h gear se-
lection), fuel injector pulse w i d t h , and i g n i t i o n t i m -
i n g advance. Refer t o group 2 1 Transmissions, for
testing, replacement, and adjustment i n f o r m a t i o n .

Fig. 12 Vehicle Distance Sensor

PART THROTTLE ^ A/C CLUTCH CUTOUT STARTER
UNLOCK RELAY ^ RELAY RELAY

Fig. 11 Neutral Safety Switch

VEHICLE DISTANCE (SPEED) SENSOR-SBEC
INPUT
The distance sensor (Fig. 12) is located i n t h e ex-
tension housing of the transmission. T h e sensor i n -
p u t is used by t h e Single Board Engine Controller
(SBEC) t o determine vehicle speed and distance t r a v -
eled.
The distance sensor generates 8 pulses per sensor
revolution. These signals are interpreted, i n conjunc-
t i o n w i t h a closed t h r o t t l e signal from t h e t h r o t t l e
position sensor, by t h e engine controller t o differen-
tiate between a closed t h r o t t l e deceleration a n d a
n o r m a l idle (vehicle stopped) condition. U n d e r decel-
eration conditions, t h e engine controller controls t h e
ISC motor to m a i n t a i n a desired M A P value. Under
idle conditions, t h e engine controller adjusts the A I S
motor t o m a i n t a i n - a desired engine speed.
AIR CONDITIONING CLUTCH RELAY-SBEC
OUTPUT
The Single Board Engine Controller (SBEC) con-
trols t h e a i r conditioning compressor t h r o u g h t h e
A/C clutch relay (Fig. 13). B y s w i t c h i n g t h e ground
p a t h for relay on and off, t h e SBEC is able to cycle
the a i r conditioning compressor c l u t c h based on
changes i n engine operating conditions.
The relay is energized w h e n t h e A/C switch is
closed (A/C has been selected) and the blower motor
switch is i n the on position. I f , d u r i n g A/C operation,
Fig. 13 A/C Clutch, ASD, Starter and Part Throttle
Un-lock Relays
the SBEC senses l o w idle speeds or a wide open
t h r o t t l e condition, i t w i l l de-energize the relay pre-
v e n t i n g a i r c o n d i t i o n i n g clutch engagement u n t i l t h e
idle speed increases or wide open t h r o t t l e condition
no longer exists.
AIR SWITCHING SOLENQID-SBEC OUTPUT
The SBEC controls t h e upstream or downstream
discharge of a i r f r o m t h e a i r pump t h r o u g h t h e a i r
s w i t c h i n g solenoid ( F i g . 14). The solenoid controls
the flow of v a c u u m to t h e a i r switching/relief valve
of the a i r p u m p system.
W h e n t h e a i r s w i t c h i n g system is i n t h e down-
stream mode o f operation t h e solenoid is n o t ener-
gized a n d v a c u u m is n o t supplied to t h e a i r
switching/relief valve. D u r i n g downstream operation
air p u m p o u t p u t is directed to the catalytic conver-
ter.
W h e n t h e a i r s w i t c h i n g system is i n t h e upstream
mode of operation, t h e solenoid is energized and vac-
u u m is supplied t o t h e a i r switching/relief valve.
 AIR SWITCHING CANISTER
Fig. 14 Air Switching, Canister Purge and EGR
Solenoids
D u r i n g upstream operation a i r p u m p o u t p u t is d i -
rected to t h e exhaust manifolds.
ALTERNATOR-SBEC OUTPUT
The SBEC regulates t h e c h a r g i n g system voltage
w i t h i n a range of 12.9 t o 15.0 volts. Refer t o Group
8A for charging system i n f o r m a t i o n .
AUTO SHUTDOWN (ASD) RELAY—SBEC OUTPUT
The A u t o Shutdown Relay ( A S D - F i g . 13) is
mounted o n t h e left i n n e r fender w e l l a n d supplies
battery voltage to t h e fuel p u m p , fuel injector, i g n i -
t i o n coil, a n d 0 sensor h e a t i n g element. T h e ground
2
circuit for t h e A S D relay i s controlled b y t h e Single
Board Engine Controller (SBEC). T h e SBEC controls
the relay operation b y s w i t c h i n g t h e g r o u n d circuit
on and off.
The SBEC monitors t h e d i s t r i b u t o r pick-up signal
to determine engine speed and compute injector syn-
chronization. I f the SBEC does n o t receive a distrib-
utor signal w h e n the i g n i t i o n s w i t c h is i n t h e " R u n "
position i t w i l l not energize (not provide a ground)
the ASD relay, stopping the b a t t e r y voltage supply to
the fuel p u m p , fuel injectors, i g n i t i o n coil, a n d 0
sensor heater element.
CANISTER PURGE SOLENOID-SBEC OUTPUT
Vacuum for the Evaporative Canister is controlled
by t h e Canister Purge Solenoid ( F i g . 14). T h e sole-
noid is controlled by t h e Single B o a r d E n g i n e Con-
troller (SBEC). The SBEC controls t h e solenoid by
switching t h e ground c i r c u i t o n a n d off based o n en-
gine operating conditions. W h e n energized, t h e sole-
noid prevents vacuum f r o m reaching t h e evaporative
canister. W h e n not energized the solenoid allows vac-
u u m to flow t o the canister.
D u r i n g warm-up and for a specified t i m e period af-
t e r hot starts the engine controller grounds the purge
solenoid causing i t t o energize, preventing v a c u u m
f r o m reaching t h e canister valve. W h e n t h e engine
reaches a specified operating temperature a n d t h e
t i m e delay i n t e r v a l has occurred t h e SBEC removes
the ground to the solenoid, de-energizing i t w h i c h a l -
lows v a c u u m t o flow t o t h e canister purge valve a n d
purge fuel vapors t h r o u g h t h e t h r o t t l e body. T h e
Purge Solenoid w i l l also be energized d u r i n g certain
idle conditions, i n order t o update t h e fuel delivery
calibration.
CHECK ENGINE LAMP-SBEC OUTPUT
The Check Engine L a m p i l l u m i n a t e s a t the bottom
of the i n s t r u m e n t panel each t i m e the i g n i t i o n key i s
t u r n e d o n and stays o n for three seconds as a b u l b
test.
I f the Single Board E n g i n e Controller (SBEC) r e -
ceives a n incorrect signal or no signal from certain
sensors or emission related systems (California vehi-
cles only) t h e l a m p i s t u r n e d on. T h i s i s a w a r n i n g
t h a t t h e SBEC has gone i n t o a l i m p - i n mode i n a n
a t t e m p t t o keep t h e system operating. I t signals a n
immediate need for service.
The l a m p can also be used to display fault codes.
Cycle t h e i g n i t i o n s w i t c h o n , off, on, off, on w i t h i n
five seconds and a n y f a u l t codes stored i n the SBEC
memory w i l l be displayed i n a series of flashes rep-
resenting digits.
EGR S0LEN0ID-SBEC OUTPUT
V a c u u m for t h e exhaust gas recirculation (EGR)
valve function is switched on and off by the EGR so-
lenoid. The solenoid is controlled by the Single Board
Engine Controller (SBEC). T h e solenoid is located on
the engine r i g h t valve cover (Fig. 14).
W h e n t h e solenoid is energized b y t h e SBEC, i t
prevents vacuum f r o m reaching t h e E G R valve
transducer and E G R valve. The solenoid is energized
d u r i n g engine w a r m - u p , closed t h r o t t l e (idle), wide
open t h r o t t l e a n d r a p i d acceleration/deceleration. I f
2 the solenoid w i r e c o n n e c t o r i s disconnected, t h e
EGR valve function w i l l be operational at a l l
times.
On California vehicles, there is a n On-Board Diag-
nostics test t h a t is performed b y t h e SBEC. The test
w i l l check t h e E G R system for failures. The SBEC
monitors E G R system performance a n d registers a
f a u l t code i f the system has failed or is degraded. T h e
dash-mounted check engine l i g h t is t u r n e d o n i n d i -
cating immediate service is required.
EMR LAMP-SBEC OUTPUT
The emission maintenance reminder (EMR) l a m p
informs t h e vehicle owner t h a t scheduled mainte-
14 - 24 FUEL SYSTEM
nance is required for c e r t a i n emission system compo-
nents. T h e SBEC determines vehicle milage b y
m o n i t o r i n g t h e vehicle distance sensor. The E M R
l a m p i l l u m i n a t e s a t 96,600, 132,000, 192,000 k m
(60,000, 82,500, a n d 120,000 miles). Refer to Group
0, L u b r i c a t i o n and Maintenance for t h e scheduled
maintenance.
FUEL INJECTORS-SBEC OUTPUT
The F u e l injectors (Fig. 15) are electro-mechanical
solenoids t h a t are d r i v e n b y t h e Single Board Engine
Controller (SBEC). T h e SBEC switches t h e ground
c i r c u i t for t h e injectors o n a n d o f f w h i l e battery volt-
age is supplied to t h e injectors t h r o u g h t h e ASD Re-
lay.
Based o n sensor i n p u t s t h e SBEC determines injec-
t o r pulse w i d t h (how long t h e injector is energized)
and w h e n t h e fuel injector should operate. W h e n
electrical c u r r e n t is supplied t o the injector, a spring
loaded p i n t l e is lifted f r o m i t s seat. T h i s allows fuel
to flow t h r o u g h past t h e p i n t l e and orifice. This ac-
t i o n causes the fuel t o f o r m a 30° cone shaped spray
p a t t e r n before entering t h e a i r stream i n the t h r o t t l e
body.
F u e l is supplied t o t h e injector constantly a t regu-
lated 14.5 psi, the unused fuel is r e t u r n e d to the fuel
tank.
Fig. 15 Fuel Injector
FUEL PUMP-SBEC OUTPUT
The SBEC controls fuel p u m p operation t h r o u g h
the auto shutdown (ASD) relay. W h e n t h e relay is
energized b y the SBEC, b a t t e r y voltage i s supplied to
the fuel p u m p . Refer to " A u t o Shutdown (ASD) Re-
lay—SBEC O u t p u t " i n t h i s section for relay opera-
tion.
IDLE SPEED CONTROL (ISC) ACTUAT0R-SBEC
OUTPUT
The Idle Speed Control A c t u a t o r (ISC) motor is
•
mounted t o t h e t h r o t t l e body and controlled b y t h e
SBEC (Fig. 16). T h e t h r o t t l e lever rests against a n
adjustment screw a t t h e e n d o f the actuator (plung-
er). The actuator extends or retracts t o control en-
gine idle speed and t o set t h r o t t l e stop angle d u r i n g
deceleration. Based o n i n p u t s f r o m t h e various en-
gine control system sensors a n d switches t h e SBEC
supplies c u r r e n t and a g r o u n d p a t h t o t h e ISC motor
to adjust the actuator position for the p a r t i c u l a r op-
e r a t i n g conditions.
D o n o t a t t e m p t to c o r r e c t a h i g h i d l e s p e e d
condition b y c h a n g i n g t h e a d j u s t m e n t s c r e w p o -
s i t i o n . W h e n t h e engine is s h u t off, t h e SBEC ex-
tends t h e ISC actuator t o i t s m a x i m u m position t o
preset a "fast i d l e " for t h e n e x t start-up. T u r n i n g the
adjustment screw i n w a r d w i l l n o t change t h e idle
speed o f a w a r m engine, b u t can cause cold s t a r t
problems due to restricted a i r flow. O n l y change t h e
adjustment screw position as o u t l i n e d i n t h e Service
Procedures section.
The ISC actuator also contains t h e idle contact
IDLE SPEED CONTROL THROTTLE LEVER
SCREW J9014-158
Fig. 16 Idle Speed Control Actuator
switch.
IGNITION C0IL-SBEC OUTPUT
The SBEC controls i g n i t i o n coil firing t h r o u g h t h e
auto shutdown (ASD) relay. W h e n t h e relay is ener-
gized b y the SBEC, b a t t e r y voltage is supplied to the
i g n i t i o n coil positive t e r m i n a l ( F i g . 17). T h e SBEC
w i l l not energize t h e A S D relay u n t i l i t receives i n -
p u t f r o m t h e d i s t r i b u t o r pick-up. Refer t o " A u t o
Shutdown (ASD) R e l a y - S B E C O u t p u t " i n t h i s sec-
t i o n for relay operation.
OVERDRIVE S0LEN0ID-SBEC OUTPUTS
On vehicles equipped w i t h overdrive, t h e SBEC
controls t h e 3-4 overdrive upshift a n d downshift
t h r o u g h t h e Overdrive solenoid ( F i g . 18). Refer to
Group 2 1 for solenoid i n f o r m a t i o n .
 + FUEL SYSTEM
POSITIVE COILjs-ENGINE GROUND
TERMINAL STRAP
Fig. 18 Overdrive Solenoid
LOCK-UP TORQUE CONVERTOR
SOLENOIDS-SBEC OUTPUTS
O n v e h i c l e s equipped w i t h a n A-999 t r a n s m i s s i o n
(except California) t h e SBEC controls torque
v e r t e r lock-up t h r o u g h the Lock-up solenoid (Fig. 19).
Refer to Group 2 1 for solenoid i n f o r m a t i o n .
MODES OF OPERATION
A s i n p u t signals to t h e SBEC change, t h e SBEC
adjusts its response to the output devices. For exam-
ple, t h e SBEC m u s t calculate different injector pulse
w i d t h and i g n i t i o n t i m i n g for idle t h a n i t does for
wide open t h r o t t l e (WOT). There are several different
modes o f operation t h a t determine how t h e SBEC re-
sponds to the various i n p u t signals.
Modes of operation are of t w o different types.
O P E N L O O P a n d CLOSED LOOP.
D u r i n g O P E N LOOP modes the SBEC receives i n -
p u t signals a n d responds only according t o preset
SBEC p r o g r a m m i n g . I n p u t from the oxygen ( 0 ) sen-
2 When the key is i n the O N position, the auto shut-
sor is not monitored d u r i n g O P E N L O O P modes.
14 - 25
Fig. 19 Lock-Up Solenoid
D u r i n g CLOSED L O O P modes t h e SBEC does
monitor the oxygen ( 0 ) sensor i n p u t . T h i s i n p u t i n -
2
dicates t o the SBEC w h e t h e r o r not t h e calculated i n -
jector pulse w i d t h results i n t h e ideal air-fuel r a t i o of
14-7 parts a i r t o 1 p a r t fuel. B y m o n i t o r i n g the ex-
haust oxygen content t h r o u g h t h e 0 sensor, t h e2
SBEC can "fine t u n e " t h e injector pulse w i d t h to
achieve o p t i m u m fuel economy combined w i t h low
emission engine performance.
The dual p o i n t fuel injection system has the follow-
i n g modes of operation:
• Ignition switch O N
• Engine start-up
• Engine w a r m - u p
• Cruise
• Acceleration
• Deceleration
• Wide Open T h r o t t l e
• I g n i t i o n s w i t c h OFF
The i g n i t i o n switch on, engine start-up (crank), en-
gine warm-up, acceleration, deceleration a n d wide
con-
t h r o t t l e modes are O P E N L O O P modes. T h e cruise
mode, w i t h t h e e n g i n e a t o p e r a t i n g t e m p e r a t u r e
is a CLOSED L O O P mode.
Ignition Switch ON Mode
This is a n O P E N L O O P mode. W h e n the dual point
fuel injection System is activated by t h e i g n i t i o n
switch* the following actions occur:
• SBEC determines a m b i e n t atmospheric a i r pres-
sure from the M A P sensor i n p u t to determine basic
fuel strategy.
• The SBEC monitors t h e coolant temperature sen-
sor i n p u t . The SBEC modifies fuel strategy based on
t h i s input.
• The SBEC monitors t h r o t t l e body temperature sen-
sor i n p u t (5.2L and 5.9L engines only).
down (ASD) relay is not energized. Therefore battery
voltage is not supplied to the fuel p u m p , i g n i t i o n coil,
fuel injector or oxygen sensor h e a t i n g relay.
Engine Start-Up Mode
This i s a n O P E N LOOP mode. The f o l l o w i n g ac-
tions occur when t h e starter motor i s engaged.
I f t h e SBEC receives a d i s t r i b u t o r signal i t w i l l en-
ergize t h e auto shutdown (ASD) relay to supply bat-
t e r y voltage to the fuel pump, fuel injector i g n i t i o n
coil, and oxygen sensor heating element. I f t h e SBEC
does not receive a d i s t r i b u t o r i n p u t , t h e A S D relay
w i l l not be energized.
W h e n t h e engine is operating a n d i d l i n g w i t h i n
±64 R P M of the target RPM, t h e SBEC compares t h e
c u r r e n t M A P value w i t h the atmospheric pressure
value i t received d u r i n g the Key-On mode. I f a m i n -
i m u m difference between the t w o i s not detected, a
pneumatic f a u l t code is set i n t o memory.
Once t h e ASD relay has been energized t h e SBEC:
• Supplies a ground p a t h to t h e injector a n d the i n -
jector is pulsed six times per engine r e v o l u t i o n i n -
stead of t h e n o r m a l three pulses per r e v o l u t i o n .
• determines injector pulse w i d t h based o n coolant
temperature, barometric pressure ( M A P sensor), and
the n u m b e r of engine revolutions since c r a n k i n g was
initiated.
• M o n i t o r s the coolant temperature sensor, d i s t r i b u -
t o r pick-up, M A P sensor, and t h r o t t l e position sensor
to determine correct i g n i t i o n t i m i n g .
Engine Warm-Up Mode
This i s a O P E N L O O P mode. The f o l l o w i n g i n p u t s
are received by the SBEC:
• coolant temperature
• idle contact switch
• m a n i f o l d absolute pressure
• engine speed (distributor pick-up)
• t h r o t t l e position
• gear position (automatic transmission)
• A/C switch
• battery voltage
The SBEC provides a ground p a t h for t h e injector
to precisely control injector pulse w i d t h (by s w i t c h i n g
the ground on and off) and fires the injector three
times per engine revolution. The SBEC controls en-
gine idle speed, t h r o t t l e stop angle, and i g n i t i o n t i m -
ing.
The SBEC controls engine idle speed a n d t h r o t t l e
stop angle. F o r vehicles equipped w i t h a m a n u a l
transmission, t h e up-shift indicator l a m p i s con-
trolled b y the SBEC according t o engine speed a n d
load.
Cruise Mode
W h e n the engine is a t operating t e m p e r a t u r e t h i s
is a CLOSED LOOP mode. D u r i n g c r u i s i n g speed t h e
following inputs are received by the SBEC:
• coolant temperature
• m a n i f o l d absolute pressure
• engine speed
• t h r o t t l e position
• exhaust gas oxygen content
• gear position (automatic transmission)
• A/C control positions
The SBEC provides a g r o u n d p a t h for t h e injector
to precisely control injector pulse w i d t h a n d fires the
injector three times per engine r e v o l u t i o n . The SBEC
controls engine idle speed, t h r o t t l e stop angle, and
i g n i t i o n t i m i n g . The SBEC controls the air/fuel m i x -
t u r e r a t i o according to t h e oxygen content i n the ex-
haust gas.
For vehicles equipped w i t h a m a n u a l transmission,
t h e up-shift indicator l a m p is controlled by t h e SBEC
according to engine speed a n d load.
Acceleration Mode
This i s a n O P E N L O O P mode. The SBEC recog-
nizes a n a b r u p t increase i n t h r o t t l e position or M A P
pressure as a demand for increased engine o u t p u t
and vehicle acceleration. The SBEC increases injec-
t o r pulse w i d t h i n response to increased fuel demand.
Deceleration Mode
This i s a O P E N L O O P mode. D u r i n g deceleration
t h e f o l l o w i n g inputs are received by the SBEC:
• coolant temperature
• m a n i f o l d absolute pressure
• idle contact switch
• engine speed
• t h r o t t l e position
• exhaust gas oxygen content
• gear position (automatic transmission)
• A/C control positions
W h e n t h e SBEC receives a closed t h r o t t l e i n p u t a t
t h e same t i m e i t senses a n a b r u p t decrease i n m a n i -
fold pressure from the M A P sensor (indicating a h a r d
deceleration) i t may reduce injector f i r i n g to once per
engine r e v o l u t i o n t o lean t h e air-fuel m i x t u r e as
sensed t h r o u g h the 0 sensor.
2
The SBEC grounds t h e EGR and evaporative purge
solenoids stopping E G R and canister purge functions.
The SBEC may cycle a i r s w i t c h i n g solenoid for short
periods o f t i m e i n response to t h e M A P sensor send-
i n g a h i g h vacuum signal.
Wide Open Throttle Mode
This is a n O P E N L O O P mode. D u r i n g wide-open-
t h r o t t l e operation, t h e f o l l o w i n g i n p u t s are received
by the SBEC:
• coolant temperature
• m a n i f o l d absolute pressure
• engine speed
• t h r o t t l e position
W h e n t h e SBEC senses wide open t h r o t t l e condi-
t i o n t h r o u g h the TPS i t w i l l provide a ground for the
EGR solenoid and evaporative canister purge sole-
• FUEL SYSTEM
noid p r e v e n t i n g EGR and canister purge functions.
The exhaust gas oxygen content i n p u t i s n o t ac-
cepted b y the SBEC and i t w i l l adjust injector pulse
w i d t h t o supply a predetermined a m o u n t o f addi-
t i o n a l fuel.
Ignition Switch OFF Mode
T h i s i s a n O P E N L O O P mode. W h e n t h e i g n i t i o n
s w i t c h i s t u r n e d t o t h e O F F position, t h e SBEC
ceases t o provide a ground for t h e auto s h u t d o w n
(ASD) relay and extends t h e ISC actuator i n a n t i c i -
p a t i o n o f the next s t a r t up. W h e n the A S D r e l a y i s
not energized, battery voltage is shut o f f from t h e
fuel p u m p , fuel injector, i g n i t i o n coil, a n d oxygen
14-27
sensor h e a t i n g element. A l l fuel injection stops.
THROTTLE BODY
The t h r o t t l e body assembly ( F i g . 2 0 or 2 1 ) is
mounted o n top of the i n t a k e m a n i f o l d a n d contains
the fuel injectors, fuel pressure regulator, idle speed
control actuator, t h r o t t l e position sensor, and m a n i -
fold absolute pressure sensor. A i r flow t h r o u g h t h e
t h r o t t l e body i s controlled by t h e t h r o t t l e blade. The
t h r o t t l e blade is connected to t h e accelerator pedal b y
t h e accelerator cable. The fuel i n l e t and r e t u r n lines
are connected t o the t h r o t t l e body.
 MAP SENSOR IDLE SPEED CONTROL FUEL INJECTORS
(ISC) ACTUATOR

IDLE SPEED CONTROL

(ISC) ACTUATOR

HEATED AIR INLET

NIPPLE
FUEL INJECTORS
MAP SENSOR
DIVERTER WIRING CONNECTOR
VACUUM HOSE
CANISTER VALVE NIPPLE
PURGE NIPPLE
FUEL RETURN
NIPPLE MAP SENSOR

FUEL INJECTORS
WIRING CONNECTOR

FUEL INLET
NIPPLE

PCV NIPPLE
THROTTLE POSITION
THROTTLE FUEL PRESSURE 8914-97
SENSOR (TPS)
LEVER REGULATOR

Fig. 20 Throttle Body Assembly-3.9L Engine

 MAP SENSOR IDLE SPEED CONTROL IDLE SPEED CONTROL FUEL INJECTORS
(ISC) ACTUATOR (ISC) ACTUATOR

HEATED AIR INLET

NIPPLE
DIVERTER FUEL INJECTORS
MAP SENSOR VALVE NIPPLE
VACUUM HOSE WIRING CONNECTOR
CANISTER
PURGE NIPPLE
MAP SENSOR
FUEL INJECTORS
WIRING CONNECTOR FUEL RETURN
NIPPLE

FUEL INLET
NIPPLE

GO
-<
THROTTLE BODY CO
THROTTLE TEMPERATURE SENSOR
LEVER
PCV NIPPLE
FUEL PRESSURE THROTTLE POSITION
REGULATOR SENSOR (TPS) 8914-107

Fig. 21 Throttle Body Assembly~~5.2L and 5.9L Engines C O

FUEL PRESSURE REGULATOR
The pressure regulator is located a t the back o f t h e
t h r o t t l e body. The regulator m a i n t a i n s fuel pressure
a t constant 100 k P a (14.5 psi) across t h e fuel injector
t i p . W h e n t h e fuel p u m p is operational, fuel flows
past t h e injectors i n t o t h e pressure regulator. T h e
fuel r e t u r n port i s blocked b y t h e a spring loaded
rubber d i a p h r a g m ( F i g . 22). W h e n fuel pressure
reaches 100 k P a (14.5 psi) i t pushes t h e d i a p h r a g m
away f r o m t h e fuel r e t u r n port a n d fuel flows
t h r o u g h t h e r e t u r n l i n e to t h e fuel t a n k . T h e dia-
p h r a g m is constantly m o v i n g from t h e open t o closed
position t o keep fuel pressure constant.

Fig. 22 Fuel Pressure Regulator Operation

 G E N E R A L DIAGNOSIS

INDEX
Page Page
Circuit Actuate Test Display 40 On Board Diagnostics 36
Circuit Actuation Test Mode 40 Sensor Read Test Mode . 41
Fault Code Description 36 Sensor Test Mode 41
Ignition Timing Procedure . . . . . . . . . . . . . . . . . . 41 Switch Test Mode . 40
Obtaining Circuit Actuation Test 40 Systems Test 40
Obtaining Sensor Read Test Mode 41 Visual Inspection 31
Obtaining Switch Test Mode 40

VISUAL INSPECTION thorough v i s u a l inspection o f the F u e l Injection Sys-

A v i s u a l inspection for loose, disconnected, or incor-
rectly routed wires a n d hoses should be made before
a t t e m p t i n g t o diagnose or service t h e fuel injection
system. A v i s u a l check w i l l help spot these faults
and save unnecessary test a n d diagnostic t i m e . A
t e m (Fig. 1) w i l l include the f o l l o w i n g checks:
(1) V e r i f y t h a t t h e 60-way connector i s f u l l y i n -
serted i n t o t h e socket o n t h e Single Board E n g i n e
Controller (SBEC) (Fig. 2).
(2) V e r i f y t h a t hoses are securely attached t o vapor
canister (Fig. 3).
(3) V e r i f y t h a t a l t e r n a t o r electrical w i r i n g a n d t h e
drive belt are correctly installed.

BOARD SINGLE
ENGINE
CONTROLLER DIAGNOSTIC
(SBEC) TOOL

CHECK ENGINE
THROTTLE LAMP
POSITION NEUTRAL LOCK-UP TORQUE CONVERTER
SENSOR SAFETY SWITCH SOLENOID
DISTANCE
SENSOR

A/C CUTOUT AUTO SHUT- PART THROTTLE

RELAY DOWN RELAY UNLOCK RELAY
COOLANT THROTTLE
TEMPERATURE 'MANIFOLD BODY
HEATED SENSOR TEMPERATURE
ABSOLUTE
OXYGEN SENSOR SENSOR
t
PRESSURE
SENSOR 5.2LAND5.9L
IDLE SPEED CONTROL ENGINES
(ISQ ACTUATOR ONLY
EGR, AIR SWITCHING AND
IGNITION CANISTER PURGE SOLENOIDS
REFERENCE
PICK-UP A/C ELECTRONIC
CYCLING CLUTCH
SWITCH
DISTRIBUTOR I
IGNITION COIL

A/C LOW IN-TANK PUMP

PRESSURE CUTOFF FUEL ALTERNATOR
SWITCH INJECTORS

SHIFT
INDICATOR
LAMP J9014-170

Fig. 1 Dual-Point Fuel Injection Components

 Fig. 2 Single Board Engine Controller
Fig. 4 Engine Ground Strap Connection
(4) V e r i f y t h a t engine g r o u n d strap is attached at
the engine dash panel (Fig. 4).
(5) Check I g n i t i o n Coil Electrical Connections (Fig.
5).
(6) V e r i f y t h a t 3-way connector is attached to dis-
t r i b u t o r (Fig. 6).
Fig. 5 Ignition Coil Connections
Fig. 6 Distributor and Oil Pressure Switch Electrical
Connections
(7) V e r i f y o i l pressure sending u n i t electrical con-
nections is f u l l y inserted (Fig. 6).
(8) V e r i f y t h a t 4-way connector is attached for
Heated Oxygen Sensor (3.9L E n g i n e — F i g . 7).
(9) V e r i f y t h a t 4-way connector is attached for
Heated Oxygen Sensor (5.2L a n d 5.9L Engines—Fig.
8).
(10) V e r i f y t h a t t h e 2-way connector is attached to
the A i r S w i t c h i n g Solenoid (Fig. 9).
(11) V e r i f y t h a t t h e 2-way connector is attached to
the Canister Purge Solenoid (Fig. 9).
(12) V e r i f y t h a t t h e 2-way connector is attached to
the E G R Solenoid (Fig. 9).
(13) Verify t h a t v a c u u m connection at A i r Switch
Solenoid is secure a n d not l e a k i n g (Fig. 10).
(14) V e r i f y t h a t v a c u u m connection a t Canister
Purge Solenoid is secure and not l e a k i n g (Fig. 10).
(15) V e r i f y t h a t v a c u u m connection at EGR Sole-
noid is secure a n d not l e a k i n g (Fig. 10).
• FUEL SYSTEM 14 - 33

EGR SOLENOID AIR SWITCHING

SOLENOID
CANISTER
PURGE
SOLENOID

DISTANCE
SENSOR
ELECTRICAL
CONNECTOR

HEATED OXYGEN SENSOR

ELECTRICAL CONNECTOR $ RR14G150 RR14G163
1 - c < ^ \ \ \ W\l

Fig. 7 Heated Oxygen Sensor Electrical Fig. 10 EGR, Air Switching, and Canister Purge
Connection—3.9L Engine Solenoids Vacuum Connections

HEATED SENSOR
ELECTRICAL CONNECTOR

8^491 8-WAY ELECTRICAL CONNECTOR

|4-WAY ELECTRICAL
CONNECTOR RR14G149
Fig. 8 Heated Oxygen Sensor Electrical
Connection—5.2L and 5.9L Engines
Fig. 11 Engine Harness to Main Harness Connection
AIR SWITCHING CANISTER
EGR (17) O n 5.2L or 5.9L engines, v e r i f y t h a t t h e 2-way
SOLENOID PURGE
SOLENOID
SOLENOID connector is attached to t h e t h r o t t l e body tempera-
t u r e sensor ( F i g . 12).

FUEL
RETURN

RR14G134

Fig. 9 EGR, Air Switching, and Canister Purge

Solenoids
RR14G194
(16) Verify engine harness to m a i n harness connec-
t i o n s are f u l l y inserted ( F i g . 11).
Fig. 12 Throttle Body Temperature Sensor—5.2L
and 5.9L Engines
 14 - 34 FUEL SYSTEM •
(18) V e r i f y t h a t t h e 3-way connector is attached to
t h e t h r o t t l e position sensor ( F i g . 13).
(19) V e r i f y t h a t t h e 3-way connector is attached to
t h e M A P sensor (Fig. 13).
(20) V e r i f y M A P Sensor V a c u u m Hose is attached
a t M A P sensor. (Fig. 13).
(21) V e r i f y t h a t 4-way connector is attached to Idle
Speed C o n t r o l (ISC) actuator ( F i g . 14).
(22) V e r i f y t h a t t h e 4-way connector is attached to
t h e harness for t h e f u e l injectors ( F i g . 14).

MAP
SENSOR TO VACUUM DIVERTER VALVE
SOURCE N V A C U U M CONNECTION
3-WAY ELECTRICAL
CONNECTOR CANISTER PURGE V A C U U M
CONNECTION 8914-99

Fig. 15 Throttle Body Vacuum Connections—Front

BI-LEVEL PURGE A N D PCV V A C U U M C O N N E C T I O N

8914-96

Fig. 13 Throttle Position Sensor and Map Sensor

IDLE SPEED CONTROL (ISQ

ACTUATOR

8914-100

Fig. 16 Throttle Body Vacuum Connections—Rear

FUEL INJECTORS (27) V e r i f y t h a t hoses are attached t o the E G R
ELECTRICAL CONNECTOR
valve back pressure transducer (Fig. 17).

TO V A C U U M
SOURCE

' IDLE SPEED CONTROL (ISQ

ACTUATOR ELECTRICAL \ ^
RR14G141
CONNECTOR \

Fig. 14 Throttle Body Electrical Connections

(23) Verify t h a t v a c u u m connections on t h e front
and rear of T h r o t t l e Body are secure a n d n o t l e a k i n g
(Figs. 15 a n d 16).
(24) Verify t h a t heated a i r door a n d M A P sensor
vacuum connections are connected a n d n o t l e a k i n g
(Fig. 15).
(25) Verify t h a t hose f r o m P C V valve is securely
attached to t h e m a n i f o l d v a c u u m p o r t (Fig. 16).
Fig. 17 EGR Valve and Transducer
(26) Verify t h a t t h e M A P sensor v a c u u m connector
is attached t o the v a c u u m p o r t a t t h e rear of t h e (28) Verify t h a t 2-way connector is attached t o
t h r o t t l e body (Fig. 15). Coolant Temperature Sensor (Fig. 18).
 • FUEL SYSTEM 14 - 35

i THERMOSTAT PART THROTTLE^A/C CLUTCH CUTOUT STARTER

SING UNLOCK R E L A Y S RELAY RELAY

COOLANT TEMPERATURE
SENSOR 2-WAY ELECTRICAL
CONNECTOR
l A U T O ^ K f DOWN
|f (ASD) RELAY RR14G225
Fig. 18 Coolant Temperature Sensor
(29) Verify power brake a n d speed control vacuum Fig. 20 Engine Compartment Relays
connectors are t i g h t (Fig. 19).
NEUTRAL SAFETY
TO MANIFOLD VACUUM SPEED CONTROL SWITCH
SOURCE VACUUM HOSE CONNECTION ELECTRICAL
CONNECTION

DISTANCE SENSOR
ELECTRICAL CONNECTION J9014-172
RR14G226
Fig. 21 Distance Sensor
Fig. 19 Power Brake and Speed Control Vacuum
Connections NEUTRAL SAFETY
SWITCH ELECTRICAL
(30) Verify t h a t a l l i g n i t i o n cables are i n correct or- CONNECTION
der and seated i n t o place.
(31) Verify t h a t a l l electrical connectors are fully
inserted i n t o relays (Fig. 20) a n d t h a t battery con-
nections are clean a n d t i g h t .
(32) Check t w o w a y Distance Sensor Electrical
Connector (Fig. 21).
(33) O n automatic transmission equipped vehicles,
verify t h a t t h e n e u t r a l safety switch electrical con-
nector is i n place (Fig. 22).
(34) I f vehicle is equipped w i t h a lock-up torque
convertor, check Torque Converter Lockup Solenoid
Electrical Connection (Fig. 22). LOCK UP SOLENOID _ .
(35) I f vehicle has overdrive (A-500 automatic ELECTRICAL CONNECTION I > RR14G214
transmission), check Overdrive Solenoid Electrical
Fig. 22 Transmission Electrical Connections
Connection (Fig. 23).
(36) Check Hose a n d W i r i n g Connections a t Fuel
Pump. Ensure t h a t w i r i n g connector is m a k i n g con-
tact w i t h t e r m i n a l s o n pump.
14 - 36 FUEL SYSTEM
PARK/NEUTRAL SAFETY SWITCH
Fig. 23 Transmission Electrical Connections
ON BOARD DIAGNOSTICS
The Single Board Engine Controller (SBEC) has
been programmed to m o n i t o r several different cir-
cuits of the fuel injection system. This m o n i t o r i n g is
•
called O n B o a r d Diagnosis. I f a problem i n a m o n i -
tored c i r c u i t is sensed often enough t o indicate an ac-
t u a l problem, i t s f a u l t code i s stored i n the SBEC for
e v e n t u a l display t o t h e service technician. I f t h e
problem is repaired or ceases t o exist, the SBEC can-
cels t h e F a u l t Code after 50 t o 100 vehicle key on/off
cycles.
FAULT CODE DESCRIPTION
W h e n a f a u l t code appears (either b y flashes of the
check engine l a m p or b y w a t c h i n g t h e Diagnostic
Tool), i t indicates t h a t t h e SBEC has recognized a n
a b n o r m a l signal i n t h e system. F a u l t codes indicate
the results of a f a i l u r e b u t never identify the failed
component directly.
To o b t a i n f a u l t codes f r o m t h e Check Engine L i g h t ,
cycle t h e i g n i t i o n k e y on-off-on-off-on w i t h i n a five
second period. C o u n t t h e flashes to determine t h e
code. T h e l i g h t w i l l flash t h e f i r s t d i g i t o f the code,
pause, t h e n flash t h e second d i g i t o f the code. For ex-
ample F a u l t Code 24 w o u l d be displayed by t w o
flashes a pause a n d four flashes.
• FUEL SYSTEM 14 - 37

FAULT CODE DESCRIPTION

Fault Code DRBII D i s p l a y Description of Fault Condition

11 Ign Reference Signal No distributor reference signal

detected during engine cranking.

12 N/A (See Key-On Info) Direct battery input to controller

disconnected within the last 50
ignition key on cycles.

13 MAP Pneumatic Signal No variation in MAP sensor signal

is detected.
or

MAP Voltage Too Low No difference is recognized between the

engine MAP reading and the stored
barometric pressure reading.

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 Vehicle Speed Signal No distance sensor signal detected during

road load conditions.

17 Low Engine Temp Engine coolant temperature remains

below normal operating temperatures
during vehicle travel (thermostat).

21 Oxygen Sensor Signal Neither rich or lean condition is detected

from the oxygen sensor input.
or

0 2 Sensor Shorted High Oxygen sensor input voltage maintained

above normal operating range.

22 Coolant Voltage Low Coolant temperature sensor input below

the minimum acceptable voltage.
or

Coolant Voltage High Coolant temperature sensor input above

the maximum acceptable voltage.

23 T/B Temp Voltage Low Throttle body temperature sensor input

below the minimum acceptable voltage
(5.2L and 5.9L engines).
or

T/B Temp Voltage High Throttle body temperature sensor input

above the maximum acceptable voltage
(5.2L and 5.9L Engines).
J9014-174
 FAULT CODE DESCRIPTION

FAULT CODE DRBII DISPLAY DESCRIPTION OF FAULT CONDITION

24 TPS Voltage Low Throttle position sensor input

below the minimum acceptable
or voltage.

TPS Voltage High Throttle position sensor input

above the maximum acceptable
voltage.

25 AIS Motor Grcuits A shorted condition detected in

one or more of the AIS control
circuits.

27 INJ 1 Control Oct Injector output driver #1 or #2

does not respond property to
the control signal.

31 Purge Solenoid Get An open or shorted condition

detected in the purge solenoid
circuit.

32 EGR Solenoid Circuit An open or shorted condition

detected in the EGR solenoid
or circuit.

EGR System Failure Required change in air-fuel ratio

not detected during diagnostic
test (California emission packages
only).

33 A/C Clutch Relay Oct An open or shorted condition

detected in the A/C clutch relay
circuit.

34 S/C Servo Solenoids An open or shorted condition

detected in the speed control
vacuum or vent solenoid circuits.

35 Idle Switch Shorted Idle contact switch input circuit

shorted to ground.
or

Idle Switch Opened Idle contact switch input circuit

opened.

36 Air Switch Solenoid An open or shorted condition

detected in the air switching
solenoid circuit.

37 PTU Solenoid Circuit An open or shorted condition

detected in the torque convertor
part throttle unlock circuit
(Engine packages with A-999 or
A-500 automatic transmissions only).

J9014-161
• » FUEL SYSTEM 14 - 39

FAULT CODE DESCRIPTION

FAULT CODE DRBII DISPLAY DESCRIPTION OF FAULT CONDITION

41 Alternator Field Get An open or shorted condition

detected in the alternator control
circuit.

42 ASD Relay Circuit An open or shorted condition

detected in the auto shutdown
or relay circuit.

Zl Voltage Sense No Zl voltage sensed when the auto

shutdown relay circuit.

45 Overdrive Solenoid An open or shorted condition

detected In the overdrive solenoid
circuit (engine packages with A-
500 or A-518 automatic
transmissions only).

46 Battery Voltage High Battery voltage sensor input above

target charging voltage during
engine operation.

47 Charging Output Low Battery voltage sense input below

target charging voltage during
engine operation and no
significant change in voltage
detected during active test of
alternator output.

51 Lean F/A Condition Oxygen sensor signal input

indicates lean fuel/air ratio
condition during engine operation.

52 Rich F/A Condition Oxygen sensor signal input

indicates rich fuel/air ratio
or condition during engine operation.

Excessive Leaning Adaptive fuel valve leaned

excessively due to a sustained
rich condition.

53 Internal Self Test Internal engine controller fault

condition detected.

62 EMR Miles Not Stored Unsuccessful attempt to update EMR

mileage in the controller EEPROM.

63 EE PROM Write Denied Unsuccessful attempt to write to

an EEPROM location by the
controller.

55 N/A Completion of fault code display

on the CHECK ENGINE lamp.

J9014-162
14 - 40 FUEL SYSTEM •
SYSTEMS TEST SWITCH TEST MODE
Z l Voltage Sense
B r a k e Switch
WARNING: APPLY PARKING BRAKE AND/OR Park/Neutral S w i t c h
BLOCK WHEELS BEFORE PERFORMING IDLE A/C S w i t c h Sense
CHECK OR ADJUSTMENT, OR ANY ENGINE RUN- Speed Control On/Off
NING T E S T S . Speed Control Set
Speed Control Resume
OBTAINING FAULT CODES Overdrive Override
(1) Connect D R B I I t o t h e diagnostic connector lo- Close T h r o t t l e S w i t c h
cated i n t h e engine compartment near t h e SBEC
(Fig. 24). CIRCUIT ACTUATION TEST MODE
The purpose of t h e c i r c u i t a c t u a t i o n test mode is to
check for t h e proper operation o f o u t p u t circuits of
devices w h i c h t h e SBEC cannot i n t e r n a l l y recognize.
The SBEC can a t t e m p t t o activate these o u t p u t s a n d
a l l o w a n observer t o verify proper operation. Most of
t h e tests available i n t h i s mode provide a n audible or
v i s u a l indication o f device operation (click o f relay
contacts, spray of fuel, etc.) W i t h t h e exception o f a n
i n t e r m i t t e n t condition, i f a device functions properly
d u r i n g i t s test, i t can be assumed t h a t t h e device, i t s
associated w i r i n g , a n d i t s d r i v e r c i r c u i t are i n w o r k -
i n g order.

OBTAINING CIRCUIT ACTUATION TEST

Fig. 24 Diagnostic Connector
Access "Actuate Solenoid/Rly" or " A c t u a t e O u t -
(2) S t a r t t h e engine i f possible, set t h e p a r k i n g
puts"
brake a n d t h e n cycle t h e transmission selector a n d
the A/C s w i t c h i f applicable. S h u t off the engine.
CIRCUIT ACTUATE TEST DISPLAY
(3) T u r n t h e i g n i t i o n switch on, access "Read F a u l t
Code D a t a " . Record a l l fault messages shown on t h e
D R B I I . Observe the check engine lamp on t h e i n s t r u - ACTUATE SOLENOID/RLY
ment p a n e l . The l a m p should l i g h t for 3 seconds t h e n Stop A l l Tests
go out ( b u l b check). A u t o Shutdown Relay
F a u l t c o d e e r a s u r e ; access erase f a u l t c o d e A i r S w i t c h Solenoid
data Purge Solenoid
E G R Solenoid
SWITCH TEST MODE A/C C l u t c h Relay
S/C Servo Solenoids
The s w i t c h inputs used by the SBEC have only t w o P T U Solenoid
recognized states, H I and L O . For this reason, t h e Overdrive Solenoid
SBEC cannot recognize the difference between a se- A l l Solenoids/Relays
lected s w i t c h position versus a n open circuit, a short
circuit, o r a defective switch. However, i f a n y one of ACTUATE OUTPUTS
these subject switches is toggled, the controller does I g n i t i o n Coil N o . l
F u e l Injector(s) # 1
have t h e capability to respond, i n d i c a t i n g t h a t i t has
F u e l Injector(s) # 2
recognized a state change. I f the change is displayed,
A I S M o t o r Open/Close.
i t can be assumed t h a t the e n t i r e switch c i r c u i t to
A l t e r n a t o r Field
the SBEC is functional.
Tachometer O u t p u t
Shift Indicator L a m p ( M a n u a l Trans O n l y )
OBTAINING SWITCH TEST MODE
Access "Read I n p u t States"
SENSOR TEST MODE ENGINE PARAMETERS MODE
Engine Speed
The sensor test mode allows t h e output o f seven T o t a l Spark Advance
sensors a n d t h e state o f three switches t o be dis- M A P Gauge Reading
played on t h e D R B I I w h i l e t h e engine is not operat- Barometric Pressure
ing. This provides a means b y w h i c h t h e entire B a t t e r y Voltage
circuit for each i n d i v i d u a l sensor and switch can be
checked, i n c l u d i n g t h e w i r i n g and Single Board E n - IGNITION TIMING PROCEDURE
gine Controller (SBEC) c i r c u i t r y .
Refer t o Group 8 D " I g n i t i o n System"
OBTAINING SENSOR READ TEST MODE
DIAGNOSTIC CONNECTOR SCHEMATIC
Access "Read Sensor V o l t a g e " or "Read Sensor V a l -
ues" D-1 GROUND

SENSOR READ TEST MODE D-2 NIC

D-3 SCI TRANS

READ SENSOR
M A P Sensor Voltage
VOLTAGE

T h r o t t l e Position
## D-4

D-5
SCI RECEIVE

J-2 IGNITION
M i n i m u m Throttle
Oxygen Sensor S i g n a l D-6 ASD RELAY
Coolant Temp Sensor
T/Body Temp Sensor (5.2L and 5.9L Engines)
J9014-156
B a t t e r y Temp Sensor

READ SENSOR VALUES

M A P Sensor Reading
T h r o t t l e Opening
Oxygen Sensor State
Coolant Temperature
T/Body Temperature (5.2L and 5.9L Engines)
B a t t e r y Temperature
Vehicle Speed
 WIRE WIRE
CAV DESCRIPTION CAV DESCRIPTION
COLOR COLOR
1 DG/RD* MAP SENSOR 37
2 TN/WT* COOLANT SENSOR 38
3 RD/WT* DIRECT BATTERY 39
4 BK/LB* SENSOR RETURN 40 BR/WT* ISC MOTOR CLOSED
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 WITH TACHOMETER)
8 DG/BK* Z-l INPUT 44
9 DB J2 45 LG SCI RECEIVE
10 46
11 LB/RD* POWER GROUND 47 WT/OR* DISTANCE SENSOR SIGNAL
12 LB/RD* POWER GROUND 48 BR/RD* SPEED CONTROL SET SWITCH
13 49 YL/RD* SPEED CONTROL ON/OFF SWITCH
14 50 WT/LG* SPEED CONTROL RESUME SWITCH
15 TN INJECTOR DRIVER #2 51 DB/YL* AUTO SHUTDOWN (ASD) RELAY
16 WT/DB* INJECTOR DRIVER #1 52 PK/BK* PURGE SOLENOID
17 53 LG/RD* SPEED CONTROL VENT SOLENOID
18 54 OR/BK* SHIFT INDICATOR LIGHT (MANUAL TRANSMISSION ONLY)
19 BK/GY* IGNITION COIL DRIVER 54 OR/BK* PART THROTTLE UNLOCK SOLENOID (AUTO TRANSMISSION)
20 DG ALTERNATOR FIELD CONTROL 55 OR/WT* OVERDRIVE SOLENOID (AUTO TRANSMISSION ONLY)
21 BK/RD* THROTTLE BODY TEMPERATURE SENSOR (5.2L AND 5.9L) 56 GY/PK* EMISSION MAINTENANCE REMINDER (EMR) LIGHT
22 OR/LB* THROTTLE POSITION SENSOR (TPS) 57
23 58
24 GY/BK* IGNITION (DISTRIBUTOR) REFERENCE PICK-UP 59
25 PK SCI TRANSMIT 60 GY/RD* ISC MOTOR OPEN
26 WIRE COLOR CODES LB LIGHT BLUE VT VIOLET
27 BR A/C SWITCH SENSE BK EJLACK LG LIGHT GREEN WT WHITE
BR EJROWN OR ORANGE YL YELLOW
28 VT IDLE CONTACT SWITCH PINK WITH TRACER
DB C)ARK BLUE PK •

29 WT/PK* BRAKE SWITCH DG I>ARK GREEN RD RED

30 BR/YL* PARK NEUTRAL SWITCH GY (3RAY TN TAN
31
32 BK/PK* CHECK ENGINE LAMP f — i " " " " n m
- i ^ t \

33 TN/RD* SPEED CONTROL VACUUM SOLENOID IIf OOOOOOOOOO | "1 o o o o o o o o o o \ \

I\11 3 4O 5O 6O 7 O8 O9 O 10 /U O J J
I O JO 2O O OOOOOOOOOO
1 1
> 1 2
'5 16 17 18 19 20 \ )
3 1 4
\ }
34 DB/OR* A/C CLUTCH RELAY \ \ 21 22 23 24 25 26 27 28 29 30 \\
%\ J J
\ it jn .« MM Mr MM. A* Ma in cn t ^+m~H^ I XI O Ci KM c £ Its. «T 11 CA In
3 2 3 3 34 35 36 3? 38 39 40 1 II
3 1

/ /#
CONNECTOR
35 GY/YL* EGR SOLENOID
TERMINAL SIDE m\ \ * i m £ m a mm mo mo mt mu «T JV I -*» J «Mt -»w w / tm
36 BK/OR* AIR SWITCHING SOLENOID SHOWN W oooooooooo! . •! o o o o o o o o o o J /I J9014-175
VJST 1—i 1—i 1—i rrJl
60-Way Single Board Engine Controller (SBEC) Wiring Connector Cavity Description—3.9L, 5.2L and 5.9L Engines
 [3 SPEED AUTO ONLYi

m
m

SIX/
#1 #2
FUEL INJECTORS
4*
CO
Single Board Engine Controller System Schematic—3.9L Engine
 PRESS [3 SPEED AUTO ONLY]
A/C SW A-999; 86
SWITCH 87A vJUUUL/ 85 4*
4*
r INSTR PNL COOLANT TEMP
87 30
T/B AIR A.I.S. LOCK/UN-LOCK
MOTOR SOLENOID
A
THROTTLE
POSITION VEHICLE a I ! !
SENSOR I SPEED
SENSOR PURGE
C4 CM
-iZ/vl SENS | |
EH SPEED
SOLENOID
22 TPS SIGNAL £ £
i <"ZD
AIR
I | < < D
SWITCHING
-^TTTTIO f
o 5 VOLT S U P P L Y H I

52
o !§s
MAP
MAP SIGNAL o PURGE SOL SOLENOID
SENSOR
SENSOR GRD ! a: 36
8 VOLT SUPPLY
u •! Zi - - AIR S W I T C H
35 EGR
O EGR SOL
24 DIST P I C K - U P
u SOLENOIDl
410 2 I N P U T
C H K E N G LAMP CHECK ENGINE
44 O / O O V E R R I D E I N P U T EMISSMMNY
30 P / N - C L U T C H I N P U T EMR LAMP

29 B R A K E S W I N P U T 14 SPEED AUTO ONLY

DISTRIBUTOR SPEED CONTROL SHFT LP/LOCK-UP 54
PICK-UP (AUTO ONLY)
SPEED CONTROL

4a S E T O/D S O L 5 5 AUTOIOCK-UP]
-oj^/SET
49 ON/OFF
34
•SO ION
A C RELAY L L
— J :
PTO&
50 RESUME
SPEED CONTROL
IGNITION
RESUMB a o H. Jl — CM
VACUUM 33 OVERDRIVE
02 | O F F _
at Q: Z £
5
5 § V
ENT
1531I I SOLENOID
START O
O UJ
w

RUN
SENSOR 85 i I I < SOLENOID
I 00 I
OFF OFF
J2 OVERDRIVE
BRAKE SWITCH ft? I
I
VENT 86
87A
AC RELAY
SET/RESET d 85
I SOLENOID

m
MODULE
ON INST PNL TO S
' PEED CONTROL 87 30
STOP [_ (AUTO ONLY)
START d
RELAY X LAMPS AC
CLUTCH

MANUAL lAUTO ALTERNATOR n

j ONLY [ONLY
30T 87 TO la
FUEL
85 87A PUMP
aAUTO
rm 86

BODY " ENGINE SHUT-DOWN

[STARTER 3 BATTERY [GROUND GROUND RELAY
#1 #2 IGNITION
FUEL INJECTORS COIL

Single Board Engine Controller System Schematic—5.2L Engine

 S. MOTOR

•<
w

[STARTER^^j
#1 #2 IGNITION
FUEL INJEaORS COIL J9014-178

Single Board Engine Controller System Schematic—5.9L Engine, Normal Duty

 4*
0*

00
-<
CO

FUEL INJECTORS J9014-179

Single Board Engine Controller System Schematic—5.9L Engine, Heavy Duty

 • FUEL SYSTEM 14-47

SERVICE PROCEDURES

INDEX
Page Page
Air Switching, Canister Purge and EGR Diagnostic Fuel System Pressure Release Procedure . . . . . . 4 7
Solenoid Service 55 Single Board Engine Controller (SBEC) Service . . 55
Heated Oxygen Sensor ( 0 Sensor) Service . . . . . 55
2 Throttle Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 7
Fuel Lines and Hoses 47 Throttle Body Components 48

FUEL LINES AND HOSES THROTTLE BODY

W h e n servicing t h e fuel portion o f the system, i t
w i l l be necessary to preform the " F u e l System Pres-
sure Relief Procedure" t o bleed fuel pressure f r o m
t h e system before removing any clamps or hoses. Use
care w h e n r e m o v i n g fuel hoses to prevent damage t o
hose or hose nipple. D u r i n g assembly always use new
hose clamps o f the correct type. T i g h t e n hose clamps
to 1 N n n (10 i n . lbs.) torque. D o not u s e a v i a t i o n
s t y l e c l a m p s o n this s y s t e m o r h o s e d a m a g e m a y
result.
FUEL SYSTEM PRESSURE RELEASE PROCEDURE
WARNING: T H E T B I FUEL SYSTEM IS UNDER A
CONSTANT PRESSURE OF APPROXIMATELY 100
KPA (14.5 PSI). BEFORE SERVICING T H E FUEL
PUMP, FUEL LINES, FUEL FILTER, THROTTLE
BODY OR FUEL INJECTOR, THE FUEL SYSTEM
PRESSURE MUST B E RELEASED.
REMOVAL
(1) Remove a i r cleaner.
(2) Perform fuel system pressure release.
(3) Disconnect battery negative cable.
(4) Disconnect v a c u u m hoses and electrical connec-
tors.
(5) Remove t h r o t t l e cable. I f equipped, remove
speed control and transmission k i c k down cables.
(6) Remove t h r o t t l e r e t u r n spring.
(7) Remove fuel i n t a k e and r e t u r n hoses (Fig. 2).
(8) Remove t h r o t t l e body m o u n t i n g screws and l i f t
t h r o t t l e body from vehicle. Remove t h r o t t l e body gas-
k e t f r o m i n t a k e manifold.
BOLTS (4) THROTTLE BODY
ASSEMBLY

(1) Loosen fuel f i l l e r cap to release fuel t a n k pres-

sure. ISOLATOR
(2) Disconnect injector w i r i n g harness f r o m engine INTAKE
harness. MANIFOLD
(3) Connect a j u m p e r w i r e t o g r o u n d t e r m i n a l
N u m b e r 1 o f the injector harness (Fig. 1) t o engine
ground. VIEW IN DIRECTION PWD
OF ARROW Y
(4) Connect a j u m p e r w i r e to the positive t e r m i n a l CLAMI
N u m b e r 2 o f the injector harness (Fig. 1) and touch
FUEL SUPPLY
the battery positive post for no longer t h a n 5 sec-
AND RETURN HOSE
onds. This releases system pressure. ASSEMBLY RR14G152
(5) Remove j u m p e r wires.
(6) Continue fuel system service. Fig. 2 Throttle Body Removal and Installation
TERMINAL #1 INSTALLATION
(1) U s i n g a new gasket, i n s t a l l t h r o t t l e body and
t i g h t e n m o u n t i n g screws t o 20 N*m (175 in-lbs)
torque.
(2) I n s t a l l fuel i n t a k e and r e t u r n hoses using new
o r i g i n a l equipment type clamps.
(3) I n s t a l l r e t u r n spring.
(4) I n s t a l l t h r o t t l e cable. I f equipped, i n s t a l l t r a n s -
TERMINAL #2 8914-123 mission kick-down and speed control cables.
(5) I n s t a l l w i r i n g connectors and v a c u u m hoses.
Fig. 11njector Harness Connectors (6) I n s t a l l a i r cleaner.
14-48 FUEL SYSTEM
(7) Reconnect negative battery cable.
THROTTLE BODY COMPONENTS
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE OF APPROXIMATELY 100 KPA
(14.5 PSI). BEFORE SERVICING THE THROTTLE
BODY OR FUEL INJECTOR THE FUEL SYSTEM
PRESSURE MUST B E RELEASED.
Perform t h e Fuel System Pressure Release proce-
dure p r i o r t o servicing fuel delivery system compo-
nents o r opening fuel hoses on t h e t h r o t t l e body.
A l w a y s reassemble throttle body components w i t h
•
new O-rings and seals where applicable. Never use
silicone lubricants o n O-rings o r seals, damage may
result.
Use care when r e m o v i n g fuel hoses to prevent
damage t o hose or hose n i p p l e . I f f u e l s y s t e m hoses
are t o b e replaced, o n l y hoses m a r k e d E F I / E F M
m a y b e u s e d . A l w a y s use new hose clamps of the
correct type w h e n reassembling a n d t i g h t e n hose
clamps t o 1 N»m (10 in.lbs.) torque. Do not use A v i -
a t i o n style clamps o n t h i s system o r hose damage
m a y result.
I t i s not necessary to remove t h e t h r o t t l e body from
t h e i n t a k e manifold w h e n r e m o v i n g o r replacing
t h r o t t l e body components (Fig. 3 or F i g ; 4).
 MAP SENSOR IDLE SPEED CONTROL FUEL INJECTORS
(ISC) ACTUATOR

IDLE SPEED CONTROL

(ISC) ACTUATOR

HEATED AIR INLET

NIPPLE
MAP SENSOR
FUEL INJECTORS
VACUUM HOSE DIVERTER
WIRING CONNECTOR
CANISTER VALVE NIPPLE
PURGE NIPPLE
FUEL RETURN
NIPPLE
MAP SENSOR
FUEL INJECTORS
WIRING CONNECTOR

CO
FUEL INLET -<
NIPPLE CO

PCV NIPPLE
THROTTLE FUEL PRESSURE THROTTLE POSITION
LEVER REGULATOR SENSOR (TPS) 8914-97

Fig. 3 Throttle Body Components—3.9L Engine CO

 IDLE SPEED CONTROL FUEL INJECTORS
MAP SENSOR IDLE SPEED CONTROL
(ISC) ACTUATOR
(ISC) ACTUATOR
cn

C/D

-<
CO

HEATED AIR INLET

NIPPLE
DIVERTER FUEL INJECTORS
MAP SENSOR VALVE NIPPLE WIRING CONNECTOR
VACUUM HOSE
CANISTER
PURGE NIPPLE
MAP SENSOR
FUEL INJECTORS
FUEL RETURN
WIRING CONNECTOR
NIPPLE

FUEL INLET
NIPPLE

THROTTLE BODY
THROTTLE TEMPERATURE SENSOR
LEVER PCV NIPPLE
FUEL PRESSURE THROTTLE POSITION
REGULATOR SENSOR (TPS) 8914-107

Fig. 4 Throttle Body Components—5.2L and 5.9L Engines

 • FUEL SYSTEM 14-51

FUEL FITTINGS THROTTLE POSITION SENSOR

(TPS)
Removal
(1) Remove a i r cleaner assembly.
(2) Perform Fuel System Pressure Release.
(3) Disconnect b a t t e r y negative cable.
(4) Loosen fuel i n t a k e and r e t u r n hose clamps.
W r a p a shop towel around each hose, t w i s t a n d p u l l
o f each hose.
(5) Remove each fitting and note i n l e t diameter
(Fig. 5). Remove copper washers.
FUEL PRESSURE
REGULATOR
THROTTLE BODY TEMPERATUR!
SENSOR RR14G154

Fig. 6 Throttle Body Temperature Sensor—5.2L and

5.9L Engines
FUEL PRESSURE REGULATOR

Removal
(1) Remove a i r cleaner assembly.
(2) Perform fuel system pressure release.
FUEL INLET
FITTING (3) Disconnect battery negative cable.
(4) Remove vacuum hose from t h r o t t l e body.
(5) Remove screws a t t a c h i n g pressure regulator to
RR14G153
t h r o t t l e body.
Fig. 5 Servicing Fuel Fitting
WARNING: PLACE A SHOP TOWEL AROUND FUEL
Installation INLET OF THE PRESSURE REGULATOR TO AB-
(1) Replace copper washers w i t h new washers. SORB ANY RESIDUAL FUEL REMAINING IN THE
(2) I n s t a l l fuel f i t t i n g s i n proper ports and t i g h t e n SYSTEM.
to 20 N n n (175 i n . lbs.) torque.
(3) U s i n g new o r i g i n a l equipment type hose (6) Remove pressure regulator f r o m t h r o t t l e body
clamps, i n s t a l l fuel r e t u r n and supply hoses. T i g h t e n (Fig. 7).
hose clamps to 1 N n n (10 i n . lbs.) torque. (7) Carefully remove O-ring f r o m pressure regula-
(4) Reconnect battery negative cable. t o r (Fig. 7). Remove gasket.
(5) U s i n g D R B I I diagnostic tester, w i t h the key i n -Li » — J M I rcZ?FUEL PRESSURE REGULATOR
t h e " R u n " position, use Special Functions " A S D F u e l
System Test", to activate the fuel pump and pressur-
ize the system. Check for leaks.
(6) R e i n s t a l l a i r cleaner assembly.

THROTTLE BODY TEMPERATURE SENSOR

Removal
(1) Remove a i r cleaner from engine.
(2) Disconnect t h r o t t l e body temperature sensor
electrical connector.
(3) Remove sensor (Fig. 6).

Installation FUEL INJECTORS FUEL PRESSURE REGULATOR

WIRING CONNECTOR VACUUM NIPPLE 8914-129
(1) A p p l y heat transfer compound (provided w i t h
new sensor) to t i p of new sensor.
Fig. 7 Servicing Fuel Pressure Regulator
(2) I n s t a l l sensor and t i g h t e n to 12 N n n (110 i n .
lbs.) torque. Installation
(3) Connect electrical connector to sensor. (1) Place new gasket on pressure regulator and
(4) I n s t a l l a i r cleaner. carefully i n s t a l l new O-ring.
 ( 2 ) Position pressure regulator o n t h r o t t l e body 5mm LOCATING 4mm LOCATING
press i n t o place, i n s t a l l m o u n t i n g screws a n d t i g h t e n
to 5 N T H ( 4 0 i n . lbs.) torque.
( 3 ) I n s t a l l v a c u u m hose to t h r o t t l e body.
(4) U s i n g D R B I I diagnostic tester, w i t h t h e key i n
the " R u n " position, use Special Functions " A S D F u e l
System Test", to activate the fuel p u m p a n d pressur-
ize t h e system. Check for leaks.
( 5 ) Reinstall a i r cleaner assembly.

FUEL INJECTORS

Removal
( 1 ) Remove a i r cleaner assembly.
( 2 ) Perform fuel system pressure release.
( 3 ) Disconnect b a t t e r y negative cable. Fig. 9 Removing Fuel Injector
(4) Remove injector hold-down clamp T o r x screw
(Fig. 8 ) . B e c a r e f u l n o t t o d a m a g e t h e s p a c e r u n -
der the clamp.
CLAMP SCREW INJECTOR HOLDDOWN

Fig. 10 Servicing Fuel Injector

Fig. 8 Removing Injector Cap Hold-Down

(5) U s i n g a s m a l l screwdriver and t h e area i n front
of the hold-down clamp for leverage, l i f t t h e caps off
the injectors.
(6) U s i n g a s m a l l screw d r i v e r placed i n t h e hole i n
the f r o n t of the electrical connector g e n t l y p r y t h e i n -
jectors from the pod (Fig. 9).
(7) M a k e sure t h e injector lower O - r i n g has been
removed from the pod (Fig. 1 0 )
Fig. 11 Fuel Injector and Injector Cap
Installation (4) Spray i n n e r surfaces o f b o t h injector pods w i t h
(1) I n s t a l l lower O-ring o n injector. O - r i n g should Mopar B r a k e a n d Carburetor Parts Cleaner to re-
b u t t against plastic f i l t e r assembly. Inspect b o t h O- move residual gasoline.
rings for cuts or tears and replace i f necessary. (Fig. (5) L i g h t l y lubricate the upper a n d lower O-rings
10). w i t h Petroleum Jelly.
( 2 ) A l i g n the injector t e r m i n a l housing w i t h t h e lo- (6) Place injector and cap i n injector pod and a l i g n
cating socket i n the injector cap. (Fig. 1 1 ) . cap locating p i n w i t h locating hole i n the casting.
(3) Press injector into cap so t h a t upper O-ring P a s s e n g e r side c a p locating p i n i s 5 m m i n d i -
flange is flush w i t h lower surface of cap. (Fig. 1 2 ) . ameter a n d w i l l only fit i n p a s s e n g e r side locat-
 Fig. 13 Servicing the MAP Sensor
Fig. 12 installing Fuel Injector Assembly
(5) L i f t t h r o t t l e position sensor off t h e t h r o t t l e
ing h o l e . D r i v e r ' s s i d e l o c a t i n g p i n i s 4 m m i n shaft (Fig. 14).
diameter (Fig. 9).
(7) Repeat steps 1-6 w i t h other injector a n d cap.
(8) Press f i r m l y o n injector caps u n t i l flush w i t h
casting surface.
(9) Place injector hold-down clamp w i t h spacer on
rear portion o f caps, a l i g n i n g t h e holes i n clamp w i t h
pins on caps. (Fig. 8).
(10) I n s t a l l clamp screw. B e sure spacer i s i n place
(Fig. 8). B e c a u s e O - r i n g squeeze m a y c a u s e c a p s
t o l i f t up, p r e s s f i r m l y o n b o t h c a p s w i t h one
h a n d to e n s u r e c a p s a r e f l u s h w h i l e i n s t a l l i n g
c l a m p s c r e w . T i g h t e n screw u n t i l snug. T i g h t e n
screw t o 4 N*m (35 in-lbs) torque.
(11) Connect negative cable t o battery. Test for
THROTTLE POSITION
leaks using D R B I I diagnostic tester. W i t h the k e y i n SENSOR (TPS) RR14G161
the " R u n " position, use Special Functions " A S D Fuel
System Test", t o activate the fuel p u m p and pressur- Fig. 14 Servicing Throttle Position Sensor
ize the system.
Installation
(12) Reinstall A i r Cleaner Assembly.
(1) I n s t a l l t h r o t t l e position sensor to t h r o t t l e body
MANIFOLD ABSOLUTE PRESSURE SENSOR w i t h t h e electrical connector positioned upward away
SERVICE from t h e engine. T i g h t e n m o u n t i n g screws to 3 N»m
(1) Remove v a c u u m hose a n d electrical connector (27 in-lbs) torque.
from sensor (Fig. 13). (2) Connect 3 w a y connector a t throttle position
(2) Remove sensor m o u n t i n g screws a n d remove sensor.
sensor (Fig. 13). (3) I n s t a l l a i r cleaner.
(3) Reverse t h e above procedure for i n s t a l l a t i o n . (4) Connect b a t t e r y cable.
Check the vacuum hose and electrical connections to
the sensor. IDLE SPEED CONTROL (ISC) ACTUATOR

THROTTLE POSITION SENSOR (TPS) Removal

(1) Remove a i r cleaner.
Removal (2) Disconnect battery negative cable.
(1) Disconnect b a t t e r y negative cable. (3) Disconnect electrical connector.
(2) Remove a i r cleaner. (4) Remove ISC motor a t t a c h i n g nuts (Fig. 15).
(3) Disconnect 3 w a y connector a t t h r o t t l e position (5) Remove t h e idle speed control actuator from the
sensor. bracket.
(4) Remove t h r o t t l e position sensor m o u n t i n g
screws.
14 - 54 FUEL SYSTEM •

Fig. 15 Idle Speed Control (ISC) Actuator Service

Installation and Adjustment Fig. 16 Adjusting the Idle Speed Control (ISC)
Actuator
WARNING: APPLY PARKING BRAKE AND/OR VACUUM MANIFOLD
BLOCK WHEELS BEFORE PERFORMING IDLE
CHECK OR ADJUSTMENT. Removal
(1) Remove the a i r cleaner.
(1) I n s t a l l t h e idle speed control actuator t o t h e (2) Disconnect battery negative cable.
support bracket w i t h washers and m o u n t i n g nuts. (3) Remove t h e t h r o t t l e body. Refer t o " T h r o t t l e
(2) A t t a c h electrical connector. Body Removal" i n this section.
(3) S t a r t t h e vehicle and allow t o r u n for two m i n - (4) Remove vacuum m a n i f o l d m o u n t i n g screw (Fig.
utes. 17).
(4) Shut vehicle off. A l l o w 60 seconds for the actu- (5) Remove manifold and any gasket m a t e r i a l o n
ator shaft t o f u l l y extend. surface o f t h r o t t l e body.
(5) Disconnect t h e w i r i n g connector t o t h e idle
speed control actuator.
(6) Disconnect the w i r i n g connector t o the coolant
temperature sensor.
(7) Hook u p a tachometer t o the engine.
(8) Start t h e vehicle.
(9) Adjust t h e extension screw o n t h e actuator
shaft (Fig. 16) u n t i l t h e r p m is w i t h i n the specifica-
tions shown:
3.9L E n g i n e :
• I f vehicle mileage is less t h a n 1000 miles, set to
2400-2500 r p m
• I f vehicle mileage is greater t h a n 1000 miles, set
to 2500-2600 r p m
5.2L a n d 5.9L E n g i n e :
• I f vehicle mileage is less t h a n 1000 miles, set to
2650-2750 r p m Fig. 17 Servicing Vacuum Manifold
• I f vehicle mileage i s greater t h a n 1000 miles, set Installation
to 2750-2850 r p m
(1) I n s t a l l vacuum m a n i f o l d w i t h a new gasket.
(10) Shut off vehicle.
(2) T i g h t e n a t t a c h i n g screws t o 4 N»m (35 i n . lbs.)
(11) Reconnect t h e ISC actuator motor electrical torque.
connector. (3) I n s t a l l t h e t h r o t t l e body. Refer t o " T h r o t t l e
(12) Reconnect the Coolant Temperature Sensor. Body I n s t a l l a t i o n " i n t h i s section, use a n e w base
gasket w h e n i n s t a l l i n g t h e t h r o t t l e body.
(4) I n s t a l l the a i r cleaner.
(5) Connect the battery negative cable.
 • FUEL SYSTEM 14-55

AIR SWITCHING, CANISTER PURGE AND EGR HEATED OXYGEN SENSOR (0 SENSOR) SERVICE
2

DIAGNOSTIC SOLENOID SERVICE

On 3.9L engines t h e oxygen sensor is located i n t h e
The solenoids are m o u n t e d to a bracket a t t h e rear exhaust systems Y-pipe ( F i g . 20). O n 5.2L a n d 5.9L
of t h e engine on t h e r i g h t side cylinder head cover engines t h e oxygen sensor i s located above the outlet
(Fig. 18). of t h e left exhaust m a n i f o l d ( F i g . 21).
(1) Remove v a c u u m hose a n d electrical connector
f r o m solenoids.
(2) Remove m o u n t i n g bracket fastener.
(3) Depress t a b o n top o f solenoid t o be replaced
and slide t h e solenoid d o w n w a r d o u t o f m o u n t i n g
bracket.
(4) Reverse above procedure t o i n s t a l l .
PRESS HERE

Fig. 20 Heated Oxygen Sensor Location—3.9L

Engine

Fig. 18 Air Switching, Canister Purge and EGR

Solenoids

SINGLE BOARD ENGINE CONTROLLER (SBEC)

SERVICE
(1) Remove a i r cleaner duct from SBEC.
(2) Remove SBEC m o u n t i n g screws (Fig. 19).
(3) Remove w i r i n g connectors from SBEC. Remove
module.
(4) Reverse above procedure for i n s t a l l a t i o n .

Fig. 21 Heated Oxygen Sensor Location—5.2L and

5.9L Engine
(1) Disconnect engine harness f r o m Oxygen Sensor
Connector (Fig. 22).

CAUTION: Take care not to pull on oxygen sensor

wires when servicing the 0 sensor.
2

WARNING: THE EXHAUST PIPE MAY BE EX-

TREMELY HOT. AVOID CONTACT WITH THE EX-
HAUST PIPE WHEN SERVICING T H E OXYGEN
SENSOR.

(2) Remove 0 sensor w i t h Tool C-4907.

2

Fig. 19 Single Board Engine Controller (SBEC)

 The o r i g i n a l 0 sensor threads were coated w i t h a n
2

anti-seize compound. The compound m u s t be removed

f r o m t h e threads i n t h e exhaust m a n i f o l d p r i o r t o
sensor i n s t a l l a t i o n .
(3) Clean t h e threads i n t h e exhaust manifold w i t h
DISTANCE a n 18 m m X 1.5 + 6E t a p .
SENSOR (4) I f t h e o r i g i n a l sensor i s t o be reinstalled, t h e
ELECTRICAL sensor threads m u s t be coated w i t h a n anti-seize
CONNECTOR
compound (Loctite 771-64 o r equivalent). N e w 0 2

sensors are packaged w i t h compound o n t h e threads

and no a d d i t i o n a l compound is required.
(5) T i g h t e n sensor t o 27 N n n (20 ft. lbs.) torque.
F o r m o r e i n f o r m a t i o n r e f e r t o G r o u p 25.
HEATED OXYGEN SENSOR
ELECTRICAL CONNECTOR $ RR14G150

Fig. 22 Heated Oxygen Sensor Electrical

Connector—3.9L Engine
SENSOR SPECIFICATIONS

N u m b e r of
Component Terminals Resistance a t ° F Thread Compound Thread Size Torque

Coolant Temperature 2 7,000 to 13,000 Ohms Preapplied 3/8-18 NPTF 27 N m

Sensor About 21 ° C , 7 0 ° F (Nonrequired) (20 ft.-lbs.)
700 to 1,000 Ohms
About 9 3 ° C , 2 0 0 ° F
Throttle Body 2 5,600 to 14,600 Ohms Silicone Heat M12 x 1.5 11 N m
Temperature Sensor About 21 ° C , 7 0 ° F Transfer Compound (Metric) (100 in.-lbs.)
(5.2Land5.9L
Engines) 400 to 1,500 Ohms
About 9 3 ° C , 2 0 0 ° F
J9014-180

SPECIAL TOOLS

C-3292

C-4907

C-4799

DIAGNOSTIC TOOL

RR14G112
 # — DRIVE SHAFTS AND UNIVERSAL JOINTS 16-1

DRIVE SHAFTS AND UNIVERSAL JOINTS

CONTENTS
Page Page

GENERAL INFORMATION . 1 SPECIFICATIONS 27

SERVICE PROCEDURES 10

G E N E R A L INFORMATION

INDEX
Page Page
Description ... ....... 1 Vibration 3
Vehicle Configuration . . . . . . . . . . . . . . . . . . . . . . . 3

DESCRIPTION tween the f r o n t axle differential housing and transfer

case. A rubber boot protects t h e drive shaft splines
from road splash.
DRIVE SHAFTS Vehicles w i t h a n extended wheelbase are equipped
R a m T r u c k and Ramcharger vehicles use t u b u l a r w i t h a two-piece rear drive shaft. The two-piece drive
steel drive shafts (Figs. 1 and 2) to transfer engine shafts have a center support b e a r i n g and a U-joint
torque f r o m the transmission t o t h e rear axle (2WD coupler between the t w o shaft-halves. The ball-type,
vehicles) a n d to transfer engine torque from t h e center support bearing i s enclosed i n a rubber-cush-
transfer case to the f r o n t and rear axles ( 4 W D vehi- ioned (insulator) support and bracket t h a t is attached
cles). U n i v e r s a l j o i n t s are used t o connect each drive to the frame crossmember.
shaft to the transmission (or the transfer case) out-
p u t shaft and to t h e drive p i n i o n gear shaft (axle) U-JOINTS
yoke. Two different types o f U-joint couplers are used
A n internally-splined, s l i d i n g type (slip) yoke ( w i t h w i t h the drive shafts:
a shaft) is located a t t h e f r o n t end o f r e a r drive • single cardan U-joint (Fig. 3) and
shafts (Fig. 1) to compensate for v a r i a t i o n s i n t h e • double cardan U-joint (Fig. 4).
distance t o the rear axle caused b y rear suspension A single cardan type U-joint (Fig. 3) is used for
spring and axle movement. T h e i n t e r n a l l y splined most drive shaft applications and is comprised of:
slip yoke shaft slides fore and a f t on the e x t e r n a l l y - • a single spider,
• four sets of spider needle bearings,
splined drive shaft t o compensate for rear axle " u p -
• four bearing seals,
and-down" movement w i t h t h e road surface (i.e., t o
• four needle bearing caps, and
shorten a n d lengthen t h e effective d r i v e shaft
• four bearing cap r e t a i n i n g clips.
length). A rubber boot protects t h e d r i v e shaft
Strap clamps and screws are used t o attach the U -
splines f r o m road splash.
j o i n t spider to the drive p i n i o n gear shaft (axle) yoke.
A s l i d i n g type (slip) yoke (Figs. 1 and 2) is also lo- The double cardan type U-joint (Fig. 4), also re-
cated a t the front end o f f r o n t drive shafts (4WD) t o ferred to as a constant velocity (CV) j o i n t , is com-
compensate for variations i n t h e distance between prised of:
the transfer case and the f r o n t axle d i f f e r e n t i a l case • two spiders,
caused b y front suspension spring and axle move- • one socket b a l l and "seats",
ment. T h e internally-splined slip yoke shaft slides • one l i n k yoke,
fore and a f t on the externally-splined d r i v e shaft t o • one socket spring,
compensate for distance v a r i a t i o n (i.e., t o shorten • one socket yoke,
and lengthen the effective drive shaft length) be- • one socket yoke needle bearing,
• two t h r u s t washers,
16-2 DRIVE SHAFTS AND UNIVERSAL JOINTS

FRONT DRIVE SHAFT v / "^^^S^L^ EI2UI

S
CRE
W -

S
HAF
T
VIEW C

J9016-18

Fig. 1 Drive Shafts

 • — DRIVE SHAFTS AND UNIVERSAL JOINTS 16 - 3

CONSTANT WASHER (LARGE OD) 3-BALL SEATS

VELOCITY (CV)

Fig. 4 Double Cardan (CV) Joint

SPLINED SLIP YOKE I f equipped for 4 W D operation, t h e front drive
J9016-19
shaft (Figs. 1 and 2) is connected t o t h e f r o n t axle
Fig. 2 Front Drive Shaft (4WD) drive p i n i o n gear shaft yoke v i a a n i n t e r n a l l y - s p l i n e d
slip yoke and a single cardan U-joint coupler (Fig. 3),
and to t h e transfer case o u t p u t shaft yoke w i t h a
BEARING
double cardan (CV) j o i n t coupler (Fig. 4 ) .

VIBRATION

VIBRA TION SOURCES

BEARING
CAP
J8916-1
Fig. 3 Single Cardan U-Joint
• eight sets o f spider needle bearings,
• sixteen bearing seals,
• eight b e a r i n g caps and r e t a i n i n g clips, a n d
• one d r i v e shaft yoke.
Capscrews are used to a t t a c h the socket yoke t o the
transfer case output shaft flange.
VEHICLE CONFIGURATION
The rear drive shaft (Fig. 1) is connected t o b o t h
t h e drive p i n i o n gear shaft (axle) yoke and t h e t r a n s -
mission (or t h e transfer case) o u t p u t shaft v i a a sin-
gle cardan U-joint coupler ( F i g . 3). A n i n t e r n a l l y -
splined, slip-yoke type U-joint coupler is also located
at the transmission (or the transfer case) end o f t h e
shaft.
Objectional v i b r a t i o n , w h i l e t r a v e l i n g o n roads/
streets w i t h a "good" surface, can o r i g i n a t e a t the fol-
l o w i n g locations:
• wheels/tires/brake drums;
• engine/mounts/engine accessories;
• clutch/torque converter/transmission; a n d
• drive shaft/U-joints/axle yoke.
Tires t h a t are "out-of-round" (i.e., r a d i a l " r u n o u t " )
or wheels/tires t h a t are excessively unbalanced w i l l
cause a l o w frequency v i b r a t i o n t h a t w i l l induce
p r o m i n e n t m i r r o r a n d door "shake". T i r e and/or
wheel faults m u s t be corrected before proceeding
w i t h t h e diagnosis. I f necessary, refer to Group
22—Tires A n d Wheels for service i n f o r m a t i o n .
B r a k e drums t h a t are excessively unbalanced w i l l
a cause harsh, low frequency v i b r a t i o n . Refer to
Group 5—brakes for service i n f o r m a t i o n .
Engine v i b r a t i o n faults can be located b y accelerat-
i n g t h e engine (transmission i n " N E U T R A L " )
t h r o u g h the speed range a n d n o t i n g t h e speed w h e n
(if) the v i b r a t i o n occurs.
Refer t o Group 21—Transmissions f o r service infor-
m a t i o n i n v o l v i n g transmissions and transfer cases.
D r i v e shaft/U-joint (driveline) v i b r a t i o n w i l l i n -
crease i n i n t e n s i t y as the vehicle speed is increased
and i t is not sensitive to engine torque. A v i b r a t i o n
t h a t occurs w i t h i n a specific speed range ((e.g., 55 to
65 m p h or 88 to 105 km/h) and does not occur above
t h a t speed range is n o t caused by d r i v e shaft unbal-
ance. Defective U-joints or a n incorrect drive shaft
angle are usually the cause of v i b r a t i o n t h a t occurs
w i t h i n a specific speed range.
 16-4 DRIVE SHAFTS AND UNIVERSAL JOINTS •
DRIVELINE VIBRATION CAUSES • cracked seam welds a t either end o f t h e d r i v e shaft
D r i v e l i n e v i b r a t i o n can be caused b y t h e drive tube, or
shaft, d r i v e p i n i o n gear shaft (axle) yokes, U-joints, • dents o r bends i n t h e d r i v e shaft t u b e .
or a n incorrect U-joint angle. V i b r a t i o n f r o m the drive p i n i o n gear shaft (axle)
V i b r a t i o n caused b y the drive shaft(s) can be t h e yoke can be the result of:
• excessive yoke " r u n o u t " ,
result of:
• loose clamp screws, or
• undercoating m a t e r i a l on the drive shaft tube(s),
• damaged yoke.
• missing drive shaft balance weight,
A n incorrect U-joint angle can produce a n out-
• excessive drive shaft " r u n o u t " , of-phase condition w i t h i n t h e U-joint t h a t results i n
• w o r n o r damaged drive shaft yokes or U-joints, v i b r a t i o n a t low or h i g h vehicle speeds.
DRIVELINE VIBRATION

Drive Condition Possible Cause Correction

DRIVE SHAFT VIBRATION 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 bolt.
f. Worn U-joint bearings. f. Replace U-joint.
9- Drive shaft damaged (bent tube) or out 9* Install replacement drive shaft..
of balance.
h. Broken rear spring. h. Replace rear spring.
i. Excessive runout or unbalanced condition. i. Reindex drive shaft 180°, test and correct as
necessary.
i- Excessive drive pinion gear shaft yoke i- Reindex drive shaft 180° and evaluate.
runout.
UNIVERSAL JOINT NOISE a. U-joint clamp screws loose. a. Tighten screws with specified torque.
b. Lack of lubrication. b. Replace U-joint.
J9016-5
D r i v e l i n e v i b r a t i o n c a n also r e s u l t f r o m loose DRIVELINE VIBRATION DIAGNOSIS
o r d a m a g e d crossmembers, s u p p o r t cushions, W h e n a driveline v i b r a t i o n condition exists, do not
leaf springs a n d d r i v e l i n e r e t a i n i n g bolts/nuts. i n i t i a t e corrective action u n t i l t h e a c t u a l source of
Refer t o G r o u p 2 2 - T i r e s A n d Wheels f o r addi- the v i b r a t i o n has been identified. T h i s i s very impor-
t i o n a l i n f o r m a t i o n i n v o l v i n g v i b r a t i o n diagnosis. t a n t i f unnecessary or ineffective repairs are t o be
avoided. T h e following diagnosis charts w i l l help to
identify t h e most common causes o f d r i v e l i n e v i b r a -
tion.
 DRIVE SHAFTS AND UNIVERSAL JOINTS 16 -

DRIVELINE VIBRATION DIAGNOSIS

STEP SEQUENCE RESULT

WHEEL/TIRE CONDITION CORRECTION NEEDED—( Q | C

1. INSPECT FOR BENT, CRACKED WHEELS ROAD TEST 1

AND CUPPED OR DAMAGED TIRES.

2. INSPECT TOR MISMATCHED TIRE SIZES
CORRECTION
OR TREAD PATTERNS.
NOT NEEDED
3. CHECK AND CORRECT TIRE INFLATION
PRESSURES AS NEEDED. / v>\ CORRECTION
4. ROAD TEST IF REPAIR OR R E P l A C B v ^ N T - ^ c ^ ^ J NEEDED—
WAS NEEDED. ROAD TEST

ROAD TEST r— VIBRATION GONE OK

O DRIVE 5-10 MPH (8-17 KM/H) ABOVE THE VIBRATION

RANGE — SHIFT TO NEUTRAL, AND
LET THE ENGINE IDLE AND COAST
THROUGH THE VIBRATION RANGE. ROAD
VIBRATES DURING
COAST

VIBRATION STOPS
TEST DURING COAST
(IN NEUTRAL)

WHEEL/TIRE BALANCE
ADD BALANCE ADD BALANCE
WEIGHTS HERE WEIGHTS HERE

o
HEAVY
?SPOT

TIRE OR WHEEL TRAMP,

SPINDLE
CORRECTIVE WEIGHT HEAVY SPOT WHEEL
? OF SPINDLE
TO
CORRECTIVE WEIGHT
OR WHEEL HOP LOCATION SHIMMY AND VIBRATION LOCATION
STATIC UNBALANCE DYNAMIC UNBALANCE
IF CORRECTION OK STOP
WAS NEEDED-
CORRECT AS NECESSARY AND ROAD REPEAT ROAD TEST
TEST (MAX. WHEEL WEIGHT ALLOWANCE ROAD TEST OR
IS 10 OZ. (283 GRAMS) NO CORRECTION
NEEDED.

J8916-11
6 DRIVE SHAFTS AND UNIVERSAL JOINTS

DRIVELINE VIBRATION DIAGNOSIS (CONT'D)

MEASURE THE
TIRE RUNOUT TIRE RADIAL RUNOUT 0.060 IN (2 MM)

TIRE LATERAL RUNOUT 0.100 IN (2.5 MM)

RADIALLY

WHEEL RUNOUT LATERAL/RADIAL

0.045 IN (1.1 MM)
DIAL

LATERALLY INDICATOR NO CORRECTION ( ^

NEEDED 1 m

WHEEL RUNOUT
MEASURE THE
LATERALLY
CORRECTION
NEEDED

REPAIR OR
REPLACE AS
NECESSARY

RADIALLY

OBSERVE THE FRONT DRIVE 1. REMOVE THE REAR DRIVE SHAFT

• SHAFT OPERATION (MARK THE SHAFT AND AXLE YOKE
FOR ASSEMBLY REFERENCE).
2. ROAD TEST WITH THE TRANSFER CASE
IN4H.

NO VIBRATION

E 0
ROAD TEST OR NOTICEABLY
REDUCED
NO CHANGE IN
VIBRATION LEVEL

INSPECT THE REAR DRIVE

SHAFT CONDITION

WORN, BINDING WORN, LOOSE BENT EXCESSIVE

BRINELLED BINDING SLIP TUBE PAINT OR REPAIR OR REPLACE SHAFT
U-JOINTS YOKE UNDERCOATING
ON TUBE ROAD TEST

J8916-12
 DRIVE SHAFTS AND UNIVERSAL JOINTS 16

DRIVELINE VIBRATION DIAGNOSIS (CONT'D)

STEP SEQUENCE RESULT

MEASURE THE FRONT DRIVE PINION GEAR SHAFT AND

TRANSFER CASE YOKE RUNOUT WITH A DIAL INDICATOR

IF THE RUNOUT IS EXCESSIVE, REINDEX THE YOKE

REFER TO THE APPLICABLE SPECIFICATION
AND AAEASURE THE RUNOUT. REPLACE THE YOKE IF
CHART FOR THE AAAXIMUM ALLOWABLE
REINDEXING DOES NOT CORRECT THE RUNOUT.*
RUNOUT AT EITHER YOKE.
INSTALL THE DRIVE SHAFT.

OK »^STOPJ
ROAD TEST

•THE REPLACEMENT YOKE RUNOUT SHOULD

BE MEASURED ALSO.
O
AAEASURE THE REAR DRIVE SHAFT
RUNOUT WITH A DIAL INDICATOR. C^)—

REINDEX THE SHAFT

180° AND AAEASURE
THE RUNOUT.

REFER TO THE APPLICABLE SPECIFICATION CHART

FOR THE AAAXIMUM ALLOWABLE RUNOUT OF THE SHAFT.

J8916-13
- 8 DRIVE SHAFTS AND UNIVERSAL JOINTS

DRIVELINE VIBRATION DIAGNOSIS (CONT'D)

STEP SEQUENCE RESULT

AAEASURE THE REAR DRIVE PINION GEAR SHAFT

UPWARD ANGLE AND ENGINE DOWNWARD ANGLE WITH
.AN INCLINOMETER
(H)—

ADJUST ANGLES
AS NEEDED

f
ROAD TEST OK

REFER TO THE APPLICABLE SPECIFICATION

CHART. USE APPROPRIATE SHIMS TO CORREC-
T S ANGLE

OBSERVE THE REAR DRIVE 1. REMOVE THE FRONT DRIVE SHAFT

SHAFT OPERATION (AAARK THE SHAFT AND AXLE YOKES FOR
ASSEMBLY REFERENCE).
2. ROAD TEST WITH THE TRANSFER CASE
IN 4H.

ROAD TEST NO VIBRATION OR

o
NOTICEABLY REDUCED

NO CHANGE IN
THE VIBRATION LEVEL"

INSPECT THE FRONT DRIVE

SHAFT CONDITION

o WORN, BINDING WORN, LOOSE

BRINELLED BINDING
BENT
TUBE
EXCESSIVE PAINT
OR UNDERCOATING REPAIR OR
U-JOINT SLIP YOKE ON TUBE REPLACE THE SHAFT

ROAD TEST

J8916-14
 DRIVE SHAFTS AND UNIVERSAL JOINTS 16

DRIVELINE VIBRATION DIAGNOSIS (CONT'D)

SUP SEQUENCE RESULT

AAEASURE THE REAR DRIVE PINION GEAR SHAFT AND TRANSFER CASE
YOKE RUNOUT WITH A DIAL INDICATOR

DIAL INDICATOR

O IF THE RUNOUT IS EXCESSIVE, REINDEX

THE YOKE AND AAEASURE THE RUNOUT. REPLACE
THE YOKE IF REINDEXING DOES NOT CORRECT
THE RUNOUT.* INSTAl^THE DRIVE SHAFT.

REFER TO THE APPLICABLE ROAD TEST

SPECIFICATION CHART FOR
THE AAAXIAAUAA ALLOWABLE RUNOUT.

•THE REPLACEAAENT YOKE RUNOUT

SHOULD BE AAEASURED ALSO

AAEASURE THE FRONT DRIVE SHAFT

RUNOUT WITH A DIAL INDICATOR

REINDEX SHAFT 1 8 0 °

REFER TO THE APPLICABLE SPECIFICATION

CHART FOR THE AAAXIAAUAA ALLOWABLE RUNOUT
OF THE SHAFT.

AAEASURE THE FRONT DRIVE PINION NOTE: THE FRONT ANGLES ARE AAEASURED
GEAR SHAFT AND FRONT DRIVE SHAFT WITH THE SAME PROCEDURES AS REAR ANGLES.
ANGLES WITH AN INCLINOAAETER REFER TO THE APPLICABLE MEASUREMENT
PROCEDURE. RECORD THE AAEASUREAAENTS.

O REFER TO THE APPLICABLE ROAD

SPECIFICATION CHART FOR THE TEST
FRONT ANGLE. USE APPROPRIATE
SHIAAS TO OBTAIN THE CORRECT STOP
ANGLE

J8916-15
 16 - 10 DRIVE SHAFTS AND UNIVERSAL JOINTS
SERVICE PROCEDURES
INDEX
Page
Drive Shaft Measurements 10
Drive Shaft Operating Angle Measurement 12
Drive Shaft—Removal/Installation . . . . . . . . . . . . . 17
Rear Axle and Axle Yoke Horizontal Measurement . 16
Rear Drive Shaft Center Bearing Service 20
SERVICE INFORMATION
PRECAUTIONS
D r i v e shafts are balanced b y t h e manufacturer t o
prevent v i b r a t i o n , therefore, before undercoating a
vehicle, the drive shaft a n d t h e U-joints should be
covered to prevent t h e undercoating m a t e r i a l from
attaching t o t h e shaft a n d t h e U-joints a n d causing
a n unbalanced condition (and v i b r a t i o n ) .
Replacement o f the drive shaft a t t a c h i n g fasteners
(e.g., screws, bolts, n u t s a n d clamps) w i t h exact re-
placements is essential for safe vehicle operation. A l -
ways replace t h e a t t a c h i n g fasteners w i t h those t h a t
have identical p a r t numbers (or w i t h equivalent at-
t a c h i n g fasteners) w h e n replacement is necessary. I n
addition, the specified torque m u s t always be applied
w h e n t i g h t e n i n g t h e fasteners d u r i n g drive shaft i n -
stallation.
LUBRICATION
The rear a n d f r o n t drive shaft single cardan U -
j o i n t s require periodic l u b r i c a t i o n . The single cardan
U-joints have a " Z e r k " type l u b r i c a t i o n f i t t i n g lo-
cated on one b e a r i n g cap (Figs. 1 a n d 2). The front
drive shaft slip yoke has a " Z e r k " type lubrication
f i t t i n g located o n t h e tube r e a r w a r d of the yoke.
The double cardan (CV) j o i n t (Figs. 1 a n d 2) at-
tached to the f r o n t drive shaft (4WD vehicles) is per-
manently lubricated when assembled during
manufacture a n d does not r e q u i r e a d d i t i o n a l lubrica-
t i o n d u r i n g i t s service life, b u t i t can be lubricated
w h e n disassembled ( i f necessary). T h e C V j o i n t
should be inspected for seal external leakage and
damage each t i m e t h e vehicle is serviced. I f seal ex-
t e r n a l leakage or damage exists, t h e C V j o i n t should
be replaced t o avoid eventual failure.
F o r vehicles w i t h a n extended wheelbase, the b a l l -
type, center support bearing is permanently l u b r i -
cated when assembled d u r i n g manufacture and does
not require a d d i t i o n a l l u b r i c a t i o n d u r i n g i t s service
life.
A l l CV/U-joints s h o u l d b e i n s p e c t e d f o r seal ex-
t e r n a l leakage a n d damage each time t h e vehicle
is s e r v i c e d . I f seal e x t e r n a l l e a k a g e o r d a m a g e
•
Page
Service Information 10
Slip Yoke Service 20
U-Joint Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
U-Joint Yoke Bore Alignment Measurement 12
exists, t h e U - j o i n t s h o u l d b e r e p a i r e d / r e p l a c e d
(as a p p l i c a b l e ) t o a v o i d e v e n t u a l f a i l u r e .
A n extreme-pressure (EP), l i t h i u m - b a s e type l u b r i -
cant should be used t o l u b r i c a t e a l l areas t h a t are
designated t o be l u b r i c a t e d a t specified time/distance
intervals. Refer t o Group 0 — L u b r i c a t i o n A n d M a i n -
tenance for a d d i t i o n a l i n f o r m a t i o n i n v o l v i n g lubrica-
tion.
No adjustments a r e p r o v i d e d t o compensate
f o r w e a r o f t h e U - j o i n t c o m p o n e n t s . W h e n exces-
sive " p l a y " e x i s t s b e t w e e n t h e s p i d e r a n d t h e
needle b e a r i n g s , t h e U - j o i n t o r c o m p o n e n t s
should b e repaired/replaced t o avoid eventual
failure.
DRIVE SHAFT MEASUREMENTS
UNBALANCE
I f drive shaft unbalance is suspected, i t can be ver-
ified (and t h e drive shaft balanced) w i t h t h e follow-
i n g procedure.
(1) Raise a n d support t h e vehicle.
(2) Clean a l l t h e foreign m a t e r i a l from t h e drive
shaft a n d t h e U-joints (e.g., m u d , road spray, under-
coating, etc.).
(3) Inspect t h e d r i v e shaft for:
• missing balance weights,
• broken welds,
• bent areas, a n d
• dents.
I f the d r i v e shaft tube o r y o k e is bent, i t must
be r e p l a c e d .
(4) E n s u r e t h a t t h e U - j o i n t spiders a n d needle
bearings are n o t w o r n , t h a t t h e U-joint b e a r i n g caps
are properly i n s t a l l e d , a n d t h a t each U-joint is cor-
rectly aligned w i t h t h e shaft (i.e., t h e yoke is n o t
bent or distorted).
(5) Measure t h e torque and, i f necessary, r e - t i g h t e n
the U-joint clamp screws.
(6) Remove t h e wheel covers a n d the wheels/tires.
I n s t a l l t h e w h e e l l u g n u t s t o r e t a i n the brake drums
i n place.
( 7 ) M a r k t h e drive shaft tube a t four positions
spaced a t 9 0 ° i n t e r v a l s a r o u n d t h e circumference of
the tube (approximately six inches i n w a r d from t h e
 + DRIVE SHAFTS AND UNIVERSAL JOINTS 18 - 11

yoke weld a t the axle end o f t h e d r i v e shaft tube).

N u m b e r t h e m a r k e d positions 1 t h r o u g h 4.
(8) Connect a tachometer t o t h e engine i g n i t i o n .
S t a r t the engine, shift t h e transmission i n t o f o r w a r d
gear and accelerate the engine u n t i l v i b r a t i o n occurs.
N o t e the a m o u n t (intensity) o f v i b r a t i o n , observe the
tachometer a n d note the engine speed (rpm) at w h i c h
t h e v i b r a t i o n occurred. Stop t h e engine.
(9) I n s t a l l a n d t i g h t e n a " w o r m - d r i v e screw" type

Fig. 5 Clamp Screw At Position "1"

hose clamp on the drive shaft w i t h t h e screw located
a t p o s i t i o n " 1 " (Fig. 5).
(10) S t a r t t h e engine, s h i f t t h e transmission i n t o
forward gear and accelerate t h e engine t o t h e speed
(rpm) at w h i c h the v i b r a t i o n occurred (above).
(11) Compare the a m o u n t (intensity) o f v i b r a t i o n t o
t h e i n i t i a l a m o u n t (intensity) o f v i b r a t i o n . I f there is
l i t t l e or no change i n the v i b r a t i o n , move the clamp
screw to one o f the other three m a r k e d positions and
repeat the v i b r a t i o n test.
(12) I f no difference i n t h e a m o u n t (intensity) o f v i -
b r a t i o n is detected w i t h t h e clamp screw located a t
a l l four positions, t h e v i b r a t i o n possibly is n o t be
caused by drive shaft unbalance.
(13) I f t h e amount (intensity) o f v i b r a t i o n de-
creased (but was not completely eliminated) w i t h the
clamp screw located a t one o f the m a r k e d positions,
i n s t a l l a second clamp o n t h e drive shaft tube w i t h
t h e screw adjacent to t h e f i r s t clamp screw (Fig. 6)
a n d repeat the v i b r a t i o n test.
(14) The combined w e i g h t o f two clamp screws a t
t h e same position could cause a n additional u n b a l -
anced condition. I f so, separate the clamp screws ap-
proximately 1/2 i n c h (1/4 i n c h above a n d 1/4 i n c h
below the m a r k e d position) a n d repeat the v i b r a t i o n
test (Fig. 7).
(15) Continue t o increase t h e separation distance
between the clamp screws a n d repeat the v i b r a t i o n
test u n t i l t h e amount ( i n t e n s i t y ) of v i b r a t i o n is a t
the lowest level. Bend the loose end o f the clamps so
t h a t the clamp screws w i l l n o t loosen.
RF489
Fig. 7 Clamp Screws Separated
(16) I n s t a l l t h e wheels/tires and the wheel covers.
Remove the supports, lower the vehicle and road test.
(17) I f the a m o u n t (intensity) of v i b r a t i o n remains
unacceptable, apply t h e same instructions (above) a t
t h e f r o n t end of t h e drive shaft.
RUNOUT
(1) Remove a l l d i r t , rust, paint, and undercoating
f r o m t h e drive shaft tube surface areas where t h e
d i a l indicator p l u n g e r w i l l contact the surface o f the
drive shaft tube.
(2) T h e d i a l i n d i c a t o r m u s t be installed perpendic-
u l a r to the shaft t u b e surface and must be f i r m l y at-
tached to a fixed surface to prevent inaccurate
measurements.
(3) Measure t h e d r i v e shaft r u n o u t a t t h e center
and a t both ends o f t h e shaft tube w i t h the d i a l i n -
dicator.
(4) Refer t o t h e D r i v e Shaft Runout Specifications
chart.
(5) Replace t h e d r i v e shaft i f the r u n o u t exceeds
the specified l i m i t a t either the front, center or rear
of the shaft tube.
 16 - 12 DRIVE SHAFTS AND UNIVERSAL JOINTS
DRIVE SHAFT RUNOUT SPECIFICATIONS
RAM TRUCK AND RAMCHARGER VEHICLES
Front of shaft. . 0.015 in. (0.38 mm)
Center of shaft . 0.015 in. (0.38 mm)
Rear of shaft 0.015 in. (0.38 mm)
NOTE: Measure front/rear runout approximately 3 inches (76
mm) from the weld seam at each end of the shaft tube.
J8916-16
U-JOINT YOKE BORE ALIGNMENT MEASUREMENT
SERVICE INFORMATION
Correct cross-alignment o f t h e f r o n t U-joint slip
yoke bores, b o t h shaft yoke bores and the drive p i n -
i o n gear shaft yoke "saddles" is very i m p o r t a n t t o
prevent drive shaft v i b r a t i o n , U-joint wear and other
vehicle performance problems. Before measuring the
drive shaft v e r t i c a l a n d horizontal angles for possible
mis-alignment, i t i s necessary to determine t h a t a l l
t h e i n d i v i d u a l yoke bores are correctly cross-aligned
(i.e., " t r u e " f r o m bore-to-bore). A l s o , e n s u r e t h a t t h e
axle drive p i n i o n gear shaft yoke n u t is tight-
e n e d c o r r e c t l y (i.e., t h e b e a r i n g " p r e l o a d " t o r q u e
is c o r r e c t ) .
The center lines o f the U - j o i n t spider bearing bores
i n b o t h yoke a r m s (for drive shafts tubes t h a t have
welded yokes a t each end) are p e r m a n e n t l y aligned
(i.e., t h e bores a r e fixed i n t h e same plane) d u r i n g
manufacture.
W h e n a drive shaft has e x t e r n a l splines a t one end
(instead of a yoke) t h a t mate w i t h a n i n t e r n a l l y -
splined slip yoke, t h e slip yoke must be installed so
t h a t t h e center l i n e o f its spider bearing bores i n the
yoke arms is a l i g n e d (i.e., i n t h e same plane) w i t h
t h e center l i n e o f t h e welded yoke a r m bores a t the
opposite end o f t h e drive shaft tube. T h e yoke a r m
bore a l i g n m e n t is accomplished by h a v i n g a double-
w i d t h master spline (tooth) w i t h i n the drive shaft ex-
t e r n a l splines t h a t mates (indexes) w i t h a double-
w i d t h space w i t h i n t h e slip yoke i n t e r n a l splines.
•
A drive shaft w i t h a slip yoke is correctly aligned
w h e n the yoke arms (and bores) a t each end o f t h e
shaft are i n t h e same plane (Fig. 8).
MEASUREMENT WITH A GAUGE BAR
Use a s t r a i g h t piece o f round, stock m e t a l w i t h t h e
same outside diameter (OD) as the yoke bore diame-
ter for a " s l i p f i t " gauge bar.
(1) Remove t h e b e a r i n g caps and t h e spider f r o m
the yoke. I f necessary, refer t o U - J o i n t S e r v i c e for
the procedure.
(2) I n s e r t the gauge bar i n t o one yoke a r m bore (or
"saddle") and continue i t t o the other yoke a r m bore
(or "saddle").
(3) I f the gauge b a r w i l l " s l i p f i t " t h r o u g h b o t h
yoke bores (or "saddles") simultaneously, t h e bores
are p r o p e r l y cross-aligned (i.e., " t r u e " ) and t h e yoke
arms are n o t distorted, twisted or otherwise m i s -
aligned.
(4) W h e n t h e gauge b a r passes t h r o u g h one yoke
a r m bore (or "saddle"), b u t t h e n contacts t h e i n n e r
face o f the opposite yoke a r m , the yoke arms are m i s -
aligned (i.e., distorted or twisted) and t h e yoke (or
drive shaft) m u s t be replaced.
MEASUREMENT WITH A PROTRACTOR
I n t h e event a gauge bar w i t h the correct diameter
is not available, yoke mis-alignment can be measure-
m e n t w i t h a level protractor according to the follow-
i n g instructions.
(1) Remove the b u r r s or nicks f r o m the yoke a r m
outer surfaces a n d the machined surface o f the nee-
dle b e a r i n g caps.
(2) Rotate the yoke so t h a t the bores i n the arms
are horizontal.
(3) Position t h e level protractor v e r t i c a l l y o n one
yoke a r m outer surface (or on the machined surface
of a b e a r i n g cap) and adjust t h e protractor so t h a t
the scale indicates zero or 90 degrees w h e n the bub-
ble is centered between the two m a r k s o n the tube.
(4) Position the level protractor a t same location on
the opposite yoke a r m (or bearing cap) and note the
position o f the bubble.
(5) I f necessary, adjust the scale so t h a t the bubble
is exactly between the m a r k s on the tube, and, i f the
bubble moves more t h a n 1/2 of-a-degree, the yoke i s
l i k e l y t o be distorted and should be replaced.
DRIVE SHAFT OPERATING ANGLE MEASUREMENT
AND ADJUSTMENT
VERTICAL ANGLES (ONE-PIECE DRIVE
SHAFT)
MEASUREMENT
(1) Shift the transmission into N E U T R A L position.
 • DRIVE SHAFTS AND UNIVERSAL JOINTS 16 - 13

Fig. 8 Drive Shaft Yoke Arm Bores Aligned in Same Plane

(2) Raise t h e vehicle on a t w i n post o r a s i m i l a r
type hoist t h a t w i l l support the vehicle a t the axles
and allow t h e wheels to be rotated.
I f a drive-on type (platform) hoist is used,
place s u p p o r t stands u n d e r each axle shaft t u b e
and lower the hoist until the wheels w i l l rotate
freely.
(3) Rotate t h e rear drive shaft u n t i l one o f t h e
d r i v e p i n i o n gear shaft (axle) yoke b e a r i n g caps is
facing downward.
(4) A t t a c h t h e magnet of a n inclinometer o n t h e
bearing cap and note the angle (Fig. 9). This is t h e
axle drive p i n i o n gear shaft angle.
(5) Rotate t h e rear drive shaft u n t i l one o f t h e
shaft rear yoke bearing caps is facing downward.
(6) A t t a c h the inclinometer magnet to the bearing
cap and note the angle.
T h e i n c l i n o m e t e r f r a m e a n d d e g r e e scale m u s t
f a c e t h e s a m e d i r e c t i o n (i.e., e i t h e r v e h i c l e - l e f t o r
vehicle-right) f o r b o t h measurements. (J23498A) J8916-34
(7) The difference between t h e t w o angles is t h e
d r i v e shaft rear angle " B " (Fig. 10). Fig. 9 Drive Pinion Gear Shaft Angle Measurement
(8) Rotate t h e drive shaft u n t i l one o f t h e slip yoke (10) Rotate t h e rear drive shaft u n t i l one o f t h e
b e a r i n g caps is facing downward. shaft front yoke bearing caps i s facing downward.
(9) A t t a c h the inclinometer magnet to the b e a r i n g (11) A t t a c h the inclinometer magnet t o the b e a r i n g
cap and note t h e angle (Fig. 11). T h i s i s the t r a n s - cap and note the angle.
mission o u t p u t shaft angle.
16 - 14 DRIVE SHAFTS AND UNIVERSAL JOINTS
.A
Fig. 10 Drive Shaft Front & Rear Angles
BEARING
CAP
MAGNET
7663
(J23498A)
Fig. 11 Transmission/Transfer Case Output Shaft
Angle Measurement
T h e i n c l i n o m e t e r f r a m e a n d d e g r e e scale m u s t
face t h e s a m e d i r e c t i o n (i.e., e i t h e r v e h i c l e - l e f t o r
vehicle-right) f o r b o t h measurements.
(12) T h e difference between the t w o angles i s t h e
drive shaft f r o n t angle " A " (Fig. 10).
(13) Compare t h e drive shaft rear angle " B " a n d
the f r o n t angle " A " (Fig. 10). The difference between
the t w o angles is the drive shaft v e r t i c a l angle (i.e.,
angle " A " m i n u s angle "B").
J9016-27
(14) T h e drive shaft v e r t i c a l angle should be a
m a x i m u m o f plus or m i n u s one degree (±1°); other-
wise, t h e drive shaft is v e r t i c a l l y misaligned. I f nec-
essary, adjustment of t h e axle d r i v e p i n i o n gear shaft
vertical angle w i l l n o r m a l l y correct t h e m i s a l i g n -
ment. T h e adjustment i s accomplished b y i n s t a l l i n g
tapered shims between t h e rear springs and the axle
spring pads.
(15) I f t h e drive shaft v e r t i c a l angle is correct, t h e
axle drive p i n i o n gear shaft angle should also be cor-
rect.
(16) A n incorrect drive shaft v e r t i c a l angle is gen-
erally caused by rear axle d r i v e p i n i o n gear shaft
yoke mis-alignment. I f t h e d r i v e p i n i o n gear shaft
yoke is mis-aligned, inspect for loose spring-to-axle
U-bolts, w h i c h w o u l d allow t h e axle tubes to rotate
on t h e springs. Also, inspect for b r o k e n springs, a n d
w o r n s p r i n g shackles, brackets a n d bushings. Repair
or replace as necessary t o correct t h e mis-alignment.
J8916-23 VERTICAL OPERATING ANGLES (TWO-PIECE
DRIVE SHAFT)
A l l o f the drive shaft U-joints m u s t operate a t t h e
correct angle to prolong t h e life o f t h e bearings. T h e
U-joint operating angles w i l l differ according t o t h e
half-shaft length. Also, t h e f r o n t half-shaft m u s t be
p a r a l l e l to the rear axle d r i v e p i n i o n gear shaft.
The front half-shaft and t h e rear half-shaft m u s t be
offset b y a m i n i m u m o f 1/2 of-a-degree from t h e
transmission/transfer case o u t p u t shaft a n d f r o m
each other.
The center U-joint operating angle can be adjusted
by replacing t h e center b e a r i n g support. A d j u s t i n g
the rear U-joint operating angle is accomplished b y
 • DRIVE SHAFTS AND UNIVERSAL JOINTS
i n s t a l l i n g tapered shims between t h e rear springs
and t h e o f rear axle spring pads.
MEASUREMENT
(1) Shift t h e transmission t o t h e N E U T R A L posi-
tion.
(2) Raise t h e vehicle on a t w i n post or a s i m i l a r
type hoist t h a t w i l l support the vehicle a t t h e axles
and allow the wheels t o be rotated.
I f a drive-on type (platform) hoist i s used,
place s u p p o r t stands u n d e r each axle shaft t u b e
a n d lower t h e hoist u n t i l t h e wheels w i l l rotate
freely.
(3) Rotate the rear drive shaft u n t i l the t r a n s m i s -
sion/transfer case yoke is i n t h e vertical position
(Fig. 12).
(4) Place a level protractor o n the front yoke and
bearing cap " A " (parallel t o t h e drive shaft). Adjust
t h e protractor so t h e bubble i n spirit level i s cen-
tered. Note the angle on the protractor scale.
(5) Repeat t h e same measurement procedure
(above) for the center yoke and bearing cap " B " , and
for the rear yoke and bearing cap "C". Note b o t h an-
gles o n t h e protractor scale.
(6) Excessive v a r i a t i o n i n measured angles " A " ,
" B " and " C " indicates drive shaft vertical m i s - a l i g n -
ment. T h e vertical a l i g n m e n t o f two-piece drive
shafts a t t h e yokes should be greater t h a n one-half
degree (1/2°) and retained as close t o one dfegree (1°)
as possible.
(7) D r i v e shaft v i b r a t i o n t h a t is not associated w i t h
unbalance or " r u n o u t " (e.g., decreasing or increasing
as engine speed increases) i s h i g h l y responsive t o
rear axle drive p i n i o n gear shaft yoke angle adjust-
YOKES MUST BE IN SAAAE PLANE
Fig. 12 Vertical Angle Measurement— Two-Piece Drive Shaft
16 - 16
ment. T h i s includes t h e center b e a r i n g support
l e n g t h adjustment for two-piece d r i v e shafts.
(8) A d j u s t m e n t o f the drive p i n i o n gear shaft yoke
v e r t i c a l angle is accomplished b y i n s t a l l i n g tapered
shims between t h e rear springs a n d t h e rear axle
spring pad, and/or correcting the center b e a r i n g sup-
port bracket length.
VERTICAL ANGLE ADJUSTMENT
The d r i v e shaft v e r t i c a l angle (i.e., angle " A " m i -
nus angle " B " , F i g . 10) i s controlled b y t h e axle drive
p i n i o n gear shaft angle. The axle d r i v e p i n i o n gear
shaft angle is adjusted between t h e rear springs and
the axle w i t h tapered shims. Tapered shims are com-
m e r c i a l l y available from automotive parts supply
sources.
I f t h e v e r t i c a l angle is not correct a t t h e transmis-
sion (or transfer case) a n d t h e vehicle i s equipped
w i t h a two-piece drive shaft, the center bearing sup-
port should be inspected for the correct l e n g t h . Shims
can be inserted between t h e support bracket a n d
frame crossmember t o correct mis-alignment, i f nec-
essary.
If angle " A " m i n u s angle " B " is greater t h a n
o n e d e g r e e p o s i t i v e ( > +1°), a n g l e " B " ( F i g . 10) i s
too small a n d must be increased.
W h e n angle " B " (Fig. 10) is too s m a l l , i t can be i n -
creased b y decreasing t h e axle d r i v e p i n i o n gear
shaft angle.
If angle " A " m i n u s angle " B " i s greater t h a n
o n e d e g r e e n e g a t i v e ( > - l ° ) ; a n g l e " B " ( F i g . 10) i s
too large a n d m u s t b e decreased.
J9016-26
16 - 16 DRIVE SHAFTS AND UNIVERSAL JOINTS •
W h e n angle " B " (Fig. 10) i s too large, i t can be de- (3) C l a m p t h e long straightedge a t r i g h t (90°) a n -
creased b y increasing t h e axle drive p i n i o n gear gles t o t h e frame r a i l s (Fig. 13). To verify, measure
shaft angle. the 9 0 degree angle w i t h t h e large carpenter's
(1) Raise t h e rear o f the vehicle and place support square.
stands under t h e frame.
(2) Position a h y d r a u l i c j a c k under t h e d i f f e r e n t i a l
housing a n d raise the j a c k j u s t enough t o support t h e
w e i g h t o f the axle.
(3) Remove t h e rear wheels/tires.
(4) Loosen t h e s p r i n g U-bolt nuts.
(5) I n s t a l l tapered shims ( w i t h t h e r e q u i r e d degree
of taper) between t h e springs a n d t h e axle s p r i n g
pads according to t h e following i n s t r u c t i o n s :
• i f angle " B " (Fig. 10) m u s t be increased (i.e., t h e
axle drive p i n i o n gear shaft angle decreased), i n s t a l l
t h e adjustment shims so t h a t t h e t h i c k e n d o f each
s h i m i s facing the front of the vehicle; a n d
• i f angle " B " (Fig. 10) m u s t be decreased (i.e., t h e
axle drive p i n i o n gear shaft angle increased), i n s t a l l
t h e adjustment shims so t h a t t h e t h i c k e n d o f each
s h i m is facing the rear o f the vehicle.
(6) T i g h t e n t h e s p r i n g U-bolt nuts:
• Model 150 a n d 250 vehicles - 6 1 N n n (45 ft-lbs)
torque; a n d Fig. 13 Horizontal Alignment Measurement
• Model 350 vehicles — 149 N n n (110 ft-lbs) torque. (4) C l a m p a short straightedge t o t h e front yoke
(7) Remove t h e h y d r a u l i c jack, i n s t a l l t h e wheels/ arms so t h a t i t is p a r a l l e l to t h e surface (Fig. 13).
tires, remove t h e support stands and lower t h e vehi- V e r i f y t h a t t h e straightedge is level w i t h a s p i r i t
cle. level. I t m u s t be exactly level for accurate measure-
(8) T i g h t e n t h e wheel l u g nuts w i t h t h e specified ments.
torque. Refer t o t h e Torque Specifications c h a r t a t (5) Measure t h e distance " X " between t h e t w o
the end o f Group 22—Tires A n d Wheels for t h e cor- straightedges f r o m both ends o f t h e short s t r a i g h t -
rect torque value. edge w i t h t h e tape measure (Fig. 13). T h e tape m u s t
be h e l d p a r a l l e l to t h e sides of vehicle frame r a i l .
HORIZONTAL ANGLES (6) T h e t w o lengths should be w i t h i n 1/16 of-
I f the drive shaft horizontal angle is n o t zero de-
an-inch (1.58 m m ) of each other. I f t h e y are not, t h e
grees (i.e., the front and rear U-joints are not i n per-
drive shaft front yoke is not properly aligned.
fect l o n g i t u d i n a l alignment), t h e f a u l t i s n o r m a l l y
(7) T h e Horizontal alignment o f ' t h e transmission/
caused b y rear axle misalignment. D r i v e shaft v i b r a -
transfer case yoke can be measured i n same manner
t i o n can also result from rear axle m i s a l i g n m e n t .
as described above, however, substitute a s t r a i g h t
piece o f r o u n d b a r stock for t h e short straightedge.
FRONT YOKE MEASUREMENT
Ensure t h a t t h e b a r fits " s n u g " i n yoke a r m bores.
Horizontal drive shaft a l i g n m e n t is as i m p o r t a n t as
Otherwise, drive a wooden wedge between t h e b a r
vertical alignment. The required tools are:
and t h e yoke shaft.
• straightedge t h a t is 20 to 40 inches (508 t o 1016
m m ) longer t h a n the rear wheel t r a c k (i.e., t h e v e h i -
REAR AXLE AND AXLE YOKE HORIZONTAL
cle w i d t h ) ; MEASUREMENT
• short straightedge;
• t w o large and t w o s m a l l C-clamps; W h e n a vehicle does not t r a c k s t r a i g h t (i.e., "dog-
• r i g i d tape measure; a n d t r a c k s " ) , rear axle mis-alignment is a common cause.
• large carpenter's square. The m i s - a l i g n m e n t usually results f r o m loose spring
(1) Inspect the condition of the engine rear mounts. U-bolt nuts, w h i c h allows the s p r i n g center bolt to be
Worn/loose engine or transmission/transfer case "sheared-off" and the axle spring pad to shift forward
mounts could cause m i s a l i g n m e n t and cause a n erro- or r e a r w a r d on t h e adjacent spring leaf. The exist-
neous measurement. ence o f rear axle mis-alignment can be determined
(2) Position the vehicle on level surface or level t h e by accurately measuring t h e distance from a fixed
vehicle (to eliminate t h e possibility o f a n incorrect point o n t h e frame r a i l to the center l i n e of the axle
measurement). shaft t u b e on each side of the vehicle. I f t h e mea-
 • DRIVE SHAFTS AND UNIVERSAL JOINTS
sured distances are n o t t h e same (or nearly t h e
same), t h e axle i s mis-aligned. A x l e a l i g n m e n t r e -
quires repair or replacement o f t h e s p r i n g a n d t i g h t -
e n i n g t h e U-bolt n u t s w i t h t h e correct torque.
Three causes o f axle horizontal mis-alignment are
possible: " hang from either U-joint during removal. Either at-
• loose or sheared s p r i n g center bolt,
• loose s p r i n g clips, a n d
• loose s p r i n g shackle brackets.
(1) Before inspecting t h e drive p i n i o n gear shaft
(axle) yoke f o r h o r i z o n t a l mis-alignment, measure
t h e rear wheel axle horizontal alignment. A mea-
surement tool can be fabricated f r o m a d r i l l rod.
(2) Fabricate t h e tool from a long piece o f 1/2-inch
(12.7-mm) diameter d r i l l r o d a n d a short piece o f 3/
4-inch (19-mm) diameter r o d w i t h one end ground to
a p o i n t (Fig. 13.)
(3) D r i l l a 1/2-inch (12.7-mm) diameter hole
t h r o u g h t h e 3/4 -inch (19-mm) diameter r o d near t h e
end opposite t h e p o i n t t o accommodate t h e 1/2-inch
(12.7-mm) diameter rod. D r i l l a n d t a p w i t h threads
a n intersecting hole a t t h e same end o f the r o d to a l -
low t h e use o f a s m a l l set screw (Fig. 13).
(4) Measure t h e distance " Y " f r o m the straightedge
to t h e center of the r e a r axle tube at each side o f t h e
vehicle w i t h t h e fabricated measuring tool (Fig. 13).
I f t h e distances v a r y more t h a n approximately 1/8 of-
an-inch (3 m m ) , inspect for one or more of the three
possible causes o f axle h o r i z o n t a l mis-alignment.
(5) Clamp t h e short straightedge to t h e drive p i n -
ion gear shaft (or use a r o u n d b a r and a wedge i f the
p i n i o n gear shaft is equipped w i t h a yoke), so t h a t
the straightedge/bar i s p a r a l l e l t o t h e surface ( F i g .
13). Verify t h a t t h e straightedge/bar is level w i t h a
s p i r i t level.
(6) Measure t h e distance " W " between t h e t w o
straightedges (or straightedge a n d bar) a t each e n d
of t h e short straightedge/bar w i t h the tape measure
(Fig. 13). Ensure t h a t t h e tape i s held p a r a l l e l to t h e
frame r a i l .
(7) T h e t w o distances should be w i t h i n 1/16 of-an-
i n c h (1.58 m m ) o f each other. I n t h e event t h a t t h e y
are not, t h e yoke i s mis-aligned and should be re-
placed.
DRIVE SHAFT— REMOVAL/INSTALLATION
ONE-PIECE REAR DRIVE SHAFT-REMOVAL
There are t w o types o f one-piece drive shafts:
• outboard slip yoke type—used w i t h Model D-150,
D-250 a n d D-350 vehicles equipped w i t h a t r a n s m i s -
sion extension housing; and
• i n b o a r d slip yoke type—used w i t h Model W-150,
W-250 a n d W-350 vehicles (i.e., vehicles equipped
w i t h a transfer case).
(1) Raise a n d support t h e vehicle.
16 - 17
(2) M a r k t h e drive shaft a n d t h e rear axle drive
p i n i o n gear shaft yoke (Fig. 14) for i n s t a l l a t i o n a l i g n -
m e n t reference.
CAUTION: Do not allow the drive shaft to drop or
tach it to the vehicle underside with wire or other-
wise support the loose end of the drive shaft to
prevent damage to the U-joints.
(3) Remove t h e rear U-joint a t t a c h i n g screws a n d
both strap clamps f r o m t h e rear axle d r i v e p i n i o n
gear shaft yoke (Fig. 14).
(4) Before r e m o v i n g the drive shaft slip yoke from
t h e transmission/transfer case output shaft ( F i g . 14),
t h e vehicle front end should be lowered s l i g h t l y t o
prevent loss o f transmission/transfer case f l u i d .
(5) Remove t h e drive shaft slip yoke f r o m t h e
transmission/transfer case output shaft yoke ( F i g . 14)
and remove t h e drive shaft from t h e vehicle. U s e
care to prevent damage to the protective boot
(and t h e d r i v e shaft a n d slip yoke splines).
(6) Examine t h e protective boot for evidence o f
damage. I f no damage is apparent, do n o t d i s t u r b t h e
boot.
CAUTION: It is very important to protect the ma-
chined, external boot contact sealing surface on the
slip yoke and the drive shaft (Fig. 14)) from damage
after the drive shaft has been removed from the ve-
hicle. Otherwise the boot possibly will not seal
properly on a rough, scored/scratched surface.
ONE-PIECE REAR DRIVE
SHAFT-INSTALLATION
(1) Raise and support the vehicle.
CAUTION: Do not allow the drive shaft to drop or
hang from either U-joint during installation. Either
attach it to the vehicle underside with wire or oth-
erwise support the loose end of the drive shaft to
prevent damage to the U-joints.
(2) V i s u a l l y a l i g n t h e drive shaft and d r i v e p i n i o n
gear shaft (axle) yoke i n s t a l l a t i o n reference m a r k s
and connect t h e drive shaft slip yoke to t h e t r a n s m i s -
sion/transfer .case output shaft yoke (Fig. 14).
(3) Position t h e drive shaft rear U-joint spider a n d
bearing caps i n t h e rear axle drive p i n i o n gear shaft
yoke "saddles" (Fig. 14). I n s t a l l t h e strap clamps a n d
screws. T i g h t e n t h e clamp screws w i t h 19 N*m (14 f t -
lbs/170 in-lbs) torque.
(4) Remove t h e supports and lower the vehicle.
TWO-PIECE REAR DRIVE SHAFT-REMOVAL
(1) Raise and support the vehicle.
 - 18 DRIVE SHAFTS AND UNIVERSAL JOINTS

FRAME

FRAME

FRONT
DRIVE SHAFT
CAPSCREW

VIEW B
CONVENTIONAL CAB
FRONT OF TRANSFER CASE
115 INCH (2921 mm)AND 131 lNCH(3327mm)
WHEELBASE
CLAMP
FRONT SCREW

CLAMP
CENTER BEARING. FRONT AXLE
ASSEMBLY DRIVE LUBRICANT FITTING
CENTER BEARING SHAFT
CLAMP SUPPORT BRACKET VIEW A
FRONT AXLE

WASHER

SCREW

CLAMP
FRONT
NUT REAR AXLE
VIEW E BOLT
CREW CAB

LUBRICANT
TRANSMISSION
FITTING REAR DRIVE SHAFT
TRANSFER CASE VIEW D
REAR AXLE
CLAMP
TRANSFER CASE
SHAFT
(TWO PIECE)
FRONT
BOOT, FRAME

FRAME
LUBRICANT
LUBRICANT
FITTING
FITTING
REAR DRIVE SHAFT VIEW C
VIEWC REAR OF TRANSFER CASE
REAR OF TRANSFER CASE INTERMEDIATE DRIVE SHAFT
ONE-PIECE REAR DRIVE SHAFT TWO-PIECE REAR DRIVE SHAFT J9016-17

Fig. 14 Drive Shaft Components

 • DRIVE SHAFTS AND UNIVERSAL JOINTS
(2) M a r k t h e drive shaft and t h e rear axle drive
p i n i o n gear shaft yoke for i n s t a l l a t i o n alignment ref-
erence.
CAUTION: Do not allow the drive shaft to drop or
hang from either U-joint during removal. Either at-
tach it to the vehicle underside with wire or other-
wise support the loose end of the drive shaft to
prevent damage to the U-joints.
CAUTION: Do not disturb the retaining strap used
to retain bearing caps on the rear U-joint spider, if
equipped.
(3) Remove the rear U - j o i n t clamp screws and both
strap clamps f r o m t h e rear axle drive p i n i o n gear
shaft yoke (Fig. 14).
(4) Detach t h e protective boot clamp from t h e front
half-shaft splines a n d slide t h e rear half-shaft slip
yoke from t h e f r o n t half-shaft a t the center bearing.
Remove t h e rear half-shaft f r o m the vehicle (Fig. 15).
(5) E x a m i n e t h e protective boot (Fig. 15) for evi-
dence o f damage. I f no damage is apparent, do n o t
disturb t h e clamp or boot.
(6) I f necessary, detach t h e protective boot clamp
and remove t h e boot from t h e rear half-shaft slip
yoke tube (Fig. 15).
(7) M a r k t h e yokes a t t h e transmission/transfer
case ( F i g . 14) for i n s t a l l a t i o n a l i g n m e n t reference
and remove t h e clamp r e t a i n i n g screws a n d strap
clamps (or flange n u t s i f equipped w i t h a brake).
16-19
(8) Remove t h e t w o center bearing support-
to-bracket r e t a i n i n g n u t s a n d bolts (Fig. 15) a n d r e -
move t h e front half-shaft ( w i t h the center bearing)
from the vehicle.
TWO-PIECE REAR DRIVE
SHAFT-INSTALLATION
(1) Clean a n d lubricate t h e front half-shaft a n d
rear half-shaft slip yoke splines.
(2) Position t h e f r o n t end o f the front half-shaft a t
t h e transmission/transfer case (Fig. 14) and s t a r t t h e
clamp screws a t t h e f r o n t yoke and t h e r e t a i n i n g
bolts a n d n u t s a t t h e center bearing support a n d
bracket (Fig. 14).
(3) A s applicable, t i g h t e n 1/4-inch diameter clamp
screws w i t h 19 N n n (170 in-lbs) torque or t i g h t e n 5/
16-inch diameter clamp screws w i t h 34 N n n (25 ft-
lbs/300 in-lbs) torque. I f equipped w i t h a brake,
t i g h t e n the u n i v e r s a l flange nuts w i t h 47 N n n (35 ft-
lbs) torque. " F i n g e r - t i g h t e n " the center bearing sup-
port-to-bracket n u t s a n d bolts.
(4) I f removed/replaced, slide t h e protective boot
over t h e rear half-shaft slip yoke tube. I n s t a l l a n d
c r i m p t h e clamp a r o u n d t h e yoke tube. A l i g n t h e
master spline w i t h t h e corresponding wide space and
slide t h e rear half-shaft slip yoke i n t e r n a l splines
over t h e front half-shaft external splines (Fig. 15).
Slide t h e boot f o r w a r d over t h e front half-shaft
splines a n d c r i m p the clamp around the splines.
Because o f the master spline i n the f r o n t half-
shaft splines a n d t h e c o r r e s p o n d i n g w i d e space
i n t h e slip y o k e splines, t h e externally splined
front h a l f - s h a f t a n d t h e i n t e r n a l l y s p l i n e d r e a r
16-20 DRIVE SHAFTS AND UNIVERSAL JOINTS
half-shaft slip yoke can b e mated only a t o n e
c o r r e c t l y a l i g n e d p o s i t i o n ( F i g . 15).
(5) A l i g n the i n s t a l l a t i o n reference m a r k s and po-
sition the rear U-joint spider i n the axle yoke saddles
(Fig. 14).
(6) I n s t a l l the U-joint strap clamps and screws (Fig.
14).
(7) A s applicable, t i g h t e n 1/4-inch diameter clamp
screws w i t h 19 N n n (170 in-lbs) torque or t i g h t e n 5/
16-inch diameter clamp screws w i t h 34 N n n (25 f t -
lbs/300 in-lbs) torque.
(8) Raise the rear wheels f r o m the surface a n d ro-
tate the drive shaft v i a the engine. This w i l l allow
the center bearing t o self-align i n the bearing sup-
port (Fig. 15). After the bearing is aligned i n the
support, t i g h t e n t h e support-to-bracket r e t a i n i n g
nuts and bolts w i t h 68 N n n (50 ft-lbs) torque.
(9) Remove the supports and lower the vehicle.
FRONT DRIVE SHAFT (4WD)-REMOVAL
(1) Raise and support the vehicle.
(2) Remove the skid plate, i f equipped.
(3) M a r k the drive shaft front yoke and the front
axle drive p i n i o n gear shaft yoke (Fig. 14) for i n s t a l -
lation a l i g n m e n t reference.
CAUTION: Do not allow the drive shaft to drop or
hang from the CV joint or the U-joint during re-
moval. Either attach it to the vehicle underside with
wire or otherwise support the loose end of the drive
shaft to prevent damage to the CV/U-joints.
(4) Remove t h e C V joint-to-transfer case flange
capscrews and lockwashers.
I f necessary, utilize a press b a r t o p r e v e n t the
CV j o i n t f r o m rotating while removing the four
capscrews.
(5) Remove the front U-joint clamp screws and both
strap clamps from the front axle drive p i n i o n gear
shaft yoke (Fig. 14). D o n o t d i s t u r b t h e r e t a i n i n g
strap used t o r e t a i n b e a r i n g caps o n the U-joint
spider, i f equipped.
(6) Remove the front drive shaft from the vehicle.
FRONT DRIVE SHAFT (4WD)-INSTALLATION
The drive shaft yoke arms at each end of the shaft,
w i t h the U-joint spider and bearings installed, must
be i n the same plane.
(1) Before i n s t a l l i n g the drive shaft, wipe the slip
yoke clean, inspect t h e machined surface for
scratches, nicks a n d burrs. Do n o t damage t h e
splines w h e n engaging the yoke.
(2) Provide a support for the drive shaft d u r i n g i n -
stallation t o prevent damage to the CV/U-joints.
(3) V i s u a l l y align the drive shaft front U-joint and
drive the drive pinion gear shaft (axle) yoke installa-
•
t i o n reference m a r k s and correctly mate the drive
shaft CV-joint yoke w i t h the transfer case o u t p u t
shaft yoke (Fig. 14).
(4) I n s t a l l t h e CV-joint yoke-to-transfer case o u t p u t
shaft yoke capscrews (Fig. 14) and t i g h t e n t h e m w i t h
34 N n n (25 ft-lbs) torque.
(5) Position t h e drive shaft front U-joint spider a n d
b e a r i n g caps i n the front axle drive p i n i o n gear shaft
yoke "saddles" (Fig. 14). I n s t a l l the strap clamps and
screws. T i g h t e n t h e clamp screws w i t h 19 N n n (14 f t -
lbs/170 in-lbs) torque.
(6) Remove the supports and lower the vehicle.
SLIP YOKE SERVICE
REMOVAL
(1) Remove the drive shaft from the vehicle. I f nec-
essary, refer to the removal procedure.
(2) Remove the clamps and the protective boot f r o m
the d r i v e shaft.
(3) Separate t h e slip yoke from the d r i v e shaft.
CLEANING AND INSPECTION
(1) Clean a l l foreign m a t e r i a l and l u b r i c a n t f r o m
the slip yoke shaft, the slip yoke shaft splines and
the drive shaft splines w i t h an appropriate cleaning
f l u i d and brush.
(2) Inspect the slip yoke splines for excessive wear
and evidence of being " t w i s t e d " .
(3) Inspect the clearance ("backlash") between the
slip yoke shaft splines and drive shaft splines.
(4) T h e slip yoke m u s t be replaced i f the spline
" b a c k l a s h " is excessive.
(5) Inspect the protective boot for excessive wear,
punctures and rips/tears. Replace i f not satisfactory
for reuse.
INSTALLATION
(1) A p p l y a coat of l u b r i c a n t to the shaft splines as
specified i n Group 0 — L u b r i c a t i o n A n d Maintenance.
(2) Position the boot and the clamp over the drive
shaft splines. C r i m p the clamp on the drive shaft.
(3) Engage t h e slip yoke and t h e drive shaft
splines.
(4) Position the boot over the slip yoke and c r i m p
the clamp on the slip yoke.
REAR DRIVE SHAFT CENTER BEARING SERVICE
W h e n a two-piece rear drive shaft is required (ve-
hicles w i t h a n extended wheelbase), a rubber insu-
lated center bearing is used to support t h e area
where the half-shafts are joined. The bearing is sup-
ported by a support and a bracket t h a t is attached to
the frame crossmember (Fig. 15).
 • DRIVE SHAFTS AND UNIVERSAL JOINTS
REMOVAL/DISASSEMBLY
(1) M a r k t h e drive shaft, rear axle and transmis-
sion/transfer case yokes for i n s t a l l a t i o n alignment
reference and remove t h e half-shafts f r o m the vehi-
cle. I f necessary, refer t o t h e r e m o v a l procedure.
CAUTION: Do not clamp the drive shaft tube in a
vise. Clamp only the forged portion of the welded
(fixed) drive shaft yoke in the vise. Also, to avoid
distorting the yoke, do not over-tighten the vise
jaws.
(2) Clamp t h e front half-shaft i n a vise and remove
t h e bearing support a n d rubber i n s u l a t o r from t h e
center bearing (Fig. 15). Discard b o t h components.
(3) Bend t h e slinger away f r o m t h e center bearing
(Fig. 15) w i t h a h a m m e r t o provide sufficient clear-
ance for i n s t a l l i n g a b e a r i n g p u l l e r tool.
(4) Remove t h e b e a r i n g f r o m t h e f r o n t half-shaft
w i t h a puller tool and remove t h e slinger. Discard
t h e bearing, t h e r e t a i n e r a n d t h e slinger (the re-
placement package includes t h e b e a r i n g plus t h e
slinger and retainer).
ASSEMBL Y/INSTALLA TION
(1) Place t h e replacement slinger, b e a r i n g and re-
t a i n e r on the front half-shaft splines (Fig. 15). Each
component is "press-fitted" o n t h e splined half-shaft.
(2) Use a r i g i d tube or pipe w i t h a n I D larger t h a n
Fig. 16 Single Cardan U-Joint At Fixed
16-21
t h e O D o f t h e splines t o force t h e components for-
w a r d onto t h e shaft splines u n t i l they are "seated" a t
t h e shaft shoulder.
(3) Clean a n d lubricate t h e front half-shaft a n d
rear half-shaft slip yoke splines.
(4) Slide the protective boot onto the rear half-shaft
slip yoke tube (Fig. 15). I n s t a l l and crimp the clamp
around the yoke tube.
(5) I n s t a l l t h e front a n d rear half-shafts. I f neces-
sary, refer t o t h e i n s t a l l a t i o n procedure.
(6) Slide t h e protective boot forward over the f r o n t
half-shaft splines and c r i m p t h e clamp around t h e
splines.
U-JOINT SERVICE
SINGLE CARDAN
U-JOINT-REMO VAUDISASSEMBL Y
Single cardan U-joints are serviceable and, i f defec-
t i v e , damaged or excessively w o r n , the needle bear-
ings, seals, spider a n d b e a r i n g caps should a l l be
replaced as a u n i t (Fig. 16).
(1) I f not removed f r o m t h e vehicle, remove t h e
drive shaft. I f necessary, refer t o t h e applicable r e -
m o v a l procedure.
Yoke—Disassembled
16-22 DRIVE SHAFTS AND UNIVERSAL JOINTS •

(2) A s applicable, remove t h e U-joint from t h e

drive shaft fixed (welded) yoke or from the slip yoke
(Figs. 16 and 17) according t o the following instruc-
tions.

CAUTION: Do not clamp the slip yoke tube or the

drive shaft tube in a vise. Clamp only the forged
portion of the fixed (welded) or the slip yoke in the
vise. Also, to avoid distorting the yoke, do not over-
tighten the vise jaws.
Before removing the U-joint and separating a slip
yoke from a fixed yoke, mark both tubes for instal-
lation alignment reference.

(3) C l a m p the fixed/slip yoke i n a vise and remove

t h e bearing cap retainers (Fig. 18). Remove the drive
shaft from the vise.
I t c a n b e h e l p f u l t o s a t u r a t e the b e a r i n g caps
w i t h penetrating oil prior to removal.
(4) Place a suitable size socket wrench (larger I D
t h a n t h e bearing cap OD) against t h e yoke a n d
around t h e perimeter o f the first bearing cap t o be
removed. This w i l l be the b e a r i n g cap receiver. Place
a socket wrench (slightly s m a l l e r O D t h a n the yoke
bore) against the opposite b e a r i n g cap. This w i l l be
the bearing cap driver. Position t h e yoke ( w i t h t h e
socket wrenches) i n a vise (Fig. 19).
(5) Compress t h e vise j a w s (Fig. 19) u n t i l t h e
smaller socket w r e n c h (driver) p a r t i a l l y forces the
opposite bearing cap out o f t h e yoke bore and into
the larger socket w r e n c h (receiver).
(6) Release t h e vise jaws, remove t h e socket
wrenches and remove the b e a r i n g cap t h a t was par-
t i a l l y forced out of the yoke bore.
J8916-28
Fig. 18 Bearing Cap Retainers
(7) Place t h e larger I D socket wrench (receiver)
against the yoke and around t h e perimeter o f the re-
m a i n i n g bearing cap. Place t h e smaller O D socket
wrench (driver) against the end o f the spider and po-
sition t h e yoke w i t h t h e socket wrenches i n a vise
(Fig. 19).
(8) Compress the vise j a w s (Fig. 19) u n t i l t h e re-
m a i n i n g bearing cap i s p a r t i a l l y forced o u t o f t h e
yoke bore and into the larger diameter socket wrench
(receiver).
(9) Remove the yoke and socket wrenches from the
vise.
(10) Remove t h e r e m a i n i n g bearing cap a n d t h e
bearings, seals and spider from the yoke bore (Figs.
16 and 17).
 • DRIVE SHAFTS AND UNIVERSAL JOINTS 16-23

YOKE RECEIVER- l u b r i c a n t t o t h e yoke bores, t h e b e a r i n g caps, t h e

needle bearings, t h e seals a n d t h e bearing contact
surfaces on t h e spider cylinders.
(2) Position the spider cylinders i n the yoke bores-
insert the seals i n t o the yoke bores a n d against the
spider cylinders; a n d tap the b e a r i n g caps ( w i t h the
needle bearings) i n t o the yoke bores far enough to re-
t a i n the spider in-place.

CAUTION: Do not clamp the drive shaft tube or the

slip yoke tube in a vise. Clamp only the forged por-
tion of each yoke in the vise. Also, to avoid distort-
ing the yoke, do not over-tighten the vise jaws.

(3) F o r a driver, place a socket w r e n c h (slightly

smaller OD t h a n t h e yoke bore) against one bearing
cap and position t h e yoke ( w i t h the socket wrench) i n
a vise (Fig. 20).
WRENCH
DRIVER YOKE VISE
J8916-29

Fig. 19 Bearing Cap Removal

(11) I f applicable, follow t h e i n s t r u c t i o n s listed
above to remove the U-joint bearing caps f r o m t h e
slip yoke (Fig. 19).

SINGLE CARDAN U-JOINT-CLEANING AND

INSPECTION

CLEANING
(1) Clean the drive shaft fixed yoke/slip yoke a r m
bores w i t h a n appropriate cleaning solvent a n d a
w i r e brush. Ensure t h a t a l l the corrosion (rust) and
foreign m a t t e r are removed f r o m the bores.
(2) Clean the bearing caps a n d bearings, seals a n d
spider (Figs. 16 and 17) i n a n appropriate cleaning
solvent and wipe t h e m dry w i t h a shop c l o t h .
D o n o t disassemble the needle b e a r i n g s . Clean J8916-30
the bearings w i t h a short, stiff b r a s h inserted
into the bearing cap and " b l o w o u t " w i t h com- Fig. 20 Bearing Cap Installation
pressed air. L u b r i c a t e the needle bearings w i t h
(4) Compress the vise jaws (Fig. 20) and force the
S A E 140w o i l f o r i n s p e c t i o n .
bearing caps i n t o t h e yoke bores w i t h t h e socket
INSPECTION wrench (driver). E n s u r e t h a t t h e c a p s a r e f o r c e d
i n t o t h e yoke bores f a r e n o u g h t o expose t h e
(1) Inspect the bearing caps, t h e needle bearings,
a n d the bearing contact surfaces on t h e spider c y l i n - b e a r i n g cap retainer grooves.
ders for evidence o f " B r i n e l l i n g " (i.e., concave, spher- (5) I n s t a l l the bearing cap retainers (Fig. 18) after
i c a l areas), excessive wear, f l a t spots, scoring and t h e bearing caps are correctly i n s t a l l e d (i.e., com-
cracks. pletely seated).
(2) Replace a l l of the U-joint components i f a n y one (6) I f applicable, a t t a c h the slip yoke t o the fixed
of the components is excessively w o r n o r otherwise yoke ( w i t h the i n s t a l l a t i o n reference m a r k s aligned)
defective. according to the instructions listed above.
(7) I n s t a l l the drive shaft. I f necessary, refer to the
SINGLE CARDAN U-JOINT-ASSEMBLY/ applicable i n s t a l l a t i o n procedure.
INSTALLATION (8) Remove the supports and lower the vehicle.
(1) A p p l y extreme pressure (EP), l i t h i u m - b a s e type
16-24 DRIVE SHAFTS AND UNIVERSAL JOINTS •

SECTION A - A
THRU LUBE FITTING

J9016-22

DOUBLE CARDAN (CV) JOINT (4WD

VEHICLES)
Double cardan (CV) j o i n t s are serviceable. I f t h e
b a l l socket yoke, b a l l , spring, bushings, seals, t h r u s t
washers, spiders or b e a r i n g caps (Fig. 21) are either
damaged or excessively w o r n , disassemble a n d repair
the C V j o i n t according t o the f o l l o w i n g instructions.

REMOVAL/DISASSEMBLY
(1) I f n o t removed f r o m t h e vehicle, remove t h e
front drive shaft. I f necessary, refer t o t h e removal
procedure.
(2) Punch reference m a r k s or otherwise identify, as
applicable, the yokes before disassembly so t h a t they
A L I G N M E N T P U N C H AAARKS J9016-20
can be assembled a t t h e i r o r i g i n a l locations to r e t a i n
the drive shaft balance (Fig. 22). Fig. 22 Yoke Assembly Reference Marks

CAUTION: Do not clamp a drive shaft tube in a vise.
Clamp only the forged portion of a yoke in the vise.
Also, to avoid distorting a yoke, do not over-tighten
the vise jaws.
It can be helpful to saturate the bearing caps with
penetrating oil prior to removal.
(3) Each bearing cap should be removed i n the se-
quence indicated i n Figure 23. T h i s sequence re-
quires the least amount of disassembly t i m e .
I f the flange yoke is removed, i t is necessary t o
remove only the t w o b e a r i n g caps a t l o c a t i o n 1
(Fig. 2 3 ) . T h i s c a n b e d e t e r m i n e d b y o b s e r v i n g
t h e t r u n n i o n s a t l o c a t i o n 1.
(4) Support the drive shaft h o r i z o n t a l l y and aligned
w i t h the base plate of a press. Shear the b e a r i n g cap
plastic r e t a i n i n g r i n g and position t h e first l i n k yoke
rear a r m over a 1 1/8-inch (30-mm) I D socket
wrench. Place Spider Press Tool C-4365-1 o n t h e
 • DRIVE SHAFTS AND UNIVERSAL JOINTS
3 4 2
Fig. 23 Bearing Cap Removal Sequence
b e a r i n g caps located i n t h e flange yoke arms ( F i g .
24). Force t h e b e a r i n g cap out o f the l i n k yoke a r m
w i t h a press.
LINK E=& C-4365-1
YOKE U S YOKE (TYPICAL)
Fig. 24 Bearing Cap Removal With Tool C-4365-1
(5) I f t h e bearing cap is n o t completely removed,
i n s e r t Spacer Tool C-4365-4 between the spider and
t h e b e a r i n g cap (Fig. 25) and complete the removal o f
t h e b e a r i n g cap.
(6) Rotate t h e d r i v e shaft 180 degrees. Shear t h e
opposite bearing cap plastic r e t a i n i n g r i n g and force
t h e b e a r i n g cap out o f t h e l i n k yoke w i t h Spacer Tool
C-4365-4 (Fig. 25) a n d a press.
(7) Disengage t h e spider t r u n n i o n s from t h e l i n k
yoke. P u l l t h e flange yoke and t h e spider f r o m t h e
centering b a l l on the b a l l support tube yoke. The b a l l
socket is p a r t of the flange yoke.
(8) P r y t h e seal f r o m t h e b a l l socket and remove
t h e washers, t h e spring, and t h e three b a l l "seats"
f r o m the b a l l socket (Fig. 26).
BALL SOCKET INSPECTION/REPLACEMENT
(1) For b a l l removal, separate the C V j o i n t between
t h e l i n k yoke and t h e flange yoke by forcing the spi-
der t r u n n i o n bushing from t h e l i n k yoke. P u l l t h e
flange yoke and the spider w i t h the b a l l socket f r o m
t h e centering b a l l as a u n i t .
16-25
Fig. 25 Bearing Cap Removal With Tool C-4365-4
WASHER (LARGE OD) 3-BALL SEATS
Fig. 26 CV Joint Components
(2) Clean and inspect t h e b a l l socket b u s h i n g for
wear. I f the bushing is worn, replace both the flange
yoke and the spider.
(3) P r y t h e seal from b a l l socket a n d remove t h e
washers, the spring and the three b a l l "seat"s.
(4) Clean a n d inspect t h e centering b a l l surface,
the seal, the b a l l "seats", the spring and the washer.
I f the components are w o r n or otherwise defective,
replacement is recommended.
(5) Remove the centering b a l l f r o m the b a l l socket
w i t h Tool Set C-4365: Screw Tool C-4365-5, Sleeve
Tool C-4365-6, Washer Tool C-4365-7, N u t Tool C-
4365-7, and Jaw Tool C-4365-8 (Fig. 27).
(6) Use Tool C-4365-3 to i n s t a l l the centering b a l l
i n the b a l l socket. Force the b a l l into the socket u n t i l
i t is "seated" f i r m l y against t h e shoulder a t the base
of the socket (Fig. 28).
(7) To i n s t a l l t h e spider, insert one b e a r i n g cap
p a r t i a l l y into one of the yoke bores a n d t h e n rotate
the yoke 180 degrees. Insert t h e spider i n t o the yoke
bore and "seat" t h e spider t r u n n i o n i n t h e b e a r i n g
cap. P a r t i a l l y insert the opposite b e a r i n g cap i n t h e
16-26 DRIVE SHAFTS AND UNIVERSAL JOINTS •
JAW- INSTALLER
TOOL
NUT
Jl 1 SP-84

fNOTE: PLACI
j THIN
CHAMFERED
[ENDS OF JAWS
\ U
NDE
Rj
«L ALL
B
J

SLEEVE-6
WASHER-7
RY240

Fig. 27 Centering Ball Removal With Tool Set

C-4365
r e m a i n i n g yoke bore. Force the bearing caps i n w a r d
w h i l e p i v o t i n g t h e spider back-and-forth t o ensure
"free" movement of the t r u n n i o n s i n the bearings.
(8) W h e n one of the retainer grooves becomes v i s i - RH189

ble i n the yoke bore, stop forcing the bearing caps i n -

Fig. 28 Centering Ball Installation With Tool C-
w a r d and i n s t a l l a retainer i n the groove. 4365-3
(9) Continue t o force the bearing caps i n w a r d u n t i l
insert t h e m i n t h e b a l l "seat" i n t h e f o l l o w i n g se-
t h e opposite retainer can be installed i n the groove.
quence:
I f difficulty is encountered i n "seating" the re-
• spring,
t a i n e r s i n t h e grooves, s t r i k e t h e y o k e a r m s • s m a l l O D washer,
f i r m l y w i t h a hammer t o "seat" the retainers. • three b a l l "seat"s w i t h t h e large opening facing
(10) Lubricate the centering b a l l and socket a n d as- o u t w a r d , and
semble the r e m a i n i n g h a l f of the C V j o i n t according • large O D washer.
to t h e same instructions (above). (2) L u b r i c a t e the seal l i p a n d press i t i n w a r d a n d
flush w i t h a n appropriate tool. The seal l i p should t i p
LUBRICATION inward.
(1) Use the l u b r i c a n t provided w i t h the b a l l "seat" (3) F i l l the l u b r i c a n t cavity w i t h t h e l u b r i c a n t pro-
service k i t to lubricate a l l the components a n d t h e n vided i n the service k i t .
• DRIVE SHAFTS AND UNIVERSAL JOINTS 16-27

SPECIFICATIONS

TORQUE SPECIFICATIONS

COMPONENT SET-TO-TORQUE RECHECK TORQUE

Center Bearing Bracket-to-Frame Bolt 68 Nnn (50 ft-lbs)

Center Bearing Support-to-Bracket Bolt 68 N»m (50 ft-lbs)

Yoke (Axle) 406 Nnn (300 ft-lbs)

Yoke (Transmission) 237 Nnn (175 ft-lbs)

Roller Bushing Clamp Bolt 1/4-28 19 Nnn (14 ft-lbs)

Roller Bushing Clamp Bolt 5/16-24 34 Nnn (25 ft-lbs)

Parking Brake-to-Flange Yoke Nut 47 Nnn (35 ft-lbs)

Front Axle U-Bolt Nut 17 Nnn (150 in-lbs)

CV Joint Screw 88 Nnn (65 ft-lbs)

Rear Axle Clamp Screw 19 Nnn (14 ft-lbs)

Transfer Case Clamp Screw 19 Nnn (14 ft-lbs)

Lubricant Fitting 3 Nnn (30 in-lbs)

J9016-28
 • — — SPRINGS/SHOCK ABSORBERS 17 - 1

SPRINGS/SHOCK ABSORBERS

CONTENTS
Page Page

GENERAL INFORMATION . 1 SPECIFICATIONS 12

SERVICE PROCEDURES .3

G E N E R A L INFORMATION

INDEX
Page Page
Shock Absorber Description 2 Vehicle Loading And Weight Distribution 2
Spring Descriptions 1

SPRING DESCRIPTIONS SHOCK

FRONT SPRINGS

2WD VEHICLES
A l l two-wheel d r i v e (2WD) R a m T r u c k and Ram-
charger vehicles are equipped w i t h a coil-spring op-
erated (independent) f r o n t suspension system a t each
side of the vehicle (Fig. 1). T h e coil springs are lo-
cated between t h e frame side r a i l bracket and t h e
lower suspension a r m . A 0.3 i n c h (7.6 m m ) ozone-re-
sistant, rubber noise isolation pad is located between
the upper e n d o f t h e coil s p r i n g and t h e frame
bracket. T h i s pad dampens noise t h a t would other- STABILIZER BAR J9017-28
wise be t r a n s m i t t e d v i a t h e metal-to-metal contact of
the spring a n d the frame bracket. A shock absorber Fig. 1 Front Coil Spring
is located inside each s p r i n g coil and i t is attached to
t h e frame side r a i l bracket a n d to the lower suspen-
sion a r m .

4WD VEHICLES
A l l four-wheel d r i v e (4WD) R a m T r u c k and Ram-
charger vehicles are equipped w i t h a leaf-spring op-
erated front suspension system (Fig. 2). The leaf
springs are the fixed-rate type and are attached to
the frame side r a i l brackets and the front axle.
The front leaf springs are attached to t h e axle FRONT EYE m m

shaft tubes a t the s p r i n g pads b y U-bolts and nuts.

REAR SPRINGS
A l l R a m T r u c k a n d Ramcharger vehicles are
equipped w i t h leaf-type rear springs. The springs
have a one-piece, rubber b u s h i n g "pressed" into t h e i r
m a i n leaf f r o n t "eye". Model 150 and Ramcharger ve-
Fig. 2 Front & Rear Leaf Springs
h i d e s are equipped w i t h a fixed-rate type leaf s p r i n g
(Fig. 2). Progressive-rate type rear leaf springs (Fig.
3) are standard equipment for a l l model 250 and 350
vehicles.
17 - 2 SPRINGS/SHOCK ABSORBERS
Fig. 3 Progressive-Type Rear Leaf Spring
A progressive-rate type leaf spring has two stages.
The first stage, comprised of the upper leaves, pro-
vides a l o w spring rate w i t h a l i g h t cargo load. The
lower leaves (second stage) g r a d u a l l y interact w i t h
the upper leaves a n d provide a n increased s p r i n g
rate for medium-to-heavy cargo loads. T h i s t y p e o f
s p r i n g ( p r o g r e s s i v e ) i s n o t t h e s a m e as a fixed-
rate w i t h a u x i l i a r y s p r i n g type o f two-stage leaf
spring ( w i t h the auxiliary spring located above
t h e m a i n leaf).
VEHICLE CONFIGURATION
The f r o n t "eye" o f each leaf spring is attached t o a
bracket t h a t is r i v e t e d to t h e frame side r a i l . The
rear "eye" o f each standard equipment leaf s p r i n g is
attached t o the frame side r a i l v i a a one-piece spring
shackle w i t h a one-piece, "pressed-in" rubber bush-
ing.
The rear leaf springs are attached to the axle shaft
tubes a t t h e s p r i n g pads b y U-bolts and nuts.
SHOCK ABSORBER DESCRIPTION
Dual-action, gas-charged, h y d r a u l i c shock absorb-
ers are used w i t h b o t h the front and rear suspension
systems for R a m T r u c k and Ramcharger vehicles.
The shock absorbers are designed to dampen t h e ve-
hicle body (i.e., spring) "up-down" movement. I n ad-
dition, rubber bushings are inserted i n t o the shock
absorber "eyes" to dampen o u t road/street surface
"shock" a n d noise.
The f r o n t a n d rear springs allow t h e wheels to
move u p and down w i t h the road/street surface semi-
independent o f t h e vehicle chassis a n d body. How-
•
ever, t h e springs alone cannot provide a completely
smooth r i d e because of the energy t h a t is stored i n
t h e springs d u r i n g compression a n d t h e n released
d u r i n g rebound. I f a s p r i n g is unrestrained, t h e en-
ergy w i l l be alternately stored and released and t h e
s p r i n g w i l l continue to oscillate i n t h i s manner u n t i l
t h e vehicle w e i g h t dampens t h e oscillations (move-
ments). A shock absorber is designed t o i m m e d i a t e l y
dampen t h e s p r i n g movements b y dissipating most o f
t h e s p r i n g energy, w h i c h w o u l d otherwise continue t o
be a l t e r n a t e l y stored and t h e n released.
A shock absorber converts mechanical s p r i n g en-
ergy i n t o heat energy v i a t h e f r i c t i o n caused b y t h e
h y d r a u l i c f l u i d ( i n t h e shock absorber) w h e n i t is
forced t h r o u g h restricted passages. T h i s causes t h e
s p r i n g to r e t u r n smoothly t o i t s n o r m a l position (i.e.,
t h e s p r i n g movement is dampened).
VEHICLE CONFIGURATION
For 2 W D vehicles, a front shock absorber is located
inside each f r o n t spring coil. I t i s attached to t h e
frame side r a i l bracket and t o t h e lower suspension
a r m (Fig. 1).
For 4 W D vehicles, t h e f r o n t shock absorber upper
ends are attached to brackets located on t h e frame
side r a i l . T h e lower ends are attached to t h e f r o n t
axle shaft t u b e brackets.
The rear shock absorber upper ends are attached t o
t h e frame crossmember a f t of t h e rear axle. T h e
lower ends are attached t o t h e spring brackets (at
t h e axle shaft tubes).
R a m T r u c k a n d Ramcharger vehicles are also
equipped w i t h jounce bumpers located a t the f r o n t o f
t h e vehicle. T h e bumpers are attached t o t h e shock
absorber brackets in-line w i t h t h e axle shaft tubes.
VEHICLE LOADING AND WEIGHT DISTRIBUTION
A R a m T r u c k or Ramcharger vehicle should always
be loaded so t h a t t h e vehicle weight c e n t e r - l i n e i s
located i m m e d i a t e l y forward of the rear axle. Correct
vehicle l o a d i n g provides proper " f r o n t tire-to-road"
contact a n d t h i s results i n m a x i m u m vehicle h a n -
d l i n g s t a b i l i t y a n d safety. Incorrect vehicle w e i g h t
d i s t r i b u t i o n can cause excessive t i r e tread wear,
s p r i n g fatigue or failure, and/or erratic steering ( w i t h
extremely incorrect weight distribution).
I n c o r r e c t vehicle weight distribution should b e
c o n s i d e r e d a s a p o s s i b l e cause d u r i n g d i a g n o s i s
f o r e r r a t i c s t e e r i n g , s p r i n g f a i l u r e , and/or exces-
sive t i r e t r e a d w e a r c o m p l a i n t s .
 • SPRINGS/SHOCK ABSORBERS 17 - 3

SERVICE PROCEDURES

INDEX
Page Page
Front And Rear Spring "Eye" Round Bushing . . . . 10 Service Diagnosis 3
Front Coil Springs (2WD)—Removal/Installation ...6 Shock Absorber Removal/Installation 4
Front Leaf Springs (4WD)—Removal/Installation . . . 7 Spring Leaf—Replacement 10
Rear Springs—Removal/Installation . . . . . . . . . . . . . 8 Stabilizer Bar— Removal/Installation . . . . . . . . . . . . 10

SERVICE DIAGNOSIS scription t h a t describes t h e condition r e q u i r i n g cor-

rection, a n d
To use t h e S p r i n g A n d S h o c k A b s o r b e r D i a g n o - • follow t h e connecting arrows t o t h e square(s) t h a t
sis chart: describe(s) t h e possible cause(s).
• select t h e uppermost square c o n t a i n i n g t h e de-

SPRING AND SHOCK ABSORBER DIAGNOSIS

SMOCK
SPRING SPRING SPRING SHOCK ABSORBER
SAGS OR NOISE BROKE ABSORBERS LEAKING
BOTTOMS NOISY FLUID

FATIGUE F R O M
SHOCK L O O S E E Y E BOLT
OPERATION LOOSE WORN
ABSORBERS OR NUT
ON S E V E R E 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
LINERS W O R N OR SEVERE
OVERLOADED INTERNALLY DEFECT
OR MISSING CORROSION

J9017-17
17-4 SPRINGS/SHOCK ABSORBERS
SHOCK ABSORBER REMOVAL/INSTALLATION
SERVICE INFORMATION
The f r o n t and r e a r shock absorbers cannot be re-
filled o r disassembled. W h e n service is required, re-
move t h e shock absorber and i n s t a l l a replacement
unit.
A shock absorber should be replaced only i f i t has
lost i t s resistance t o s p r i n g movement (i.e., does not
dampen) or i f there i s a f l u i d leak. E x i s t e n c e of a
thin f l u i d c o a t i n g o n the outside of the s h o c k a b -
sorber cylinder is not cause t o replace t h e shock
absorber.
FRONT/2WD VEHICLES-REMOVAL
(1) Raise t h e vehicle. Position supports a t t h e ex-
treme f r o n t ends o f t h e frame r a i l s and t h e n lower
the f r o n t of the vehicle onto t h e supports.
(2) T u r n t h e wheels i n t h e direction necessary to
provide the best possible access t o the shock absorber
upper bracket.
(3) Remove t h e shock absorber stud (upper) n u t
and the upper r e t a i n e r (Fig. 4).
FRONT SHOCK ABSORBER J9017-29
Fig. 4 Front Shock Absorber & Coil Spring (2WD)
(4) Remove the t w o lower r e t a i n i n g bolts, guide the
shock absorber d o w n t h r o u g h t h e coil s p r i n g and re-
move i t f r o m t h e vehicle t h r o u g h the lower suspen-
sion a r m (Fig. 4).
FRONT/2WD VEHICLES-INSTALLATION
(1) E x t e n d t h e shock absorber completely, i n s t a l l
the lower retainer o n t h e shock absorber stud (Fig.
4). Inspect the b u s h i n g a n d t h e sleeve t o ensure they
are i n proper position a n d n o t excessively w o r n or
•
broken (Fig. 4).
(2) C a r e f u l l y guide the shock absorber u p t h r o u g h
the lower suspension a r m and the coil spring, and i n -
sert t h e stud t h r o u g h the bushing (Fig. 4).
(3) I n s t a l l the upper retainer and the n u t (Fig. 4).
T i g h t e n t h e n u t w i t h 34 N»m (25 ft-lbs) torque.
(4) A l i g n t h e lower end o f the shock absorber w i t h
the holes i n t h e lower suspension a r m and i n s t a l l t h e
r e t a i n i n g bolts. T i g h t e n the bolts " f i n g e r - t i g h t " .
(5) Raise t h e vehicle, remove t h e supports a n d
lower t h e vehicle t o t h e surface. T i g h t e n t h e r e t a i n -
i n g bolts w i t h 23 N n n (17 ft-lbs/200 in-lbs) torque.
FRONT/4WD VEHICLES-REMOVAL
(1) Raise t h e vehicle. Position supports a t t h e ex-
treme f r o n t ends o f the frame r a i l s and t h e n lower
the f r o n t o f the vehicle onto the supports.
(2) T u r n t h e wheels i n t h e direction necessary t o
provide t h e best possible access to the shock absorber
upper bracket (Fig. 5).
(3) Remove the t w o nuts and bolts t h a t attach the
shock absorber upper bracket to the frame r a i l (Fig.
5). R e m o v e t h e b r a c k e t l o w e r n u t a n d bolt, r e -
move t h e u p p e r n u t , r o t a t e t h e b r a c k e t u n t i l
there i s sufficient c l e a r a n c e b e t w e e n t h e s h o c k
a b s o r b e r a n d the u p p e r bolt for r e m o v a l , a n d r e -
move t h e u p p e r bolt.
(4) Remove the shock absorber lower a t t a c h i n g n u t
and t h e outer r e t a i n e r . Remove t h e shock absorber
and t h e i n n e r r e t a i n e r from the stud (Fig. 5).
(5) A f t e r r e m o v i n g the shock absorber w i t h the up-
per bracket f r o m t h e vehicle, remove t h e bracket
from the shock absorber i f the shock absorber is be-
i n g replaced (Fig. 5).
FRONT/4WD VEHICLES-INSTALLATION
(1) I f applicable, before i n s t a l l i n g a replacement
shock absorber o n t h e vehicle, attach t h e upper
bracket to the shock absorber (Fig. 5).
(2) Before i n s t a l l i n g t h e shock absorber, ensure
t h a t t h e b u s h i n g i s inserted i n t h e shock absorber
"eye".
E n s u r e that t h e s h o c k a b s o r b e r i s positioned
on t h e s t u d w i t h t h e r e t a i n e r s c o r r e c t l y located
o n e i t h e r s i d e o f t h e b u s h i n g ( F i g . 5).
(3) Position the large I D retainer and the shock ab-
sorber "eye" on t h e stud. Position t h e s m a l l I D r e -
t a i n e r on the stud a n d install the a t t a c h i n g n u t (Fig.
5). T i g h t e n the n u t " f i n g e r - t i g h t " .
(4) Position t h e shock absorber and t h e upper
bracket a t the frame r a i l and i n s t a l l the bracket up-
per b o l t and n u t . Rotate the bracket u n t i l the lower
bolt hole is aligned w i t h the frame r a i l bolt hole and
i n s t a l l t h e lower b o l t and n u t (Fig. 5). T i g h t e n t h e
nuts " f i n g e r - t i g h t " .
 • SPRINGS/SHOCK ABSORBERS 17-5

FRONT

RETAINER
(SMALL DIAMETER)

RETAINER
RN814 (LARGE DIAMETER)

Fig. 5 Front Shock Absorber & Leaf Spring (4WD)

(5) Raise t h e vehicle, remove t h e supports a n d (3) Remove t h e l o c k n u t and t h e outer r e t a i n e r from
lower t h e vehicle to t h e surface. T i g h t e n t h e shock the spring bracket stud (Fig. 6).
absorber upper bracket a t t a c h i n g n u t s and the lower (4) Remove t h e rear shock absorber and the i n n e r
s t u d n u t w i t h 75 N»m (55 ft-lbs) torque. retainer from the vehicle (Fig. 6).

REAR-REMOVAL REAR—INSTALLA TION

(1) Raise a n d support the vehicle. (1) Before i n s t a l l i n g t h e shock absorber, ensure
(2) Remove the r e t a i n i n g l o c k n u t and bolt from t h e t h a t t h e bushings is inserted i n t h e shock absorber
frame crossmember a t the upper end of the shock ab- "eyes".
sorber (Fig. 6). Ensure that the shock absorber is positioned
BOLT on the spring bracket stud w i t h retainers lo-
LOCKNUT c a t e d o n e i t h e r side o f t h e b u s h i n g ( F i g . 6).
(2) Position the i n n e r retainer and shock absorber
"eye" on the spring bracket stud. I n s t a l l the outer re-
tainer and the l o c k n u t (Fig. 6). T i g h t e n t h e locknut
"finger-tight".
(3) Rotate the shock absorber u p w a r d b y p i v o t i n g i t
on t h e lower stud and position t h e upper end o f the
SPRING shock absorber a t the frame crossmember.
BRACKET BUMPER (4) A l i g n t h e upper b u s h i n g bore w i t h t h e frame
AND STUD
crossmember hole and insert t h e bolt t h r o u g h t h e up-
X per shock absorber "eye" and t h e crossmember ( F i g .
LOCKNUT 6).
OUTER
INNER RETAINER (5) I n s t a l l t h e locknut on t h e upper b o l t a n d
RETAINER J9017-31 tighten i t "finger-tight".
(6) Raise t h e vehicle, remove t h e supports a n d
Fig. 6 Rear Shock Absorber Removal/Installation
lower the vehicle to t h e surface.
 17 - 6 SPRINGS/SHOCK ABSORBERS •
(7) T i g h t e n t h e shock absorber locknuts w i t h 82
N n n (60 ft-lbs) torque.

FRONT COIL SPRINGS (2WD)-REMOVAL/

INSTALLATION

REMOVAL
(1) Block t h e brake pedal i n t h e " u p " (non-
depressed) position. Raise the vehicle o n a hoist. Po-
s i t i o n supports a t t h e extreme f r o n t ends o f t h e
frame r a i l s and lower the hoist. Remove the applica-
ble wheel cover and wheel/tire.
(2) Remove the brake caliper r e t a i n e r and the a n t i -
r a t t l e spring. Remove the b r a k e caliper from the disc
rotor b y s l i d i n g i t out and t h e n away f r o m the rotor.
I f necessary, refer t o Group 5—Brakes for removal
information. Support t h e brake caliper o u t -
of-the-way. D o n o t a l l o w t h e c a l i p e r h a n g f r o m o r
b e s u p p o r t e d b y t h e b r a k e f l u i d hose. Remove the
inboard brake pad. FRONT SHOCK ABSORBER J9017-29
(3) Remove t h e dust cap, t h e cotter p i n , t h e n u t
Fig. 7 Coil Spring Suspension
lock, t h e adjustment n u t , t h e washer, and the outer
wheel bearing.
(4) Carefully slide t h e hub/rotor f r o m the steering
k n u c k l e spindle. D o n o t a l l o w t h e seal o r t h e i n -
ner wheel bearing t o contact t h e steering
k n u c k l e spindle threads, otherwise the threads,
t h e b e a r i n g , a n d t h e seal c o u l d b e d a m a g e d .
(5) Remove t h e a t t a c h i n g screws a n d t h e brake
splash shield.
(6) Remove t h e shock absorber from t h e vehicle
and t h e shock absorber upper b u s h i n g from t h e
bracket (Fig. 7). I f necessary, refer to t h e removal
procedure.
(7) Remove the s t r u t bar (Fig. 7). I f necessary, refer
to the removal procedure.
(8) I n s t a l l Spring Compressor Tool DD-1278 i n the
spring (Fig. 8) and t i g h t e n the n u t " f i n g e r - t i g h t " , and
t h e n loosen the n u t 1/2 of-a-turn.
(9) Remove the cotter pins and the lower and upper
b a l l stud nuts a t the steering k n u c k l e .
(10) I n s t a l l B a l l Stud Loosening Tool C-3564-A o n
the lower b a l l stud. T u r n the threaded portion o f the
tool a n d " l o c k " t h e tool securely against t h e lower
stud (Fig. 8).
(11) Expand t h e tool sufficiently enough to place
force on the lower b a l l stud a n d t h e n s t r i k e the steer- Fig. 8 Spring Compressor & Ball Stud Loosening
i n g k n u c k l e sharply w i t h a h a m m e r t o loosen t h e Tools Installed
stud. D o n o t a t t e m p t t o f o r c e t h e s t u d o u t o f t h e
INSTALLATION
steering knuckle w i t h the loosening tool.
(1) Position t h e s p r i n g ( w i t h t h e rubber isolation
(12) Remove the loosening tool and remove the b a l l
pad) on t h e suspension a r m (Fig. 7) and i n s t a l l t h e
stud w i t h a n appropriate tool.
spring compressor tool. Compress the s p r i n g u n t i l the
(13) Slowly loosen t h e coil s p r i n g compressor tool
lower suspension a r m b a l l stud can be properly posi-
u n t i l a l l tension is relieved f r o m the spring.
tioned i n t h e steering k n u c k l e bore.
(14) Remove t h e s p r i n g compressor tool a n d t h e
spring w i t h the rubber isolation pad (Fig. 7).
 • SPRINGS/SHOCK ABSORBERS 17 - 7

(2) I n s t a l l the r e t a i n i n g n u t s on t h e b a l l studs and (11) T i g h t e n the shock absorber n u t and bolts w i t h
t i g h t e n t h e upper n u t w i t h 142 N n n (105 ft-lbs) the specified torque.
torque and t h e lower n u t , i f a 11/16-16 bolt, w i t h 183 (12) Test the vehicle brakes and t h e suspension for
N n n (135 ft-lbs) torque or, i f a 3/4-16 bolt, w i t h 237 proper operation.
N n n (175 ft-lbs) torque. I n s t a l l replacement cotter
pins. FRONT LEAF SPRINGS (4WD)—REMOVAL/
(3) I n s t a l l t h e strut (Fig. 7). T i g h t e n t h e strut-to- INSTALLATION
lower suspension a r m bolts w i t h 136 N n n (100 ft-lbs)
torque. T i g h t e n the s t r u t f r o n t n u t w i t h 70 N-m (50 REMOVAL
ft-lbs) torque. I n s t a l l the s p r i n g p i n . (1) Use a chain hoist or a h y d r a u l i c crane con-
(4) Connect t h e stabilizer b a r ( i f equipped) a n d nected t o tow hooks o r t o t h e frame t o raise the ve-
t i g h t e n t h e l i n k w i t h 11 N n n (100 in-lbs) torque. Re- hicle u n t i l a l l weight i s removed from t h e front
move the s p r i n g compressor tool. springs.
(5) I n s t a l l t h e shock absorber b u s h i n g i n t h e (2) W i t h the front tires i n contact w i t h the surface,
bracket. Place the lower retainer o n the s t u d a n d po- position support stands under the frame side r a i l s .
s i t i o n the shock absorber w i t h i n t h e coil s p r i n g (Fig. (3) Remove t h e nuts, t h e lockwashers, and t h e U -
7). I n s t a l l and t i g h t e n t h e upper stud n u t a n d t h e bolts t h a t attach t h e s p r i n g t o t h e axle shaft tubes
lower r e t a i n i n g bolts " f i n g e r - t i g h t " . (Figs. 9 and 10).
A f t e r the vehicle has been l o w e r e d t o t h e sur-
f a c e , t i g h t e n t h e u p p e r s t u d n u t w i t h 34 N n n (25
ft-lbs) t o r q u e a n d t h e l o w e r r e t a i n i n g b o l t s w i t h
23 N n n (17 ft-lbs/200 i n - l b s ) .
(6) Position the brake splash shield on t h e steering
k n u c k l e , i n s t a l l a n d t i g h t e n t h e a t t a c h i n g screws
w i t h 23 N n n (200 in-lbs) torque.
(7) Carefully i n s t a l l t h e hub/rotor on t h e steering
k n u c k l e spindle, followed b y t h e outer wheel bearing,
t h e washer and the adjustment n u t . T i g h t e n the ad-
j u s t m e n t n u t w i t h 48 N n n (35 ft-lbs) torque w h i l e ro-
t a t i n g hub/rotor. Stop t h e hub/rotor r o t a t i o n a n d
loosen t h e adjustment n u t t o completely release t h e
wheel bearing "preload". Next, t i g h t e n t h e adjust-
m e n t n u t "finger-tight", and i n s t a l l n u t lock and cot-
t e r p i n . T h e result of t h e adjustment should be
0.0001 t o 0.003 inch (0.0025 t o 0.76 m m ) "end play".
Clean the dust cap, apply a l i g h t coat o f wheel bear-
i n g l u b r i c a n t to t h e inside surface and i n s t a l l i t on
t h e hub.
(8) Position the inboard brake p a d o n t h e brake L E F T S I P E
J9017-32
caliper adapter w i t h t h e pad flanges engaged w i t h
t h e adapter rails. Slowly slide t h e caliper i n t o posi- Fig. 9 Front Suspension W/Model 44 Axle—W-150,
t i o n i n t h e adapter and over t h e brake rotor. A l i g n
W-250, W-350 & AW-150 Vehicles
t h e caliper on t h e adapter r a i l s . Use care t o avoid (4) Remove t h e spring front "eye" pivot n u t a n d
p u l l i n g the protective dust boot f r o m the grooves as bolt, the rear spring shackle nuts, the spring shackle
t h e caliper piston a n d boot slide over t h e inboard plates, and remove the s p r i n g from the vehicle (Figs.
brake pad. 9 and 10).
I f necessary, r e f e r t o G r o u p 5 — B r a k e s f o r a d -
ditional installation information. INSPECTION
(9) I n s t a l l t h e a n t i - r a t t l e springs and t h e retainer (1) Inspect the s p r i n g a n d shackle "eye" bushings,
the shackle bolts, t h e shackle plates, t h e shackle
clips, and t i g h t e n w i t h 20 N n n (15 ft-lbs/180 in-lbs)
bracket and t h e spring "eye" (pivot) bolts for exces-
torque.
sive wear and damage. Replace a l l excessively w o r n
T h e i n b o a r d shoe a n t i - r a t t l e s p r i n g m u s t a l -
and damaged components (Figs. 9 and 10).
ways be installed o n t o p o f the retainer spring
(2) Examine the condition of the s p r i n g center bolt
plate.
(Figs. 9 and 10) and ensure t h a t the n u t is correctly
(10) I n s t a l l t h e wheel/tire a n d t h e wheel cover.
tightened. I f necessary, t i g h t e n t h e center bolt n u t
Raise the vehicle, remove the supports, lower the ve-
w i t h 20 N n n (15 ft-lbs) torque.
hicle and remove the block from t h e brake pedal.
 17 - 8 SPRINGS/SHOCK ABSORBERS
SPRING
Fig. 10 Front Suspension W/Model 60 Axle—W-350
Vehicles
(3) Inspect t h e s p r i n g leaf a l i g n m e n t clips. T h e
clips m u s t not be damaged or bent. The clips should
be t i g h t around t h e spring leaves, b u t n o t t i g h t
enough t o " b i n d " the spring leaves. Replace damaged
clips.
(4) Inspect for broken s p r i n g leaves and replace as
necessary.
T h e r e a r s p r i n g s a r e d e s i g n e d t o f u n c t i o n sat-
isfactorily without lubricant added between the
leaves; h o w e v e r , f o r a b n o r m a l o p e r a t i n g c o n d i -
tions, a slight application o f l u b r i c a n t between
the leaves w i l l i m p r o v e t h e s p r i n g a c t i o n .
F r o n t leaf springs do not have plastic-tip liners.
INSTALLATION
(1) A l i g n t h e spring front " e y e " w i t h t h e bolt hole
i n t h e f r o n t bracket a n d i n s t a l l t h e "eye" p i v o t bolt
and n u t (Figs. 9 and 10).
(2) Position the shackle plates a t t h e s p r i n g rear
"eye" a n d t h e frame r a i l bracket, and i n s t a l l t h e re-
t a i n i n g n u t s (Figs. 9 and 10).
(3) T i g h t e n the shackle plate n u t s a n d t h e front
"eye" p i v o t bolt n u t u n t i l a l l separation between t h e
metal is removed.
(4) Position the spring on t h e axle shaft tube so
t h a t t h e spring center bolt is inserted i n t o t h e locat-
i n g hole i n the axle tube s p r i n g pad (Figs. 9 and 10).
(5) I n s t a l l the U-bolts, replacement lockwashers
and t h e r e t a i n i n g nuts (Figs. 9 a n d 10).
(6) T i g h t e n the nuts u n t i l t h e y force t h e lockwash-
ers flush against t h e spring bracket.
•
(7) Remove t h e supports a n d lower t h e vehicle so
t h a t t h e weight is being supported b y t h e tires (i.e.,
the springs).
(8) T i g h t e n t h e s p r i n g r e t a i n i n g n u t s according to
the following specifications:
• U-bolt nuts - 129 N - m (95 ft-lbs) torque;
• axle spring pad stud n u t s (9/16-18 stud) — 129
N-m (95 ft-lbs) torque;
• axle spring pad stud n u t s (Model 44 A x l e ) — 142
N-m (105 ft-lbs) torque;
• axle spring pad stud n u t s (Model 60 Axle) — 156
N-m (115 ft-lbs) torque;
• s p r i n g front "eye" pivot bolt n u t — 108 N-m (80 f t -
lbs) torque; a n d
• shackle plate nuts — 108 N - m (80 ft-lbs) torque.
REAR SPRINGS—REMOVAL/INSTALLATION
REMOVAL
(1) Use a chain hoist/crane or a h y d r a u l i c l i f t posi-
tioned a t t h e frame a f t o f the rear axle to raise t h e
vehicle u n t i l a l l w e i g h t is removed from t h e rear
springs.
T h e v e h i c l e m u s t b e r a i s e d e i t h e r b y a hoist/
c r a n e o r a l i f t p o s i t i o n e d u n d e r t h e f r a m e side
r a i l a t the crossmember a f t o f the axle. Use care
to a v o i d b e n d i n g t h e side r a i l flange.
(2) W i t h the front tires i n contact w i t h the surface,
position support stands under t h e frame side rails.
(3) Remove t h e nuts, t h e lockwashers, a n d t h e U -
bolts t h a t attach t h e s p r i n g to t h e axle shaft tubes
(Figs. 1 1 , 12 and 13).
NUT J9017-30
Fig. 11 Rear Spring—Model 150 Vehicles
 • SPRINGS/SHOCK ABSORBERS
Fig. 13 Rear Spring & Auxiliary Spring—D/W-250 &
D/W-350 Vehicles
(4) Remove the n u t s and bolts from t h e s p r i n g front
and rear "eyes", and remove the s p r i n g from the ve-
hicle (Figs. 1 1 , 12 and 13).
INSPECTION
(1) Inspect the spring and shackle " e y e " bushings,
t h e shackle bolts, t h e shackle, t h e shackle bracket
and the s p r i n g "eye" (pivot) bolts for excessive wear
17 - 9
and damage. Replace a l l excessively w o r n and d a m -
aged components (Figs. 1 1 , 12 and 13).
(2) Examine the condition o f t h e s p r i n g center b o l t
(Figs. 1 1 , 12 and 13) and ensure t h a t the n u t i s cor-
rectly tightened. I f necessary, t i g h t e n the center b o l t
n u t w i t h 20 N-m (15 ft-lbs) torque.
(3) Inspect t h e spring leaf a l i g n m e n t clips. T h e
clips m u s t not be damaged or bent. The clips should
be t i g h t around t h e spring leaves, b u t n o t t i g h t
enough t o " b i n d " the spring leaves. Replace damaged
clips.
(4) Inspect for broken s p r i n g leaves and replace as
necessary.
T h e r e a r springs a r e d e s i g n e d to function s a t -
isfactorily without l u b r i c a n t a d d e d b e t w e e n t h e
leaves; however, for a b n o r m a l o p e r a t i n g c o n d i -
tions, a slight application o f l u b r i c a n t b e t w e e n
the leaves w i l l improve the s p r i n g action.
L i g h t - d u t y , 2 W D vehicle springs are equipped w i t h
plastic-tip liners. These tips should not be l u b r i c a t e d ,
b u t may be replaced i f excessively w o r n or missing.
Vehicles w i t h heavy-duty suspensions do n o t have
plastic-tip liners.
INSTALLATION
(1) Position t h e spring on t h e axle shaft tube so
t h a t the spring center bolt i s inserted i n t o t h e locat-
i n g hole i n the axle tube s p r i n g pad (Figs. 1 1 , 12 a n d
13).
(2) A l i g n the spring front "eye" w i t h the bolt hole
i n t h e front bracket and i n s t a l l t h e "eye" pivot b o l t
and n u t (Figs. 1 1 , 12 and 13).
(3) A l i g n the spring rear "eye" w i t h the bolt hole i n
the spring shackle or the rear bracket (as applicable)
and i n s t a l l the spring "eye" p i v o t bolt and n u t (Figs.
1 1 , 12 and 13).
(4) T i g h t e n t h e spring front a n d rear "eye" p i v o t
bolt nuts u n t i l a l l separation between t h e m e t a l is
removed.
(5) I n s t a l l t h e U-bolts, replacement lockwashers
and t h e r e t a i n i n g nuts (Figs. 1 1 , 12 and 13).
(6) T i g h t e n the nuts u n t i l t h e y force the lockwash-
ers flush against the spring bracket.
(7) A l i g n t h e a u x i l i a r y s p r i n g w i t h t h e p r i m a r y
spring (Figs. 1 1 , 12 and 13).
(8) Remove t h e supports a n d lower t h e vehicle so
t h a t the weight is being supported by the tires (i.e.,
the springs).
(9) T i g h t e n t h e spring r e t a i n i n g nuts according to
the following specifications:
• U-bolt nuts (1/2-20) - 88 N-m (65 ft-lbs) torque;
• U-bolt nuts (9/16-18) - 149 N - m (110 ft-lbs)
torque;
• 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; and
17-10 SPRINGS/SHOCK ABSORBERS
• s p r i n g f r o n t and rear "eye" pivot bolt n u t (3/4-16)
- 183 N n n (135 ft-lbs) torque.
SPRING LEAF-REPLACEMENT
S p r i n g leaves ( i f broken) can be replaced w i t h r e -
placement leaves, however, i f a spring has t a k e n a
"set" (i.e., has lost significant height), i t should be re-
placed.
(1) Remove t h e s p r i n g from t h e vehicle. I f neces-
sary, refer t o the removal procedure.
(2) Remove the s p r i n g leaf alignment clips.
(3) Clamp the spring i n a vise and remove the n u t
a n d the center bolt (Fig. 14).
•
(1) Raise and support the vehicle so t h a t the s p r i n g
is relaxed and the t i r e s s l i g h t l y contacting the sur-
face.
(2) A s applicable, remove t h e s p r i n g front or rear
"eye" pivot bolt and remove t h e front or rear o f t h e
s p r i n g from t h e frame r a i l bracket or t h e s p r i n g
shackle.
(3) Use a n appropriate d r i v e r tool a n d force t h e
o r i g i n a l b u s h i n g out o f the s p r i n g "eye".
(4) I n s t a l l t h e replacement b u s h i n g w i t h a n appro-
priate tool.
(5) A s applicable, insert t h e e n d o f the spring i n
the frame r a i l bracket or the s p r i n g shackle, i n s t a l l
t h e pivot bolt and t h e r e t a i n i n g n u t . Do not t i g h t e n
the pivot bolt r e t a i n i n g n u t u n t i l the f u l l w e i g h t o f
the vehicle is supported b y the springs.
(6) Remove t h e supports a n d lower the vehicle t o
the surface.
(7) T i g h t e n the s p r i n g "eye" p i v o t b o l t n u t w i t h t h e
specified torque. Refer t o t h e Torque Specifications
chart.

STABILIZER BAR-REMOVAL/INSTALLATION

REMOVAL
(1) Remove the l i n k rod r e t a i n i n g n u t a t each end
of the stabilizer bar (Figs. 15 a n d 16).

Fig. 14 Leaf Spring Disassembly

(4) Insert a long d r i f t or punch i n t o the center bolt
hole and slowly release the vise jaws.
(5) Remove t h e spring from t h e vise and replace
t h e broken/defective leaf. Insert a long d r i f t or punch
i n t o the s p r i n g center bolt hole.
(6) Position t h e spring between vise jaws a n d
slowly t i g h t e n t h e vise jaws w h i l e r e t a i n i n g t h e
s p r i n g leaves aligned w i t h the long d r i f t or punch.
(7) Remove the drift/punch from the spring center
bolt hole a n d i n s t a l l a replacement center bolt and
n u t (Fig. 14).
(8) T i g h t e n the n u t w i t h 20 N n n (15 ft-lbs) torque
or u n t i l t h e center o f the spring has no "gaps" be-
t w e e n t h e leaves ( m a x i m u m of 54 Nmi/40 ft-lbs
torque).
(9) I n s t a l l the alignment clips.
(10) I n s t a l l the spring i n the vehicle. I f necessary
refer t o the i n s t a l l a t i o n procedure.
Fig. 15 Stabilizer Bar—2WD Vehicles
FRONT AND REAR SPRING "EYE" ROUND
' (2) Remove t h e outer retainers and rubber bush-
BUSHING
ings from the l i n k rods (Figs. 15 and 16).
The s p r i n g front/rear "eye" round (one-piece) bush- (3) A s applicable, remove the bolts or n u t s from the
i n g can be replaced w i t h the spring installed on the U-shaped stabilizer bar support brackets and remove
vehicle according to the following instructions. the stabilizer bar f r o m the vehicle (Figs. 15 and 16).
• SPRINGS/SHOCK ABSORBERS 17 - 11

INSTALLATION
(1) Position t h e stabilizer b a r ends over t h e l i n k
rods and i n s t a l l t h e U-shaped support brackets a n d
bolts/nuts (Figs. 15 a n d 16). T i g h t e n t h e bolts/nuts
w i t h 23 N n n (17 ft-lbs/200 in-lbs) torque.
(2) I n s t a l l t h e outer retainers and rubber bushings
on the l i n k rods (Figs. 15 and 16).
(3) I n s t a l l t h e l i n k r o d n u t s (Figs. 15 a n d 16).
T i g h t e n t h e n u t s w i t h 11 N n n (100 in-lbs).

Fig. 16 Stabilizer Bar— 4WD Vehicles

17-12 SPRINGS/SHOCK ABSORBERS

SPECIFICATIONS

TORQUE SPECIFICATIONS

COMPONENT SET-TO-TORQUE RECHECK TORQUE

SPRINGS (FRONT)
Shackle Bolt Nut and Front Eye Bolt (1/2-20) 108 N T n (80 ft-lbs)
Axle Spring Plate Stud (Model 60 Axle) 156 N » m (115 ft-lbs)
Axle Spring Plate Stud (Model 44 Axle) 142N*m (105 ft-lbs)
Axle Spring Plate Stud Nut (9/16-18) 129 N « m (95 ft-lbs)
U-Bolt Nut (9/16-18) 129 N » m (95 ft-lbs)

SPRINGS (REAR)
Shackle Bolt Nut and Front Eye Bolt (1/2-20) 88 N*m (65 ft-lbs)
Shackle Bolt Nut and Front Eye Bolt (5/8-18) 135 N*m (100 ft-lbs)
Shackle Bolt Nut and Front Eye Bolt (3/4-16) 183 N » m (135 ft-lbs)
U-Bolt Nut (1/2-20) 88 N « m (65 ft-lbs)
U-Bolt Nut (9/16-18) 149 N*m (110 ft-lbs)
Aux. Spring Pad Bracket-to-Frame Nut (3/8-16) 41 N » m (30 ft-lbs)

SHOCK ABSORBERS (FRONT) 2WD VEHICLES

Upper Bushing Retaining Nut (3/8-24) 34 N*m (25 ft-lbs)
Lower Nut (5/16-18) 23 N n n (200 in-lbs)
Shock Absorber Lower Stud-to-Axle Nut (3/4-16) 156 N n n (115 ft-lbs)
Shock Absorber Lower Nut (1/2-20) 75 N n n (55 ft-lbs)
Shock Absorber Upper Nut (1/2-20) 7 5 N « m (55 ft-lbs)

SHOCK ABSORBERS (REAR)

Lower Nut (1/2-20) 82 N n n (60 ft-lbs)
Upper Nut (1/2-20) 82 Nnm (60 ft-lbs)

JOUNCE BUMPERS
Front Jounce Bumper Retaining Nut 20 N n n (180 in-lbs)
Front Jounce Bumper Bracket-to-Frame Nut (1/2-13) (4WD) 102 N n n (75 ft-lbs)
D-130, W-150, a n d Sport Utility
Rear Jounce Bumper Retaining Nut 20 N n n (180 in-lbs)
Rear Jounce Bumper Mounting Bracket-to-Frame Nut (3/8-16) 41 N n n (30 ft-lbs)
D a n d W230 and 3 5 0 Models
Rear Jounce Bumper Retaining Nut 23 N n n (200 in-lbs)

STABILIZER BAR
2WD Vehicles
Link Rod-to-Front Strut Rod Nuts (5/16-18) 23 N n n (200 in-lbs)
Stabilizer Bar Bracket-to-Frame Nuts (7/16-14) 68 N n n (50 ft-lbs)
U-Shaped Bracket-to-Mounting Bracket Nut (5/16-18) 23 N n n (200 in-lbs)
Stabilizer Bar-to-Link Rod Nut (5/16-18) 11 N n n (100 in-lbs)
4WD Vehicles
U-Shaped Bracket-to-Frame Nuts (5/16-18) 23 N n n (200 in-lbs)
Link Rod-to-Spring Bracket Nut (1/2-13) 102 N n n (75 ft-lbs)
Stabilizer Bar to Link Rod Nut (5/16-18) 11 N n n (100 in-lbs)

UPPER SUSPENSION ARM (2WD)

Camber/Caster Adjustment Cam Nut 95 N n n (70 ft-lbs)
Upper Ball Joint-to-Steering Knuckle Nut 142 N n n (105 ft-lbs)

LOWER SUSPENSION ARM (2WD)

Arm-to-Frame Pivot Bolt Nut (5/8-18 & 3/4-16) 237 Nnn (175 ft-lbs)
Lower Ball Joint-to-Steering Arm Nut HD 237 Nnn (175 ft-lbs)
SD 183 Nnn (135 ft-lbs)
Strut Rod-to-Lower Arm Nut (1/2-13) 136 Nnn (100 ft-lbs)
Strut Rod Front Nut 70 Nnn (52 ft-lbs)

STEERING KNUCKLE
Steering Knuckle-to-Steering Arm Nut Heavy Duty Suspension 305 N n n (225 ft-lbs)
Standard Suspension 294 N n n (217 ft-lbs)
J9017-38
• STEERING 19-1

STEERING

CONTENTS
Page Page

GENERAL INFORMATION 1 SPECIFICATIONS 70

MANUAL STEERING GEAR SERVICE 6 STEERING COLUMN SERVICE 54
POWER STEERING GEAR SERVICE 16 STEERING LINKAGE SERVICE ...4
POWER STEERING PUMP SERVICE 39

GENERAL INFORMATION

INDEX
Page Page
Service Precautions 3 Steering System Description 1

STEERING SYSTEM DESCRIPTION steering gear; t h e interconnecting hoses a n d f i t t i n g s ;

a belt-driven power steering pump w i t h a n i n t e g r a l
R a m T r u c k a n d Ramcharger vehicles can be f l u i d reservoir (Fig. 2); and the steering l i n k a g e . The
equipped w i t h either m a n u a l steering or a power (as- power steering gear a n d p u m p can be adjusted a n d
sisted) steering system. A recirculating-ball type i n t e r n a l l y serviced.
steering gear is used for b o t h systems (Fig. 1).
MANUAL
GEAR POWER
GEAR

Fig. 2 Power Steering Pump

J8919-6
Fig. 1 Steering Gears
A m a n u a l steering system consists of a steering
gear and t h e steering linkage.
A power (assisted) steering system consists of a
Steering wheel movement is transferred by t h e
steering column shaft to t h e steering gear v i a a u n i -
versal j o i n t coupler. The steering gear converts t h e
r o t a t i o n a l movement of the steering column shaft to
transverse movement for t h e t i e rods. T h e t i e rods
and the tie-rod ends transfer t h i s movement to t h e
steering k n u c k l e arms and t h e wheels/tires w h i l e s i -
multaneously accommodating movement o f the vehi-
cle f r o n t suspension.
19-2 STEERING
I f t h e front t i r e t r e a d b e c o m e s w o r n , t h e steer-
i n g effort w i l l increase because o f the decrease
i n surface f r i c t i o n .
STEERING LINKAGE
DESCRIPTION—2WD VEHICLES
The steering l i n k a g e for 2 W D vehicles (Fig. 3) con-
sists o f a steering gear p i t m a n a r m , a center l i n k ,
t w o t i e rods ( w i t h removal and adjustable ends), a n d
a n idler a r m . T h e adjustment sleeves a t the tie-rod
ends provide for "toe" position adjustment. T h e t i e
rod threaded-ends have r i g h t - h a n d threads to accept
the adjustment sleeve.
TIE
Fig. 3 Steering Linkage—2WD Vehicles
The center l i n k is connected to the p i t m a n a r m a t
one end and to the idler a r m at the opposite end. The
inner tie-rod ends are connected to t h e center l i n k
and the outer tie-rod ends are connected to the steer-
i n g knuckle arms (Fig. 3).
MANUAL STEERING GEAR
DESCRIPTION
The m a n u a l steering gears ( F i g . 4) installed i n
Ram T r u c k and Ramcharger vehicles are designed t o
provide easy steering w i t h m i n i m u m friction w i t h i n
the steering gear. A r e c i r c u l a t i n g b a l l n u t travels u p
and down on a wormshaft t h a t is supported by recir-
c u l a t i n g balls, w h i c h function as the w o r m (screw)
thread. The wormshaft and b a l l n u t are supported i n
the steering gear housing b y a n adjustable, b a l l -
t h r u s t type upper and lower bearing.
POWER STEERING GEAR
DESCRIPTION
The power steering gear is comprised of a gear
housing t h a t contains a p i t m a n (sector) shaft w i t h
sector gear, a power piston w i t h gear teeth t h a t are
"broached" into the side of the piston (which are i n
•
WORMSHAFT ADJUSTER PLUG
Fig. 4 Manual Steering Gear
constant mesh w i t h t h e pitman/sector shaft gear
teeth), and a wormshaft t h a t connects t h e steering
column shaft to t h e power piston v i a a fabric and
rubber coupler.
The steering valve, located o n top of the steering
gear, directs t h e flow of f l u i d i n the steering gear.
F l u i d i s supplied t o the steering gear b y a belt (en-
gine) d r i v e n , constant displacement, vane-type p u m p
v i a a h i g h pressure hose. F l u i d is r e t u r n e d to t h e
pump reservoir f r o m the steering gear v i a a low pres-
sure, r e t u r n hose.
BUILD DATE
The steering gear b u i l d date code is stamped i n t o
the p i t m a n (sector) shaft adjustment screw combina-
t i o n a l u m i n u m gasket and date tag w i t h a four d i g i t
number. T h e first three digits represent the day of
the year. T h e f o u r t h d i g i t represents the year. F o r
example, b u i l d date code 2908 means the 290th day
(i.e., Oct. 16) o f 1989.
POWER STEERING PUMP
DESCRIPTION
H y d r a u l i c f l u i d pressure is provided for operation
of the power steering gear by a belt d r i v e n power
steering p u m p (Fig. 2). The power steering pump is a
constant displacement, vane-type pump. The pump
housing and t h e i n t e r n a l components are combined
w i t h t h e reservoir to form a one-piece mechanism.
The " h a m c a n " shaped, i n t e g r a l reservoir has a pres-
sure hose attachment located at t h e rear of t h e
pump. The power steering pump is connected to the
steering gear v i a a h i g h pressure hose and a l o w
pressure, r e t u r n hose. The pump shaft has a
"pressed-on" p u l l e y t h a t is belt driven by the crank-
shaft pulley.
 • STEERING
B e c a u s e o f the u n i q u e shaft b e a r i n g s , the dif-
ferent flow c o n t r o l l e v e l s a n d the different p u m p
displacements, R a m T r u c k a n d Ramcharger
p o w e r s t e e r i n g p u m p s a r e n o t interchangeable
w i t h p u m p s i n s t a l l e d i n other v e h i c l e s .
STEERING COLUMNS
DESCRIPTION
Two general types o f steering columns are installed
on R a m T r u c k a n d Ramcharger vehicles: a fixed,
non-tiltable c o l u m n a n d a t i l t a b l e column. The m u l t i -
position, t i l t a b l e c o l u m n i s optionally available.
The t i l t a b l e steering column has a "spring-loaded",
movable upper h o u s i n g t h a t provides multi-steering
wheel positions i n a v e r t i c a l plane.
The i g n i t i o n key/lock cylinder a n d t h e i g n i t i o n
switch are located i n t h e steering column. W h e n the
key/lock cylinder is t u r n e d t o the L O C K position, the
i g n i t i o n s w i t c h and t h e steering shaft cannot be op-
erated. For vehicles w i t h a n automatic transmission,
the lock mechanism also prevents operation o f the
column-mounted gear shift/selector mechanism.
The center, slip-type (telescoping) intermediate
19-3
shaft is attached t o t h e steering gear shaft w i t h a
flexible coupler a n d to t h e steering c o l u m n shaft
w i t h a universal j o i n t .
B o t h types of steering columns have anti-theft pro-
visions, plus they are energy-absorbing (i.e., collapse
f r o m impact i n t h e event o f a front-end collision).
SERVICE PRECAUTIONS
Periodic l u b r i c a t i o n of t h e steering linkage b a l l
studs is a requirement, refer t o Group 0 — L u b r i c a t i o n
and Maintenance for the correct l u b r i c a n t specifica-
t i o n a n d t h e recommended t i m e interval/distance
schedule.
The tie-rod end "boot" seals can be replaced sepa-
r a t e l y a n d should always be inspected for damage
w h e n the vehicle chassis is lubricated.
A l l front s u s p e n s i o n components t h a t c o n t a i n
r u b b e r s h o u l d b e tightened only w h e n the s u s -
p e n s i o n s y s t e m i s at the n o r m a l height a b o v e the
surface a n d w i t h the complete weight of the v e -
h i c l e o n the wheels/tires. R u b b e r bushings
should never be lubricated with a petroleum-
based lubricant.
Safety goggles s h o u l d b e w o r n a t a l l times
w h e n i n v o l v e d w i t h p o w e r steering s e r v i c e .
 19-4 STEERING •
STEERING LINKAGE SERVICE

INDEX
Page Page
Steering Linkage—Removal/Installation 4 Tie-Rod End—Removal/Installation ............. 4

TIE-ROD END—REMOVAL/INSTALLATION

SERVICE INFORMATION
Before r e m o v i n g a tie-rod end, t h e "boot" seal
should be closely inspected for excessive wear and
damage. I f a seal is damaged (i.e., t h e b a l l stud ex-
posed), i t should be removed and the tie-rod end b a l l
s t u d inspected. I f t h e b a l l stud is n o t excessively
w o r n or corroded (i.e., "rusted") and t h e lubricant is
i n - t a c t (and is not contaminated), i n s t a l l a replace-
m e n t seal; otherwise, a complete replacement tie-rod
end should be installed. Lubricate t h e tie-rod end
b a l l stud w i t h "long-life" chassis l u b r i c a n t (e.g., M O -
P A R M u l t i - M i l e a g e L u b r i c a n t , or a n equivalent prod-
uct).

REMOVAL
(1) Raise a n d support t h e vehicle.
(2) Remove t h e cotter p i n a n d t h e r e t a i n i n g n u t
f r o m t h e applicable tie-rod end b a l l stud (i.e., either
a t t h e steering k n u c k l e or a t the center l i n k ) .
Removal o f a tie-rod e n d ball stud from a Fig. 1 Tie-Rod End Removal
steering k n u c k l e a r m bore o r f r o m a center l i n k 2 — F r o n t Suspension).
bore b y methods other than using a n appropri- P o s i t i o n t h e c l a m p o n t h e sleeve ( F i g . 2) so that
a t e p u l l e r t o o l (e.g., T o o l C-3894-A) w i l l d a m a g e the retaining b o l t is located o n the b o t t o m side
t h e t i e - r o d e n d b a l l s t u d seal. o f t h e sleeve a n d t h e c l a m p s l o t i s a l i g n e d with
(3) A s applicable, i n s t a l l Puller Tool C-3894-A on t h e sleeve s l o t .
t h e tie-rod end b a l l stud a t the steering knuckle (Fig. (4) A f t e r adjustment, t i g h t e n the sleeve clamp bolt
1) or a t the center l i n k . w i t h 20 N«m (177 in-lbs) torque.
(4) A p p l y sufficient force w i t h t h e puller tool (Fig.
1) to loosen t h e tie-rod end b a l l stud from the steer- STEERING LINKAGE-REMOVAL/INSTALLATION
i n g k n u c k l e a r m bore or from the center l i n k bore.
(5) Loosen t h e applicable tie-rod sleeve clamp n u t
SERVICE INFORM A TION
a n d bolt a n d un-thread t h e tie-rod end from t h e
Before r e m o v i n g a tie-rod end, idler a r m , p i t m a n
sleeve.
(steering) a r m or center l i n k (Fig. 2), a l l t h e b a l l
INSTALLATION stud "boot" seals should be closely inspected for ex-
cessive wear a n d damage. I f a seal is damaged (i.e.,
(1) Thread t h e replacement tie-rod end into the t i e
the b a l l stud is exposed), i t should be removed a n d
r o d sleeve.
the b a l l stud inspected. I f the b a l l stud is n o t exces-
(2) A s applicable, insert the tie-rod end ball stud
sively w o r n or corroded (i.e., "rusted") and t h e l u b r i -
i n t o the steering k n u c k l e a r m bore or the center l i n k
cant is in-tact (and is n o t contaminated), i n s t a l l a
bore (Fig. 2). I n s t a l l t h e stud r e t a i n i n g n u t a n d
replacement seal; otherwise, a complete replacement
t i g h t e n i t w i t h 61 N n n (45 ft-lbs) torque. I n s t a l l a re-
component should be installed. Lubricate t h e b a l l
placement cotter p i n i n t h e b a l l stud.
stud w i t h "extended-life" chassis lubricant (e.g., M O -
(3) Remove t h e supports and lower the vehicle to
P A R M u l t i M i l e a g e L u b r i c a n t , or an equivalent
t h e surface. Adjust the wheel "toe" position (refer to
multi-purpose, N L G I Grade 2 E P l u b r i c a n t ) .
t h e A l i g n m e n t Specifications chart w i t h i n G r o u p
 • STEERING 19 - 5

TIE INSTALLATION
(1) Replace a l l steering l i n k a g e components (Fig. 2)
t h a t are e i t h e r damaged or excessively w o r n .
(2) Position t h e idler a r m bracket a t the frame and
i n s t a l l t h e r e t a i n i n g n u t s on t h e bolts ( F i g . 2).
T i g h t e n t h e r e t a i n i n g n u t s w i t h 54 N n n (40 ft-lbs)
torque.
(3) I n s t a l l t h e p i t m a n (steering) a r m o n t h e steer-
i n g gear p i t m a n (sector) shaft. T i g h t e n t h e r e t a i n i n g
n u t w i t h 237 N n n (175 ft-lbs) torque.

CAUTION: Care must be exercised when installing a

center link. It is possible to install it back to front
(i.e., reversed position), which will result in incor-
Fig. 2 Steering Linkage rect geometry and tie rod-to-center link and tie rod-
to-strut interferences during vehicle jounce. Viewed
REMOVAL
from the front of the vehicle, the center link ends
(1) Raise and support the vehicle.
should turn upward. Viewed from the side of the ve-
(2) Remove the cotter pins a n d r e t a i n i n g n u t s from
hicle, the ends should turn toward the front of the
t h e tie-rod ends and center l i n k b a l l studs.
vehicle. The tie-rod ball studs enter the center link
R e m o v a l o f a b a l l s t u d ( F i g . 1) f r o m a s t e e r i n g
bores from the rear.
k n u c k l e a r m b o r e , from a c e n t e r l i n k b o r e o r a
p i t m a n ( s t e e r i n g ) a r m b o r e ( F i g . 2) b y m e t h o d s
(4) Position t h e center l i n k b a l l studs a t t h e idler
o t h e r t h a n u s i n g a n a p p r o p r i a t e p u l l e r t o o l (e.g.,
a r m and a t t h e p i t m a n (steering) a r m (Fig. 2). I n s t a l l
T o o l C-3894-A) w i l l d a m a g e t h e b a l l s t u d s e a l .
and t i g h t e n t h e b a l l s t u d r e t a i n i n g n u t s w i t h 54 N n n
(3) Remove the outer tie-rod end b a l l studs from
(40 ft-lbs) torque. I n s t a l l replacement cotter pins i n
t h e steering knuckle a r m bores (Fig. 2). Use care to
t h e b a l l studs.
avoid damaging the seals.
(5) Connect t h e tie-rod end b a l l studs to t h e steer-
(4) Remove the i n n e r tie-rod end b a l l studs from
i n g k n u c k l e arms a n d t o t h e center l i n k (Fig. 2).
t h e center l i n k bores (Fig. 2). Use care t o avoid dam-
T i g h t e n t h e r e t a i n i n g n u t s w i t h 6 1 N n n (45 ft-lbs)
aging the seals.
torque and i n s t a l l replacement cotter pins i n t h e b a l l
(5) Remove the center l i n k b a l l stud from t h e idler
studs.
a r m bore (Fig. 2). Use care t o avoid damaging t h e
(6) Remove t h e supports a n d lower t h e vehicle to
seal.
the surface. Adjust t h e wheel "toe" position (refer to
(6) Remove the center l i n k b a l l stud from t h e p i t -
t h e A l i g n m e n t Specifications chart w i t h i n G r o u p
m a n (steering) a r m bore (Fig. 2). Use care t o avoid
2 — F r o n t Suspension).
damaging the seal. Remove the steering l i n k a g e from
Position the clamp o n the tie-rod adjustment
the vehicle.
sleeve ( F i g . 2) so t h a t t h e r e t a i n i n g b o l t i s l o -
(7) Remove the idler a r m bracket r e t a i n i n g n u t s
c a t e d o n t h e b o t t o m s i d e o f t h e sleeve a n d t h e
from the frame bolts (Fig. 2).
c l a m p s l o t i s a l i g n e d w i t h t h e sleeve s l o t .
(8) Remove the r e t a i n i n g n u t a n d t h e p i t m a n
(7) After adjustment, t i g h t e n t h e sleeve tie-rod ad-
(steering) a r m from t h e steering gear p i t m a n (sector)
j u s t m e n t sleeve clamp bolt w i t h 20 N n n (177 in-lbs)
shaft w i t h Removal Tool C-4150.
torque.
19-6 STEERING

MANUAL S T E E R I N G G E A R S E R V I C E

INDEX
Page Page
Adjustments On-Bench 14 Installation . . 15
Assembly 13 On-Vehicle Adjustments . 7
Cleaning And Inspection 12 Pitman Shaft Seal—Replacement 8
Diagnosis . 6 Removal/Disassembly 8
Disassembly 9 Service Information 6

SERVICE INFORMATION
M a n u a l steering gears (Fig. 1) are designed t o pro-
vide easy steering w i t h m i n i m u m f r i c t i o n w i t h i n t h e
steering gear. A r e c i r c u l a t i n g b a l l n u t travels u p a n d
down on a wormshaft t h a t is supported by recirculat-
i n g balls, w h i c h function as the w o r m (screw) t h r e a d .
The wormshaft and b a l l n u t are supported i n t h e
steering gear housing b y a n adjustable, b a l l - t h r u s t
type upper and lower bearing.
WORMSHAFT ADJUSTER PLUG
The sector shaft and the sector gear are i n t e g r a l .
The sector shaft gear teeth mesh w i t h the rack teeth
on the r e c i r c u l a t i n g b a l l n u t . T h e teeth mesh (lash)
adjustment i s provided b y the sector shaft gear ad-
j u s t m e n t screw, w h i c h extends t h r o u g h the housing
cover.
The sector shaft gear teeth a n d t h e b a l l n u t rack
teeth are designed so t h a t a t i g h t e r meshing exists
between t h e t w o w h e n the front wheels are s t r a i g h t
ahead. Correct meshing between t h e sector shaft
gear and b a l l n u t rack teeth is obtained by adjusting
a n adjustment screw, w h i c h moves t h e sector shaft
gear endwise and produces t h e desired meshing o f
the tapered sector shaft gear and b a l l n u t rack teeth.
The wormshaft bearing adjustment p l u g is adjusted
to provide t h e correct "preloading" o f t h e upper and
lower wormshaft t h r u s t bearings.

DIAGNOSIS
To use t h e M a n u a l Steering Gear Diagnosis chart:
read the conditions described w i t h i n the upper, bold-
outlined squares a n d select t h e condition t h a t re-
quires correction and follow the connecting lines i n t o
the squares describe t h e possible causes. I n most i n -
stances, t h e required corrective action is obvious,
however, a n asterisk (*) indicates a n existing service
procedure t h a t is located w i t h i n a n applicable group
of t h i s m a n u a l .
Fig. 1 Manual Steering Gear
 • STEERING 19 - 7

MANUAL STEERING GEAR DIAGNOSIS

I
PULL TO ONE WHEEL TRAMP

1
EXCESSIVE PLAY |
| SIDE (TENDENCY (EXCESSIVE
Oft LOOSENESS HARD
Of VEHICLE TO VERTICAL
IN IMS STIERINGl STEERING
VEER IN ONE MOTION
WHIIL
•DIRECTION ONL OF WHEELS)

FRONT WHEEL INCORRECT TIRE LOW OR

IMPROPER INCORRECT
BEARINGS PRESSURES OR BENT STEERING UNEVEN
FRONT END TIRE
IMPROPERLY TIRE SIZES LINKAGE TIRE
ALIGNMENT PRESSURE
ADJUSTED NOT UNIFORM PRESSURE

INSUFf IC»ENT
:

STEERING WHEEL
BROKIEN OR LUBRICANT LOOSE
LINKAGE BEARINGS DRAGGING
BADLY SAGGING IN STE ERING STEERING
WOR N OR IMPROPERLY BRAKES REAR 5>PRING LINKAGE
GEA R OR
L a DSE ADJUSTED
UNK AGE

WORM SHAFT FRC>NT

WORNCm LOOSE SECTOR SHAFT WORN OR
SUSPE NSION IMPROPER
FRON TSUS- ADJUSTMENT ADJUSTMENT INOPERATIVE
PIVOIr s o R FRONTEND
P E N S O M PIVOTS LOOSE LOOSE SHOCK
BALL JOINTS AUGh IMENT
OR BALIL JOINTS ABSORBERS
FROZEN

GREASE, OIL OR
STEERING ARM STEERING TIRES OR
STEERING GEAR BRAKE FLUID ON GEAR SHAFT
LOOSE ON WHEEL LOOSE WHEELS
MOUNTING BRAKE UNINGS ADJUSTED
STEERING ON STEERING OUT OF
BOLTS LOOSE (UPON BRAKING TOO TIGHT
GEAR SHAFT SHAFT BALANCE
ONLY)

* TESTS, ADJUSTMENTS AND PROCEDURES ARE DESCRIBED IN THIS MANUAL RN817

SIDE COVER
ON-VEHICLE ADJUSTMENTS BUSHING
Two adjustments are p r o v i d e d for m a n u a l s t e e r i n g
BUSHING v
gears (Figs. 2 a n d 3). T h e w o r m s h a f t b e a r i n g "pre-
l o a d " t o r q u e a d j u s t m e n t a n d t h e b a l l n u t rack/sector
shaft gear t e e t h mesh (lash) a d j u s t m e n t .

WORMSHAFT ADJUSTER PLUG

BALLS AND GUIDES \ LOCKNUT
OIL SEAL-^ /
SEAL
SECTOR SHAFT

BALL NUT

LASH
ADJUSTER
SCREW

RN789

WORM Fig. 3 Ball Nut Rack/Sector Shaft Gear Teeth Mesh

WORM BEARING
BEARING (LOWER) (Lash) Adjustment
(UPPER)
be determined t h a t t h e w o r m s h a f t b e a r i n g "preload"
t o r q u e is properly adjusted.
The wormshaft bearing "preload" torque adjust-
BALL NUT SECTOR RH36
ment is provided by the wormshaft thrust bearing

Fig. 2 Wormshaft "Preload" Torque Adjustment plug adjuster t h a t threads into the housing at the
l o w e r end of the wormshaft.
Before a n a d j u s t m e n t c a n be i n i t i a t e d for t h e b a l l
Safety goggles should be worn at a l l times
n u t rack/sector shaft gear t e e t h mesh (lash), i t m u s t
w h e n involved w i t h steering gear service.
19 - 8 STEERING
WORMSHAFT BEARING "PRELOAD" TORQUE
ADJUSTMENT
(1) Disconnect a n d remove t h e p i t m a n (steering)
a r m from t h e p i t m a n (sector) shaft w i t h Tool C-4150
(Fig. 4).
Fig. 4 Pitman (Steering) Arm Removal
(2) Remove the h o r n contact cover.
(3) Loosen the sector shaft adjustment screw lock-
n u t a n d un-thread the adjustment screw 1/2 to 2
t u r n s (Fig. 3). This w i l l relieve any f r i c t i o n load t h a t
could exist between the closely meshed b a l l n u t rack
and sector shaft gear teeth.
(4) T u r n the steering wheel to the r i g h t "stop" and
t h e n back 1/2 t u r n . Position Tool C-3380 (or a n ap-
propriate torque wrench) on steering shaft n u t .
(5) Rotate the steering shaft from t h e r i g h t "stop"
t o w a r d t h e straight ahead position w i t h Tool C-3380
w h i l e n o t i n g the indicated "preload" torque.
(6) T h e torque required to rotate the steering shaft
should be between 0.56 a n d 0.68 N»m (4 a n d 6 i n -
lbs). I f t h e torque is not w i t h i n t h i s range, a "pre-
l o a d " torque adjustment is necessary.
(7) Loosen the p l u g adjuster locknut (Fig. 2).
(8) T u r n the p l u g adjuster clockwise to increase the
" p r e l o a d " torque a n d counterclockwise t o decrease
the torque.
(9) W h i l e preventing t h e p l u g adjuster f r o m rotat-
ing, t i g h t e n the locknut securely, and t h e n measure
the wormshaft bearing "preload" torque.
BALL NUT RACK/SECTOR SHAFT GEAR
TEETH MESH (LASH) ADJUSTMENT
The sector shaft gear adjustment screw (located i n
housing cover) raises or lowers the position of t h e
shaft to provide t h e correct mesh between t h e t a -
•
pered sector shaft gear teeth a n d t h e tapered b a l l n u t
rack teeth. This adjustment c a n be accurately com-
pleted only after t h e wormshaft b e a r i n g "preload"
torque has been correctly adjusted.
(1) Rotate the steering wheel g e n t l y from one
"stop" t o t h e other and accurately count t h e number
of rotations. T u r n t h e steering wheel back exactly
h a l f way to the center position.
(2) T u r n t h e sector shaft adjustment screw clock-
wise t o remove a l l t h e lash t h a t exists between t h e
b a l l n u t rack and sector shaft gear t e e t h , and t h e n
t i g h t e n t h e adjustment screw l o c k n u t w i t h 47 N»m
(35 ft-lbs) torque.
(3) Rotate t h e steering wheel approximately 1/4
t u r n away from the overcenter position. T h e n , w i t h a
torque wrench on t h e steering wheel n u t , measure
the torque required t o rotate t h e steering wheel
t h r o u g h t h e overcenter position. T h e indicated over-
center drag torque should be 1.6 N»m (14 in-lbs). The
measured (drag) torque represents t h e t o t a l of t h e
wormshaft bearing "preload" torque a n d t h e b a l l n u t
rack/sector shaft gear teeth mesh f r i c t i o n load. Re-
adjust t h e sector shaft adjustment screw ( i f neces-
sary) t o obtain the correct drag torque.
(4) After t h e adjustment have been completed,
place t h e front wheels i n a s t r a i g h t ahead position,
and, w i t h t h e steering gear a n d steering wheel cen-
tered, i n s t a l l the p i t m a n (steering) a r m lockwasher
and n u t on the p i t m a n shaft.
(5) T i g h t e n p i t m a n (steering) a r m r e t a i n i n g n u t
w i t h 237 N n n (175 ft-lbs) torque. I n s t a l l a replace-
ment cotter p i n .
(6) I n s t a l l the h o r n contact cover.
REMOVAL/DISASSEMBLY
REMOVAL
(1) Remove the t w o bolts f r o m t h e wormshaft-
to-steering shaft coupler.
(2) Remove the p i t m a n (steering) a r m f r o m the pit-
m a n shaft w i t h Tool C-4150 (Fig. 4).
(3) Remove the steering gear-to-frame bolts and re-
move t h e gear from t h e vehicle.
PITMAN SHAFT SEAL—REPLACEMENT
(1) Raise and support t h e vehicle. Place t h e front
wheels i n the straight-ahead position.
(2) Disconnect t h e center l i n k f r o m t h e p i t m a n
(steering) a r m .
(3) M a r k the p i t m a n (steering) a r m and the p i t m a n
shaft positions for i n s t a l l a t i o n reference and remove
the p i t m a n a r m from the p i t m a n shaft w i t h a p u l l e r
tool (Fig. 4).
(4) Remove the p i t m a n shaft seal w i t h a pointed
tool or a screw driver w i t h a s m a l l blade.
 • STEERING
(5) Inspect t h e condition of the steering gear l u b r i -
cant. I f i t is contaminated (e.g., contains m e t a l p a r t i -
cles), remove a n d recondition t h e steering gear.
CAUTION: A protective wrap must be used to en-
close the shaft threads/splines during the shaft seal
installation. If the shaft seal is installed over ex-
posed shaft threads or splines, the seal lip could be
cut or distorted and result in leakage after installa-
tion.
(6) W r a p t h e p i t m a n shaft threads/splines w i t h 0 . 1 -
m m (0.005-in) t h i c k shimstock (or a single layer o f
the t h i n n e s t plastic tape available) to protect the re-
placement seal d u r i n g i n s t a l l a t i o n .
(7) Lubricate t h e l i p of the replacement seal w i t h
chassis l u b r i c a n t . Slide t h e seal over t h e shimstock/
tape and shaft and into the steering gear housing re-
cess. Remove t h e shimstock/tape f r o m t h e shaft.
Complete t h e seal i n s t a l l a t i o n by t a p p i n g the seal
w i t h a s m a l l plastic m a l l e t to "seat" i t i n the housing
recess.
(8) W i t h t h e a r m and t h e shaft i n s t a l l a t i o n refer-
ence m a r k s aligned, position t h e p i t m a n (steering)
a r m o n t h e p i t m a n shaft.
(9) I n s t a l l t h e washers and t h e r e t a i n i n g n u t on
the p i t m a n shaft a n d t i g h t e n t h e n u t w i t h 237 N n n
(175 ft-lbs) torque. I n s t a l l a replacement cotter p i n .
(10) Connect t h e center l i n k to the p i t m a n (steer-
ing) a r m . T i g h t e n t h e r e t a i n i n g n u t w i t h 54 N n n (40
ft-lbs) torque. I n s t a l l a replacement cotter p i n .
(11) Remove t h e supports and lower t h e vehicle.
DISASSEMBLY
(1) Remove t h e flexible coupling.
(2) Position t h e steering gear i n a vise and clamp i t
in-place at t h e m o u n t i n g bosses only.
(3) Rotate t h e wormshaft from stop-to-stop a n d
count t h e t o t a l number o f rotations. Rotate t h e
wormshaft i n t h e reverse direction 1/2 o f t h e t o t a l
n u m b e r of rotations to center i t and the b a l l n u t .
(4) Remove t h e p i t m a n (sector) shaft adjustment
screw locknut. Remove the cover r e t a i n i n g bolts,
cover, a n d gasket (Fig. 5).
(5) Slide t h e adjustment screw head (Fig. 6) out o f
the p i t m a n (sector) shaft T-slot and remove i t a n d
the shim(s).
(6) Retain t h e shim(s) for "end-play" measurement
d u r i n g assembly.
(7) Remove t h e p i t m a n (sector) shaft, t h e w o r m -
shaft bearing "preload" torque adjustment p l u g lock-
n u t , and t h e adjustment p l u g (Fig. 6).
(8) Remove t h e wormshaft and the b a l l n u t (Fig. 7).
(9) Remove (pry) the p i t m a n (sector) shaft and t h e
wormshaft seals from t h e steering gear housing (Fig.
8).
19 - 9
Fig, 5 Pitman (Sector) Shaft Removal
WORMSHAFT AND BALL NUT-DISASSEMBLY
(1) Remove t h e upper bearing from t h e wormshaft
(Fig. 6).
CAUTION: Do not allow the ball nut to rotate freely
and travel to either extreme end of the wormshaft.
This could damage the tangs at the ends of the re-
circulating ball guides (Fig. 6).
(2) Remove t h e r e c i r c u l a t i n g b a l l guide clamp r e -
t a i n i n g screws, t h e clamp a n d t h e guides ( F i g . 6).
Separate t h e half-guides a n d place t h e r e c i r c u l a t i n g
balls aside i n a container.
(3) H o l d t h e b a l l n u t over a cloth a n d remove t h e
r e m a i n i n g r e c i r c u l a t i n g balls f r o m t h e b a l l n u t cir-
cuits b y r o t a t i n g t h e wormshaft back and f o r t h u n t i l
the balls drop o u t on t h e cloth.
T h e r e a r e a t o t a l o f 50 r e c i r c u l a t i n g b a l l s
w i t h i n t h e b a l l n u t a n d t h e g u i d e s (25 i n e a c h
circuit).
(4) Remove t h e wormshaft f r o m t h e b a l l n u t ( F i g .
6).
WORMSHAFT AND BALL NUT-CLEANING
AND INSPECTION
(1) Clean a l l t h e components i n a cleaning solvent
and d r y t h e m w i t h a clean cloth and/or compressed
air.
(2) Inspect each component for wear, scoring,
cracks, nicks a n d surface p i t t i n g . Replace as neces-
sary.
WORMSHAFT AND BALL NUT-ASSEMBLY
CAUTION: The ball nut teeth are wider and deeper
on one side than on the other. When assembling
the wormshaft and ball nut, position the ball nut so
that the wider/deeper side of the teeth is closer to
the housing cover opening after installation.
19 - 10 STEERING •
COVER

BEARING
CAP

J8919-12

Fig. 6 Manual Steering Gear—Exploded View

 • STEERING 19 - 11

EQUAL EQUAL
THREADS THREADS

Fig. 7 Wormshaft & Bail Nut Removal

SEALS

TEETH
DOWNWARD J8919-14

Fig. 9 Wormshaft & Ball Nut

To a i d the recirculating ball installation, rotate
wormshaft back and f o r t h slightly while insert-
ing t h e balls.

Fig. 8 Shaft Seal Removal

(1) Position t h e b a l l n u t w i t h the r e c i r c u l a t i n g b a l l
guide holes facing u p w a r d and the b a l l n u t teeth fac-
i n g downward. I n s t a l l t h e wormshaft i n the b a l l n u t .
Rotate t h e shaft and t h r e a d i t i n t o t h e n u t u n t i l a n
equal number o f shaft threads are visible a t each end
of the n u t (Fig. 9).
(2) I n s t a l l one r e c i r c u l a t i n g b a l l i n each b a l l guide
hole. Move t h e wormshaft up/down a n d side-to-side
u n t i l t h e balls r o l l i n t o t h e b a l l n u t threads a t t h e
bottom of wormshaft a n d support the wormshaft.
(3) Assemble and i n s t a l l the b a l l guides i n the b a l l
n u t (Fig. 10).
(4) Divide t h e r e m a i n i n g 48 r e c i r c u l a t i n g balls i n t o
two groups and i n s t a l l 24 balls i n each b a l l n u t cir-
cuit. Insert the balls i n the b a l l n u t circuits t h r o u g h
the holes i n t h e b a l l guides (Fig. 10).
WORMSHAFT RH43
Fig. 10 Recirculating Ball Installation
(5) Place t h e b a l l guide clamp on the b a l l n u t and
i n s t a l l t h e clamp r e t a i n i n g screws (Fig. 6). T i g h t e n
the screws w i t h 14 N n n (10 ft-lbs) torque.
CAUTION: To avoid damaging the tangs on the ball
guide ends, do not allow the wormshaft to travel to
the end of the thread in either direction.
(6) L u b r i c a t e the wormshaft threads w i t h chassis
l u b r i c a n t and rotate t h e shaft to move i t in-and-out
of t h e b a l l n u t and distribute the lubricant.
(7) L u b r i c a t e t h e wormshaft upper bearing w i t h
chassis l u b r i c a n t and install i t on the wormshaft.
19-12 STEERING •
WORMSHAFT BEARING ADJUSTMENT ADJUSTMENT PULLER
PLUG-DISASSEMBLY CAP LOCKNUT
(1) P r y o u t and remove the wormshaft lower bear-
i n g r e t a i n e r f r o m the adjustment p l u g (Fig. 11).

SLIDE HAMMER J8919-17

Fig. 11 Wormshaft Lower Bearing Retainer Removal
(2) Remove the wormshaft lower bearing from the
Fig. 12 Bearing Cup Removal
adjustment' p l u g .

WORMSHAFT BEARING ADJUSTMENT INSTALLATION

PLUG-CLEANING/INSPECTION TOOL
(1) Clean a l l t h e components i n cleaning solvent
and dry w i t h a clean cloth only.
(2) Inspect each component for wear and damage.
Replace as necessary.

WORMSHAFT BEARING ADJUSTMENT BEARING

PLUG-ASSEMBLY
(1) I f t h e lower bearing cup m u s t be replaced, re-
move t h e o r i g i n a l cup (Fig. 12) and i n s t a l l a replace-
m e n t cup ( F i g . 14) according to t h e following
instructions:
• i n s t a l l a spare locknut on t h e adjustment p l u g
(Fig. 12) a n d clamp t h e cap i n a vise ( c l a m p t h e
vise j a w s o n the l o c k n u t only);
• assemble a puller tool and a slide hammer;
• position t h e puller tool legs between t h e bearing
cup and t h e inside o f the adjustment p l u g (Fig. 12);
• t i g h t e n t h e puller tool screw (Fig. 12) to expand Fig. 13 Bearing Cup Installation
and h o l d t h e legs i n position;
• move t h e slide hammer weight outward to remove CLEANING AND INSPECTION
the b e a r i n g cup from the adjustment p l u g (Fig. 12);
(1) Clean t h e housing and the p i t m a n shaft w i t h
• remove t h e adjustment p l u g from the vise and re-
cleaning solvent a n d d r y them w i t h a clean cloth
move t h e spare locknut; and
and/or compressed air.
• i n s t a l l a replacement bearing cup i n t h e adjust-
(2) Inspect t h e housing for cracks, porosity, dam-
m e n t p l u g w i t h a n appropriate i n s t a l l a t i o n tool (Fig.
13). aged threads and scoring/distortion of the gasket sur-
(2) L u b r i c a t e t h e wormshaft lower bearing and face area. Repair or replace as necessary.
place i t i n t h e bearing cup. (3) Inspect the p i t m a n shaft contact surface and the
(3) I n s t a l l the lower bearing retainer on the adjust- p i t m a n (sector) shaft gear teeth for wear, p i t t i n g , and
ment p l u g . I f necessary, tap the retainer l i g h t l y w i t h other damage. Replace as necessary.
a plastic m a l l e t to "seat" i t .
 • STEERING 19 - 13

(4) Insert t h e p i t m a n (sector) shaft i n t h e steering BEARING

gear housing shaft bore a n d inspect for excessive CUP
shaft or housing shaft bore wear. The shaft should
have a smooth, "bind-free" fit w i t h no visible side
play w h e n installed i n t h e shaft bore.
(5) I f the shaft fit i s loose b u t i t is not v i s i b l y w o r n ,
t r a i l fit a replacement p i t m a n (sector) shaft i n t h e
housing shaft bore. I f t h e replacement shaft also has
a loose f i t , replace t h e housing. However, i f the re-
placement p i t m a n fits properly, replace t h e o r i g i n a l
p i t m a n (sector) shaft.
(6) Measure t h e p i t m a n shaft adjustment screw fit
and "end-play" i n t h e T-slot (Fig. 14). When i n -
stalled, the adjustment screw m u s t rotate freely and
not b i n d i n any position. Measure the "end-play" b y
i n s e r t i n g a feeler gauge between the screw head and
the T-slot surface. T h e " e n d - p l a y " m u s t not ex-
c e e d 0.05 m m (0.002 i n ) . I f t h e " e n d - p l a y " ex-
ceeds t h e s p e c i f i e d l i m i t , select a n d i n s t a l l a
replacement s h i m that reduces the "end-play" t o J8919-20
b e l o w the specified l i m i t .
Fig. 15 Wormshaft Upper Bearing Cup Removal

Fig. 14 Adjustment Screw End-Play Measurement

(7) Inspect t h e wormshaft shaft upper bearing and
b e a r i n g cup for wear, looseness, flat spots, p i t t i n g ,
cracks, and other damage. I f either t h e bearing or
the bearing cup is damaged, both components must
be replaced.
(8) I f the cup fits loosely i n t h e housing, t r i a l fit a
replacement cup. I f t h e replacement cup also fits
loosely, replace t h e housing. I f the replacement cup
fits properly, replace only t h e o r i g i n a l bearing cup.
ASSEMBLY
(1) I f the o r i g i n a l wormshaft upper bearing cup
m u s t be replaced because of damage, remove i t w i t h
a hammer and a brass punch (Fig. 15).
Fig. 16 Wormshaft Upper Bearing Cup Installation
(2) I n s t a l l a replacement bearing cup w i t h a n ap-
propriate i n s t a l l a t i o n tool (Fig. 16).
D o not i n s t a l l t h e w o r m s h a f t o r the p i t m a n
shaft s e a l s a t this time.
(3) Lubricate a l l the components w i t h chassis l u b r i -
cant.
(4) Place t h e steering gear housing i n a vise.
Clamp t h e vise jaws on the housing m o u n t i n g bosses
only.
(5) I n s t a l l t h e wormshaft and b a l l n u t i n the steer-
i n g gear housing.
19 - 14 STEERING
BALL NUT
CENTER GROOVE
Fig. 17 Pitman Shaft & Bali Nut Engagement
CAUTION: Ensure that the ball nut is installed with
the wide/deep side of the ball nut teeth facing to-
ward the cover opening.
(6) I n s t a l l t h e wormshaft bearing adjustment cap
i n t h e housing and t i g h t e n i t only enough to remove
the wormshaft "end-play".
(7) I n s t a l l t h e l o c k n u t on the wormshaft bearing
adjustment cap b u t do n o t t i g h t e n i t a t t h i s t i m e .
(8) Pack t h e steering gear housing w i t h as m u c h
chassis l u b r i c a n t as possible.
To be able t o p a c k t h e m a x i m u m a m o u n t o f l u -
bricant into the housing, the ball n u t must be
m o v e d b a c k a n d f o r t h f o r b e t t e r access t o t h e
housing interior. Rotate the wormshaft i n one
d i r e c t i o n u n t i l t h e b a l l n u t ceases. P a c k t h e u n -
obstructed e n d o f the housing full o f lubricant,
rotate the shaft i n t h e opposite d i r e c t i o n a n d re-
peat the p a c k i n g procedure.
(9) Place t h e b a l l n u t (Fig. 17) i n t h e centered po-
sition (i.e., rotate t h e wormshaft from "stop-to-stop"
and count t h e t o t a l number rotations, and then ro-
tate wormshaft i n t h e reverse direction 1/2 of the to-
t a l number of rotations to center the b a l l n u t ) .
(10) Lubricate t h e p i t m a n shaft w i t h chassis l u b r i -
cant and insert i t i n t h e steering gear housing. E n -
gage the center tooth on t h e shaft w i t h the center
groove on the b a l l n u t .
(11) Apply chassis l u b r i c a n t to t h e replacement
housing cover gasket a n d position i t so t h a t i t sur-
rounds the housing cover opening.
(12) Place t h e shim(s) on t h e adjustment screw and
thread the screw into t h e cover to a depth of 2 to 3
threads.
•
(13) Slide t h e head of t h e adjustment screw i n t o
t h e p i t m a n shaft T-slot and, w i t h t h e cover i n place,
rotate t h e screw counterclockwise t o t h r e a d i t i n t o
t h e cover. Rotate t h e screw u n t i l t h e cover almost
comes i n contact w i t h the gasket.
(14) I n s t a l l t h e cover r e t a i n i n g bolts a n d "finger-
t i g h t e n " t h e m only. Continue t i g h t e n i n g t h e adjust-
m e n t screw counterclockwise u n t i l t h e cover is t i g h t
against t h e gasket and t h e n loosen t h e screw 1/2 r o -
tation.
(15) T i g h t e n t h e cover bolts w i t h 6 1 N*m (45 ft-lbs)
torque.
CAUTION: A protective wrap must be used to en-
close the shaft threads/splines during the shaft seal
installation. If the shaft seals are installed over ex-
posed shaft splines or threads, the seal lips could
be cut or distorted and result in leakage after as-
sembly.
(16) I n s t a l l t h e p i t m a n shaft a n d wormshaft seals
according to t h e following procedure:
• w r a p t h e p i t m a n shaft threads/splines w i t h 0 . 1 -
m m (0.005-in) t h i c k shimstock (or a single layer o f
the t h i n n e s t plastic tape available) to protect t h e re-
placement seals d u r i n g i n s t a l l a t i o n ;
• l u b r i c a t e t h e lips o f t h e replacement seals w i t h
chassis l u b r i c a n t ;
• slide t h e seals over the shimstock/tape a n d shaft
and i n t o t h e steering gear housing recess;
• remove t h e shimstock/tape from t h e shaft;
• complete t h e seal i n s t a l l a t i o n by t a p p i n g t h e seals
i n t o t h e recesses w i t h a s m a l l plastic mallet; a n d
• ensure t h a t each seal is f u l l y "seated" i n the hous-
i n g recess.
(17) Rotate t h e wormshaft and observe t h e steering
gear operation. W i t h the adjustment screw and t h e
cap loose, t h e wormshaft should rotate freely and not
" b i n d " i n either direction of r o t a t i o n . I f the steering
gear " b i n d s " , repair as necessary.
(18) Inspect for l u b r i c a n t leakage from t h e shaft
seals. I f there is a leak at either seal, replace t h e de-
fective seal(s).
ADJUSTMENTS ON-BENCH
A r e c i r c u l a t i n g - b a l l type steering gear requires t w o
adjustments after assembly:
• w o r m s h a f t bearing "preload" torque, and
• p i t m a n (sector) shaft overcenter drag torque.
CAUTION: Adjust the steering gear in the following
order only. Always adjust the wormshaft bearing
"preload" torque first, and then adjust the pitman
shaft overcenter drag torque last. Failure to do so
could result in damage to the gear or improper
steering response.
 • STEERING
(1) T i g h t e n the wormshaft bearing adjustment p l u g
u n t i l i t is " s n u g " t i g h t against t h e bearing, t h e n
loosen the adjustment cap 1/4 of-a-turn.
(2) I n s t a l l a l o w c a l i b r a t i o n (e.g., inch-pounds)
torque b a r w i t h a socket w r e n c h o n t h e splined end
of t h e wormshaft.
T h e " p r e l o a d " t o r q u e a d j u s t m e n t m u s t b e ac-
complished with the wormshaft rotated away a
m a x i m u m o f 1/2 o f - a - t u r n from e i t h e r t h e f u l l -
r i g h t o r the full-left t u r n stop positions.
(3) Rotate t h e wormshaft clockwise or counterclock-
wise t o the stop position and t h e n away 1/2 of-a-turn
f r o m the stop position.
(4) T i g h t e n the wormshaft b e a r i n g adjustment p l u g
(Fig. 18) u n t i l t h e torque r e q u i r e d t o rotate t h e
wormshaft i s 0.6 to 1.0 N T H (5 t o 8 in-lbs) torque.
ADJUSTMENT TORQUE BAR
CAP WITH SOCKET WRENCH
J89 19-23
Fig. 18 Wormshaft Bearing "Preload" Torque
Adjustment
(5) T i g h t e n t h e adjustment cap l o c k n u t w i t h 68
N T H (50 ft-lbs) torque a n d measure t h e "preload"
torque. I f necessary, adjust t h e "preload" torque
a g a i n . Record t h e "preload" torque for later refer-
ence.
CAUTION: Do not attempt to adjust the pitman shaft
overcenter drag torque before the wormshaft bear-
ing "preload" torque has been adjusted.
(6) Adjust the p i t m a n shaft overcenter drag torque:
• rotate t h e wormshaft f r o m stop-to-stop, count t h e
t o t a l number o f rotations, and rotate t h e wormshaft
i n t h e reverse direction 1/2 o f the t o t a l n u m b e r of ro-
t a t i o n s t o center the b a l l n u t / p i t m a n shaft;
• place a l o w calibration (e.g., inch-pounds) torque
b a r w i t h a socket wrench o n t h e wormshaft splines
19 - 15
(Fig. 19) and, w h i l e r o t a t i n g the wormshaft back and
forth overcenter, t i g h t e n t h e p i t m a n shaft adjust-
ment screw u n t i l t h e torque required to rotate t h e
shaft is 1.6 N * m (14 in-lbs);
TORQUE BAR
AND SOCKET
WRENCH
J8919-24
Fig. 19 Overcenter Drag Torque Adjustment
• t h e overcenter d r a g torque represents t h e t o t a l of
the wormshaft bearing "preload" torque and t h e b a l l
n u t rack/sector shaft gear teeth mesh f r i c t i o n load
(re-adjust the sector shaft adjustment screw, i f neces-
sary to obtain the correct drag torque);
• hold t h e p i t m a n shaft adjustment screw a n d
t i g h t e n t h e locknut w i t h 47 N T H (35 ft-lbs) torque;
and
• after t i g h t e n i n g t h e locknut, measure t h e over-
center drag torque again and re-adjust t h e torque, i f
necessary.
I f the adjustment screw is allowed t o rotate
w h i l e t i g h t e n i n g t h e l o c k n u t , t h e complete over-
center d r a g torque adjustment procedure must
be repeated.
INSTALLATION
(1) Position the steering gear a t the frame r a i l and
i n s t a l l t h e attaching bolts. T i g h t e n t h e a t t a c h i n g
bolts w i t h 136 N-m (100 ft-lbs) torque.
(2) Connect t h e steering intermediate shaft to t h e
steering gear.
(3) W i t h the p i t m a n a r m and the shaft i n s t a l l a t i o n
reference marks aligned, position t h e p i t m a n (steer-
ing) a r m on the p i t m a n shaft.
(4) I n s t a l l t h e washers a n d t h e r e t a i n i n g n u t on
the p i t m a n shaft and t i g h t e n t h e n u t w i t h 237 N T H
(175 ft-lbs) torque. I n s t a l l a replacement cotter p i n .
19-16 STEERING •
(5) Connect the center l i n k to the p i t m a n (steering) (6) Remove t h e supports a n d lower t h e vehicle,
a r m . T i g h t e n the r e t a i n i n g n u t w i t h 54 N n n (40 f t -
lbs) torque. I n s t a l l a replacement cotter p i n .
POWER S T E E R I N G G E A R S E R V I C E

INDEX
Page Page
Power Steering Gear—Initial Operation 38 Power Steering Hose—Removal/Installation 38
Power Steering Gear—Removal/Installation 16 Service Information . . .: 16
Power Steering Gear—Repair Service . . . . . . . . . 17

SERVICE INFORMATION
R a m T r u c k and Ramcharger vehicles are equipped
w i t h a recirculating b a l l , variable r a t i o power steer-
i n g gear. Steel balls r i d i n g i n helical grooves func-
t i o n as a r o l l i n g thread between the wormshaft and
t h e rack piston. Teeth on the side of t h e rack piston
mesh w i t h the sector shaft gear teeth. T h e control
valve is housed inside the steering gear housing, ne-
g a t i n g t h e need for an externally located valve.
I f t h e hydraulic fluid pressure i n the steering sys-
t e m should fail, the driver, b y using more effort to
t u r n t h e steering wheel, can control t h e vehicle
steering manually (i.e., w i t h o u t power assist).
S a f e t y goggles s h o u l d be w o r n at a l l times
w h e n involved w i t h p o w e r steering g e a r or
p u m p service.

POWER STEERING
GEAR-REMOVAL/INSTALLATION J8919-11

Fig. 1 Pitman (Steering) Arm Removal

REMOVAL
(1) Place the front wheels i n a straight-ahead posi- INSTALLATION
tion. (1) Position t h e steering gear a t the frame r a i l , i n -
stall a n d t i g h t e n t h e a t t a c h i n g bolts "finger-tight".
(2) Place a d r a i n pan under the steering gear.
Center t h e steering gear and a l i g n the steering col-
(3) Disconnect t h e f l u i d hoses from t h e steering
u m n shaft and the stub shaft.
gear. Raise and secure the hoses above the reservoir
(2) I n s t a l l the bolts i n the steering column shaft-to-
fluid level to prevent excessive fluid loss. Cap t h e
stub shaft coupling and t i g h t e n w i t h 45 N-m (33 f t -
ends of the hoses to prevent any entry o f foreign ma-
lbs) torque.
terial.
(3) I f necessary, re-position the steering gear at the
(4) Disconnect the steering column shaft f r o m the
frame t o e l i m i n a t e any b i n d i n g and t i g h t e n the at-
stub shaft.
taching bolts w i t h 136 N-m (100 ft-lbs) torque.
(5) Raise and support the vehicle.
(4) W i t h the p i t m a n (steering) a r m and shaft i n -
(6) Disconnect t h e center l i n k from t h e p i t m a n
stallation reference m a r k s aligned, position the p i t -
(steering) arm.
m a n (steering) a r m on the p i t m a n shaft.
(7) Remove t h e p i t m a n (steering) a r m r e t a i n i n g
T h e p i t m a n (steering) a r m n u t a n d l o c k w a s h e r
n u t and washer, m a r k the p i t m a n (steering) a r m and
must b e r e p l a c e d w i t h either e x a c t replacements
the p i t m a n shaft positions for i n s t a l l a t i o n reference
(same p a r t n u m b e r s ) , o r w i t h e q u i v a l e n t r e p l a c e -
and remove the p i t m a n (steering) a r m f r o m the p i t -
ments, i f r e p l a c e m e n t i s n e c e s s a r y .
m a n shaft w i t h an appropriate puller tool (Fig. 1).
(5) I n s t a l l t h e lockwasher and the r e t a i n i n g n u t on
(8) Remove the steering gear r e t a i n i n g bolts at the
the p i t m a n shaft and t i g h t e n the n u t w i t h 237 N-m
frame r a i l and remove the steering gear from the ve-
(175 ft-lbs) torque.
hicle.
• STEERING
(6) Connect the center l i n k t o the p i t m a n (steering)
a r m . T i g h t e n t h e r e t a i n i n g n u t w i t h 54 N»m (40 f t -
lbs) torque. I n s t a l l a replacement cotter p i n .
(7) Remove the supports and lower the vehicle.
POWER STEERING GEAR REPAIR SERVICE
SERVICE INFORMATION
The recirculating-ball type power steering gear i n -
stalled on R a m T r u c k and Ramcharger vehicles (Fig.
2) has a "variable steering r a t i o " .
Safety goggles should b e w o r n a t a l l times
w h e n involved with power steering gear o r
p u m p service.
19-17
POWER STEERING SYSTEM SERVICE
DIAGNOSIS
To use t h e System Service Diagnosis charts, look
for t h e "condition" t h a t describes the m a l f u n c t i o n
t h a t requires correction, t h e n move to t h e r i g h t to
the "possible cause" of t h e malfunction and t h e n fur-
ther t o t h e r i g h t for t h e "correction". I n most i n -
stances t h e corrective action involves routine repair.
However, a service procedure for t h e corrective ac-
t i o n is n o r m a l l y available w i t h i n a Service Group i n
this manual.
• STEERING 19 - 19

SYSTEM SERVICE DIAGNOSIS

CONDITION POSSIBLE CAUSE CORRECTION

HISSING NOISE IN 0) There is some noise in all power steering
STEERING GEAR systems. One of the most common is a
hissing sound most evident at standstill
parking. 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.
(1) Slight hiss is normal and in no way affects
steering. Do not replace valve unless hiss
is extremely objectionable. A replacement
valve will also exhibit slight noise and is
not always a cure. Investigate clearance
around flexible coupling rivets. Be sure
steering shaft and gear are aligned so
flexible coupling rotates in a flat plane
and is not distorted as shaft rotates. Any
metal-to-metal contacts through flexible
coupling will transmit valve hiss into
passenger compartment through the
steering column.

RATTLE OR CHUCKLE (1) Gear loose on frame. H) Check gear-to-frame mounting screws.
NOISE IN STEERING Tighten screws to 88 N»m (65 foot pounds)
GEAR torque.

(2) Steering linkage looseness. (2) Check linkage pivot points for wear.
Replace if necessary.

(3) Pressure hose touching other parts of car. (3) Adjust hose position. Do not bend tubing
by hand.

(4) Loose pitman shaft over center adjustment. (4) Adjust to specifications.

NOTE: A slight rattle may occur on turns

because of increased clearance off the "high
point." This is normal and clearance must not
be reduced below specified limits to eliminate
this slight rattle.

(5) Loose pitman arm. (5) Tighten pitman arm nut to specifications.

SQUAWK NOISE IN (1) Damper O-ring on valve spool cut. (1) Replace damper O-ring.
STEERING GEAR
WHEN TURNING OR
RECOVERING FROM A
TURN

POOR RETURN O F 0) Tires not properly inflated. (1) Inflate tires to specified pressure.
STEERING WHEEL TO
CENTER

(2) Lack of lubrication in linkage and ball (2) Lube linkage and ball joints.
joints.

(3) Lower coupling flange rubbing against (3) Loosen pinch bolt and assemble properly.
steering gear adjuster plug.

(4) Steering gear to column misalignment. (4) Align steering column.

J89 19-28
 SYSTEM SERVICE DIAGNOSIS (CONT'D)

CONDITION POSSIBLE C A U S E CORRECTION

POOR RETURN (5) Improper front wheel alignment. (5) Check and adjust as necessary.
OF STEERING WHEEL
TO CENTER (Continued) With front wheels still on alignment pads
of front-end machine, disconnect pitman
arm of linkage from pitman shaft of gear.
Turn front wheels by hand. If wheels will
not turn or turn with considerable effort,
determine if linkage or ball joints are
binding.

(6) Steering linkage binding. (6) Replace pivots.

(7) Ball joints binding. (7) Replace ball joints.

(8) Steering wheel rubbing against housing. (8) Align housing.

(9) Tight or frozen steering shaft bearings. (9) Replace bearings.

(10) Sticking or plugged valve spool. (10) Remove and clean or replace valve.

(11) Steering gear adjustments over (11) Check adjustment with gear out of car.
specifications. Adjust as required.

(12) Kink in return hose. (12) Replace hose.

CAR LEADS TO ONE (1)
SIDE OR THE OTHER
(KEEP IN MIND ROAD
CONDITION AND (2)
WIND. TEST CAR IN
BOTH DIRECTIONS ON
FLAT ROAD)
Front end misaligned. (1) Adjust to specifications.
Unbalanced steering gear valve. (2) Replace valve.
N O T E : If this is cause, steering effort will
be very light in direction of lead and
normal or heavier in opposite direction.

MOMENTARY (1) Low oil level. (1) Add power steering fluid as required.
INCREASE IN EFFORT
WHEN TURNING
WHEEL FAST TO (2) Pump belt slipping. (2) Tighten or replace belt.
RIGHT OR LEFT

(3) High internal leakage. (3) Check pump pressure. (See pressure test)

STEERING WHEEL (1) Low oil level. (1) Fill as required.

SURGES OR JERKS
WHEN TURNING WITH
ENGINE RUNNING (2) Loose pump belt. (2) Adjust tension to specification.
ESPECIALLY DURING
PARKING
(3) Steering linkage hitting engine oil pan at (3) Correct clearance.
full turn.

(4) Insufficient pump pressure. (4) Check pump pressure. (See pressure
test.) Replace relief valve if defective.

J8919-27
• STEERING 19-21

SYSTEM SERVICE DIAGNOSIS (CONT'D)

CONDITION POSSIBLE CAUSE CORRECTION

(5) Pump flow control valve sticking. (5) Inspect for varnish or damage, replace
if necessary.

EXCESSIVE WHEEL (1) Air in system. (1) Add oil to pump reservoir and bleed by
KICKBACK OR LOOSE operating steering. Check hose connectors
STEERING for proper torque and adjust as required.

(2) Steering gear loose on frame. (2) Tighten attaching screws to specified
torque.

(3) Steering linkage joints worn enough to be (3) Replace loose pivots.
loose.

(4) Worn poppet valve. (4) Replace poppet valve.

(5) Loose thrust bearing preload adjustment. (5) Adjust to specification with gear out of
vehicle.

(6) Excessive overcenter lash. (6) Adjust to specification with gear out of
car.

HARD STEERING OR (1) Loose pump belt. (1) Adjust belt tension to specification.
LACK O F ASSIST

(2) Low oil level. (2) Fill to proper level. If excessively low,
check all lines and joints for evidence of
NOTE: Low oil level will also result in excessive external leakage. Tighten loose
pump noise. connectors.

(3) Steering gear to column misalignment. (3) Align steering column.

NOTE: IF CHECKS (1)

THROUGH (5) DO NOT
REVEAL CAUSE OF
HARD STEERING,
REFER TO PRESSURE
TEST
(4) Lower coupling flange rubbing against (4) Loosen pinch bolt and assemble properly.
steering gear adjuster plug.

(5) Tires not properly inflated. (5) Inflate to recommended pressure.

Further possible causes could be:

(6) Sticky flow control valve. In order to diagnose conditions such as listed
in (6), (7), (8), (9) a test of the entire power
steering system is required.

(7) Insufficient pump pressure output.

(8) Excessive internal pump leakage.

(9) Excessive internal gear leakage.

J8919-26
19-22 STEERING •
SYSTEM SERVICE DIAGNOSIS (CONT'D)

CONDITION POSSIBLE C A U S E CORRECTION

FOAMING MILKY (1) Air in the fluid, and loss of fluid due to (1) Check for leak and correct. Bleed system.
POWER STEERING internal pump leakage causing overflow. Extremely cold temperatures will cause
FLUID, LOW FLUID system aeriation should the oil level be
LEVEL AND low. If oil level is correct and pump still
POSSIBLE LOW foams, remove pump from vehicle and
PRESSURE separate reservoir from housing. Check
welsh plug and housing for cracks. If
plug is loose or housing is cracked,
replace housing.

LOW PRESSURE DUE (1) Flow control valve stuck or inoperative. (1) Remove burrs or dirt or replace. Flush
TO STEERING PUMP system.

(2) Pressure plate not flat against cam ring. (2) Correct.

LOW PRESSURE DUE (1) Pressure loss in cylinder due to worn piston (1) Remove gear from car for disassembly
TO STEERING GEAR ring or badly worn housing bore. and inspection of ring and housing bore.

(2) Leakage at valve rings, valve body-to- (2) Remove gear from car for disassembly
worm seal. and replace seals.

J8919-25

FLUID LEAKAGE-DETECTION (3) Check and correct the f l u i d level i n t h e reser-

I n a d d i t i o n to t h e following procedure, a "black
l i g h t " detection device can be used to locate power
steering f l u i d leakage. The dye m u s t be installed and
mixed w i t h the power steering f l u i d for t h i s purpose.
CAUTION: If the fluid reservoir cap is not properly
tightened after a fluid level check, the result can be
fluid leakage and possible loss of the cap. Ensure
that the cap is securely tightened when installing it.
(1) Power steering f l u i d leakage is possible from
the f o l l o w i n g steering gear areas:
• hoses a n d f i t t i n g s ;
• " p r e l o a d " torque adjustment cap seal;
• stub shaft seals;
• housing b a l l p l u g ;
• p i t m a n shaft cover, gasket, adjustment screw and
locknut;
• p i t m a n shaft seals;
• housing end-plug seal; and
• cracked or porous housing.
(2) Raise and support t h e f r o n t of t h e vehicle.
Clean t h e exterior surfaces of the steering gear, the
pump and reservoir, t h e hoses and the f i t t i n g s thor-
oughly.
voir. I f the reservoir is overfilled, d r a i n t h e excess
fluid d o w n to the correct level before proceeding.
(4) Inspect for aerated ( m i l k y color) fluid, w h i c h
can cause an overflow from the reservoir and be mis-
t a k e n for a n actual fluid leak.
(5) Inspect and t i g h t e n a l l the hose connections a t
the steering gear and a t the pump.
(6) S t a r t the engine. Have a helper t u r n t h e steer-
i n g wheel to the left and to the r i g h t several times
w h i l e y o u search for t h e source of the fluid leak.
Contact t h e stops momentarily i n each direction.
Stop t h e engine when the source of the fluid leak is
located.
PITMAN SHAFT SEAL-REPLACEMENT
(1) Raise and support the vehicle. Place t h e front
wheels i n a straight-ahead position.
(2) Disconnect the center l i n k from t h e p i t m a n
(steering) a r m .
(3) M a r k the p i t m a n (steering) a r m and the p i t m a n
shaft positions for i n s t a l l a t i o n reference and remove
the p i t m a n (steering) a r m from t h e p i t m a n shaft
w i t h a n appropriate p u l l e r tool (Fig. 23).
(4) Place a d r a i n pan under the steering gear.
(5) Remove t h e p i t m a n shaft seal r e t a i n i n g r i n g
w i t h " s n a p " r i n g pliers and remove the outer backup
washer f r o m the shaft bore.
 • STEERING
CAUTION: To prevent excessive fluid loss and
pump wear, do not hold the steering wheel in an ex-
treme left-turn position for more than one or two
seconds at a time.
(6) S t a r t t h e engine a n d m o m e n t a r i l y hold t h e
steering wheel i n a n extreme l e f t - t u r n position to ac-
tuate t h e spool valve. T h i s should develop enough
pressure o n t h e upper side o f t h e rack piston and i n
the p i t m a n shaft chamber t o force t h e p i t m a n shaft
seals a n d t h e r e m a i n i n g backup washer o u t o f the
shaft bore ( F i g . 3).
BACKUP
WASHERS
SINGLE-UP DOUBLE-UP
SEAL SEAL J8919-30
Fig. 3 Seals, Backup Washers & Retaining Ring
(7) Stop t h e engine a n d remove t h e seals and
backup washer f r o m the p i t m a n shaft. Discard the
seals.
(8) Inspect t h e outer circumference surface area of
the seals for damage to t h e rubber covers. I f the
outer circumference surface area is scored, inspect
the shaft bore i n t h e housing for burrs. I f present, re-
move t h e b u r r s f r o m the bore before i n s t a l l i n g the
replacement seals.
(9) Inspect t h e seal contact surface area on the pit-
m a n shaft for p i t t i n g and roughness. I f pitted, re-
place t h e shaft.
(10) Remove a l l rust, foreign m a t e r i a l a n d rough
areas f r o m t h e seal contact surface area o n the pit-
m a n shaft w i t h a crocus cloth.
(11) L u b r i c a t e t h e replacement seals and t h e
backup washers w i t h power steering f l u i d .
CAUTION: A protective wrap must be used to en-
close the shaft threads/splines during seal installa-
tion. If the shaft seals are installed over exposed
19-23
shaft threads or splines, the seal lips could be cut
or distorted and result in leakage after installation.
(12) W r a p t h e p i t m a n shaft threads/splines w i t h
0.1-mm (0.005-in) t h i c k shimstock (or a single layer
of t h e t h i n n e s t plastic tape available) to protect t h e
replacement seals d u r i n g i n s t a l l a t i o n .
(13) I n s t a l l t h e single-lip seal first, a n d t h e n t h e
i n n e r backup washer ( F i g . 3) w i t h a seal i n s t a l l a t i o n
tool. Position t h e seal a n d t h e washer only f a r
enough i n t h e shaft bore to provide sufficient clear-
ance for t h e second seal, t h e outer backup washer
and t h e r e t a i n i n g r i n g . D o n o t f o r c e t h e seal
against t h e i n n e r bore surface.
CAUTION: For proper sealing, ensure that the seals
are spaced so that they are separately "seated" in
the shaft bore.
(14) I n s t a l l t h e "double-lip" seal a n d t h e outer
backup washer (Fig. 3) w i t h a seal i n s t a l l a t i o n tool.
Position t h e seal a n d t h e backup washer only far
enough i n t h e shaft bore to provide sufficient clear-
ance for t h e r e t a i n i n g r i n g .
(15) Remove t h e shimstock/tape from t h e shaft. I n -
stall t h e r e t a i n i n g r i n g (Fig. 3). Ensure t h a t t h e r i n g
is "seated" correctly i n t h e housing bore groove.
(16) W i t h t h e p i t m a n (steering) a r m a n d shaft i n -
s t a l l a t i o n reference m a r k s aligned, position t h e p i t -
m a n (steering) a r m on t h e p i t m a n shaft.
T h e p i t m a n (steering) a r m n u t a n d l o c k w a s h e r
m u s t be replaced w i t h either exact replacements
(same p a r t n u m b e r s ) , o r w i t h e q u i v a l e n t r e p l a c e -
m e n t s , i f r e p l a c e m e n t i s necessary.
(17) I n s t a l l t h e lockwasher and the r e t a i n i n g n u t
on t h e p i t m a n shaft a n d t i g h t e n t h e n u t w i t h 237
N-m (175 ft-lbs) torque.
I n s t a l l a replacement cotter p i n .
(18) Connect the center l i n k to the p i t m a n (steer-
ing) a r m . T i g h t e n t h e r e t a i n i n g n u t w i t h 54 N m (40
#
ft-lbs) torque. I n s t a l l a replacement cotter p i n .
(19) Remove t h e supports and lower t h e vehicle.
(20) F i l l t h e reservoir w i t h power steering f l u i d .
(21) S t a r t t h e engine and allow i t to operate a t idle
speed for a t least three minutes. D o n o t t u r n t h e
steering wheel d u r i n g this time.
(22) T u r n t h e steering wheel to the left a n d to t h e
r i g h t a n d inspect for fluid leakage. A d d power steer-
i n g fluid as required.
(23) Remove t h e d r a i n pan.
END-PLUG SEAL-REPLACEMENT
(1) Raise a n d support t h e vehicle. Place t h e f r o n t
wheels i n a straight-ahead position.
(2) Place a d r a i n p a n under the steering gear.
(3) Rotate t h e end-plug r e t a i n i n g r i n g u n t i l one
end o f t h e r i n g is positioned under the adjacent hole
located i n t h e side of t h e gear housing. " U n s e a t " a n d
 19-24 STEERING •
force the r i n g from the groove b y i n s e r t i n g a p u n c h vise. During assembly, lubricate all the components
t h r o u g h t h e hole i n the housing (Fig. 4). with power steering fluid except when instructed
otherwise.

(1) D r a i n the fluid, position the steering gear i n a

vise a n d clamp i t in-place w i t h t h e p i t m a n shaft
downward. Use the un-machined bosses for c l a m p i n g
pads (Fig. 5).

BOSS

Fig. 4 End-Plug Retaining Ring Removal

CAUTION: Do not turn the wheel any farther than J8919-32
necessary because, otherwise, the recirculating
balls will drop out of the rack piston circuit and fall Fig. 5 Steering Gear Clamped In A Vise
inside the rack piston chamber. (2) Rotate the housing end-plug r e t a i n i n g r i n g u n -
t i l one end o f the r i n g is positioned under t h e adja-
(4) T u r n the steering wheel slowly to the left u n t i l cent hole located i n t h e side of the gear housing.
t h e r a c k piston forces the end-plug out of the housing " U n s e a t " and force the r i n g from the groove b y i n -
and t h e n t u r n the steering wheel back to the center serting a p u n c h t h r o u g h the hole i n the housing (Fig.
position. 6).
(5) Remove and discard t h e end-plug O-ring seal.
(6) L u b r i c a t e t h e replacement O-ring seal w i t h
power steering fluid and i n s t a l l i t on the end plug.
(7) I n s t a l l the end p l u g and the r e t a i n i n g r i n g .
(8) Lower the vehicle.
(9) F i l l t h e fluid reservoir w i t h power steering
fluid.
(10) S t a r t the engine and allow i t to operate a t idle
speed for a t least three m i n u t e s . D o n o t t u r n t h e
steering wheel d u r i n g this time.
(11) T u r n the steering wheel to the left and t o the
r i g h t and inspect for fluid leakage. A d d power steer-
i n g fluid as required.
(12) Remove the d r a i n pan.

POWER STEERING GEAR-DISASSEMBLY

CAUTION: Cleanliness is extremely important when

repairing a power steering gear. Maintain the bench,
the tools and the components clean at all times.
Thoroughly clean the exterior of the gear with
cleaning solvent before disassembly and drain as
much of the fluid as possible. Use protective vise Fig. 6 End-Plug Retaining Ring Removal
jaws at all times when clamping components in a
• STEERING 19 - 25

1. PISTON END-PLUG 15. BOLT 29. O-RING SEAL 43. SMALL THRUST WASHER
2. TEFLON RING 16. HOSE CONNECTOR SEAT 30. O-RING SEAL 44. SPACER
3. O-RING SEAL 17. CHECK VALVE 31. WORMSHAFT 45. RETAINING RING
4. RACK PISTON 18. CHECK VALVE SPRING 32. BEARING RACE 46. NEEDLE BEARING
5. BLACK & SILVER BALLS 19. HOSECONNECTORSEAT 33. THRUST BEARING 47. SINGLE-LIP SEAL
6. BALL HALF-GUIDE 20. STUB SHAFT 34. BEARING RACE 48. BACK-UP WASHER
7. BALL HALF-GUIDE 21. VALVE BODY 35. NEEDLE BEARING 49. DOUBLE-LIP SEAL
8. CLAMP 22. O-RJNG SEAL 36. DUST SEAL 50. BACK-UP WASHER
9. CLAMP BOLT 23. TEFLON RING 37. RETAINING SNAP RING 51. RETAINING SNAP RING
10. GEAR HOUSING 24. O-RING SEAL 38. SEAL 52. SPRING WASHER
11. PITMAN SHAFT 25. TEFLON RING 39. ADJUSTMENT CAP 53. RETAINING NUT
12. COVER GASKET 26. O-RING SEAL 40. O-RING SEAL 54. O-RING SEAL
13. COVER 27. TEFLON RING 41. LARGE THRUST WASHER 55. HOUSING END-PLUG
14. LOCKNUT 28. SPOOL VALVE 42. THRUST BEARING 56. RETAINING RING
J8919-33

Fig. 7 Power Steering Gear—Exploded View

 19-26 STEERING •
CAUTION: Do not rotate the stub shaft any farther RACK
than necessary because, otherwise, the recirculat- PISTON
ing balls will drop out of the circuits and cause the
pitman shaft and rack piston teeth to disengage. If
the teeth become disengaged, remove the cover
and the pitman shaft and engage the teeth.

(3) Rotate t h e stub shaft counterclockwise ( w i t h a

12-point deep wrench a n d a ratchet handle) u n t i l the
rack piston forces t h e end p l u g o u t o f the housing.
(4) Remove and discard t h e end-plug O-ring seal.
(5) Rotate t h e stub shaft clockwise 180 degrees t o
remove t h e rack piston end p l u g (Fig. 7).

CAUTION: The rack piston end plug could break

during removal if it is not initially "unseated" by
striking it with a plastic-tipped hammer.

(6) S t r i k e t h e rack piston end p l u g sharply w i t h a

plastic-tipped hammer a n d use a 13-mm (1/2-in)
square d r i v e ratchet to remove t h e end p l u g . D o n o t
use a r a t c h e t w i t h a w o r n d r i v e l u g o r w i t h a
drive l u g that is r o u n d e d o n the b o t t o m corners. Fig. 8 Rack Piston Removal
(7) H o l d t h e p i t m a n shaft adjustment screw w i t h SPANNER
a n A l l e n wrench to prevent t h e screw f r o m t u r n i n g WRENCH
and remove the locknut (Fig. 7). Discard the locknut.
(8) Remove t h e p i t m a n shaft cover a t t a c h i n g bolts
and lockwashers from t h e housing (Fig. 7).
(9) Thread the p i t m a n shaft adjustment screw i n t o
the cover w i t h and A l l e n w r e n c h u n t i l t h e cover can
be removed from t h e screw. Remove t h e cover from
the housing and discard t h e gasket (Fig. 7).
(10) Rotate the stub shaft u n t i l t h e p i t m a n shaft
teeth are centered i n the housing. T a p the end of the
p i t m a n shaft w i t h a plastic-tipped h a m m e r a n d re-
move i t f r o m the housing (Fig. 7). D o n o t disassem-
ble t h e p i t m a n shaft, i t is serviced a n d replaced
as a u n i t o n l y .
(11) Insert a n arbor tool i n the r a c k piston u n t i l i t
stops a t t h e end of the wormshaft (Fig. 8).
(12) G r i p the tool f i r m l y a n d t u r n t h e stub shaft
counterclockwise t o force t h e rack piston on the arbor
tool (Fig. 8). Remove t h e tool and t h e rack piston as
a u n i t f r o m the steering gear housing.
(13) Loosen t h e w o r m s h a f t b e a r i n g "preload" Fig. 9 Wormshaft "Preload" Adjustment Cap
torque adjustment cap l o c k n u t w i t h a brass d r i f t and Removal
remove i t from t h e cap. Remove t h e adjustment cap
STEERING GEAR HOUSING—DISASSEMBLY
from the housing w i t h a spanner w r e n c h (Fig. 9).
(1) Remove t h e p i t m a n shaft seal r e t a i n i n g r i n g
(14) Remove t h e complete valve body f r o m t h e
f r o m t h e shaft bore groove w i t h "snap" r i n g pliers.
housing b y p u l l i n g o u t w a r d on t h e splined end of the
Remove the outer backup washer from the shaft bore
stub shaft.
(Fig. 11).
(15) Remove the wormshaft lower t h r u s t bearing
I f t h e u p p e r seal i s d i f f i c u l t t o r e m o v e , f o r c e i t
and the conical bearing races f r o m t h e wormshaft.
o u t o f the shaft bore f r o m the t o p o f the housing.
Note t h e relative position of each race for assembly
I n extreme situations, i t m a y b e necessary t o
reference (Fig. 10).
force o u t b o t h the needle bearing a n d the u p p e r
 •
VALVE O-RING WORM CONICAL
BODY SEAL SHAFT RACES

THRUST
BEARING J8919-36

Fig. 12 Pitman Shaft Needle Bearing Removal

(2) Inspect t h e p i t m a n shaft bore. I f i t is badly
scored or w o r n , replace t h e housing. However, s l i g h t
scratches i n t h e bore are u s u a l l y acceptable.
(3) Inspect t h e hose connector "seats" a n d t h e pop-
pet check valve. I f they are deeply scored, cracked or
w o r n , they m u s t be replaced.
(4) Inspect the b a l l p l u g i n t h e housing (Fig. 13). I f
f l u i d leakage past t h e b a l l p l u g occurred before dis-
assembly or i f i t is raised above t h e housing surface,
the housing m u s t be replaced.
BALL

SINGLE-LIP DOUBLE-LIP
SEAL SEAL J8919-30

Fig. 11 Seals, Backup Washers & Retaining Ring

seal s i m u l t a n e o u s l y . D i s c a r d t h e s e a l a n d t h e
n e e d l e b e a r i n g i f t h e y a r e r e m o v e d by t h i s
method.
(2) Remove t h e p i t m a n shaft needle b e a r i n g f r o m
t h e housing i n n e r bore w i t h t h e appropriate removal
tools (Fig. 12).
J8919-38
STEERING GEAR HOUSING—INSPECTION
(1) Clean t h e steering gear housing t h o r o u g h l y Fig. 13 Steering Gear Housing & Ball Plug
w i t h cleaning solvent. (5) Inspect a l l t h e r e t a i n i n g r i n g grooves a n d 0 -
r i n g seal m a t i n g surfaces. I f any are chipped, scored,
19-28 STEERING •
cracked or otherwise w o r n , replace the housing. (4) I n s t a l l the single-lip seal first, and t h e n the i n -
ner backup washer w i t h a seal i n s t a l l a t i o n tool. Po-
STEERING GEAR HOUSING—ASSEMBLY sition t h e seal and washer o n l y f a r enough i n t h e
(1) Lubricate the p i t m a n shaft bore i n the housing, shaft bore t o provide sufficient clearance for the sec-
the replacement needle bearing, the l i p seals and the ond seal, t h e outer backup washer and the r e t a i n i n g
backup washers w i t h power steering f l u i d (Fig. 14). r i n g (Fig. 14). D o n o t f o r c e t h e s e a l a g a i n s t t h e i n -
ner bore surface.
• RETAINING RING
BACKUP WASHER CAUTION: For proper sealing, ensure that the seals
are spaced so that they are separately "seated" in
DOUBLE-UP SEAL the shaft bore.
BACKUP WASHER
(5) I n s t a l l the double-lip seal and the outer backup
SINGLE-LIP SEAL
washer ( F i g . 16) w i t h a seal i n s t a l l a t i o n tool. Posi-
t i o n the seal and the backup washer only f a r enough
NEEDLE BEARING i n t h e shaft bore to provide sufficient clearance for
the r e t a i n i n g r i n g .
(6) I n s t a l l t h e r e t a i n i n g r i n g (Fig. 14). Ensure t h a t
the r i n g is "seated" correctly i n the bore groove.
^ / SEAL
J1 ( INSTALLATION
if A S TOOL

J8919-39

Fig. 14 Pitman Shaft Bearing, Seals & Washers

(2) I n s t a l l the replacement needle bearing w i t h the
appropriate i n s t a l l a t i o n tools (Fig. 15).
(3) Insert t h e bearing i n t h e p i t m a n shaft inner
bore u n t i l i t is approximately 0.76 m m (0.03 i n ) be-
low the shoulder of the inner bore.

Fig. 16 Pitman Shaft Seal Installation

PRELOAD TORQUE ADJUSTMENT CAP-DISASSEMBLY
(1) Remove the t h r u s t b e a r i n g r e t a i n i n g r i n g f r o m
the adjustment cap w i t h a s m a l l p r y b a r (Fig. 17).
Discard t h e r e t a i n i n g r i n g . U s e c a r e t o p r e v e n t
d a m a g i n g the needle b e a r i n g bore.
(2) Remove the t h r u s t bearing spacer, t h e t h r u s t
bearing washers, the t h r u s t b e a r i n g and t h e O-ring
seal f r o m t h e adjustment cap ( F i g . 18). Discard t h e
seal.
(3) Remove the stub shaft seal r e t a i n i n g "snap"
r i n g from the adjustment cap w i t h "snap" r i n g pliers
J8919-37 (Fig. 18).
(4) Remove (and discard) t h e stub shaft dust seal
Fig. 15 Pitman Shaft Needle Bearing Installation and the o i l seal from t h e adjustment cap (Fig. 18).
 • STEERING 19-29

RETAINING
RING

NEEDLE
BEARING
REMOVAL
TOOL

J8919-41
J8919-43
Fig. 17 Thrust Bearing Retaining Ring Removal
Fig. 19 Stub Shaft Needle Bearing Removal
LARGE (3) Replace a l l defective components.
RETAINING
THRUST
SNAP RING WASHER
'STUB SHAFT PRELOAD TORQUE ADJUSTMENT CAP-ASSEMBLY
DUST SEAL SMALL (1) L u b r i c a t e t h e adjustment cap and t h e compo-
THRUST WASHER
nents w i t h power steering fluid.
(2) Place the stub shaft needle b e a r i n g o n the i n -
s t a l l a t i o n tool w i t h t h e bearing manufacturer's iden-
t i f i c a t i o n n u m b e r facing t o w a r d t h e tool.
(3) Position t h e b e a r i n g and the tool over the i n n e r
bore a n d press the bearing i n t o the bore u n t i l i t is
flush w i t h the bottom surface o f the outer bore.
(4) I n s e r t the stub shaft o i l seal far enough i n t o the
seal bore t o provide sufficient clearance for the dust
seal and t h e r e t a i n i n g r i n g (Fig. 18).
NEEDLE (5) L u b r i c a t e the dust seal w i t h petroleum j e l l y and
BEARING i n s t a l l i t i n the seal bore w i t h t h e rubber side facing
o u t w a r d (Fig. 18).
RETAINING
SPACER RING (6) I n s t a l l t h e r e t a i n i n g "snap" r i n g . Ensure t h a t
ADJUSTMENT
the r i n g i s properly "seated" i n the cap groove.
CAP J8919-42
(7) L u b r i c a t e the O-ring seal w i t h petroleum j e l l y
and i n s t a l l i t i n the cap seal groove (Fig. 18).
Fig. 18 "Preload" Torque Adjustment Cap
(8) Position t h e large t h r u s t washer, t h e t h r u s t
(5) Remove the stub shaft needle bearing from t h e bearing, t h e s m a l l t h r u s t washer a n d t h e spacer o n
adjustment cap w i t h a n appropriate removal tool the adjustment cap (Fig. 18).
(Fig. 19). T h e r a d i a l l o c a t i o n s o f the s p a c e r notches a r e
not i m p o r t a n t . H o w e v e r , d o n o t d a m a g e t h e
PRELOAD TORQUE ADJUSTMENT CAP—INSPECTION
notches d u r i n g installation.
(1) Clean t h e adjustment cap and i t s components (9) Press t h e replacement r e t a i n i n g r i n g i n t o t h e
t h o r o u g h l y w i t h cleaning solvent. stub shaft needle bearing bore w i t h a brass or
(2) Inspect the adjustment cap and a l l the compo- wooden d r i f t .
nents for wear, scoring, nicks, cuts and d i s t o r t i o n .
 19 - 30 STEERING •
VALVE BODY AND STUB SHAFT-DISASSEMBLY LOCATING
PIN
CAUTION: The valve body is a precisely manufac-
tured unit with components selectively fitted to con-
form to tolerances as close as 0.00082 mm (0.0004
in). The unit is hydraulically and mechanically bal-
anced during manufacture. If replacement is neces-
sary, the complete valve body must be replaced. To
avoid possible damage, the valve body should not
be disassembled unless absolutely necessary. If the
valve spool damper O-ring seal requires replace-
ment, remove the valve spool only as instructed in
the following procedure.

( 1 ) H o l d t h e valve body i n both hands w i t h t h e

stub shaft downward a n d t a p t h e e n d o f t h e stub
shaft l i g h t l y against t h e workbench u n t i l t h e stub
shaft cap disengages from t h e valve body (Fig. 2 0 ) .
( 2 ) Remove and discard t h e stub shaft cap-to-worm-
shaft O-ring seal. STUB
SHAFT J8919-45

Fig. 21 Stub Shaft Removal

DAMPER TEFLON
O-RING RINGS {3)
SEAL

STUB
SHAFT

O-RING
SEAL

SPOOL
VALVE

Fig. 20 Stub Shaft Cap Disengagement O-RING VALVE

SEALS (3) BODY J8919-46
CAUTION: Do not pull the stub shaft out too far be-
yond the specified distance because the spool Fig. 22 Valve Body & Stub Shaft Disassembly
valve could become cocked in the valve body.
(6) Remove t h e damper O-ring seal f r o m t h e spool
valve ( F i g . 22). Discard the O - r i n g seal.
(3) P u l l o u t w a r d o n t h e cap end o f t h e stub shaft
(7) C u t t h e teflon rings a n d t h e i n n e r O-ring seals
u n t i l i t clears the valve body b y approximately 6.35
(located between t h e teflon r i n g s and t h e valve body)
mm ( 1 / 4 in).
and remove t h e m from the valve body. Carefully c u t
( 4 ) Carefully disengage t h e stub shaft locating p i n
the rings w i t h either a knife or diagonal pliers.
from t h e hole i n t h e spool valve and remove t h e stub
shaft from the valve body (Fig. 2 1 ) . VALVE BODY AND STUB SHAFT-INSPECTION
( 5 ) Rotate t h e spool valve a n d remove i t f r o m t h e
(1) Clean a l l t h e components i n cleaning solvent
valve body (Fig. 2 2 ) . I f t h e spool v a l v e becomes
and open a l l of t h e fluid passages b y b l o w i n g w i t h
cocked, carefully r e a l i g n i t a n d t h e n remove i t . compressed a i r . I f t h e stub shaft locating p i n or t h e
 • STEERING 19-31

spool valve locating hole is either cracked, exces- DAMPER TEFLON

sively w o r n or broken, replace t h e complete valve O-RING RINGS (3)
body. S m a l l flat s p o t s o n e i t h e r side o f t h e s t u b SEAL
shaft l o c a t i n g p i n h e a d a r e n o r m a l a n d accept-
STUB
able. SHAFT
(2) I f t h e stub shaft ground surfaces has scores,
nicks or b u r r s t h a t cannot be removed w i t h crocus
cloth, replace t h e complete valve body. Inspect t h e O-RING
outside surface area o f the spool valve and t h e inside SEAL
surface area o f t h e valve body for nicks, b u r r s and
wear. S l i g h t wear is n o r m a l on t h e valve m a t i n g sur-
faces. I f a n y s e r i o u s defects c a n n o t b e r e m o v e d
w i t h crocus cloth, replace t h e complete valve
body.
(3) I f t h e s m a l l notch i n t h e s k i r t of the valve body SPOOL
is excessively w o r n , replace t h e complete valve body VALVE
(Fig. 23).
NOTCH
O-RING VALVE
SEALS (3) BODY J8919-46

Fig. 24 Valve Body & Stub Shaft Assembly

VALVE
BODY J8919-47

Fig. 23 Valve Body Inspection

(4) L u b r i c a t e t h e spool valve w i t h power steering
fluid and check t h e f i t of the spool valve i n t h e valve
body w i t h o u t t h e spool valve dampener O-ring seal
J8919-48
installed. I f t h e spool valve does n o t rotate easily
w i t h i n t h e valve body, replace t h e complete valve Fig. 25 O-Ring Seal Installation
body.
The teflon rings c a n appear slightly distorted
w h e n first installed; however, d u r i n g operation,
VALVE BODY AND STUB SHAFT—ASSEMBLY
h o t p o w e r s t e e r i n g fluid w i l l cause t h e m t o
(1) L u b r i c a t e t h e replacement i n n e r O-ring seals
straighten out.
and t h e teflon rings (Fig. 24) w i t h power steering
(3) Lubricate t h e spool valve dampener O-ring seal
fluid.
w i t h petroleum j e l l y and i n s t a l l i t i n t h e spool valve
(2) I n s t a l l t h e i n n e r O-ring seals i n t h e valve body
groove (Fig. 24).
r i n g grooves (Fig. 25) a n d i n s t a l l the teflon rings o n
(4) Lubricate t h e spool valve and valve body w i t h
top o f t h e O-ring seals. U s e c a r e t o a v o i d d a m a g -
power steering fluid and carefully insert t h e spool
ing the teflon rings during installation.
valve i n t h e valve body (Fig. 24).
 19-32 STEERING
(5) Move t h e spool valve t h r o u g h t h e valve body
u n t i l t h e stub shaft locating p i n hole i n t h e spool
valve i s visible and the spool valve is flush w i t h the
notched end o f the valve body.
(6) Carefully insert t h e stub shaft i n t o t h e spool
valve u n t i l t h e stub shaft locating p i n is aligned w i t h
the locating p i n hole i n the spool valve (Fig. 25).
CAUTION: Ensure that the stub shaft cap notch is
aligned with the valve body pin before installing the
valve body in the steering gear housing.
(7) A l i g n t h e notch i n the stub shaft cap w i t h the
locating p i n i n the valve body and press t h e spool
valve a n d t h e stub shaft i n t h e valve body (Fig. 26).
LOCATING
PIN
STUB SHAFT
CAP N O T C H J8919-49
Fig. 26 Stub Shaft Installation
(8) L u b r i c a t e the stub shaft cap-to-wormshaft O-
r i n g seal w i t h power steering f l u i d and position i t i n
the cap groove.
PITMAN SHAFT AND COVER—INSPECTION
(1) Inspect t h e cover-to-housing contact surface.
(2) Inspect t h e p i t m a n shaft sector teeth, upper
contact surface and bearing/seal contact surface (Fig.
27).
(3) Replace the cover and t h e shaft i f they are se-
verely w o r n , scored or p i t t e d . I f t h e p i t m a n shaft ad-
j u s t m e n t screw head fits loose i n the T-slot, replace
the p i t m a n shaft.
RACK PISTON/WORMSHAFT—DISASSEMBLY
(1) Remove the b a l l r e t u r n guide clamp.
(2) Place t h e complete assembly on clean paper and
remove t h e b a l l r e t u r n guides, t h e wormshaft w i t h
•
UPPER
CONTACT
SURFACE
S E C T O R TEETH
BEARING/
SEAL
CONTACT
SURFACE
J8919-50
Fig. 27 Pitman Shaft Inspection
a n arbor tool, and t h e r e c i r c u l a t i n g balls. E n s u r e
t h a t a l l 24 b a l l s a r e r e m o v e d a n d r e t a i n e d .
(3) Remove the arbor tool f r o m the wormshaft.
(4) Remove the teflon piston r i n g and t h e O-ring
seal f r o m t h e rack piston (Fig. 28).
RACK PISTON/WORMSHAFT-ASSEMBLY
(1) Lubricate a l l o f t h e components w i t h power
steering f l u i d .
(2) I n s t a l l t h e O-ring seal i n t h e rack piston groove
(Fig. 50). D o n o t a l l o w t h e O - r i n g seal t o b e c o m e
twisted d u r i n g installation.
(3) I n s t a l l t h e teflon piston r i n g over t h e O-ring
seal.
(4) Insert t h e wormshaft completely i n t o the rack
piston.
(5) I n s t a l l t h e r e c i r c u l a t i n g balls i n the rack piston
b y alternately i n s t a l l i n g one black b a l l followed b y
one silver b a l l u n t i l a t o t a l o f 18 balls have been i n -
stalled i n t h e inner r e t u r n guide hole (Fig. 29). A f t e r
i n s t a l l i n g each b a l l , press i t downward t o provide
space for t h e next b a l l .
(6) Rotate the wormshaft counterclockwise (viewed
f r o m the steering shaft end) t o route the balls i n t o
the circuit. T h e w o r m s h a f t w i l l s p i r a l o u t o f t h e
r a c k p i s t o n as i t i s r o t a t e d a n d t h e b a l l s a r e c i r -
culated.
(7) F i l l one b a l l r e t u r n half-guide w i t h petroleum
j e l l y and i n s t a l l the six r e m a i n i n g balls i n the b a l l
r e t u r n half-guide (Fig. 30). Ensure t h a t the balls i n
t h e half-guide are installed alternately b y color (i.e.,
a black b a l l followed b y a silver ball) and are i n a l -
t e r n a t i n g color sequence w i t h the balls previously i n -
stalled i n the rack piston.
 • STEERING 19 - 33

O-RING BALL
SEAL RETURN
GUIDE

J8919-51 J8919-53

Fig. 28 Rack Piston Fig. 30 Ball Return Guide

INNER RETURN (11) Do n o t p e r m i t t h e tool to separate from t h e
GUIDE HOLE
wormshaft u n t i l t h e rack piston is completely i n -
stalled on t h e wormshaft.
ARBOR

J8919-52

Fig. 29 Recirculating Ball Installation

(8) Mate t h e t w o half-guides and insert t h e assem-
18919-54
bled b a l l r e t u r n guide i n t o t h e guide holes i n t h e
rack piston.
(9) I n s t a l l t h e b a l l r e t u r n guide clamp, t h e lock-
washers a n d t h e r e t a i n i n g screws. T i g h t e n t h e POWER STEERING GEAR-ASSEMBLY
screws w i t h 14 N*m (10 ft-lbs) torque. A l l components must be clean and lubricated w i t h
(10) Insert a n arbor tool ( F i g . 31) i n t o t h e w o r m - power steering fluid (except as stated otherwise) be-
shaft and position t h e end of the assembled rack pis- fore assembly.
t o n ( w i t h tool) o n wooden blocks. Ensure t h a t t h e (1) Clamp t h e steering gear housing i n a vise w i t h
rack piston i s supported w i t h wooden blocks after i t the p i t m a n shaft bore facing downward. Use t h e u n -
is inverted ( F i g . 31). machined housing bosses for t h e clamping pads (Fig.
32).
19-34 STEERING •
into the valve body fluid grooves, "seat" the valve
body only by pushing on the outer diameter surface
of the valve body with your fingertips (Fig. 34). E n -
sure that the teflon rings do not bind inside the
housing. The valve body is correctly "seated" when
all or most of the fluid return hole in the steering
gear housing is visible.

(4) A l i g n t h e narrow slot i n t h e valve body w i t h

the locating p i n i n the wormshaft (Fig. 34) a n d i n s e r t
the valve body i n t o the steering gear housing, "seat"
the valve body i n the housing (Fig. 34).
WORMSHAFT
LOCATING
PIN

J8919-32

Fig. 32 Steering Gear Housing

(2) I n s t a l l t h e wormshaft conical bearing races a n d
the lower t h r u s t bearing. I n s t a l l t h e first conical
b e a r i n g race followed b y t h e t h r u s t bearing, and t h e n
the second conical b e a r i n g race ( F i g . 33). B o t h o f
t h e c o n i c a l b e a r i n g r a c e s m u s t b e i n s t a l l e d so
t h a t t h e t o p o f e a c h c o n e faces t h e b o t t o m o f t h e
gear housing.

VALVE O-RING WORM CONICAL

BODY SEAL SHAFT RACES

J8919-56

Fig. 34 Valve Body Installation

THRUST
BEARING J8919-36
Fig. 33 Lower Thrust Bearing & Race Installation
(3) I n s t a l l t h e stub shaft cap-to-valve body O-ring
seal i n t h e v a l v e body so t h a t i t is "seated" against
the i n n e r edge o f the stub shaft cap (Fig. 34).
CAUTION: Do not press against the stub shaft to
"seat" the valve body. This could cause the stub
shaft and cap to separate from the valve body and
allow the spool valve dampener O-ring seal to slip
(5) I n s t a l l a seal protector tool over t h e end o f t h e
stub shaft ( F i g . 35).
(6) I n s t a l l t h e adjustment cap over t h e end o f t h e
stub shaft (Fig. 35).
(7) T i g h t e n t h e adjustment cap w i t h a spanner
wrench u n t i l i t "seats" against the valve body. A p -
p r o x i m a t e l y 27 N*m (20 ft-lbs) torque is r e q u i r e d t o
"seat" t h e cap.
(8) Remove t h e seal protector tool after i n s t a l l i n g
the adjustment cap.
(9) Insert t h e rack piston i n t o t h e steering gear
housing u n t i l t h e wormshaft engages w i t h t h e v a l v e
body a n d t h e stub shaft.
Use c a r e t o p r e v e n t d a m a g e t o t h e p i s t o n r i n g
during installation.
(10) Rotate t h e stub shaft clockwise t o force t h e
rack piston i n t o t h e steering gear housing. Do not re-
move the arbor tool u n t i l t h e valve body piston r i n g
has entered t h e housing bore.
(11) Rotate t h e stub shaft u n t i l the rack piston cen-
ter groove is aligned w i t h t h e center o f t h e p i t m a n
shaft bearing bore.
 • STEERING
Fig. 35 Adjustment Cap Installation
(12) Lubricate t h e p i t m a n shaft adjustment screw
cover gasket w i t h petroleum j e l l y and place i t on the
cover. Ensure t h a t the rubber seal i n the gasket is
properly "seated" i n the cover groove.
(13) Position t h e cover over the p i t m a n shaft and
t h r e a d the cover onto t h e adjustment screw u n t i l i t
contacts the p i t m a n shaft.
(14) I n s t a l l the p i t m a n shaft w i t h the long, center
sector tooth meshing w i t h t h e rack piston center
groove.
(15) Ensure t h a t t h e adjustment screw cover gasket
is correctly i n place before attaching the cover t o the
steering gear housing. I n s t a l l the cover lockwashers
and bolts. T i g h t e n the bolts w i t h 6 1 N-m (45 ft-lbs)
torque.
(16) Thread the adjustment screw locknut half-way
on t h e adjustment screw. I f necessary, insert a n
A l l e n wrench i n t o the adjustment screw head t o pre-
v e n t i t from t u r n i n g w h i l e t h r e a d i n g the n u t on i t .
(17) I n s t a l l t h e e n d p l u g i n t h e rack piston.
T i g h t e n the p l u g w i t h 68 N n n (50 ft-lbs) torque.
(18) Lubricate t h e steering gear housing end-plug
O - r i n g seal w i t h power steering f l u i d and position i t
on the end p l u g .
(19) I n s t a l l and "seat" the end p l u g i n the steering
gear housing. I f necessary, tap the end p l u g l i g h t l y
w i t h a plastic m a l l e t to "seat" i t properly.
(20) I n s t a l l t h e end-plug r e t a i n i n g r i n g w i t h t h e
r i n g end gap n o t a l i g n e d w i t h the hole inside t h e
steering gear housing. Tap l i g h t l y on the p l u g t o en-
sure t h a t the r i n g is "seated" properly.
(21) Adjust the wormshaft bearing "preload" torque
19-35
J8919-58
Fig. 36 Adjustment Cap Index Mark
and t h e p i t m a n shaft overcenter drag torque accord-
i n g t o t h e procedures listed w i t h i n P o w e r S t e e r i n g
Gear—Adjustments On Bench.
POWER STEERING GEAR-ADJUSTMENTS ON
BENCH
A f t e r assembly, the steering gear requires t w o ad-
justments:
• w o r m s h a f t bearing "preload" torque, and
• p i t m a n shaft overcenter drag torque.
CAUTION: Adjust the steering gear in the following
order only. Always adjust the wormshaft bearing
"preload" torque first, and then adjust the pitman
shaft overcenter drag torque last. Failure to do so
could result in damage to the gear or improper
steering response.
WORMSHAFT BEARING PRELOAD TORQUE-ADJUSTMENT
(1) T i g h t e n the wormshaft bearing adjustment cap
w i t h a spanner wrench u n t i l i t is "seated" i n t h e
steering gear housing. Approximately 27 N»m (20 ft-
lbs) torque is required t o "seat" the cap i n the hous-
ing.
(2) Score a n index m a r k on the steering gear hous-
i n g adjacent t o one of the spanner wrench t i g h t e n i n g
holes i n t h e adjustment cap (Fig. 36).
(3) Measure counterclockwise 4.7 to 6.3 m m (3/16
to 1/4 i n ) f r o m the index m a r k and score a n adjust-
m e n t reference m a r k on the housing (Fig. 37).
(4) Rotate the adjustment cap counterclockwise u n -
t i l t h e spanner wrench t i g h t e n i n g hole i n t h e cap
(adjacent t o the index m a r k ) is aligned w i t h the ad-
j u s t m e n t reference m a r k on the housing.
19-36 STEERING
Fig. 37 Adjustment Reference Mark
(5) I n s t a l l the adjustment cap l o c k n u t and t i g h t e n
i t w i t h 115 N-m (85 ft-lbs) torque. Ensure t h a t the
adjustment cap does n o t rotate w h i l e t i g h t e n i n g the
locknut.
(6) Rotate the stub shaft clockwise to the stop, t h e n
rotate i t counterclockwise 1/4 of-a-turn.
(7) Use a low c a l i b r a t i o n (e.g., inch-pounds) torque
bar w i t h a m a x i m u m capacity o f 6 N-m/50 in-lbs
torque and a 12-point deep socket wrench to measure
the "preload" torque r e q u i r e d to rotate the stub shaft
(and wormshaft). Rotate the stub shaft a t a constant
speed (rpm) and measure t h e wormshaft "preload"
torque w i t h the beam of the torque bar at or near the
vertical position (Fig. 38).
(8) Record the wormshaft bearing "preload" torque
measurement. T h e "preload" torque required t o ro-
tate the stub shaft (and wormshaft) should be 0.45 to
1.13 N-m (4 to 10 in-lbs). I f the torque measurement
is not w i t h i n the specified torque range:
• the adjustment cap could be n o t tightened cor-
rectly or i t could have rotated w h i l e the l o c k n u t was
being tightened;
• the steering gear could be assembled incorrectly;
or
• the t h r u s t bearings and the races could be defec-
tive.
(9) I f necessary, correct the cause for the incorrect
"preload" torque and readjust the adjustment cap.
PITMAN SHAFT OVERCENTER DRAG
TORQUE-ADJUSTMENT
CAUTION: Do not attempt to adjust the pitman shaft
overcenter drag torque before the wormshaft bear-
ing "preload" torque has been adjusted.
•
Fig. 38 Wormshaft Bearing "Preload" Torque
Measurement
(1) Rotate the p i t m a n shaft adjustment screw coun-
terclockwise u n t i l i t is f u l l y extended, t h e n rotate i t
180 degrees clockwise.
(2) Rotate the stub shaft from stop-to-stop, count
the t o t a l n u m b e r of rotations, and rotate t h e stub
shaft i n the reverse direction 1/2 of t h e t o t a l n u m b e r
of rotations t o center the steering gear.
W h e n t h e s t e e r i n g g e a r i s c e n t e r e d , t h e flat
area o n the s t u b shaft s h o u l d face u p w a r d a n d
be p a r a l l e l w i t h t h e a d j u s t m e n t screw cover
( F i g . 39) a n d t h e p i t m a n s h a f t m a s t e r s p l i n e
s h o u l d b e a l i g n e d w i t h t h e a d j u s t m e n t s c r e w as
i l l u s t r a t e d i n F i g u r e 40.
(3) Place a low calibration (e.g., inch-pounds)
torque bar w i t h a m a x i m u m capacity of 6 N-m/50 i n -
lbs torque a n d a 12-point deep socket wrench on the
stub shaft. Place the torque bar i n a v e r t i c a l position
for t h e measurement. Rotate the torque bar 45 de-
grees each side of vertical position )center) a n d
record the highest overcenter drag torque measured
at or near the steering gear center position (Fig. 41).
(4) T h e overcenter drag torque m u s t conform (as
applicable) t o the following specifications:
• for n e w steering gears (less t h a n 400 miles/640
k m ) — t h e overcenter drag torque should be equal t o
the previously measured wormshaft bearing "pre-
l o a d " torque plus an additional 0.45 to 0.90 N-m (4 t o
8 in-lbs) torque b u t must not exceed a m a x i m u m o f 2
N-m (18 in-lbs) torque; and
• for used steering gears (400 miles/640 k m or more-
)—the overcenter drag torque should be equal t o the
previously measured wormshaft bearing torque plus
 • STEERING
Fig. 40 Steering Gear Centered (Reference)
an additional 0.5 to 0.6 N - m (4 to 5 in-lbs) torque b u t
do not exceed a m a x i m u m of 2 N - m (18 in-lbs)
torque.
(5) i f necessary, adjust t h e overcenter d r a g torque
by r o t a t i n g the p i t m a n shaft adjustment screw clock-
wise u n t i l the specified overcenter d r a g torque is ob-
tained. H o l d the p i t m a n shaft adjustment screw and
t i g h t e n the locknut w i t h 27 N - m (20 ft-lbs) torque af-
ter the adjustment is completed (Fig. 42). I f t h e a d -
j u s t m e n t s c r e w is a l l o w e d t o r o t a t e w h i l e
19-37
Fig. 41 Pitman Shaft Overcenter Drag Torque
Measurement
Fig. 42 Tightening Adjustment Screw Locknut
tightening the locknut, the complete overcenter
d r a g t o r q u e adjustment p r o c e d u r e m u s t be re-
peated.
(6) I n s t a l l t h e steering gear according to t h e i n s t a l -
l a t i o n procedure.
(7) F i l l the p u m p reservoir w i t h power steering
fluid and purge the system according to the proce-
dure listed w i t h i n P o w e r S t e e r i n g G e a r — I n i t i a l
Operation.
 19-38 STEERING
INITIAL OPERATION
(1) F i l l t h e pump reservoir a n d operate t h e engine
u n t i l t h e power steering fluid reaches t h e n o r m a l op-
e r a t i n g temperature o f approximately 77°C (170°F),
t h e n stop t h e engine.
(2) Turn t h e wheels t o a f u l l - l e f t - t u r n position a n d
add power steering fluid u n t i l t h e reservoir is f u l l .
(3) S t a r t t h e engine. Operate i t a t h i g h idle speed
and t h e n observe the fluid level on t h e dipstick. A d d
fluid, i f necessary.
(4) Purge t h e system o f a i r b y t u r n i n g t h e wheels
f r o m side-to-side w i t h o u t contacting t h e stops. F l u i d
w i t h a i r i n i t w i l l have a " m i l k y - r e d " color. M a i n t a i n
the reservoir f u l l of fluid.
Because a i r is compressible, i t m u s t b e elimi-
n a t e d f r o m t h e f l u i d b e f o r e n o r m a l s t e e r i n g ac-
tion c a n be obtained.
(5) R e t u r n t h e wheels t o t h e straight-ahead posi-
t i o n a n d operate the engine for a n a d d i t i o n a l 2 to 3
minutes, t h e n stop t h e engine.
(6) Road test the vehicle t o ensure t h a t the steering
system functions n o r m a l l y a n d has no noise.
(7) Observe t h e fluid level. A d d fluid as necessary
to fill t h e reservoir w i t h t h e system stabilized a t t h e
n o r m a l operating temperature.
CAUTION: If the fluid reservoir cap is not properly
tightened after a fluid level check, the result can be
fluid leakage and possible loss of the cap. Ensure
that the cap is securely tightened when installing it.
POWER STEERING
HOSE—REMOVAL/INSTALLATION
Cap t h e hose open ends and t h e pump/steering gear
fittings to prevent e n t r y of foreign m a t e r i a l .
WARNING: POWER STEERING FLUID (AND PUMP
COMPONENTS) AND THE EXHAUST SYSTEM CAN
BE EXTREMELY HOT IF THE ENGINE HAS BEEN
RECENTLY OPERATING. DO NOT START THE EN-
GINE WITH ANY LOOSE OR DISCONNECTED
HOSES. DO NOT ALLOW THE HOSES TO TOUCH A
HOT EXHAUST MANIFOLD OR THE CATALYTIC
CONVERTER.
REMOVAL
(1) I f applicable, remove t h e fasteners f r o m t h e
hose r e t a i n i n g brackets a t a l l locations.
(2) Disconnect the hose f r o m t h e steering gear
valve body fitting and d r a i n t h e fluid from t h e p u m p
and reservoir v i a the open end o f the hose.
(3) Disconnect the opposite end o f the hose f r o m t h e
pump fitting a n d remove t h e hose f r o m t h e vehicle.
INSTALLATION
W h e n a n o r i g i n a l power steering fluid hose is be-
i n g i n s t a l l e d or a replacement hose is being installed,
i t is essential t h a t the f o l l o w i n g precautions be em-
ployed:
•
• avoid sharp bends i n t h e hose (a 5-inch approxi-
mate radius m i n i m u m is recommended);
• hose must r e m a i n a t least one i n c h away f r o m a l l
pulleys, battery, a n d b r a k e t u b i n g , a n d t w o inches
away from t h e exhaust m a n i f o l d ; a n d
• protective plastic foam sleeves m u s t be i n s t a l l e d
where the hose contacts other components or vehicle
body metal.
(1) Wipe t h e hose open ends and t h e pump/steering
gear fittings clean.
(2) Connect t h e hose a t t h e steering gear valve
body fitting a n d a t t h e p u m p fitting. I f applicable,
route the hose to t h e r e t a i n i n g brackets w h i l e avoid-
i n g extreme bends or " k i n k i n g " t h e hose. The hose
must r e m a i n away f r o m t h e exhaust system compo-
nents. Do n o t distort t h e hose tube ends.
(3) I f applicable, i n s t a l l a n d properly t i g h t e n a l l
bracket fasteners.
(4) Where used, t h e protective plastic foam sleeves
must be properly positioned on t h e hose t o prevent
chafing caused by contact w i t h other components.
(5) T i g h t e n the fittings a t t h e p u m p a n d a t t h e
steering gear w i t h 30 N - m (22 ft-lbs) torque.
(6) After t h e hose i s i n s t a l l e d , inspect a n d test for
fluid leaks.
POWER STEERING GEAR—INITIAL OPERATION
(1) F i l l t h e p u m p reservoir a n d operate t h e engine
u n t i l the power steering fluid reaches t h e n o r m a l op-
erating temperature o f approximately 77°C (170°F),
t h e n stop t h e engine.
(2) T u r n t h e wheels to a f u l l - l e f t - t u r n position a n d
add power steering fluid u n t i l t h e reservoir is f u l l .
(3) Start t h e engine. Operate i t a t h i g h idle speed
and then observe t h e fluid level on t h e dipstick. A d d
fluid, i f necessary.
(4) Purge t h e system o f a i r by t u r n i n g t h e wheels
from side-to-side w i t h o u t contacting t h e stops. F l u i d
w i t h a i r i n i t w i l l have a " m i l k y - r e d " color. M a i n t a i n
the reservoir f u l l o f fluid.
Because a i r i s c o m p r e s s i b l e , i t m u s t b e e l i m i -
n a t e d f r o m t h e f l u i d b e f o r e n o r m a l s t e e r i n g ac-
tion can be obtained.
(5) R e t u r n the wheels t o t h e straight-ahead posi-
t i o n and operate t h e engine for a n a d d i t i o n a l 2 t o 3
minutes, t h e n stop t h e engine.
(6) Road test the vehicle t o ensure t h a t the steering
system functions n o r m a l l y a n d has no noise.
(7) Observe t h e fluid level. A d d fluid as necessary
to fill the reservoir w i t h t h e system stabilized a t t h e
normal operating temperature.
CAUTION: If the fluid reservoir cap is not properly
tightened after a fluid level check, the result can be
fluid leakage and possible loss of the cap. Ensure
that the cap is securely tightened when installing it.
 • STEERING 19-39

POWER STEERING PUMP SERVICE

INDEX
Page Page
Fluid Level 39 Pump—Removal/Installation 46
Hose—Removal/Installation . . . . . . . . . . . . . . . . . . 45 Pump Repair Service 46
Operation 39 Service Diagnosis 39
Pressure Test 44

OPERATION
Rectangular p u m p vanes rotated b y t h e shaft
d r i v e n rotor move t h e fluid from t h e i n t a k e t o t h e
cam r i n g pressure cavities. As t h e rotor begins to
t u r n , centrifugal force moves t h e vanes against t h e
inside surface of t h e cam r i n g to p i c k u p residual
fluid. T h i s fluid is t h e n forced i n t o t h e h i g h pressure
area. A s more fluid is picked up by t h e vanes, fluid is
forced i n t o t h e cavities of the t h r u s t plate t h r o u g h
t w o crossover holes i n t h e cam r i n g a n d pressure
plate. T h e crossover holes empty i n t o t h e h i g h pres-
sure area between t h e pressure plate a n d t h e hous-
i n g end cover.
W h e n t h e h i g h pressure area is filled, fluid flows
under t h e vanes i n t h e rotor slots, forcing t h e vanes
to follow t h e inside oval surface of the c a m r i n g . As Fig. 1 Power Steering Pump
the vanes reach t h e restricted area o f the c a m r i n g ,
FLUID LEVEL
fluid is forced out f r o m between the vanes. W h e n ex-
cess fluid flow is generated d u r i n g high-speed opera-
t i o n , a regulated amount of fluid r e t u r n s to t h e pump CAUTION: The fluid level should be "checked" with
i n t a k e side t h r o u g h t h e flow control valve. T h e flow engine off to prevent injury from moving compo-
control valve reduces the power required t o d r i v e t h e nents. Do not use automatic transmission fluid to
p u m p and reduces temperature " b u i l d - u p " . supplement the fluid in the reservoir. Do not overfill
the reservoir.
W h e n steering conditions cause t h e m a x i m u m a l -
lowable safe pressure to be exceeded (e.g., t u r n i n g Wipe t h e reservoir filler cap clean of foreign mate-
the wheels against t h e steering "stops") t h e pressure r i a l , t h e n check t h e f l u i d level ( F i g . 1). The dipstick
b u i l t u p i n t h e steering gear also exerts pressure on should indicate F U L L C O L D w h e n t h e fluid is a t
the s p r i n g end of the flow control valve. T h i s end of n o r m a l ambient temperature (approximately 21°C t o
the valve houses the pressure relief valve. H i g h pres- 27°C/70°F to 80°F). Replenish t h e fluid, i f necessary,
sure l i f t s t h e relief valve b a l l from i t s "seat" and a l - with M O P A R Power Steering Fluid, Part No.
lows fluid t o flow t h r o u g h a trigger orifice located i n 4318056, o r a n e q u i v a l e n t f l u i d .
t h e outlet fitting. T h i s reduces t h e pressure on t h e
spring e n d o f t h e flow control valve, w h i c h t h e n SERVICE DIAGNOSIS
opens a n d allows t h e fluid t o r e t u r n t o t h e i n t a k e
There is some noise i n a l l power steering systems.
side o f t h e pump. T h i s action l i m i t s t h e m a x i m u m
One o f the most common is a hissing sound most ev-
pressure o u t p u t of the pump to a safe level.
ident a t vehicle standstill or p a r k i n g . Hiss is a h i g h
W i t h n o r m a l operating conditions, t h e pressure re-
frequency noise s i m i l a r t o t h a t experienced w h i l e
quirements o f the p u m p are below m a x i m u m , caus- slowly closing a water tap. T h e noise is present i n
i n g t h e pressure r e l i e f valve to r e m a i n closed. every valve and results f r o m h i g h velocity fluid pass-
Safety goggles s h o u l d be w o r n a t a l l times i n g t h e valve orifice edges. There is no relationship
w h e n i n v o l v e d w i t h p o w e r s t e e r i n g p u m p ser- between this noise a n d performance of t h e steering
vice. pump. " H i s s " can be expected w h e n t h e steering
A power steering pump can be identified b y i t s wheel is a t the end of t r a v e l or w h e n slowly t u r n i n g
" h a m c a n " shaped reservoir (Fig. 1). the wheels at vehicle s t a n d s t i l l .
19-40 STEERING •
PUMP SERVICE DIAGNOSIS

CONDITION POSSIBLE CAUSE CORRECTION

CHIRP NOISE IN (1) Loose belt. 0) Adjust belt tension to specification.

STEERING PUMP

BELT SQUEAL (1) Loose belt. (1) Adjust belt tension to specification.
(PARTICULARLY
NOTICEABLE AT
FULL WHEEL
TRAVEL AND STAND
STILL PARKING)

GROWL NOISE IN (1) Excessive back pressure in hoses or steering (1) Locate restriction and correct. Replace
STEERING PUMP gear caused by restriction. part if necessary.

GROWL NOISE IN (D Scored pressure plates, thrust plate or (1) Replace parts and flush system.
STEERING PUMP rotor.
(PARTICULARLY
NOTICEABLE AT
STAND STILL (2) Extreme wear of cam ring. (2) Replace parts.
PARKING

GROAN NOISE IN (1) Low oil level. (1) Fill reservoir to proper level.
STEERING PUMP

(2) Air in the oil. Poor pressure hose connection. (2) Tighten connector to specified torque.
Bleed system by operating steering from
right to left - full turn.

RATTLE NOISE IN (1) Vanes not installed properly. (1) Install properly.
STEERING PUMP

(2) Vanes sticking in rotor slots. (2) Free up by removing burrs, varnish,
or dirt.

SWISH NOISE IN (1) Defective flow control valve. (1) Replace part.
STEERING PUMP

WHINE NOISE 0) Pump shaft bearing scored. (1) Replace housing and shaft. Flush system.
IN STEERING PUMP

HARD STEERING OR (1) Loose pump belt. (1) Adjust belt tension to specification.
LACK O F ASSIST

(2) Low oil in reservoir. (2) Fill to proper level. If excessively low,
check all lines and joints for evidence of
NOTE: Low oil level will also result in excessive external leakage. Tighten loose
pump noise. connectors.

(3) Steering gear to column misalignment. (3) Align steering column.

(4) Lower coupling flange rubbing against (4) Loosen pinch bolt and assemble properly.
steering gear adjuster.

(5) Tires not properly inflated. (5) Inflate to recommended pressure.

J8919-68
• STEERING 19-41

PUMP SERVICE DIAGNOSIS (CONT'D)

CONDITION POSSIBLE CAUSE CORRECTION

Further possible causes could be:

(6) Sticking flow control valve. In order to diagnose conditions such as

listed in (6), (7), (8), (9) a pressure test
of the entire power steering system is
(7) Insufficient pump pressure output. required.

(8) Excessive internal pump leakage.

(9) Excessive internal gear leakage.

FOAMING MILKY 0) Air in the fluid, and loss of fluid due to 0) Check for leaks and correct. Bleed
POWER STEERING internal pump leakage causing overflow. system. Extremely cold temperatures will
FLUID, LOW FLUID cause system aeriation should the oil
LEVEL AND level be low. If oil level is correct and
POSSIBLE LOW pump still foams, remove pump from
PRESSURE vehicle and separate reservoir from body.
Check welsh plug and body for cracks.
If plug is loose or body is cracked,
replace body.

LOW PUMP (1) Flow control valve stuck or inoperative. (1). Remove burrs or dirt or replace. Flush
PRESSURE system.

(2) Pressure plate not flat against cam ring. (2) Correct.

MOMENTARY (1) Low oil level in pump. (1) Add power steering fluid as required.
INCREASE IN EFFORT
WHEN TURNING
WHEEL FAST TO (2) Pump belt slipping. (2) Tighten or replace belt.
RIGHT OR LEFT

(3) High internal leakage: (3) Check pump pressure. (See pressure
test.)

STEERING WHEEL (1) Low oil level. (1) Fill as required.

SURGES OR JERKS
WHEN TURNING WITH
ENGINE RUNNING (2) Loose pump belt. (2) Adjust tension to specification.
ESPECIALLY DURING
PARKING
(3) Steering linkage hitting engine oil pan at (3) Correct clearance.
full turn.

(4) Insufficient pump pressure. (4) Check pump pressure. (See pressure
test.) Replace flow control valve if
defective.

(5) Sticking flow control valve. (5) Inspect for varnish or damage, replace
if necessary.

EXCESSIVE WHEEL (1) Air in system. 0) Add oil to pump reservoir and bleed by
KICKBACK OR LOOSE operating steering. Check hose connectors
STEERING for proper torque and adjust as required.

J8919-69
19-42 STEERING •
PUMP SERVICE DIAGNOSIS (CONT'D)

CONDITION POSSIBLE CAUSE CORRECTION

LOW PUMP PRESSURE (1) Flow control valve stuck or inoperative.
(2) Pump pressure plate not seating (flat) against
cam ring.
(3) Extreme wear of cam ring.
(4) Scored pressure plate, thrust plate, or rotor.
(5) Vanes not installed properly.
(6) Vanes sticking in rotor slots.
(7) Cracked or broken thrust or pressure plate.
(1) Remove burrs or dirt. Replace valve if
damaged.
(2) Disassemble pump and correct.
(3) Replace parts. Flush system.
(4) Replace parts. Flush system.
(5) Install properly.
(6) Freeup by removing burrs, varnish, or dirt.
(7) Replace part.
J8919-70
• STEERING 19 - 43

PUMP LEAKAGE DIAGNOSIS

REPLACE "O" RING SEAL AND TIGHTEN HOSE FITTING NUT TO

30 N-m ( 2 2 FT. LBS.)

VIEW
TIGHTEN FITTING TO 55 N-m (40 FT. LBS.) IF LEAKAGE
PERSISTS, REPLACE "O" RING SEAL.

REPLACE RESERVOIR.

2}
CHECK OIL LEVEL. IF LEAKAGE PERSISTS WITH THE CORRECT
LEVEL AND CAP TIGHT, REPLACE THE CAP.'

VIEW B
REPLACE RESERVOIR 'O" RING.
REPLACE DRIVESHAFT SEAL

ft

VIEW
PR800C
19 - 44 STEERING
PRESSURE TEST
The f o l l o w i n g procedure can be used to test the op-
eration o f the power steering system while i n s t a l l e d
on the vehicle.
Safety goggles s h o u l d b e w o r n a t a l l times
w h e n i n v o l v e d w i t h power steering p u m p pres-
sure testing.
(1) Check and adjust the power steering p u m p belt
tension as necessary. I f necessary, refer to the proce-
dure.
(2) Place a d r i p p a n under the engine and discon-
nect the power steering pump h i g h pressure hose ei-
ther a t the p u m p or a t the steering gear (whichever
is t h e most convenient). M a i n t a i n t h e hose e n d
raised above the reservoir to prevent fluid loss.
(3) Connect Pressure Test Gauge Tool C-3909E t o
the pump pressure hose and to an adapter hose (use
an a d d i t i o n a l adapter hose i f necessary). Connect the
test gauge between the power steering p u m p and the
steering gear (Fig. 2).
Fig. 2 Pressure Test Gauge
CAUTION: Ensure that the test gauge is connected
in the fluid pressure circuit between the pump and
the steering gear.
•
pressure should be i n the range o f 207-345 k P a (30-
50 psi) a n d should definitely be less t h a n 690 k P a
(100 psi). I f the pressure is 690 k P a (100 psi) or
more, inspect the hoses for restrictions and repair as
necessary.
CAUTION: The following test procedure involves
testing the maximum pump pressure output and the
flow control valve operation. Do not close the test
gauge valve for more than five seconds at a time
because this could damage the pump.
(8) Close t h e test gauge valve f u l l y , t h e n i m m e d i -
ately open i t . Repeat t h i s procedure three times and
record t h e highest pressure indicated o n t h e test
gauge each t i m e the test gauge valve is closed.
(9) Compare the highest indicated pressures. I f the
pressure indications are a t least 8 900 k P a (1,300
psi) a n d t h e variance o f the three pressure indica-
tions is w i t h i n the 345 kPa (50 psi) allowable v a r i -
ance, t h e p u m p is functioning n o r m a l l y .
F o r example: i f the highest i n d i c a t e d pressures
a r e 8 930 k P a , 8 990 k P a a n d 9 050 k P a (1,305
p s i , 1,315 p s i a n d 1,325 psi), t h e y a r e a c c e p t a b l e
and, because the pressure variance is w i t h i n the
345 k P a (50 p s i ) a l l o w a b l e v a r i a n c e , t h e p u m p
operation is normal.
(10) I f t h e highest indicated pressures are more
t h a n the acceptable l i m i t of 9 930 kPa (1,450 psi) for
pressure r e l i e f or the pressures are not w i t h i n t h e
345 k P a (50 psi) allowable variance, the flow control
valve is n o t functioning correctly. Remove a n d clean
the valve (Fig. 3). Remove burrs w i t h a crocus cloth
or a fine g r i t hone. I f the system is contaminated,
flush i t .
FLOW
CONTROL
VALVE

(4) Open t h e test valve completely. Rotate t h e

valve counterclockwise to open i t .
(5) F i l l the fluid reservoir w i t h power steering f l u i d
as necessary.
(6) Insert a thermometer i n the fluid reservoir. Op-
erate t h e engine u n t i l t h e power steering f l u i d
reaches the n o r m a l operating temperature of 66°C to
77°C (150°F to 170°F).
T u r n i n g t h e wheels f r o m "stop-to-stop" w i l l
a i d w i t h h e a t i n g t h e f l u i d . D o n o t h o l d t h e steer-
i n g w h e e l a g a i n s t t h e " s t o p " f o r a n e x t e n d e d pe-
r i o d o f t i m e b e c a u s e t h i s w i l l cause t h e p u m p t o
over-heat a n d damage i n t e r n a l components.
(7) W i t h t h e engine at a speed of approximately
J8919-65
600 to 800 r p m and the gauge valve open, the i n i t i a l Fig. 3 Flow Control Valve
 • STEERING
CAUTION: The power steering system is a closed
system. Contaminated fluid in either the pump or in
the steering gear is circulated to the other unit. If
the system is exceptionally contaminated, the pump
and the steering gear must be disassembled and
cleaned, and all the hoses removed and flushed.
CAUTION: Do not force the pump to operate against
a "stop" for more than 2 to 4 seconds at a time be-
cause, otherwise, pump damage will result.
CAUTION: To prevent causing flat spots on the
front tires, do not turn the steering wheel more than
five times without moving the vehicle to change the
tire-to-floor contact surface area.
(11) I f the p u m p operation i s acceptable (i.e., t h e
highest indicated pressures are w i t h i n t h e specified
pressure r e l i e f range a n d variance), continue w i t h
t h e test. W i t h t h e gduge valve open, t u r n the steer-
i n g wheel to t h e extreme left a n d r i g h t positions to
force the p u m p t o operate against t h e stops (Fig. 4).
Record the highest indicated pressure a t each steer-
i n g wheel position.
WITH VALVE OPEN TURN STEERING WHEEL
ALL THE WAY LEFT AND
RIGHT. RECORD HIGHEST
PRESSURE AT EACH STOP.
J8919-66 properly
Fig. 4 Pressure Test
(12) Compare t h e extreme left a n d t h e r i g h t t u r n
pressures w i t h t h e previously noted pump highest
o u t p u t pressures. I f the p u m p highest output pres-
sures are not duplicated w h e n t h e p u m p is forced to
operate against either stop, t h e steering gear is leak-
i n g i n t e r n a l l y a n d m u s t be disassembled a n d r e -
paired.
(13) Stop t h e engine a n d remove t h e test equip-
19-41
m e n t . Connect t h e pressure hose t o t h e p u m p (or
steering gear).
(14) Repair t h e system as necessary and correct t h e
fluid level. Remove t h e d r i p pan.
HOSE—REMOVAL/INSTALLATION
Remove/install power steering hoses w i t h vehicle
raised o n a hoist. Cap t h e hose open ends a n d t h e
p u m p a n d steering gear ports t o prevent e n t r y o f for-
eign m a t e r i a l .
WARNING: POWER STEERING FLUID (AND PUMP
COMPONENTS) AND THE EXHAUST SYSTEM CAN
BE EXTREMELY HOT IF THE ENGINE HAS BEEN
RECENTLY OPERATING. DO NOT START THE EN-
GINE WITH ANY LOOSE OR DISCONNECTED
HOSES. DO NOT ALLOW THE HOSES TO TOUCH A
HOT EXHAUST MANIFOLD OR THE CATALYTIC
CONVERTER.
HOSE REMOVAL
(1) I f applicable, remove t h e fasteners f r o m t h e
hose r e t a i n i n g brackets a t a l l locations.
(2) Disconnect t h e hose from t h e steering gear
u n i o n and d r a i n the fluid from the pump and reser-
v o i r v i a the open end o f the hose.
(3) Disconnect the opposite end of the hose f r o m t h e
p u m p u n i o n and remove the hose from the vehicle.
HOSE INSTALLATION
W h e n either t h e o r i g i n a l hose o r a replacement
hose is being i n s t a l l e d , the following instructions are
essential:
• route the hose(s) and i n s t a l l t h e m i n the same lo-
c a t i o n ^ ) as o r i g i n a l l y installed before removal;
• route t h e hose(s) w i t h smooth curves (i.e., avoid
sharp bends a n d k i n k s ) ;
• t i g h t e n t h e b o t h hose fittings w i t h 30 N - m (22 f t -
lbs) torque;
• hose(s) m u s t r e m a i n a t least one inch away f r o m
a l l pulleys, t h e battery, and the brake t u b i n g , a n d a t
least t w o inches away from the exhaust manifold;
• w h e n used, t h e protective sponge sleeves m u s t be
positioned to prevent hose contact and chaf-
i n g f r o m other components i n engine compartment;
and
• after a hose(s) i s installed, inspect (and test) for
leaks w h i l e system is being purged of a i r (refer t o
P u m p Installation).
(1) Wipe the hose open ends, the pump fitting a n d
steering gear fitting clean.
(2) Connect t h e hose a t the steering gear fitting
and a t t h e p u m p fitting. A s applicable, route the
hose t o t h e r e t a i n i n g brackets w h i l e avoiding ex-
t r e m e bends or " k i n k i n g " the hose. The hose m u s t re-
19-46 STEERING
m a i n away f r o m t h e exhaust system components. Do
not distort the hose tube ends.
(3) A s applicable, i n s t a l l and t i g h t e n the bracket
fasteners w i t h the correct torque.
(4) When used, t h e protective foam sleeves m u s t be
properly positioned on t h e hose t o prevent chafing
caused by contact w i t h other components.
(5) After the hose is installed, inspect and test for
leaks. Refer t o P u m p I n s t a l l a t i o n for the procedure.
•
PUMP SHAFT SEAL REPLACEMENT
To service t h e p u m p shaft seal, i t i s necessary t o
remove the p u m p from the vehicle, and disassemble
and assemble t h e p u m p according to t h e instructions
provided i n P u m p R e p a i r S e r v i c e — P u m p D i s a s -
sembly/Assembly.
S a f e t y g o g g l e s s h o u l d b e w o r n a t a l l times
w h e n i n v o l v e d w i t h p o w e r s t e e r i n g p u m p ser-
vice.

PUMP—REMOVAL/INSTALLATION PUMP REPAIR SERVICE

The power steering pump m u s t be removed f r o m
REMOVAL the vehicle for t h e following service procedures.

CAUTION: The drive belt must be loosened before WARNING: THE POWER STEERING FLUID (AND
removing the pump. Do not attempt to remove the THE PUMP COMPONENTS) AND THE EXHAUST
pump without loosening the belt because, if not SYSTEM CAN B E EXTREMELY HOT IF THE ENGINE
loosened, the pulley will be damaged. HAS BEEN RECENTLY OPERATING.
Safety goggles should be worn at all times when
(1) Loosen the p u m p drive belt as instructed i n the
involved with power steering pump service.
drive belt adjustment procedure. Refer t o C o o l i n g
S y s t e m — G r o u p 7. Remove the belt from the p u m p
pulley. PULLEY REMOVAL
(2) Place a d r a i n p a n under t h e power steering
pump. CAUTION: Do not hammer on pulley because this
(3) Clamp the f l u i d r e t u r n hose and disconnect the will damage it and/or the pump.
hoses from t h e power steering pump. Cap t h e f i t -
(1) Remove t h e pulley from the p u m p shaft w i t h
tings.
the removal tools as indicated (Fig. 5).
(4) Remove the f r o n t bracket a t t a c h i n g bolts.
(5) Remove the pump-to-rear bracket bolts/nuts and
remove the pump. W i t h the p u m p removed, remove
the front bracket f r o m t h e p u m p , i f necessary.

PUMP INSTALLA TION

(1) I f removed, a t t a c h the front m o u n t i n g bracket
to the pump.
(2) Position the p u m p i n t h e rear bracket, i n s t a l l
the r e t a i n i n g bolts/nuts and t i g h t e n w i t h 28 N - m (21
ft-lbs) torque.
(3) I n s t a l l t h e front bracket-to-engine bolts a n d
t i g h t e n w i t h 28 N - m (21 ft-lbs) torque.
(4) Connect t h e f l u i d hoses to t h e pump. T i g h t e n Fig. 5 Pulley Removal
the both hose f i t t i n g s w i t h 30 N - m (22 ft-lbs) torque.
(5) I n s t a l l the drive belt and adjust the tension ac- (2) Replace the pulley i f i t is either bent, cracked,
or loose on the shaft.
cording to the adjustment procedure. Refer to C o o l -
i n g S y s t e m — G r o u p 7 . T i g h t e n the adjustment bolts
PULLEY INSTALLATION
w i t h 41 N - m (30 ft-lbs) torque. D o n o t p r y o n t h e
(1) I n s t a l l t h e pulley on the pump shaft w i t h I n -
p u m p reservoir; use t h e square hole p r o v i d e d i n
stallation Tool C-4063 (Fig. 6). Do not use the tool
the bracket.
adapters.
CAUTION: Do not use automatic transmission fluid (2) Ensure t h a t t h e tool a n d the pulley r e m a i n
to fill the reservoir. aligned w i t h t h e p u m p shaft t o prevent t h e pulley
from being "cocked" on the shaft.
(6) F i l l the reservoir w i t h power steering f l u i d . I f (3) Force the pulley on the shaft u n t i l i t is " f l u s h "
necessary, refer to P u m p I n i t i a l O p e r a t i o n (below) w i t h the end o f the shaft.
for detailed instructions.
 • STEERING 19 - 47

Fig. 6 Pulley Installation

PUMP DISASSEMBL Y Fig. 8 Pump Clamped In A Vise
The power steering pump i n s t a l l e d i n R a m V a n (Fig. 8) and t h e n t i l t i n g the reservoir slightly back
and Wagon vehicles is a vane-submerged type pump and f o r t h to "unseat" t h e O-ring seal. Remove and
(Fig. 7). discard the reservoir O-ring seal (Fig. 9).
(8) Remove t h e m o u n t i n g stud and t h e pressure
hose fitting seals from the counterbored spaces i n the
pump housing (Fig. 9). Discard the seals.
(9) Remove the end plate r e t a i n i n g r i n g (Fig. 10):
• insert a small punch i n the 3.1-mm (1/8-in) d i a m -
eter hole i n the p u m p housing opposite the flow con-
t r o l valve orifice;
• force the r e t a i n i n g r i n g u p w a r d w i t h a punch; and
• remove the r e t a i n i n g r i n g from the pump housing
by i n s e r t i n g a p r y tool under the r i n g and t u r n i n g i t .
(10) Remove the end plate and the spring from the
p u m p housing (Fig. 9). I f the end plate is not loose,
t i l t i t s l i g h t l y or t a p i t w i t h a plastic hammer t o
loosen i t .
(11) Remove the p u m p housing from the vise.
(12) Remove the flow control valve and the valve
spring from t h e p u m p housing (Fig. 9). I n v e r t t h e
J8919-81
p u m p housing to allow the valve and spring to slide
Fig. 7 Vane-Submerged Type Pump out of the orifice.
(1) Remove the pump m o u n t i n g brackets, as neces- CAUTION: Ensure that the outer (exposed) end of
sary. the pump shaft has no corrosion before removing it
(2) I f applicable, remove t h e fluid reservoir filler from the pump housing. If corrosion exists, use
cap and d r a i n t h e fluid. I n s t a l l t h e reservoir filler crocus cloth to remove it. Failure to remove corro-
cap. sion from the shaft can result in a damaged (non-
(3) Clean the pump exterior w i t h cleaning solvent. reusable) shaft seal and bushing.
(4) Remove t h e pump pulley w i t h a n appropriate
puller tool (Fig. 5). (13) Tap the outer end o f the pump shaft w i t h a
(5) Clamp t h e pump housing front h u b i n a vise plastic hammer (Fig. 11) u n t i l the pressure plate, the
w i t h the pump shaft p o i n t i n g d o w n w a r d (Fig. 8). D o p u m p r i n g and rotor, the t h r u s t plate, and the shaft
n o t over-tighten the vise j a w s because t h i s w i l l can be removed as a u n i t from t h e pump housing
distort the bearing. (Fig. 12).
(6) Remove the pump pressure hose fitting and the (14) Remove t h e r e t a i n i n g r i n g from the pump
m o u n t i n g studs. Discard the stud seals and the hose shaft (Fig. 13). Discard the r e t a i n i n g r i n g .
fitting O-ring seal (Fig. 9). (15) Remove t h e cam (pump) r i n g and rotor, and
(7) Remove t h e reservoir b y gently " t a p p i n g " t h e the t h r u s t plate from the shaft (Fig. 9). Use c a r e t o
filler tube back a n d f o r t h w i t h a plastic hammer a v o i d d r o p p i n g the r o t o r vanes.
 1. O-RING SEAL (FITTING)
2. CAP/DIPSTICK
3. RESERVOIR
4. END PLATE
5. SPRING
6. PRESSURE PLATE
7. RING 16. O-RING SEAL (STUD)
23 22
8. SNAP RING (SHAFT) 17. PLUG
9. ROTOR VANE 18. PLUG 25. RING DOWEL PIN
10. ROTOR 19. PUMP HOUSING 26. FLOW CONTROL VALVE
11. THRUST PLATE 20. SHAFT SEAL 27. SPRING
12. RING DOWEL PIN 21. BUSHING 28. O-RING SEAL (VALVE)
13. SHAFT 22. PLUG 29. RETAINING RING (END PLATE)
14. O-RING SEAL (END PLATE) 23. O-RING SEAL (RESERVOIR) 30. MOUNTING STUD
15. O-RING SEAL (PRESSURE PLATE) 24. O-RING SEAL (STUD) 31. FITTING (PRESSURE HOSE) J8919-1

Fig. 9 Vane-Submerged Type Pump—Exploded View

RETAINING
RING

Fig. 11 Pump Shaft Removal

J8919-84
Fig. 10 End Plate Retaining Ring Removal
(16) Remove t h e e n d plate O - r i n g seal a n d t h e
shaft seal (Fig. 14). U s e c a r e t o a v o i d d a m a g i n g
the p u m p housing bore.
PUMP CLEANING AND INSPECTION
(1) Clean a l l t h e m e t a l components w i t h m i n e r a l
spirits (Fig. 9). E i t h e r d r y the components w i t h com-
pressed a i r or wipe t h e m d r y w i t h a clean, lint-free
cloth.
(2) Inspect the flow control valve and ensure t h a t i t
slides freely i n the p u m p housing bore (Fig. 9). I f i t
binds, inspect b o t h t h e valve and the pump housing
bore for foreign objects, scratches and burrs. B u r r s
 • • STEERING
Fig. 13 Pump Shaft Retaining Ring Removal
can be removed w i t h crocus cloth. Replace t h e valve
or pump housing i f either are damaged a n d n o t re-
pairable.
The flow c o n t r o l valve is serviced as a u n i t
o n l y a n d i t m u s t n o t be disassembled.
(3) Inspect t h e capscrew i n t h e end o f t h e flow con-
t r o l valve for tightness. I f loose, t i g h t e n i t w i t h care
to avoid damaging t h e machined surfaces.
(4) Inspect t h e pressure plate and t h e t h r u s t plate
surfaces for flatness and, w h e n installed, ensure t h a t
t h e y w i l l be p a r a l l e l w i t h t h e p u m p r i n g . Inspect a l l
t h e components for cracks a n d scoring ( F i g . 9). Re-
place any component t h a t is defective or damaged.
A h i g h l y polished surface always exists o n t h e
pressure plate, the thrust plate a n d t h e p u m p
r i n g as a r e s u l t o f n o r m a l f r i c t i o n . D o n o t c o n -
fuse this c o n d i t i o n w i t h scoring.
(5) Inspect a l l the rotor vanes for ease o f movement
i n t h e rotor slots. Inspect t h e p u m p shaft for w o r n
splines, cracks, and other defects (Fig. 9). Replace a l l
19 - 49
SCREWDRIVER OIL SEAL
Fig. 14 Pump Seal Removal
excessively w o r n or damaged components. Replace
the discarded pump shaft r e t a i n i n g r i n g ( i t should
not be reused).
(6) Inspect t h e pump housing for wear, cracks, po-
rosity and damage (Fig. 9). Replace t h e p u m p hous-
i n g i f any of the conditions listed exist.
(7) Inspect t h e pressure hose/flow control valve fit-
t i n g (Fig. 9). I f damaged, replace i t .
(8) Inspect t h e end plate a n d r e t a i n i n g r i n g ( F i g .
9). I f either one is damaged, replace i t . Do not reuse
the r e t a i n i n g r i n g i f i t is bent or distorted. I f the con-
dition is uncertain, replace t h e r e t a i n i n g r i n g .
(9) Inspect t h e bushing a n d t h e seal ( F i g . 9). Re-
place, i f damaged.
(10) Assemble t h e pump according to t h e instruc-
tions provided w i t h i n t h e assembly procedure.
PUMP ASSEMBLY
CAUTION: Do not allow any foreign objects to enter
the pump housing during assembly. All compo-
nents must be clean and lubricated with power
steering fluid. Install replacement seals, retaining
rings and O-ring seals during assembly. Used, dam-
aged and worn seals will cause leakage, noise and
rapid wear after assembly.
(1) I n s t a l l t h e pump shaft seal w i t h a n appropriate
installation tool (Fig. 15).
(2) Lubricate w i t h petroleum j e l l y a n d i n s t a l l t h e
replacement seal i n the t h i r d groove i n t h e p u m p
housing bore (Fig. 16).
(3) Clamp t h e pump housing i n a vise w i t h t h e
large bore side facing downward. D o n o t o v e r -
tighten t h e vise j a w s because this w i l l d a m a g e
the bearing.
(4) Insert both dowel pins i n t h e t h r u s t plate.
(5) Insert t h e splined end o f t h e p u m p shaft
t h r o u g h t h e t h r u s t plate and t h e rotor, a n d i n s t a l l
the r e t a i n i n g r i n g on t h e end o f the shaft (Figs. 17
and 18). O p e n t h e r e t a i n i n g r i n g o n l y w i d e
 19 - 50 STEERING
Fig. 15 Pump Shaft Seal Installation
THIRD
GROOVE J8919-96
Fig. 16 Pump Housing Bore
e n o u g h t o s l i d e i t o v e r t h e e n d o f t h e s h a f t . The
rotor must slide easily on the splines.
(6) Insert t h e pump shaft i n t h e p u m p housing
(Fig. 19). Ensure t h a t the dowel pins are properly en-
gaged i n the t h r u s t plate.
(7) I n s t a l l t h e cam (pump) r i n g (Fig. 19) o n t h e
dowel pins w i t h t h e pump r o t a t i o n arrow ( F i g . 20)
facing upward.
(8) I n s t a l l a l l 10 rotor vanes i n t h e rotor slots
(Figs. 19 and 21) w i t h the rounded edges o f the vanes
facing outward.
(9) Lubricate t h e outside diameter surface and the
chamfered edge of the pressure plate w i t h petroleum
jelly.
(10) I n s t a l l t h e pressure plate o n the dowel pins
(Fig. 19) w i t h the plate spring groove facing upward.
•
Fig. 17 Thrust Plate & Rotor Assembly
Fig. 18 Rotor Retaining Ring Installation
(11) Place a large socket wrench o n top of t h e pres-
sure plate a n d force t h e plate downward approxi-
mately 1.5 m m (1/16 i n ) t o "seat" i t (Fig. 22).
(12) Lubricate t h e e n d plate seal (Fig. 9) w i t h pe-
t r o l e u m j e l l y a n d i n s t a l l i t i n t h e second groove i n
the p u m p housing bore.
(13) I n s t a l l t h e s p r i n g i n t h e center groove i n t h e
pressure plate (Fig. 9).
(14) Lubricate t h e e n d plate outside diameter sur-
face w i t h petroleum j e l l y and i n s t a l l the plate i n t h e
p u m p housing (Fig. 23). .
(15) Press t h e end plate d o w n w a r d and i n s t a l l t h e
end plate r e t a i n i n g r i n g (Fig. 23).
(16) I n s t a l l t h e s p r i n g over the hex-nut end o f the
flow control valve (Fig. 9).
(17) I n s t a l l the flow control valve and s p r i n g i n the
p u m p housing bore w i t h t h e hex-nut end of t h e valve
facing the i n t e r i o r o f t h e housing bore (Fig. 24).
(18) I n s t a l l the m o u n t i n g stud O - r i n g seals and the
flow control valve O - r i n g seal i n t h e counterbored
holes i n t h e pump housing (Fig. 25).
 • STEERING 19 - 51

VANES

PRESSURE
PLATE
* HOUSING THRUST PLATE

PR2359A

Fig. 19 Pump Shaft, Cam Ring & Pressure Plate Installation

DOWEL PUMP
PIN RING
LOCATING
HOLES
ARROW
UP

Fig. 20 Cam Ring Installation

(19) Position the fluid reservoir O - r i n g seal on t h e
p u m p housing (Fig. 25).
CAUTION: When installing the fluid reservoir, use
care to prevent damaging the O-ring seal. While ap-
plying pressure on the reservoir to "seat" it, guide
the seal into the seal grooves with a wooden or a
plastic tool.
(20) Lubricate the i n n e r edge of t h e fluid reservoir
w i t h petroleum j e l l y a n d position t h e reservoir on t h e
p u m p housing. Force t h e reservoir d o w n w a r d t o
"seat" i t on t h e pump housing.
(21) Inspect the a l i g n m e n t o f the m o u n t i n g stud O-
r i n g seals (Fig. 25) after i n s t a l l i n g t h e fluid reser-
voir. Re-align the seals, i f necessary.
(22) I n s t a l l t h e m o u n t i n g studs ( F i g . 25) and
t i g h t e n t h e m w i t h 48 N - m (35 ft-lbs) torque.
(23) I n s t a l l the O-ring seal on t h e pressure hose/
flow control valve f i t t i n g (Fig. 25) a n d i n s t a l l the fit-
ROTOR
VANE J8919-99
Fig. 21 Rotor Vane Installation
t i n g i n t h e flow control valve bore. T i g h t e n the
f i t t i n g w i t h 55 N - m (40 ft-lbs) torque.
(24) I n s t a l l t h e pump shaft p u l l e y w i t h the appro-
priate i n s t a l l a t i o n tool (Fig. 26).
(25) I n s t a l l t h e pump on the engine. I f necessary,
refer to t h e i n s t a l l a t i o n procedure.
PUMP INITIAL OPERATION
(1) F i l l t h e p u m p reservoir a n d operate the engine
u n t i l t h e power steering fluid reaches the n o r m a l op-
e r a t i n g temperature o f approximately 77°C (170°F),
t h e n stop t h e engine.
T u r n i n g the w h e e l s from "stop-to-stop" w i l l
a i d w i t h h e a t i n g the fluid. D o not h o l d the steer-
i n g w h e e l a g a i n s t the " s t o p " for a n extended pe-
 VALVE AND
SPRING

Fig. 22 Seating Pressure Plate

J8919-101

Fig. 24 Flow Control Valve/Spring Installation

RETAINING
RING J8919-100
Fig. 23 End Plate Installation
r i o d of time b e c a u s e this w i l l c a u s e t h e p u m p to
over-heat a n d d a m a g e i n t e r n a l c o m p o n e n t s .
(2) T u r n the wheels t o a f u l l - l e f t - t u r n position and
add power steering f l u i d u n t i l the reservoir is f u l l .
(3) Start t h e engine. Operate i t a t h i g h idle speed
and t h e n observe the f l u i d level o n t h e dipstick. A d d
f l u i d , i f necessary.
(4) Purge t h e system of a i r b y t u r n i n g t h e wheels
from side-to-side w i t h o u t contacting the stops. F l u i d
w i t h a i r i n i t w i l l have a " m i l k y - r e d " color. M a i n t a i n
the reservoir f u l l of f l u i d .
B e c a u s e a i r i s c o m p r e s s i b l e , i t m u s t be e l i m i -
nated from the fluid before n o r m a l steering a c -
tion c a n be obtained.
(5) R e t u r n t h e wheels t o t h e straight-ahead posi-
t i o n and operate t h e engine for a n additional 2 to 3
minutes, t h e n stop the engine.
(6) Road test the vehicle to ensure t h a t the steering
system functions n o r m a l l y and has no noise.
(7) Observe t h e f l u i d level. A d d f l u i d as necessary
to f i l l the reservoir w i t h the system stabilized a t t h e
n o r m a l operating temperature.
CAUTION: If the fluid reservoir cap is not properly
tightened after a fluid level check, the result can be
fluid leakage and possible loss of the cap. Ensure
that the cap is securely tightened when installing it.

\
 STEERING 19 -

CAP
EXPANSION PLUG— DO NOT REMOVE.
IF DEFORMED OR DISLODGED,
REPLACE HOUSING

HOUSING

STUDS
48 NEWTON METRES
(35 FOOT- POUNDS)

FITTING
55 NEWTON METRES
SEAL
(40 FOOT- POUNDS) PR811A

Fig. 25 Pump & Reservoir Seals

PULLEY*" RH31

Fig. 26 Pump Shaft Pulley Installation

19 - 54 STEERING
S T E E R I N G COLUMN S E R V I C E
INDEX
Page
Service Information 54
Standard/Fixed Steering Column—
Disassembly/Assembly 57
SERVICE INFORMATION
The steering columns (i.e., standard/fixed and t i l t -
able) i n s t a l l e d i n Ram V a n and Wagon vehicles have
anti-theft provisions, plus they are energy-absorbing
(i.e., collapse f r o m impact i n the event of a front-end
collision). T h e steering columns are designed t o col-
lapse a t a c o n t r o l l e d r a t e f r o m impact w h e n a front-
end collision is encountered. T h e collapsing action
reduces t h e l i k e l i h o o d of the driver contacting (be-
cause o f i n e r t i a ) a " f i x e d " steering wheel. I f t h e
driver continues forward into the wheel, the column
w i l l continue collapsing at the same controlled rate
and, i n so doing, reduce the force of the impact.
The steering columns have four p r i n c i p a l compo-
nents (Figs. 1 and 2):
• a column j a c k e t w i t h a slotted mesh section de-
signed t o shorten by " r o l l i n g u p " a t its lower end;
SPRING
JACKET
ASSEMBLY
Fig. 1 Steering Column—Console Shift
Page
Steering Column—Removal/Installation . . . . . . . . . 55
Tiltable Steering Column—Disassembly/Assembly . 63
• a two-piece, slip-type (telescoping) transmission
gear shift tube interconnected b y plastic inserts;
• a two-piece, slip-type (telescoping) steering shaft
(upper and lower shafts) connected b y plastic f r i c t i o n
collars and shear pins; and
• a support bracket t h a t connects t h e steering col-
u m n to t h e i n s t r u m e n t panel (the bracket allows the
column t o slide f o r w a r d b u t prevents r e a r w a r d move-
m e n t t o w a r d the driver).
The center section of the steering column jackets
has side-staggered slot perforations and i t is r i v e t e d
to an expansion m a n d r e l . U p o n application o f a force,
the rivets w i l l shear and t h e column jacket w i l l col-
lapse.
The gear shift tube consists o f two sections de-
signed t o slip-fit (telescope) together. These sections
are interconnected and held together by injections o f
plastic t h a t f o r m t h e interconnecting inserts a n d t h e
shear pins. U n d e r impact, there is a gradual p a r i n g
BUMPER
TURN SIGNAL AND
FLASHER SWITCH
JACKET
ASSEMBLY
GROMMET
STEERING PLATE
SHAFT ASSEMBLY PU875
 • STEERING
Fig. 2 Steering Cc
away o f the inserts b y t h e " k n i f e - l i k e " edge i n t h e
adjoining tube section.
The steering column shaft is comprised o f two sec-
tions. T h e upper shaft (section) is solid a n d has a
double-flatted lower end. The lower shaft (section) is
hollow and formed to f i t over t h e double-flatted end
of the upper shaft. T h e purpose o f the f l a t t e d section
is t o provide continued steering action even though
the column is completely "collapsed". Plastic is i n -
jected t h r o u g h four holes i n t h e lower, hollow shaft
i n t o a p a i r o f a n n u l a r grooves on the solid p o r t i o n of
the shaft. T h e four s m a l l holes, w h e n f i l l e d w i t h
plastic, f o r m the shear pins. Upon impact, t h e shear
pins shear-off a n d t h e shaft gradually collapses
against a resistance provided by the plastic collars i n
the a n n u l a r grooves.
The support bracket is designed to r e s t r a i n the col-
u m n f r o m being shifted t o w a r d the driver d u r i n g i m -
pact. I t incorporates t w o "break-away capsules" t h a t
allow the support bracket to slip off of the attaching
points, p e r m i t t i n g the steering column t o compress or
y i e l d i n a forward direction under a severe impact a t
the driver side.
W h e n t h e column is installed i n t h e vehicle, i t is
n o r m a l l y n o t susceptible t o damage. However, when
i t is removed, special care must be t a k e n d u r i n g han-
d l i n g . W h e n the column is removed from the vehicle,
actions such as a sharp blow on the end of the steer-
19 - 55
SNAP RING
mn—Column Shift
i n g shaft o r the s h i f t levers, leaning o n t h e column,
or d r o p p i n g t h e c o l u m n could shear or loosen t h e
plastic shear pins or rivets t h a t r e t a i n t h e column
r i g i d . I t is, therefore, suggested t h a t the removal and
i n s t a l l a t i o n , and t h e disassembly and assembly pro-
cedures be carefully followed w h e n servicing a steer-
ing column.
CAUTION: Bumping, jolting and hammering on the
steering column shaft and gear shift tube must be
avoided during all service procedures. If the shear
pins are broken, the controlled length of the col-
lapsing features will be altered and cause these
components to be unfit for additional use. If the
steering column shaft or the gear shift tube are
damaged, they cannot be repaired, they must be re-
placed.
The necessary special tools and t h e i r usage are also
described i n the following service procedures.
Safety goggles s h o u l d b e w o r n a t a l l times
w h e n i n v o l v e d w i t h steering c o l u m n service.
STEERING COLUMN-REMOVAL/INSTALLATION
REMOVAL
(1) Disconnect the negative (ground) cable from the
battery.
19 - 56 STEERING •
(2) For vehicles equipped w i t h a column shift, dis- TURN SIGNAL SWITCH
connect t h e l i n k rod b y p r y i n g i t out of t h e grommet
i n the shift lever (Fig. 3).

TURN SIGNAL LEVER

PRYING TOOL

RN829

Fig. 3 Link Rod Removal From Grommet Fig. 5 Turn Signal Lever
(12) Remove the i n s t r u m e n t panel steering c o l u m n
(3) Remove t h e steering c o l u m n shaft-to-steering
cover a n d the lower reinforcement.
gear shaft coupler clamp bolt.
(13) Remove the nuts t h a t attach steering c o l u m n
(4) Disconnect the w i r e connectors a t steering col-
support bracket to the i n s t r u m e n t panel support.
umn jacket.
(14) C a r e f u l l y remove the lower section o f the cou-
(5) Remove t h e steering wheel center pad (Fig. 4).
pler f r o m t h e steering gear wormshaft, t h e n remove
HORN WIRE TERMINAL MUST 12 O'CLOCK the steering column out t h r o u g h passenger compart-
BE IN 10 O'CLOCK POSITION IN POSITION m e n t . Use care to avoid damaging the p a i n t or t r i m .
ORDER FOR TURN SIGNAL CANCEL PART OF
t p BE IN CORRECT POSITION COLUMN (15) I n s t a l l a r e p l a c e m e n t grommet f r o m t h e r o d
10 O'CLOCK POSITION ASSEMBLY s i d e o f t h e l e v e r w i t h pliers and a back-up washer
CABLE ASSEMBLY to " s n a p " t h e grommet i n t o place (Fig. 6). Use M O -
(TILT COLUMN) P A R M u l t i p u r p o s e L u b r i c a n t (or an equivalent l u b r i -
SKIRT cant) t o a i d i n s t a l l a t i o n of t h e grommet. A
SCREW <2) replacement grommet should be used whenever
CABLE ASSEMBLY STANDARD the r o d i s disconnected f r o m the lever.
COLUMN
DIRECTION OF INSTALLATION
BACK-UP WASHER
CABLE
ASSEMBLY
(STANDARD
COLUMN)
PAD STEERING WHEEL
ASSEMBLY (REFERENCE) PU499

Fig. 4 Steering Wheel (Typical)

(6) Disconnect t h e h o r n wire(s) and remove t h e
horn s w i t c h ( i f applicable).
(7) Remove t h e steering wheel r e t a i n i n g n u t . Re-
move the steering wheel w i t h Tool C-3428B. D o n o t
b u m p o r h a m m e r o n steering c o l u m n shaft t o re-
move wheel.
(8) Remove the t u r n signal lever (Fig. 5).
(9) Remove t h e floor plate-to-floor pan a t t a c h i n g
screws.
(10) To expose the steering c o l u m n bracket, refer to
Electrical—Group 8.
(11) Disconnect t h e automatic transmission shift
indicator pointer cable f r o m t h e shift housing ( i f ap-
plicable).
RN830
Fig. 6 Replacement Grommet Installation
INSTALLATION
(1) I n s t a l l the ground clip on the left capsule slot
(Fig. 7). The plastic capsules should be pre-assembled
i n t h e bracket slots. Insert the column t h r o u g h t h e
floor pan opening w h i l e being careful t o avoid d a m -
a g i n g t h e p a i n t and the t r i m .
(2) W i t h t h e front wheels i n the " s t r a i g h t - a h e a d "
position a n d the master splines on the steering gear
shaft a n d t h e coupler aligned, engage t h e coupler
 • STEERING 19-57

(12) I f applicable, connect the transmission shift se-

lector indicator pointer a t i t s approximate o r i g i n a l
location.
(13) I f applicable, slowly move t h e transmission
shift selector lever f r o m " 1 " or " L " (low) t o " P "
(PARK) w h i l e pausing briefly at each selector posi-
tion. The indicator pointer m u s t a l i g n w i t h each i n -
dicator position (i.e., P,R,N,D, and L or 1,2,3).
(14) I n s t a l l t h e lower reinforcement and the i n s t r u -
ment panel steering column cover.

STANDARD/FIXED STEERING
COLUMN—DISASSEMBLY/ASSEMBLY
RN832 Safety g o g g l e s s h o u l d b e w o r n a t a l l t i m e s
w h e n i n v o l v e d wdth steering c o l u m n service.
Fig. 7 Ground Clip & Spacer Installation
w i t h the shaft a n d i n s t a l l the clamp bolt. D o n o t a p - DISASSEMBLY
p l y force a t t h e t o p o f t h e steering c o l u m n shaft. (1) P r y t h e w i r i n g t r o u g h retainers o u t w a r d a n d
(3) Position t h e steering column w i t h t h e bracket l i f t t h e w i r i n g t r o u g h from t h e retainers. Replace-
slots on t h e a t t a c h i n g studs. I n s t a l l , b u t d o n o t ment retainers could be necessary for assembly.
t i g h t e n , the t w o upper bracket washers a n d nuts. (2) To remove the transmission shift lever ( i f appli-
(4) After e n s u r i n g t h a t both breakaway capsules cable), use m a s k i n g tape to protect the p a i n t and a
are f u l l y "seated" i n the slots i n the column support deep socket wrench t o re-enforce t h e shift housing,
bracket, t i g h t e n the t w o upper bracket n u t s w i t h 12 t h e n " d r i v e " the r e t a i n i n g r o l l p i n out w i t h a punch.
N»m (110 in-lbs) torque. (3) Remove the breakaway capsules and secure the
steering c o l u m n i n a vise b y clamping a t t h e column
(5) Position the floor plate over the floor p a n open-
support bracket. Do not distort the bracket.
i n g , center i t a r o u n d t h e column, t h e n i n s t a l l a n d
(4) Remove t h e t w o screws t h a t attach t h e lock
t i g h t e n the a t t a c h i n g bolts.
housing cover t o t h e lock housing and remove t h e
(6) Place the steering wheel on the steering column
lock housing cover.
shaft w i t h the master splines aligned. I n s t a l l the re-
(5) Remove the wash/wipe switch (Fig. 8).
t a i n i n g n u t a n d t i g h t e n w i t h 6 1 N»m (45 ft-lbs)
torque. D o n o t f o r c e t h e s t e e r i n g w h e e l o n t o t h e
shaft b y " d r i v i n g " i t w i t h a h e a v y object; force i t
d o w n onto the shaft w i t h the retaining n u t .
(7) I n s t a l l the h o r n s w i t c h components on the steer-
i n g wheel. Connect the h o r n switch w i r e connector.
I f necessary, refer t o G r o u p 8 — E l e c t r i c a l f o r
installation o f the h o r n switch.
(8) Connect the w i r e connectors a t the steering col-
u m n jacket.
* (9) Connect t h e b a t t e r y ground (negative) cable,
test the operation of t h e l i g h t s and horns. I f applica-
ble, reset the clock.
(10) I f applicable, connect the shift l i n k rod to t h e
transmission shift lever b y i n s e r t i n g and "snapping"
the r o d in-place i n t h e grommet w i t h pliers. T h e
grommet m u s t be installed i n t h e lever before
t h e r o d i s i n s e r t e d i n t o t h e g r o m m e t . Use M O P A R
Fig. 8 Wash/Wipe Switch Removal/Installation
Multipurpose L u b r i c a n t (or a n equivalent product) to
aid the i n s t a l l a t i o n . (6) I f applicable, p u l l the cover up the speed control
(11) I f applicable, adjust t h e transmission shift stalk a n d remove t h e t w o screws t h a t attach t h e
linkage. W h e n e v e r t h e s t e e r i n g c o l u m n i s loos- m u l t i - f u n c t i o n control s t a l k sleeve t o t h e wash/wipe
ened o r removed, t h e shift linkage must be ad- switch.
justed and tested. Refer to Group (7) Rotate t h e control stalk shaft to the f u l l clock-
2 1 — T r a n s m i s s i o n for t h e shift linkage adjustment. wise position a n d remove t h e shaft from t h e switch
by p u l l i n g i t s t r a i g h t out of the switch (Fig. 9).
19 - 58 STEERING •

Fig. 9 Multi-Function Control Stalk Removal/

Installation
Fig. 11 Ignition Key Lamp
(8) Remove t h e t u r n signal a n d flasher switch re-
t a i n i n g screws and l i f t t h e switch u p w a r d out of t h e
way (Fig. 10).

STEERING SHAFT STEERING COLUMN

Fig. 10 Turn Signal & Flasher Switch Removal Fig. 12 Bearing Housing Screw & Upper "Snap"
Retaining Ring Removal
(9) Detach t h e h o r n a n d t h e key l a m p ground
wires.
(10) Remove t h e r e t a i n i n g screw and l i f t t h e i g n i -
t i o n k e y l a m p o u t o f t h e way (Fig. 11).

STEERING SHAFT DISASSEMBLY

(1) Remove t h e four screws t h a t attach t h e bearing
housing t o t h e lock housing (Fig. 12).
(2) Remove t h e " s n a p " r e t a i n i n g r i n g f r o m t h e up-
per end o f t h e steering shaft (Fig. 12).

CAUTION: Do not allow steering shaft to slide out

of the jacket.

(3) Remove t h e b e a r i n g housing from t h e shaft

(Fig. 13).
(4) Remove t h e lock plate spring and t h e lock plate
from t h e steering shaft (Fig. 13). Fig. 13 Bearing Housing & Lock Plate Removal
(5) Remove t h e steering column shaft from t h e LOCK HOUSING DISASSEMBLY
lower end o f t h e c o l u m n . (1) Remove t h e i g n i t i o n key. Remove t h e screw and
l i f t out t h e i g n i t i o n k e y buzzer/chime switch from t h e
 • STEERING
lock housing (Fig. 14).
Fig. 14 Ignition Key Buzzer/Chime Switch Removal
(2) Remove the two screws t h a t attach t h e i g n i t i o n
switch to t h e lock housing.
(3) Remove the i g n i t i o n s w i t c h from t h e lock hous-
i n g b y r o t a t i n g i t 90 degrees o n the rod and s l i d i n g i t
off the rod.
(4) Remove the two a t t a c h i n g screws from the d i m -
mer switch and disengage t h e switch from t h e actu-
ator rod (Fig. 15).
Fig. 15 Dimmer Switch
(5) Remove the t w o screws t h a t attach t h e bell-
crank and slide the bellcrank u p i n t o t h e lock hous-
i n g u n t i l i t can be disconnected from t h e i g n i t i o n
switch actuator rod.
(6) Place t h e key/lock cylinder i n t h e L O C K posi-
t i o n and remove t h e key. I n s e r t t w o s m a l l diameter
p r y bars (or other appropriate tools) into both key/
lock cylinder release holes a n d push i n w a r d t o re-
lease the spring loaded lock retainers. T h e key/lock
c y l i n d e r l o w e r release hole is located i m m e d i -
ately a b o v e the buzzer/chime s w i t c h a t t a c h i n g
s c r e w hole. A t the same t i m e , p u l l the key/lock cyl-
inder out of the lock housing bore (Fig. 16).
(7) Grasp t h e lock lever a n d spring and p u l l t h e m
s t r a i g h t out of the lock housing (Fig. 16).
19 - 59
Fig. 16 Key/Lock Cylinder & Lock Levers
(8) Remove t h e four lock housing-to-column jacket
hex-head a t t a c h i n g screws and remove the lock hous-
i n g plate a n d housing f r o m jacket (Fig. 17).
Fig. 17 Lock Housing Screw Removal/Installation
(9) W h e n r e m o v i n g t h e lock housing from t h e
steering c o l u m n jacket, rotate i t 90 degrees to disen-
gage i t f r o m t h e i g n i t i o n switch actuator rod.
SHIFT TUBE DISASSEMBLY/ASSEMBLY (COLUMN SHIFT
ONLY)
(1) To remove t h e shift tube, use Tool C-4584 to
force t h e s h i f t tube o u t of the plastic shift housing
(Fig. 18).
(2) To i n s t a l l t h e shift tube, use Tool C-4584 w i t h
I n s t a l l a t i o n Tool C-4584-2. Ensure t h a t t h e keyway
is aligned w i t h t h e slot i n t h e plastic shift housing
(Fig. 19).
INSPECTION
(1) A f t e r cleaning, inspect a l l t h e components for
wear and damage (Fig. 20).
(2) Inspect t h e t u r n signal switch for distorted, bro-
k e n or damaged components (Fig. 20).
19 - 60 STEERING •
PLASTIC SHIFT SHIFT
HOUSING HOUSING SHIFT
TUBE
JACKET

KEY WAY
PU938A

PU937A
Fig. 18 Shift Tube Removal
(3) Inspect t h e wire i n s u l a t i o n for w o r n , chafed or
bare w i r e areas.
(4) Inspect t h e steering shaft bearing (Fig. 20) for
smooth operation a n d l u b r i c a t e i t w i t h m u l t i -
Fig. 19 Shift Tube Installation
purpose, N L G I grade 2 E P (extreme pressure) l u b r i -
cant (e.g., M O P A R M u l t i m i l e a g e L u b r i c a n t , or a n
equivalent l u b r i c a n t ) . I f t h e bearing has a n y evi-
dence of roughness or wear, i t should be replaced.
 TURN SIGNAL AND SCREW (4) BELLCRANK
ASSEMBLY TORQUE TORQUE
FLASHER SWITCH ASSEMBLY
(D LET N-m IN. LBS.
SPRING IN
ASSEMBLED POSITION ® 10 90
4 35
3 24
2 16
®
LOCK PLATE
SPRING

LOCK
PLATE

SCREW (4)

JACKET
ASSEMBLY

LOCK
IGNITION HOUSING
SWITCH ROD COVER
VIEW IN DIRECTION
OF ARROW Y RN122

Fig. 20 Upper Part Of Steering Column

19-62 STEERING
(5) Inspect t h e floor plate grommet and replace i t i f
i t i s damaged.
(6) Inspect t h e steering column shaft for spline/
t h r e a d damage and any defects (Fig. 21).
Fig. 21 Steering Column Shaft
ASSEMBLY
D u r i n g assembly of t h e components (Fig. 20), apply
a t h i n coat o f multi-purpose, N L G I grade 2 E P (ex-
t r e m e pressure) l u b r i c a n t (e.g., M O P A R M u l t i m i l e -
age L u b r i c a n t , or a n equivalent l u b r i c a n t ) to a l l
contact (friction) surfaces.
(1) Clamp the steering column i n a vise (at the col-
u m n support bracket) so t h a t b o t h ends of the col-
u m n are accessible.
CAUTION: Never use steel rivets (instead of alumi-
num) to connect the column tube to the mandrel
because this connection must shear upon impact.
(2) Inspect t h e steering column tube-to-mandrel
r i v e t s for tightness. Replace ( i f necessary) w i t h 1/8-
i n c h diameter by 1/4-inch long (1/8-inch grip) a l u m i -
n u m " b l i n d " rivets.
(3) I f applicable, position the crossover load s p r i n g
and t h e transmission shift lever i n t h e shift housing
and t a p the pivot p i n i n t o place (Fig. 22).
SHIFT LEVER SPRING SHIFT SHIFT
RN785 r , I N
POSITION
Fig. 22 Transmission Shift Lever Installation
(4) Assemble the key/lock cylinder plunger s p r i n g
and i n s t a l l i t on the lock housing.
(5) I n s t a l l the shift lever gate o n the lock housing
(Fig. 23).
(6) Place the shift lever i n mid-position ( i f applica-
ble) and "seat" the lock housing on top o f the j a c k e t
•
Fig. 23 Lock Housing & Shift Gate
w h i l e a l i g n i n g t h e keyway i n the h o u s i n g w i t h t h e
slot i n the jacket. Insert a l l four screws and slowly
t i g h t e n each screw alternately, and i n steps, t o en-
sure proper " s e a t i n g " o f t h e lock h o u s i n g o n t h e
jacket. T i g h t e n t h e screws w i t h 10 N n n (90 in-lbs)
torque (Fig. 17).
(7) To i n s t a l l the d i m m e r switch (Fig. 15), firmly
"seat" t h e push rod i n t o t h e switch. Compress t h e
switch u n t i l two 0.093-inch diameter d r i l l b i t shanks
can be inserted i n t o the a l i g n m e n t holes. Re-position
the upper end o f the push rod i n t h e pocket o f t h e
wash/wipe switch (Fig. 8). T h i s can be accomplished
by touch, or i f necessary, b y r e m o v i n g t h e c o l u m n
lower cover. W i t h a l i g h t r e a r w a r d force on t h e
switch, i n s t a l l the two r e t a i n i n g screws. Remove t h e
d r i l l bits. The s w i t c h should " c l i c k " w h e n t h e lever is
lifted; and " c l i c k " again, as the lever r e t u r n s , i m m e -
diately before i t reaches t h e stop i n t h e down posi-
t i o n (Fig. 15).
(8) Lubricate and assemble the t w o lock levers, the
p i n and the lock lever s p r i n g (Fig. 24).
S T E P II
RN786
Fig. 24 Lock Levers & Spring Assembly
(9) I n s t a l l t h e assembled components i n t h e lock
housing. "Seat" the p i n firmly i n t h e bottom of the
 • STEERING
slots. Ensure t h a t t h e lock lever s p r i n g l e g is f i r m l y
in-place i n the casted notch (Fig. 15).
(10) I n s t a l l t h e i g n i t i o n switch actuator rod from
the bottom of the lock housing v i a t h e slotted hole i n
the housing and attach i t to the bellcrank. Insert t h e
b e l l c r a n k into t h e lock housing w h i l e p u l l i n g t h e i g -
n i t i o n switch rod down the column, and t h e n "seat"
the bellcrank o n t h e m o u n t i n g surface (Fig. 20). I f
applicable, the transmission shift lever should be i n
the P A R K position.
(11) Place t h e i g n i t i o n switch o n t h e i g n i t i o n
s w i t c h actuator rod and rotate i t 90 degrees t o lock
the r o d into position.
(12) To i n s t a l l the i g n i t i o n lock, t u r n t h e key to t h e
L O C K position and remove the key. T h i s w i l l cause
the buzzer/chime operating lever t o r e t r a c t i n t o t h e
key/lock cylinder. N o w insert the key/lock cylinder
i n t o t h e lock housing f a r enough t o contact t h e
s w i t c h actuator. I n s e r t the key, force i t i n w a r d and
rotate t h e key/lock cylinder. W h e n t h e components
are aligned, the key/lock cylinder w i l l move i n w a r d
and the spring loaded retainers w i l l "snap" i n t o place
and " l o c k " the cylinder i n t h e housing.
(13) W i t h the key/lock cylinder i n the L O C K posi-
t i o n and the i g n i t i o n switch i n the L O C K position
(the second detent position from the top), t i g h t e n t h e
i g n i t i o n switch r e t a i n i n g screws.
(14) Route t h e buzzer/chime switch wires b e h i n d
the w i r i n g post and down t h r o u g h the space between
the lock housing and the steering c o l u m n jacket. Re-
move the i g n i t i o n switch key, position t h e switch i n
the housing and t i g h t e n the r e t a i n i n g screws.
SHAFT INSTALLATION
CAUTION: During installation, do not strike the
steering column shaft with a hammer (or other
heavy object) because this could damage the col-
lapsible connection.
(1) I n s t a l l the bearing and the spring on t h e steer-
i n g column shaft. Lubricate and i n s t a l l the rubber O-
r i n g seal i n the lower groove on the upper end o f the
shaft (Fig. 21). I n s e r t the shaft completely i n t o t h e
steering column.
(2) Force the upper bearing into the upper bearing
housing. The b e a r i n g must be f u l l y "seated" i n t h e
b e a r i n g cavity.
(3) Push u p w a r d on the steering column shaft to
compress the b e a r i n g spring and r e t a i n t h e shaft i n
t h i s position u n t i l t h e "snap" r e t a i n i n g r i n g is i n -
stalled i n the shaft groove.
(4) Lubricate t h e inside of the lock plate (to pre-
vent r a t t l e ) and i n s t a l l the lock plate on t h e steering
c o l u m n shaft (Fig. 13).
(5) I n s t a l l the upper bearing "snap" r e t a i n i n g r i n g
on the steering shaft (Fig. 12).
19 - 83
(6) I n s t a l l the four screws t h a t attach the b e a r i n g
h o u s i n g t o the lock housing (Fig. 12).
KEY LAMP AND TURN SIGNAL SWITCH INSTALLATION
(1) I n s t a l l t h e i g n i t i o n switch k e y l a m p on t h e
b e a r i n g housing (Fig. 11).
(2) I n s t a l l t h e t u r n signal switch o n the b e a r i n g
h o u s i n g (Fig. 10). Route the wires f r o m the t u r n sig-
n a l s w i t c h and t h e key lamp t h r o u g h t h e opening be-
tween t h e bearing housing and t h e lock housing a n d
down along the bottom of the steering column jacket.
T i g h t e n the three attaching screws w i t h 3 N n n (24
in-lbs) torque.
(3) Assemble t h e wash/wipe switch, t h e stalk a n d
cover, t h e m u l t i - f u n c t i o n control switch, t h e cover,
and t h e knob (Fig. 9).
(4) Place the wash/wipe switch i n the lock housing,
route t h e wires t h r o u g h t h e lock housing and t h e
shift housing, and attach t h e m t o t h e t u r n signal
switch.
(5) Route t h e dimmer switch actuator r o d u p
t h r o u g h the housings and insert i t i n t o the "pocket"
i n t h e wash/wipe switch.
(6) Compress the dimmer switch u n t i l two 0.093-
i n c h diameter d r i l l b i t shanks can be inserted i n t o
the t w o a l i g n m e n t holes. W i t h one end o f the rod i n
the wash/wipe switch and the other end o f the rod i n
the d i m m e r switch, apply a s l i g h t u p w a r d force a n d
attach t h e d i m m e r switch to the bracket. Remove the
d r i l l b i t s . The switch should " c l i c k " w h e n the lever i s
lifted; a n d " c l i c k " again, as the lever r e t u r n s and i m -
mediately before i t reaches the "stop" i n the " d o w n "
position.
(7) I n s t a l l the t u r n signal lever cover.
(8) I n s t a l l the breakaway capsules.
(9) Position t h e w i r i n g t r o u g h in-place over t h e
wires. U s e c a r e t o a v o i d " p i n c h i n g " t h e w i r e s be-
tween t h e t r o u g h a n d t h e steering c o l u m n
j a c k e t . I n s t a l l replacement w i r e retainers, i f neces-
sary.
(10) I n s t a l l the steering column i n t h e vehicle. Re-
fer t o t h e i n s t a l l a t i o n procedure.
TILTABLE STEERING COLUMN—DISASSEMBLY/
ASSEMBLY
Safety goggles s h o u l d b e w o r n a t a l l times
w h e n i n v o l v e d w i t h steering c o l u m n service.
CONSOLE TRANSMISSION SHIFT
COLUMN-DISASSEMBLY
T h i s type of steering column is basically the same
as a t i l t a b l e steering column w i t h a column t r a n s -
mission shift. T h e service disassembly procedure is
the same except as listed below.
 19 - 64 STEERING •
(1) A f t e r t h e support is removed f r o m t h e steering
c o l u m n j a c k e t , i t w i l l be evident t h a t there is no
t r a n s m i s s i o n s h i f t tube.
(2) T h e lock i n h i b i t e r system, consisting of a plastic
housing, a n actuator, and a spring, can be l i f t e d out
from t h e top end of t h e steering column jacket.

DISASSEMBLY
(1) Remove t h e t w o bolts t h a t attach t h e lower
bracket to t h e lower b e a r i n g support.
(2) Remove t h e w i r e protector from t h e steering
column jacket.
(3) R e t a i n t h e steering column i n a vise b y clamp-
i n g i t o n t h e capsule bracket.
(4) Remove t h e t i l t lever. Push the hazard w a r n i n g
Fig. 26 Multi-Function Control Stalk Removal/
knob i n w a r d a n d u n - t h r e a d i t to remove i t . Installation
(5) Remove t h e i g n i t i o n key l a m p dome f r o m the
lock h o u s i n g (Fig. 25).

Fig. 27 Lock Plate Retaining Ring

Removal/Installation
(11) Remove the three t u r n signal s w i t c h a t t a c h i n g
screws and place the shift bowl i n the low (1) posi-
Fig. 25 Upper Part Of Steering Column t i o n . W r a p a piece of tape around t h e connector a n d
the wires to prevent "snagging" w h e n r e m o v i n g t h e
(6) P u l l t h e knob off the end of the wash/wipe
s w i t c h (Fig. 28). Remove the s w i t c h a n d t h e w i r e
(multi-function) switch stalk (Fig. 26)
harness.
(7) P u l l t h e cover up the s t a l k and remove the
screws t h a t attach the sleeve to the wash/wipe
(multi-function) switch. Remove the sleeve (Fig. 26).
(8) Rotate t h e shaft i n the wash/wipe (multi-func-
tion) s w i t c h t o the f u l l clockwise position and remove
the shaft by p u l l i n g i t s t r a i g h t out of the wash/wipe
switch (Fig. 26).
(9) Depress t h e lock plate w i t h Depressing Tool C-
4156 a n d p r y the r e t a i n i n g r i n g out of the steering
column shaft groove w i t h a s m a l l p r y bar (Fig. 27).
The f u l l t e n s i o n o f t h e u p p e r b e a r i n g s p r i n g
s h o u l d n o t b e c o m p l e t e l y r e l i e v e d w^ith T o o l C-
4156 b e c a u s e t h i s w i l l a l l o w t h e r e t a i n i n g r i n g t o
slide t o o easily a n d cause t h e r e m o v a l to be
m o r e d i f f i c u l t . Remove the lock plate, the canceling
cam, a n d t h e upper bearing spring. Fig. 28 Connector & Wires Taped
(10) Remove the switch actuator screw and a r m .
 • STEERING 19-65

(12) Remove t h e i g n i t i o n switch key lamp.

(13) The key/lock cylinder can be removed w h e n i n
any position r a n g i n g from ACCESSORY t o O N .
However, t h e L O C K position is recommended be-
cause o f i t s accessible location.
(14) Insert a t h i n tool (small screwdriver or s h i m -
stock) into t h e slot adjacent t o t h e switch a t t a c h i n g
screw boss ( r i g h t - h a n d slot) a n d depress t h e s p r i n g
l a t c h located a t the bottom of the slot, w h i c h releases
t h e key/lock cylinder. Remove t h e key/lock cylinder
(Fig. 29).

Fig. 30 Key Buzzer/Chime Switch & Wedge Spring

Fig. 29 Key/Lock Cylinder Removal

I f the key/lock c y l i n d e r i s n o t r e m o v e d before
the switch, i t must be i nthe O N position t o re-
m o v e t h e buzzer/chime switch.
Fig. 31 Wash/Wipe Switch Pivot Pin Removal
CAUTION: if the wedge spring (Fig. 30) is dropped terclockwise u n t i l t h e "ears" a l i g n w i t h t h e slots i n
during removal, it could fall into the column and the housing; and remove t h e retainer, t h e s p r i n g and
this will require complete steering column disas- the guide ( F i g . 32).
sembly to retrieve the spring.

(15) The buzzer/chime switch can be pulled s t r a i g h t

out of the h o u s i n g (Fig. 30). Use a "straightened" pa-
per clip (or a s i m i l a r section of stiff wire) w i t h a hook
bent on one end t o " h o o k " t h e exposed wedge s p r i n g
loop, t h e n p u l l s t r a i g h t out on t h e w i r e t o remove
b o t h t h e s p r i n g and t h e switch.
(16) Remove the three housing cover screws and re-
move t h e housing cover (Fig. 25). W i t h t h e cover re-
moved, t h e wash/wipe switch c a n be removed. I f
necessary, t h e wash/wipe switch pivot p i n can be
forced out w i t h a p u n c h (Fig. 31). Also, i f necessary,
the t i l t - l e v e r slot (opening) shield and t h e d i m m e r Fig. 32 Tilt Spring Retainer Removal
switch actuator rod c a n be removed from t h e cover.
(18) Remove t h e dimmer switch attaching screws.
(17) Place t h e steering column i n t h e complete U P
Remove t h e d i m m e r switch. Separate t h e d i m m e r
position. Remove t h e t i l t spring retainer w i t h a large
s w i t c h f r o m t h e rod by p u l l i n g i t away from t h e rod.
P h i l l i p s screwdriver. Insert t h e screwdriver i n t h e
(19) Push t h e upper steering column shaft i n w a r d
opening; force i t i n w a r d approximately 3/16 of-
sufficiently t o remove the shaft inner race "seat" and
an-inch; rotate i t approximately 1/8 of-a-turn coun-
the i n n e r race.
19 - 66 STEERING
(20) W i t h t h e i g n i t i o n switch i n t h e ACCESSORY
position, remove t h e i g n i t i o n switch attaching screws
and t h e i g n i t i o n s w i t c h (Fig. 33).
Fig. 33 ignition Switch Removal
(21) Position P i v o t P i n Removal Tool C-4016 over
the steering c o l u m n shaft pivot p i n a n d t h r e a d t h e
s m a l l portion o f t h e tool screw f i r m l y i n t o t h e p i n .
Prevent t h e screw f r o m t u r n i n g w i t h a wrench a n d
t u r n the n u t clockwise w i t h a second wrench to w i t h -
draw t h e pivot p i n f r o m t h e support (Fig. 34). Use
the same process t o remove t h e opposite pivot p i n .
RF12
Fig. 34 Pivot Pin Removal
(22) Use the t i l t release lever to disengage t h e lock
shoes. Remove t h e bearing housing by p u l l i n g u p -
w a r d and extend t h e rack completely. Move the hous-
i n g t o t h e left t o disengage t h e rack from t h e
actuator. Rotate t h e housing clockwise to detach t h e
d i m m e r switch actuator rod. Remove t h e actuator.
(23) Remove t h e coupler from t h e lower end of the
steering column shaft. The double coupler is attached
to t h e shaft w i t h a r o l l p i n .
(24) Remove the steering column shaft from the up-
per end of the steering column.
CAUTION: Do not drop or contact the steering shaft
with a heavy object because the plastic pins could
shear.
(25) Separate t h e steering shaft by removing t h e
center spheres and t h e anti-lash spring (Figs. 35 a n d
36).
•
Fig. 35 Steering Column Shaft
Separation/Engagement
Fig. 36 Steering Column Shaft Centering Spheres
(26) Remove t h e four bolts t h a t attach t h e support
to t h e lock plate a n d remove t h e support f r o m t h e
end o f t h e steering column jacket. I f necessary, re-
move t h e t w o attaching screws a n d t h e shift gate
f r o m t h e support. The dimmer switch rod is removed
along w i t h t h e support.
(27) Remove t h e shift tube r e t a i n i n g r i n g w i t h a
s m a l l p r y bar. Remove t h e t h r u s t washer.
(28) Remove t h e t w o screws t h a t r e t a i n t h e lower
b e a r i n g a n d remove t h e lower bearing from t h e
steering c o l u m n jacket.
(29) Remove t h e shift tube f r o m t h e b o w l w i t h Re-
m o v a l Tool C-4120 (Fig. 37). Insert t h e b u s h i n g on
the e n d o f t h e tool i n t h e shift tube a n d force t h e
tube o u t o f the bowl w i t h t h e tool.
CAUTION: Do not strike with a hammer or pull on
the lower or the upper shift tube because the plas-
tic connection could be sheared.
(30) Remove t h e shift tube f r o m t h e steering col-
u m n j a c k e t a t t h e lower end.
 • STEERING
RN836
Fig. 37 Shift Tube Removal From Bowl
(31) Remove t h e steering column jacket a t t a c h i n g
plate b y s l i d i n g i t o u t o f t h e jacket notches and t i p -
p i n g i t down t o w a r d t h e bowl h u b a t the 12 O'clock
position and t h e n under the jacket opening. Remove
t h e wave washer.
(32) Remove t h e b o w l f r o m t h e steering column
j a c k e t and t h e shift lever s p r i n g from t h e b o w l b y
w i n d i n g t h e s p r i n g u p w i t h pliers and p u l l i n g out-
ward.
BEARING HOUSING—DISASSEMBLY
(1) Remove t h e lock bolt s p r i n g by removing t h e
spring r e t a i n i n g screw and t h e n m o v i n g t h e s p r i n g
clockwise t o remove i t f r o m t h e bolt (Fig. 38).
Fig. 38 Sector & Bolt Spring
(2) L i g h t l y t a p t h e drive shaft w i t h a small h a m -
mer and s m a l l p u n c h t o separate i t from the sector.
Remove t h e d r i v e shaft, the sector and the bolt. Re-
move the rack and t h e rack s p r i n g (also the s h i m , i f
used).
19 - 67
(3) Remove the t i l t release lever p i n w i t h a p u n c h
and hammer. Remove the lever and the release lever
spring. T o r e l i e v e t h e s p r i n g tension o n t h e r e -
lease l e v e r , p u s h t h e shoes i n w a r d a n d i n s e r t /
f o r c e a b l o c k b e t w e e n t h e t o p o f t h e shoes ( o v e r
t h e slots) a n d t h e b e a r i n g h o u s i n g .
(4) Remove t h e lock shoe p i n w i t h p u n c h and h a m -
mer. Remove t h e lock shoes a n d t h e lock shoe
springs.
(5) Remove t h e bearings from the bearing housing
o n l y i f t h e y m u s t b e r e p l a c e d . Remove the separa-
tor and the balls f r o m the bearing. Place t h e housing
on a w o r k surface. W i t h a pointed punch against t h e
back surface o f the race, carefully drive t h e race out
of the housing w i t h a hammer. Repeat the process for
t h e other race. Do not re-use the bearings.
INSPECTION
(1) Inspect a l l t h e bearings and t h e bearing race
"seats" for " b r i n e l l i n g " , nicks, scratches a n d exces-
sive wear.
(2) Inspect t h e steering column shaft centering
spheres ( F i g . 36) for nicks, damage a n d excessive
wear. I f damage exists, inspect the shaft couplers for
nicks, b u r r s and r o u g h surface areas.
(3) Inspect t h e actuator housing, t h e shift lever
bowl and the support for cracks and other damage.
(4) Inspect t h e t u r n signal switch for distorted, bro-
k e n and damaged components.
(5) Inspect t h e h o r n and t u r n signal wires for w o r n
and chafed insulation/bare w i r e areas.
(6) Inspect t h e steering column shaft and t h e t r a n s -
mission shift tube for loose and broken plastic shear
connections.
ASSEMBLY
The l u b r i c a n t recommended for use d u r i n g steering
column assembly is multi-purpose, N L G I Grade 2 E P
(extreme pressure) l u b r i c a n t (e.g., M O P A R M u l t i M i -
leage L u b r i c a n t , or a n equivalent product).
BEARING HOUSING-ASSEMBLY
(1) I n s t a l l t h e bearings i n the bearing housing, i f
removed.
(2) I n s t a l l the lock shoe springs, the lock shoes, and
t h e shoe p i n i n t h e bearing housing. Use a n 0.18-
i n c h diameter rod (approximately) t o a l i g n the shoes
for p i n i n s t a l l a t i o n .
W i t h t h e t i l t lever slot (opening) p o s i t i o n e d a t
t h e l e f t side o f t h e c o l u m n a n d t h e shoes f a c i n g
u p w a r d , i n s t a l l t h e f o u r - s l o t shoe o n t h e l e f t
side.
(3) I n s t a l l the spring, the release lever, and t h e p i n
i n the bearing housing. T o r e l i e v e t h e s p r i n g t e n -
s i o n o n t h e r e l e a s e l e v e r , p u s h t h e shoes i n w a r d
a n d insert/force a b l o c k b e t w e e n t h e t o p o f t h e
shoes ( o v e r t h e slots) a n d t h e b e a r i n g h o u s i n g .
 19-68 STEERING
(4) I n s t a l l the shaft i n the housing. L i g h t l y tap t h e
sector onto the shaft far enough t o "seat" i t on t h e
shaft.
(5) I n s t a l l the lock bolt and engage i t w i t h t h e sec-
tor cam surface.
(6) I n s t a l l t h e r a c k and the spring. Engage t h e
block t o o t h on t h e rack w i t h the block t o o t h on the
sector. I n s t a l l t h e e x t e r n a l t i l t release lever.
(7) I n s t a l l the b o l t s p r i n g and the spring r e t a i n i n g
screw (Fig. 38). T i g h t e n t h e screw w i t h 4 N n n (34 i n -
lbs) torque.
(8) I n s t a l l t h e s h i f t lever spring i n t h e b o w l b y
w i n d i n g i t up w i t h pliers and pushing i n w a r d . Slide
the b o w l into the steering column jacket.
(9) Position the wave washer and the steering col-
u m n j a c k e t a t t a c h i n g plate i n the jacket. Maneuver
the j a c k e t a t t a c h i n g plate into the notches i n t h e
jacket b y t i p p i n g t h e jacket attaching plate t o w a r d
the b o w l hub a t t h e 12 O'clock position a n d under
the j a c k e t opening. Slide the jacket a t t a c h i n g plate
into t h e notches i n the jacket.
(10) Carefully i n s t a l l the shift tube i n lower end o f
the jacket. A l i g n t h e key i n the tube w i t h t h e key-
way i n the bowl a n d use Tool C-4119 to p u l l t h e shift
tube i n t o the bowl (Fig. 39).
CAUTION: Do not push or tap on the end of the
transmission shift tube. Install the thrust washer
and the retaining ring by pulling the bowl upward to
compress the wave washer.
Fig. 39 Shift Tube Installation
(11) Slide the d i m m e r switch actuator rod t h r o u g h
the hole i n the support. Route the rod between the
bowl a n d the steering column jacket.
(12) I n s t a l l the support by a l i g n i n g the " U " i n the
support w i t h the " U " notch i n the steering column
jacket. Insert the four attaching screws t h r o u g h the
support and into the jacket attaching plate. T i g h t e n
the screws w i t h 7 N»m (60 in-lbs) torque.
(13) I n s t a l l the lower bearing ( i f removed) a t the
lower end of the steering column jacket.
•
(14) I n s t a l l the centering spheres and t h e a n t i - l a s h
spring i n t h e upper steering c o l u m n shaft (Figs. 35
and 36). I n s t a l l the lower steering c o l u m n shaft a t
same side o f t h e spheres t h a t t h e s p r i n g ends pro-
trude.
Do a t r i a l engagement o f the u p p e r a n d lower
steering c o l u m n shafts to ensure t h a t the m a s t e r
s e r r a t i o n a t t h e u p p e r shaft i s o n t h e same side
as t h e m a s t e r s e r r a t i o n a t t h e l o w e r s h a f t .
(15) Position the shift bowl i n t h e P A R K position
( t u r n counterclockwise t o the stop). I n s t a l l t h e i g n i -
t i o n s w i t c h actuator rod from t h e bottom, between
the bowl a n d t h e steering column jacket. Guide t h e
back o f the coupling i n t o the support slot.
(16) I n s t a l l the bearing housing over t h e steering
column shaft and engage the r a c k over t h e end of t h e
i g n i t i o n s w i t c h actuator rod.
(17) Position the access hole of the b e a r i n g housing
over the end o f the dimmer s w i t c h actuator rod. Ro-
tate the housing counterclockwise t o i n s t a l l i t .
(18) R e t a i n the lock shoes i n the disengaged posi-
t i o n and maneuver the bearing housing over steering
column shaft u n t i l t h e pivot holes a l i g n w i t h t h e
holes i n the support.
(19) I n s t a l l the pivot pins. I n s e r t t h e m as f a r as
possible w i t h p a l m pressure f r o m your h a n d t o pre-
vent broaching o f t h e support pivot hole. Once
started, complete the i n s t a l l a t i o n w i t h a s m a l l h a m -
mer and punch.
(20) I n s t a l l the wash/wipe s w i t c h s t a l k pivot and
force the p i v o t p i n i n the cover ( i f removed). Test the
pivot for ease of movement. I f restricted, t a p t h e
other end o f t h e p i n back to provide clearance.
(21) I n s t a l l the wash/wipe s w i t c h .
(22) I n s t a l l the t i l t lever slot (opening) shield i n
the cover ( i f removed). Position t h e cap over the d i m -
mer switch actuator rod. Guide the end o f the actua-
tor r o d i n t o t h e pivot slot d u r i n g t h e cover
i n s t a l l a t i o n . Position the cap so t h a t the cover w i l l
slide over i t .
(23) Place the lock housing i n the complete " u p "
position, i n s t a l l the guide after e n s u r i n g there is suf-
ficient l u b r i c a n t between the guide and the peg on
the support, the t i l t spring, and the t i l t s p r i n g re-
tainer. Then, w i t h a Phillips screwdriver inserted i n
the retainer slot, t u r n the retainer clockwise t o en-
gage i t (Fig. 32).
(24) I n s t a l l the bearing inner race and the "seat".
(25) I n s t a l l the lock housing cover and t i g h t e n the
screws w i t h 11 N n n (100 in-lbs) torque (Fig. 30).
(26) Connect the buzzer/chime switch to the s p r i n g
clip w i t h the formed end of the clip located under the
end o f the switch and the spring "bowed" away f r o m
the switch on the side opposite t h e contact. Push the
switch and t h e spring into the hole i n the lock hous-
i n g cover w i t h the contacts facing t o w a r d the key/
lock cylinder bore (Fig. 30).
 • STEERING 19 - 69

(27) I n s t a l l the i g n i t i o n switch key lamp. wash/wipe switch. T h i s can be accomplished by

(28) Insert t h e t u r n signal switch w i r e harness and touch, or i f necessary, by r e m o v i n g the lower column
connector t h r o u g h the cover, t h e bearing housing and cover. A p p l y a l i g h t u p w a r d force on the switch and
the shift bowl. Push t h e hazard w a r n i n g plunger i n - i n s t a l l t h e a t t a c h i n g screws. Remove the d r i l l bits.
w a r d . I n s t a l l t h e t u r n signal s w i t c h and t i g h t e n the The switch should " c l i c k " w h e n the lever is lifted,
and " c l i c k " again, as t h e lever r e t u r n s and i m m e d i -
screws w i t h 3 N»m (25 in-lbs) torque.
ately before i t reaches t h e " s t o p " i n the " d o w n " posi-
(29) I n s t a l l the hazard w a r n i n g knob and screw,
t i o n (Fig. 40).
and p u l l t h e knob o u t w a r d . I n s t a l l the cancelling
cam spring, t h e cancelling cam (carrier) and the lock
plate.
(30) Use Tool C-4156 to depress t h e lock plate and
i n s t a l l a r e p l a c e m e n t r e t a i n i n g r i n g on the steering
column shaft (Fig. 27).
(31) I n s t a l l t h e t i l t release lever ( i f removed) and
the t u r n signal s w i t c h lever. Refer to E l e c t r i c a l -
— G r o u p 8 for speed control i n f o r m a t i o n .
(32) To i n s t a l l i g n i t i o n switch lock, t u r n the key to
the L O C K position and remove t h e key. This w i l l
cause the buzzer operating lever to retract i n the
key/lock cylinder. N o w insert t h e key/lock cylinder
i n t o the housing far enough to contact the shaft.
Force i t i n w a r d and move the i g n i t i o n switch actua-
t o r rod up and down to a l i g n t h e components. When
the components a l i g n , the key/lock cylinder w i l l
move i n w a r d and t h e spring-loaded retainer w i l l
"snap" into place " l o c k i n g " the key/lock cylinder i n
the lock housing.
(33) When i n s t a l l i n g the i g n i t i o n switch, position
the key/lock cylinder i n the L O C K detent position
and remove t h e key. Then place the i g n i t i o n switch
i n the L O C K position (second detent position from PR676A
the bottom).
(34) Insert t h e i g n i t i o n switch actuator rod i n t o the
Fig. 40 Dimmer Switch
slider hole a n d attach i t loosely to the steering col- (36) I n s t a l l the w i r e protector over t h e w i r e har-
u m n jacket w i t h two screws. Push t h e switch l i g h t l y ness on t h e steering c o l u m n jacket. Use care to avoid
up the column jacket t o w a r d t h e lock housing (to re- " p i n c h i n g " t h e wires.
move the lash i n the actuator rod) and t i g h t e n the (37) Remove the steering c o l u m n from t h e vise.
attaching screws. C a u t i o n s h o u l d b e e x e r c i s e d t o (38) Position the lower bracket on the steering col-
prevent m o v i n g the s w i t c h out of the detent po- u m n . I n s t a l l and t i g h t e n the t w o attaching bolts w i t h
sition. U s e o n l y t h e c o r r e c t l e n g t h s c r e w s . 12 N»m (105 in-lbs) torque.
T i g h t e n the screws w i t h 4 N-m (34 in-lbs) torque. (39) A l i g n the steering c o l u m n shaft a n d coupler
(35) To i n s t a l l the d i m m e r switch, f i r m l y insert master splines and i n s t a l l t h e coupler at the lower
and "seat" the push rod i n the switch. Compress the end of the shaft. Place a support under the coupler at
switch u n t i l t w o 0.093-inch diameter d r i l l b i t shanks the U-joint a n d i n s t a l l t h e clamp bolt.
can be inserted i n t o the a l i g n m e n t holes. Re-position (40) I n s t a l l the steering c o l u m n i n the vehicle. Re-
the upper end of the push rod i n the "pocket" of the fer to the i n s t a l l a t i o n procedure.
19-70 STEERING
SPECIFICATIONS
MANUAL STEERING GEAR SPECIFICATIONS
Wormshaft Bearing Preload Torque . . 0.6-0.9 N*m (5 to 8 in-lbs)
Pitman Shaft Overcenter
0 5-1 N*m (4 to 10 in-lbs)
(in addition to above)
Maximum Steering Gear Torque . . . . . . . . .2 N-m (18 in-lbs)
total (maximum)
chassis grease
. . . . . . . . . . . . . . . . . . 24:1
J9019-2
POWER STEERING GEAR
Steering Gear Type Recirculating ball with
hydraulic assist.
. . . . . . . . . . 16.2-20:1 (Variable Ratio)
Steering Fluid, Dexron II,
or equivalent.
Steering Gear Lubricants. Lubricate pitman shaft
seals, bearings races, and rack
piston recirculating balls with
petroleum jelly. Lubricate all other
parts with power steering fluid.
•
SPECIFICATIONS
Steering Gear Adjustments:
Wormshaft Bearing Preload Torque. .0.45-1.13 N » m
(4 to 10 in-lbs)
Pitman Shaft Overcenter drag torque
New Gear
(less than 400 miles/640 k m ) . . . . 0.45-0.90 N *m (4 to 8 in-lbs)
in addition to wormshaft bearing
preload but not to exceed
combined total of 2 N « m (18 in-lbs)
Used Gear
(over 400 miles/640 km) 0.5-0.6 N » m (4 to 5 in-lbs)
in addition to wormshaft bearing
preload but not to exceed
combined total of 2 N •m (18 in-lbs)
Caution: Gears must be adjusted exactly as outlined in Steer-
ing Gear Adjustments-On Bench. Failure to adhere
to the recommended procedures may result in gear
damage or improper steering response.
J9019-12
 TORQUE SPECIFICATIONS

COMPONENT SET-TO-TORQUE RECHECK TORQUE

Sector Shaft Adjustment Screw Locknut

(Manual Steering Gear) 47 N « m (35 ft-lbs)

Sector Shaft Cover Bolt

(Manual Steering Gear) 34 N*m (25 ft-lbs)

Power Steering Gear Housing-to-Frame Bolt/Nut 136 N*m (100 ft-lbs)

Sector Shaft Adjustment Screw Locknut (Power Steering Gear) 38 N « m (28 ft-lbs)

Sector Shaft Cover Bolt (Power Steering Gear) 203 N » m (150 ft-lbs)

High Pressure Hose Fitting (At Pump and Gear) 30 N » m (22 ft-lbs)

Steering Wheel-to-Shaft Nut Non-Tilt or Tilt Column 61 N*m (45 ft-lbs)

Steering Column Bracket-to-Support Stud Nut 2 N » m (20 in-lbs)

Steering Column Bracket-to-instrument Panel Support Nut 12 N*m (110 in-lbs)

Steering Column Shaft-to-Steering Gear Coupler Bolt 23 N*m (200 in-lbs)

Steering Column Support Plate Bolt 7 N*m (60 in-lbs)

 • TRANSMISSION—TRANSFER CASE 21 - 1

TRANSMISSION-TRANSFER C A S E
CONTENTS
Page Page

A833 MANUAL TRANSMISSION 1 NP435 MANUAL TRANSMISSION 36

A998/S9I/727 AUTOMATIC TRANSMISSIONS . 43 NP205 TRANSFER CASE 130
A500/518 AUTOMATIC TRANSMISSION 111 NP241 TRANSFER CASE 138
NP2500 MANUAL TRANSMISSION 16

A833 MANUAL TRANSMISSION

INDEX
Page Page
General Information 1 Service Out Of Vehicle . . . . . . . . . . . . . . . . . . . . . . 5
Service Diagnosis 2 Specifications 149
Service In Vehicle 3 Tightening Reference 154

GENERAL INFORMATION leakage around the countershaft.

TRANSMISSION COMPONENTS
The A833 is a f u l l y synchronized, four-speed, m a n -
u a l transmission (Fig. 1 and 2). I t is used p r i m a r i l y
for s i x cylinder engine applications. F o u r t h gear is
an overdrive range w i t h a ratio of .71:1.
The transmission i n p u t shaft is supported b y a b a l l
b e a r i n g i n the front o f the transmission case and a n
by a n oilite pilot bushing i n t h e crankshaft p i l o t
b u s h i n g bore. The mainshaft front end is supported
by r o l l e r bearings i n the end of the m a i n drive p i n i o n
and b y a b a l l bearing i n the front of the extension
housing. The output end of the mainshaft is splined
to the s l i d i n g universal j o i n t yoke. The j o i n t is sup-
ported b y a bushing i n the extension housing.
The countershaft gear is supported by a double row
of needle type roller bearings a t each end. Gear end
t h r u s t is controlled b y t h r u s t washers between t h e
ends o f the gear a n d t h e transmission case. T h e
a l i g n m e n t of the needle type roller bearings w i t h i n
the gear is m a i n t a i n e d b y a t u b u l a r spacer and four
t h r u s t washers.
The countershaft is n o t a press f i t i n t h e case
bores. T h e shaft has a .12 m m (.005 inch) diameter
clearance. A n expansion p l u g is pressed into a
counter bore a t the front of the case t o prevent o i l
The reverse idler gear is supported on a bronze
bushing pressed into the gear.
A magnetic disc is attached to the bottom, rear of
the case. The magnet collects and prevents circula-
t i o n of chips i n the transmission o i l .
Gearshifting is m a n u a l l y operated t h r o u g h shift
control rods attached to the transmission shift levers
(Fig. 2). A n y forward gear may be engaged w h i l e the
vehicle is i n motion t h r o u g h the use o f synchronizing
clutches.
The transmission synchronizers are serviced as as-
semblies. Except for t h e stop rings, synchronizer
parts are not interchangeable.
The transmission may be used as a n aid to decel-
eration. Downshifting w i t h o u t double c l u t c h i n g is
possible as a l l forward speeds are synchronized. Refer
to Specifications for downshift speed l i m i t s .
RECOMMENDED LUBRICANTS
The p r i m a r y lubricant recommended for the over-
drive-4 is A T F PLUS, type 7176 automatic t r a n s m i s -
sion fluid. However, when heavy d u t y operation is
anticipated, SAE gear lubricants meeting A P I grade
G L 5 quality can also be used for quieter operation.
These lubricants include 75W-90, 80W-90, 85W-90
and 90W.
21 - 2 MANUAL TRANSMISSION
TRANSMISSION IDENTIFICATION
Transmission identification information i s located
on a machined pad a t the r i g h t side of the t r a n s m i s -
sion case (Fig. 1). Information provided includes the
transmission and vehicle identification numbers. Re-
fer t o t h i s information when ordering replacement
parts.
Fig. 2 Transmission Operating Levers
SERVICE DIAGNOSIS
The majority of transmission malfunctions are
caused by insufficient lubricant, incorrect l u b r i c a n t ,
misadjusted linkage, loose m o u n t i n g components, or
improper operation.
HARD SHIFTING
A l o w l u b r i c a n t level, misadjusted linkage, dam-
aged linkage, or w o r n , damaged i n t e r n a l shift compo-
nents are the most common causes of h a r d s h i f t i n g .
I f h a r d shifting is also accompanied by gear clash,
synchronizer components may be w o r n or damaged.
•
H a r d s h i f t i n g may also be caused b y insufficient
l u b r i c a t i o n o f linkage components, o r a loose o r mis-
aligned gear shift housing. E i t h e r f a u l t can r e s u l t i n
linkage b i n d and h i g h shift efforts.
NOISY OPERATION
Transmission noise is most often a result o f w o r n
or damaged components. Chipped, b r o k e n gear or
synchronizer teeth and b r i n n e l l e d , spalled bearings
a l l cause noise. A b n o r m a l wear a n d damage t o inter-
n a l components is frequently the end result o f insuf-
ficient l u b r i c a n t , non-recommended lubricants, or
improper operation.
SLIPS OUT OF GEAR
Transmission disengagement m a y be caused b y
misadjusted or damaged linkage, o r w o r n synchro-
nizer c l u t c h teeth on the m a i n s h a f t gears. Incorrect
assembly w i l l also contribute to gear disengagement.
LOW LUBRICANT LEVEL
Insufficient transmission l u b r i c a n t i s u s u a l l y t h e
result o f leaks, or inaccurate f l u i d level check or re-
fill method. Leaks w i l l be evident b y the presence of
gear o i l a r o u n d the leak point. I f leakage i s not evi-
dent, the condition is probably t h e result o f a n u n -
derfill condition.
I f air powered l u b r i c a t i o n equipment is used t o fill
a transmission, be sure t h e e q u i p m e n t is properly
calibrated. E q u i p m e n t out of c a l i b r a t i o n can lead to
an u n d e r f i l l condition.
CLUTCH PROBLEMS
W o r n , damaged, or misaligned c l u t c h components
can cause h a r d shifting, gear clash a n d noise.
A w o r n p i l o t bushing w i l l cause noise a n d i n p u t
shaft misalignment. The result i s h a r d s h i f t i n g and
noise.
A w o r n or damaged clutch disc, pressure plate, or
release b e a r i n g can cause h a r d s h i f t i n g a n d gear
clash.
Damaged or w o r n clutch h y d r a u l i c components, or
leaks i n t h e f l u i d lines or cylinders w i l l cause h a r d
shifting a n d gear clash. A major f a i l u r e of one o f the
clutch h y d r a u l i c cylinders w i l l cause incomplete
clutch release or engagement.
Be sure t h a t the clutch components are a l l i n good
condition before removing t h e transmission for re-
pair.
 • MANUAL TRANSMISSION 21 - 3

SERVICE I N VEHICLE

INDEX
Page Page
Extension Housing Yoke Seal Replacement ...... 4 Shift Linkage Removal/Installation 3
Gearshift Linkage Adjustment . 3 Speedometer Pinion And Adapter Service . . . . . . . . 3

SHIFT LINKAGE REMOVAL/INSTALLATION GEARSHIFT LINKAGE ADJUSTMENT

A n a l i g n i n g tool is required t o hold t h e levers i n
LINKAGE REMOVAL (FIGS. 3 AND 4j t h e floor shift assembly i n the n e u t r a l crossover po-
(1) Disconnect the battery negative cable. s i t i o n for alignment. The tool can be fabricated i n
(2) Remove the boot cover r e t a i n i n g screws and t h e shop f r o m 1/4 inch diameter rod as shown i n F i g -
slide the boot u p w a r d on t h e shift lever. ure 4.
(3) Remove t h e shift lever b y disengaging the lever
lock w i t h an .010 inch feeler gauge (Fig. 3). ADJUSTMENT PROCEDURE
(4) Remove t h e r e t a i n i n g clips and washers t h a t at- (1) I n s t a l l the shift lever a l i g n i n g tool to hold the
tach t h e floor shift assembly t o the control rods. levers i n n e u t r a l crossover position (Fig. 4).
T h e n disengage the rods from the shift assembly le- (2) Disconnect the control rods from t h e levers i n
vers. the floor shift assembly.
(5) Remove the bolts and washers a t t a c h i n g the (3) Place the assembly levers i n N e u t r a l position
floor shift assembly to the extension housing m o u n t - (Fig. 4).
i n g plate and remove the shift assembly. (4) Rotate the threaded ends of the shift control
(6) Remove t h e shift control rods i f necessary. rods to adjust rod length. Adjust the rods to a "free
p i n f i t " i n the levers. S t a r t w i t h the 1-2 control rod.
T h e n adjust the 3-4 rod followed by the reverse rod.
I t may be necessary to remove the clip at the lever
end of the 1-2 rod to rotate i t .
(5) I n s t a l l the control rod attaching washers and
clips.
(6) Remove the alignment tool and check s h i f t i n g
action.

Fig. 3 Hand Lever Removal/Installation

LINKAGE INSTALLATION
(1) Position the floor shift assembly on the exten-
sion housing m o u n t i n g plate and i n s t a l l the assem-
b l y attaching bolts and lock washers. T i g h t e n the Fig. 4 Linkage Adjustment
bolts to 41 N-m (30 ft-lbs) torque.
(2) Connect t h e shift rods to the lever assembly and
SPEEDOMETER PINION AND ADAPTER SERVICE
i n s t a l l the rod attaching washers and clips. Rear axle gear ratio and t i r e size determines speed-
(3) I n s t a l l the hand lever i n the floor shift assem- ometer gear usage. I f the gear must be replaced, con-
b l y (Fig. 3). s u l t t h e parts catalogue for correct application.
(4) Slide the boot and boot cover down the h a n d le-
ver a n d position t h e m on the floorpan. T h e n i n s t a l l ADAPTER AND PINION REMOVAL
and t i g h t e n t h e cover and boot attaching screws. (1) Raise the vehicle and position a d r a i n pan u n -
(5) Reconnect the battery negative cable. der the speedometer adapter.
21 - 4 MANUAL TRANSMISSION
(2) Disconnect the wires f r o m t h e distance sensor
(Fig. 5).
(3) Loosen t h e distance sensor coupling and remove
the sensor f r o m the speedometer adapter (Fig. 5).
(4) Remove the bolt a n d retainer securing t h e
speedometer p i n i o n adapter i n t h e extension h o u s i n g
(Fig. 5).
(5) Carefully work t h e adapter a n d p i n i o n o u t o f
the extension housing.
(6) Remove and discard t h e adapter O-ring.
(7) Inspect t h e adapter. I f transmission fluid i s
found i n t h e coupling section of the adapter housing,
the o i l seal i s l e a k i n g a n d w i l l require replacement.
Refer to A d a p t e r O i l Seal Replacement
LOCK OIL
Fig. 5 Speedometer Adapter And Pinion
Components
ADAPTER OIL SEAL REPLACEMENT
(1) Remove t h e C-shaped lock r i n g securing t h e
seal i n t h e adapter (Fig. 5).
(2) Remove the old seal from t h e adapter w i t h a
small screwdriver or hooked tool.
(3) Start t h e new seal i n t h e adapter by h a n d a n d
insert t h e lock r i n g i n t h e adapter.
(4) Seat t h e seal i n t h e adapter w i t h tool C-4004
(Fig. 6). Press t h e seal and lock r i n g into place u n t i l
the i n s t a l l e r tool bottoms.
ADAPTER LOCK RING
OIL SEAL
RH263
Fig. 6 installing Adapter Oil Seal And Lock Ring
•
ADAPTER AND PINION INSTALLATION
CAUTION: Before installing the pinion and adapter
assembly make sure the adapter flange and the
mating area in the extension housing are perfectly
clean. Dirt, sand, or foreign material will cause mis-
alignment resulting in speedometer pinion gear
damage.
(1) Thoroughly clean t h e adapter flange a n d
adapter m o u n t i n g surface i n t h e extension housing.
These surfaces m u s t be clean for proper adapter
a l i g n m e n t and speedometer operation.
(2) I n s t a l l a new O-ring on t h e adapter.
(3) Lu b ric a t e t h e adapter o i l seal a n d O - r i n g w i t h
transmission fluid.
(4) Count t h e number of teeth on t h e p i n i o n gear
and i n s t a l l t h e gear i n t h e adapter. Be sure t o count
the gear teeth b e f o r e i n s t a l l i n g t h e gear.
(5) Note t h e range numbers on t h e adapter face
(Fig. 7). These numbers correspond to t h e n u m b e r of
teeth on t h e speedometer p i n i o n gear.
(6) Insert t h e adapter i n the extension housing.
(7) Rotate t h e adapter u n t i l t h e r e q u i r e d range
numbers are a t a six o-clock position (Fig. 7). Be sure
the adapter range numbers correspond to t h e n u m b e r
of teeth on t h e pinion.
(8) L i g h t l y push t h e adapter a l l the w a y i n t o t h e
extension housing.
(9) I n s t a l l t h e adapter retainer. T i g h t e n t h e re-
t a i n e r bolt to 100 in-lbs ( H N » m ) torque.
(10) I n s t a l l t h e distance sensor on t h e adapter.
T i g h t e n t h e sensor coupling n u t t o 150 in-lbs (17
N»m) torque and i n s t a l l t h e sensor wires.
(11) Check a n d top off the transmission l u b r i c a n t
level i f necessary.
Fig. 7 Indexing Speedometer Adapter
EXTENSION HOUSING YOKE SEAL REPLACEMENT
(1) Raise the vehicle a n d position a d r a i n p a n u n -
der the extension housing.
(2) M a r k position o f t h e propeller shaft a n d rear
axle yokes for alignment reference.
 • MANUAL TRANSMISSION 21 - 5

SPECIAL TOOL

Fig. 9 Installing Yoke Seal

Fig. 8 Removing Yoke Seal
(3) Disconnect the propeller shaft at the axle yoke
and remove the shaft:
(4) Remove the oil seal with tool C-3985 (Fig. 8).
(5) Install the new seal with tool C-3972 (Fig. 9).
Start the seal in the housing and tap it into place
until the tool bottoms against the housing.
(6) Check condition of the slip yoke surface of the
propeller shaft. Reduce minor corrosion, scratches, or
nicks with crocus cloth or 400 grit sandpaper. Re-
place the slip yoke if severely scored or rusted.
(7) Align and install the propeller shaft.
(8) Check and top off the transmission lubricant
level if necessary. Correct level is to the edge of the
fill plug hole.
(9) Remove the drain pan and lower the vehicle.

S E R V I C E OUT O F V E H I C L E

INDEX
Page Page
Cleaning and Inspection . . 10
10 Transmission Installation 15
Transmission Assembly . . 11
11 Transmission Removal . . . . . . . . . . . . . . . . . . . . . . 5
Transmission Disassembly .... 6

TRANSMISSION REMOVAL (12) Remove the transmission-to-clutch housing

bolts.
(1) Shift the transmission into Neutral. Then re- (13) Slide the transmission rearward until the
move the shift lever, linkage and control rods. drive pinion shaft clears the clutch disc.
(2) Raise the vehicle and drain the transmission lu-
TRANSMISSION
bricant.
(3) Mark the propeller shaft and rear axle yokes for
assembly alignment.
(4) Disconnect and remove the propeller shaft.
(5) Disconnect the wires from the distance sensor.
T h e n loosen the sensor coupling and remove the sen-
sor from the speedometer adapter.
(6) Remove the speedometer adapter and pinion
gear.
(7) Disconnect the backup lamp switch wires.
(8) Install engine support fixture C-3487-A. Be sure
the support ends are seated on the underside of the
oil pan flange.
(9) Raise the engine slightly with the support fix-
ture.
(10) Disconnect the insulator from the extension
housing (Fig. 1).
RN845
(11) Support the transmission with a suitable jack
and remove the center crossmember (Fig. 1). Fig. 1 Crossmember And Insulator
21 - 6 MANUAL TRANSMISSION
(14) P u l l t h e transmission completely away from
the c l u t c h housing and remove t h e transmission from
under t h e vehicle.
(15) T h o r o u g h l y clean t h e transmission exterior,
preferably w i t h steam cleaning equipment.
(16) M o u n t t h e transmission i n a repair stand (Fig.
2). U s e a n adapter m o u n t i n g plate t h a t w i l l use a l l o f
the t r a n s m i s s i o n a t t a c h i n g bolts t o secure the trans-
mission t o t h e adapter a n d stand.
•
r e m a i n engaged w i t h synchronizer sleeves, w o r k
forks o u t o f sleeves and remove t h e m from case.
(5) Remove o p e r a t i n g lever a t t a c h i n g n u t s a n d r e -
move levers f r o m shafts ( F i g . 3).
(6) Inspect c o n d i t i o n o f shift fork and reverse lever
shafts. M a k e sure shaft surfaces are free o f b u r r s be-
fore removal. T h i s is necessary t o avoid d a m a g i n g
bores i n gearshift d u r i n g removal w h i c h could r e s u l t
i n leakage after reassembly.

DRIVE PINION BEARING GEARSHIFT HOUSING

RETAINER

EXTENSION
HOUSING

SEAL

BACKUP LAMP SWITCH

1-2 OPERATING LEVER

RH79

Fig. 2 Transmission Mounted In Repair Stand

TRANSMISSION DISASSEMBLY (7) Remove s h i f t fork shafts and reverse lever o u t
of gearshift h o u s i n g (Fig. 3).
(8) Remove O - r i n g retainers and O-rings f r o m shaft
GEARSHIFT HOUSING AND SHIFT
bores i n gearshift housing.
MECHANISM REMOVAL
(9) Remove E - r i n g from interlock lever pivot p i n
(1) Remove reverse operating lever from shaft (Fig.
and remove i n t e r l o c k levers a n d spring ( F i g . 3).
2).
(2) Remove gearshift housing bolts. (10) Remove reverse detent spring a n d b a l l f r o m
(3) Move operating levers into N e u t r a l (Fig. 2). bore i n side o f case (Fig. 3).
(4) P u l l gearshift housing out of case. I f shift forks
 MANUAL TRANSMISSION 21 - 7

BEARING GASKET
RETAINER * G A 5 E T

SNAP SNAP PROMT

RING RING BEARING ^ J ^ f FILL, PLUG

EXPANSION
PLUG
/ DRIVE PINION
(INPUT SHAFT)
MAINSHAFT
ROLLER BEARINGS
RETAINING RING

E-CLIP

INTERLOCK
LEVERS
SEALS
AND
RETAINERS

LEVER~^-|

NUTS

SECOND
GEAR

STOP
RING
CLUTCH
STOP
1.2 RING
SLEEVE SNAP
AND RING
REVERSE SNAP
GEAR RING BAFFLE
GASKET

J9021-101

Fig. 3 Overdrive-4 Transmission Components

21 - 8 MANUAL TRANSMISSION

EXTENSION HOUSING/MAINSHAFT/DRIVE
EXTENSION EXTENSION -X/
PINION REMOVAL HOUSING GASKET HOUSING
(1) Remove bolts a t t a c h i n g extension housing to
transmission case.
(2) Rotate extension housing to expose rear o f coun-
tershaft (Fig. 4). Reinstall one o f the housing bolts to
hold i t i n position.
(3) Centerpunch or d r i l l a hole i n t h e countershaft
expansion p l u g a t front o f case.
(4) Reach t h r o u g h hole i n expansion p l u g and push
countershaft r e a r w a r d u n t i l t h e shaft Woodruff key REVERSE IDLER
GEAR
is exposed. T h e n remove t h e key.
(5) Push countershaft forward against expansion DRIVE REVERSE
PINION SHIFT LEVER RH84
plug. T h e n t a p shaft f o r w a r d u n t i l i t drives expan-
sion p l u g out front of case. Fig. 5 Removing/Installing Extension Housing And
(6) Insert arbor tool C-3938 t h r o u g h front of case Mainshaft
and i n t o countershaft gear. Remove countershaft as (12) Slide t h i r d and overdrive (O/D) synchronizer
arbor tool pushes shaft o u t rear of case. sleeve s l i g h t l y forward.
(7) Lower countershaft gear to bottom o f case. Keep (13) Slide reverse i d l e r gear t o center o f gear shaft.
countershaft gear t h r u s t washers i n position i f possi- (14) Tap extension housing r e a r w a r d w i t h plastic
ble. m a l l e t u n t i l mainshaft rear bearing i s free of case.
(8) Remove bolt h o l d i n g extension housing and ro- (15) Remove extension housing a n d mainshaft as
tate housing back to n o r m a l position. assembly (Fig. 5).
(9) Remove drive p i n i o n bearing r e t a i n e r bolts and
remove retainer and gasket. Discard the gasket.
(10) Remove o i l seal f r o m retainer w i t h p r y tool. To
avoid leakage around n e w seal, do n o t n i c k or
scratch seal bore i n retainer or surface on w h i c h seal
bottoms.
(11) T a p drive p i n i o n and bearing out front o f case
w i t h brass drift.
GASKET EXTENSION BOLT
(IN CENTER HOLE
ON RIGHT SIDE)

BEARING
RETAINER
EXTENSION
(TURNED UPSIDE DOWN)

EXPANSION
PLUG
RH80

Fig. 4 Rotating Extension Housing For Access To Countershaft

 • MANUAL TRANSMISSION 21 - 9

MAINSHAFT DISASSEMBLY 1ST AND 2ND CLUTCH CLUTCH STOP 1ST SPEED GEAR
(1) Refer to Figure 6 for location o f various gears,
synchronizer sleeves a n d clutches before disassem-
b l i n g mainshaft.
(2) Remove snap r i n g t h a t r e t a i n s g e a r t r a i n o n
mainshaft (Fig. 7).
(3) Remove O/D stop r i n g f r o m mainshaft (Fig. 6).
(4) Remove and inspect 3rd a n d O/D synchronizer
c l u t c h gear and sleeve assembly from mainshaft (Fig.
7). D o n o t d i s a s s e m b l e c l u t c h g e a r , sleeve, s h i f t
struts, o r springs unless inspection indicates re-
placement p a r t is required.

Fig. 6 Mainshaft Gear Identification

O/D SPEED GEAR 3RD AND O/D

Fig. 9 Removing/Installing Mainshaft

Fig. 7 Removing/Installing Mainshaft Geartrain Snap

Ring
(5) Compress mainshaft rear bearing snap r i n g
w i t h long nose pliers (Fig. 8).
(6) H o l d rear bearing snap r i n g i n compressed po-
s i t i o n and p u l l mainshaft and b e a r i n g o u t o f exten-
sion housing (Fig. 9).
(7) Remove mainshaft rear b e a r i n g snap r i n g ( F i g .
10).
(8) Remove rear b e a r i n g from mainshaft w i t h steel
plates (or bearing splitter) a n d shop press. I n s e r t
steel plates on front side o f 1st speed gear and press
mainshaft t h r o u g h a n d o u t of rear bearing. Do n o t
damage gear teeth w h e n removing bearing.
Fig. 10 Removing/Installing Rear Bearing Snap Ring
(9) Remove rear bearing, bearing snap r i n g , 1st
gear and 1st gear stop r i n g from mainshaft.
(10) Remove snap r i n g t h a t retains 1st a n d 2 n d
clutch gear a n d sleeve assembly on mainshaft (Fig.
11).
(11) Remove 2nd speed gear (Fig. 11).
(12) Remove and inspect 1st a n d 2 n d clutch gear
and sleeve assembly f r o m mainshaft. D o n o t disas-
21-10 MANUAL TRANSMISSION
Fig. 11 Removing/Installing 1-2 Clutch Gear And
Snap Ring
semble components p a r t s u n l e s s i n s p e c t i o n i n d i -
cates replacement p a r t i s r e q u i r e d .
DRIVE PINION/COUNTERSHAFT GEAR
DISASSEMBLY
(1) Remove snap r i n g t h a t r e t a i n s d r i v e p i n i o n
bearing to p i n i o n shaft.
(2) Remove p i n i o n bearing w i t h shop press a n d
press plates or bearing remover tool.
(3) Remove pilot bearing snap r i n g a n d remove 16
bearing rollers from bore i n d r i v e p i n i o n .
(4) Remove countershaft gear a n d t h r u s t washers
f r o m bottom of case.
(5) Remove arbor tool from countershaft gear. T h e n
remove needle bearings, t h r u s t washers a n d spacers
from gear. Total o f 76 needle bearings are used.
REVERSE GEAR/SHAFT/LEVER/FORK
REMOVAL
The reverse idler gear shaft is a n extremely t i g h t
f i t i n the case. To avoid damaging t h e shaft or t h e
case, remove t h e shaft only as described i n t h e fol-
l o w i n g procedure. Power steering wormshaft seal re-
mover tool C-3638 and a 7/16 socket are r e q u i r e d for
shaft removal.
(1) Remove backup lamp switch.
(2) Place 7/16 socket (1/4 or 3/8 i n c h drive) o n end
of power steering wormshaft seal remover tool C-
3638 (Fig.-12).
(3) Position tool i n case w i t h 7/16 socket against
end of shaft and opposite e n d o f tool against case
(Fig. 12).
(4) T u r n screw of tool of tool C-3638 t o press shaft
out o f case. I f shaft does n o t come a l l t h e w a y o u t of
case, use a 7/16 deep socket and/or a 3 i n c h extension
to press shaft completely o u t o f case.
(5) Remove reverse idler gear f r o m case a n d re-
move woodruff key from idler gear shaft.
(6) Following steps need only be performed i f o i l
leakage around reverse lever shaft was noted (Fig.
12).
•
REMOVED LEVER RH93
Fig. 12 Removing Reverse Idler Gear Shaft
(7) Remove a n y b u r r s from reverse lever shaft to
avoid d a m a g i n g eases bore.
(8) Carefully push reverse lever shaft i n w a r d and
remove i t f r o m case.
(9) Remove shaft seal a n d seal retainer from case
bore.
CLEANING AND INSPECTION
Clean t h e transmission case thoroughly w i t h sol-
vent. D r y t h e case and gears w i t h compressed a i r b u t
d o n o t use compressed a i r o n a n y o f t h e bearings.
A l l o w t h e bearings t o a i r d r y o r wipe t h e m d r y w i t h
clean shop towels.
The magnetic disc a t t h e b o t t o m of the case can be
removed for cleaning by p r y i n g off t h e magnet re-
t a i n i n g clip. A f t e r cleaning t h e magnetic disc w i t h a
clean cloth, t h e disc and r e t a i n i n g clip can be r e i n -
stalled b y pressing t h e clip onto t h e r i b i n t h e case.
Transmission Case
Inspect the case for cracks, stripped bolt threads, or
damaged gasket m a t i n g surfaces. Check t h e gasket
and machined surfaces for severe scoring, cracks,
nicks, or a n y condition t h a t w o u l d render t h e case
u n f i t for f u r t h e r service. T h e front m a t i n g surface
should be smooth. M i n o r scratches, burrs or nicks
can be reduced w i t h sandaper or a fine tooth m i l l
file. I f any bolt threads are stripped, i n s t a l l Helicoil,
or equivalent, t h r e a d inserts.
Mainshaft
Inspect t h e mainshaft gear a n d bearing surfaces
(Fig. 13). Check for signs o f wear, scoring, or any
condition t h a t w o u l d not allow t h e shaft to be reused.
Be sure t h e snap r i n g grooves i n the shaft are i n

good condition, i f t h e grooves are w o r n , or damaged,
replace t h e shaft. D o not a t t e m p t t o reuse i t .
SNAP THRUST SNAP
J
RING GROVE FACE RING GROOVE
\»»»»]
7 SNAP
7 RH91
AAAINSHAFT RING GROOVE
Fig. 13 Mainshaft Snap Ring And Thrust Surfaces
Bearings/Thrust Washers
Inspect t h e roller, b a l l a n d needle bearings. Be
sure t h e bearings are clean a n d d r y before inspec-
t i o n . Replace a n y b e a r i n g t h a t is r o u g h , corroded,
b r i n n e l l e d , galled, w o r n , o r scored. Lubricate t h e
bearings w i t h engine o i l after inspection.
Check condition o f t h e countershaft gear t h r u s t
washers, replace t h e washers i f cracked, worn, or
damaged i n any way.
Gears
Inspect a l l of t h e transmission gears for worn, bro-
k e n , chipped teeth. Replace gears as necessary. M i -
nor nicks or b u r r s o n gear t e e t h can be dressed off
w i t h a n oilstone.
Inspect the teeth and splines on the drive pinion. I f
either are excessively w o r n , o r are broken or chipped,
a new p i n i o n should be i n s t a l l e d . I f t h e o i l seal con-
tact area on the p i n i o n is p i t t e d , rusted, or scratched,
a new p i n i o n should be i n s t a l l e d to preserve the o i l
seal and prevent c l u t c h c o n t a m i n a t i o n .
Levers/Forks/Gearshift Housing
Inspect t h e interlock levers, shift forks, operating
levers and shafts. Be sure these parts are free of dis-
t o r t i o n , or cracks a t the detent and clearance notches
a n d a t each end o f levers. Check the shift forks for
wear on the pads and shafts. Replace components ex-
h i b i t i n g damage or excessive wear.
Inspect the shaft bores i n t h e gearshift housing. Be
sure the bores are free o f b u r r s . The seal surfaces o f
t h e housing must be i n good condition and not dam-
aged i n a n y way. Verify t h a t t h e operating lever
shafts f i t smoothly and are bind-free.
Synchronizer Components
Inspect the splines and t e e t h o n t h e synchronizer
clutch gears and sleeves. I f there is evidence of chip-
p i n g or excessively w o r n t e e t h , i n s t a l l new parts a t
reassembly. Be sure each c l u t c h sleeve slides easily
on the clutch gear.
MANUAL TRANSMISSION 21 - 11
Synchronizer springs should be i n place w i t h t h e
t a n g inside t h e cavity o f one s t r u t and should n o t
show signs o f interference w i t h t h e polished gear
cones or inside diameters o f t h e clutch gears.
Inspect the stop r i n g s for cracks and wear. I f rings
are cracked or show signs o f extreme wear o n
threaded bore, i n s t a l l new r i n g s a t reassembly. Test
new rings for good f i t o n gear cones w i t h m i n i m u m
wobble. Check synchronizer s t r u t s for wear or break-
age.
Synchronizers a r e t o be serviced as a n assembly.
Except for stop r i n g s , synchronizer parts should not
be interchanged.
TRANSMISSION ASSEMBLY
REVERSE GEAR/SHAFT/LEVER/FORK
INSTALLATION
(1) I n s t a l l reverse lever i n case bore.
(2) Lubricate n e w lever shaft o i l seal w i t h petro-
l e u m j e l l y and i n s t a l l seal i n and seal retainer i n
case bore.
(3) Insert reverse idler gear shaft i n end o f case.
Tap idler shaft i n t o case far enough to p e r m i t i n s t a l -
l a t i o n o f reverse i d l e r gear o n shaft.
(4) A l i g n reverse lever i n slot o f reverse idler gear
and slide gear onto shaft. B e s u r e l e v e r s l o t i n g e a r
i s t o w a r d r e a r o f case.
(5) A l i g n woodruff key slots i n case a n d idler gear
shaft and t a p shaft 3/4 o f w a y i n t o case. T h e n insert
woodruff k e y i n shaft a n d t a p shaft i n w a r d u n t i l
shaft is flush w i t h case surface.
(6) I n s t a l l backup l a m p s w i t c h and gasket. T i g h t e n
switch to 20 N»m (15 ft-lbs) torque.
COUNTERSHAFT GEAR/DRIVE PINION
INSTALLATION
(1) Coat bore of countershaft gear a t each end w i t h
petroleum j e l l y and i n s t a l l bearing spacer and arbor
tool C-3938 i n bore. Be sure to center spacer and ar-
bor i n gear as shown (Fig. 14).
COUNTERSHAFT
GEAR
SPECIAL TOOL
C-3938 ARBOR
RH95
Fig. 14 Arbor Tool Centered In Countershaft Gear
(2) Coat t h e countershaft needle bearing rollers,
spacers and t h r u s t washers w i t h petroleum j e l l y .
21-12 MANUAL TRANSMISSION •
(3) I n s t a l l first set of 19 bearing rollers on each end (9) Secure b e a r i n g o n p i n i o n shaft w i t h new i n n e r
of countershaft (Fig. 3). Then i n s t a l l a bearing spacer snap r i n g . B e sure snap r i n g is f u l l y seated. T h i s
on each end o f shaft. Seat spacers against bearing snap r i n g i s a select f i t for m i n i m u m e n d play.
rollers. (10) L u b r i c a t e m a i n s h a f t p i l o t roller bearings w i t h
(4) I n s t a l l second set o f 19 bearing rollers on each generous q u a n t i t y o f petroleum j e l l y a n d i n s t a l l r o l l -
end o f countershaft. T h e n i n s t a l l r e m a i n i n g bearing ers i n drive p i n i o n ( F i g . 17).
spacers on each end o f shaft ( F i g . 3). (11) Secure p i l o t r o l l e r bearings i n drive p i n i o n
(5) I n s t a l l t h r u s t washers o n ends o f countershaft w i t h new snap r i n g ( F i g . 17).
(Fig. 3). E x t r a petroleum j e l l y applied to t h r u s t
BEARING DRIVE PINION SNAP RING
washers w i l l hold t h e m i n place d u r i n g i n s t a l l a t i o n .
(6) Position countershaft gear assembly i n case
(Fig. 15). A l l o w gear assembly t o rest a t bottom o f
case. B e s u r e t h r u s t w a s h e r s s t a y i n p o s i t i o n .
(7) Verify gear a l i g n m e n t (Fig. 16). Be sure reverse
idler gear w i l l not interfere w i t h movement of coun-
tershaft gear. Also be sure countershaft gear t h r u s t
washers are s t i l l i n place.

Fig. 15 Positioning Countershaft Gear In Case

REVERSE IDLER REVERSE IDLER BACKUP LAMP Fig. 18 Installing Bearing Retainer Oil Seal
EXTENSION HOUSING BUSHING
REPLACEMENT
(1) Remove extension housing yoke seal.
(2) D r i v e o l d b u s h i n g out of housing w i t h tool C-
3974 (Fig. 19).
(3) Slide new b u s h i n g on i n s t a l l i n g end of tool C-
3974.
(4) A l i g n o i l hole i n bushing w i t h o i l slot i n exten-
sion housing a n d d r i v e new b u s h i n g i n t o place (Fig.
19).
(5) Position n e w seal i n extension housing a n d
drive seal i n t o housing w i t h tool C-3972.

SYNCHRONIZER ASSEMBLY
Fig. 16 Gear, Shaft And Lever Placement (1) Assemble 1-2 a n d 3rd-0/D synchronizer parts i n
order shown (Figs. 20 and 21):
(8) I n s t a l l outer snap r i n g on drive p i n i o n bearing.
(2) Place a stop r i n g flat o n bench. Then place
Then press bearing onto drive p i n i o n . Be sure snap
clutch gear o n r i n g a n d i n s t a l l sleeve over clutch
r i n g groove i n bearing is facing t o w a r d front (Fig.
gear.
17). Seat bearing f u l l y against shoulder on pinion.
 • MANUAL TRANSMISSION 21 -13

TOOL INSTALLING (2) Install 1-2 synchronizer assembly onto main-

BUSHING shaft and against second speed gear. B e sure front
stop ring lugs are indexed i n clutch gear (Fig. 20).
(3) Install new 1-2 clutch gear retaining snap ring
(Fig. 11).
(4) Install rear stop ring i n 1-2 synchronizer clutch
gear. B e sure stop ring lugs are indexed i n clutch
INSTALLING'
gear.
END BUSHING TOOL RH98 (5) Install first speed gear on mainshaft with syn-
chronizer cone of gear facing clutch gear and sleeve
Fig. 19 Replacing Extension Housing Bushing (Fig. 11).
(3) Drop struts in clutch gear slots and snap i n first (6) Position mainshaft rear bearing outer snap ring
strut spring. Place one tang of spring inside one of on mainshaft (Fig. 10).
(7) Press rear bearing onto mainshaft. Secure bear-
the struts.
ing on shaft with new snap ring (Fig. 10). T h i s snap
(4) T u r n assembly over and position i t on remain-
ring is a select fit for minimum end play.
ing stop ring.
(8) Install partially assembled mainshaft into ex-
(5) Install second strut spring. Place one tang of
tension housing far enough to engage bearing outer
second spring inside a different strut.
snap ring i n slot i n housing snap ring groove (Fig. 9).
CLUTCH STOP RING SNAP RING (9) Compress outer snap ring with pliers (Fig. 8).
T h e n push mainshaft into housing until rear bearing
CP
GEAR
bottoms against thrust shoulder i n housing.
FORWARD (10) Release rear bearing outer snap ring and fully
(POSITION LONG seat i t i n extension housing groove (Fig. 8).
HUB FORWARD) (11) Install overdrive gear onto front of mainshaft
with synchronizer cone facing front.
(12) Install overdrive gear stop ring.
(13) Install third-overdrive synchronizer assembly
on mainshaft and against overdrive gear. B e sure
CLUTCH SLEEVE
-STRUTS AND REVERSE GEAR shift fork slot i n synchronizer sleeve i s toward rear
and that stop ring lugs are indexed i n clutch gear
STRUT SPRINGS (2)
and sleeve.
STOP RING RH99 (14) Install new geartrain retaining snap ring on
mainshaft (Fig. 7).
Fig. 20 First-Second Synchronizer Components (15) Coat remaining stop ring with petroleum jelly
and install i t i n third-overdrive sleeve and gear. B e
CLUTCH*. STOP RING
GEAR
sure stop ring is indexed i n clutch gear and sleeve.
SLEEVE (16) Coat new extension housing gasket with a l l
FORWARD purpose chassis grease and position it on housing.
(17) Slide reverse idler gear to center of shaft and
move third-overdrive synchronizer sleeve as far for-
ward as possible but do not dislodge the struts. This
is necessary to provide installation clearance for the
STRUT SPRINGS (2) mainshaft.
(18) Insert mainshaft assembly into transmission
CLUTCH GEAR case (Fig. 5). T i l t assembly as required to clear idler
(POSITION LONG and cluster gears.
HUB FORWARD)
(19) Place third-overdrive synchronizer sleeve i n
LUG—STOP RING
TO CLUTCH GEAR RH100 neutral position.
(20) Rotate extension housing on mainshaft for ac-
Fig. 21 Third-O/D Synchronizer Components cess to rear of countershaft (Fig. 4). Install one hous-
ing bolt to hold housing i n position and prevent it
MAINSHAFT/EXTENSION HOUSING
from moving rearward.
ASSEMBLY AND INSTALLATION
(1) Install second speed gear onto mainshaft (with DRIVE PINION/COUNTERSHAFT
synchronizer cone toward rear) and against shoulder INSTALLATION
on shaft (Fig. 11). (1) Insert drive pinion assembly through front of
case.
21 - 14 MANUAL TRANSMISSION •
(2) A l i g n p i n i o n and mainshaft and push or t a p (10) Position 1-2 and third-overdrive synchronizer
p i n i o n i n t o place. I f mainshaft is properly seated i n sleeves a n d reverse idler gear i n N e u t r a l position.
p i n i o n r o l l e r bearings, p i n i o n bearing outer snap r i n g
w i l l seat f l u s h w i t h front face of transmission case. I f
components are misaligned, check t o see i f a s t r u t ,
p i n i o n r o l l e r , or stop r i n g is out o f position.
(3) H o l d countershaft gear i n place a n d t u r n t r a n s -
mission upside down.
(4) L o w e r countershaft gear u n t i l gear teeth mesh
w i t h d r i v e p i n i o n gear and mainshaft gears. M a k e
sure countershaft gear t h r u s t washers a m i bear-
i n g spacers are still i n position o n a r b o r tool.
(5) Rotate countershaft gear t h r u s t washers u n t i l
washer tangs are aligned w i t h slots i n case.
(6) S t a r t countershaft into bore a t rear o f case.
T h e n p u s h shaft f o r w a r d u n t i l shaft is approximately
h a l f way i n t o case and gear.
(7) I n s t a l l woodruff key. i n countershaft and push
shaft a l l w a y i n t o gear and case. B e sure shaft i s
flush w i t h rear of case face. Remove arbor tool after Fig. 22 Gearshift Housing Components
shaft i n s t a l l a t i o n .
(8) Remove h o l d i n g bolt and rotate extension hous-
i n g i n t o proper a l i g n m e n t w i t h the case.
(9) I n s t a l l and t i g h t e n extension housing bolts t o
68 N n n (50 ft-lbs) torque.
(10) Rotate transmission assembly to n p r m a l . posi-
tion.
(11) I n s t a l l bearing retainer and new gasket. Coat
threads o f r e t a i n e r bolts w i t h sealing compound be-
fore i n s t a l l a t i o n . Then i n s t a l l and t i g h t e n bolts t o 4 1
N n n (30 ft-lbs) torque.
(12) I n s t a l l n e w expansion p l u g i n countershaft
bore a t f r o n t o f case.

GEARSHIFT HOUSING ASSEMBLY AND

INSTALLATION (FIGS. 22 AND 23)
(1) I n s t a l l interlock levers on pivot p i n and secure
w i t h E-clip (Fig. 22).
(2) I n s t a l l interlock spring on levers w i t h pliers
(Fig. 23).
(3) L u b r i c a t e shift lever shafts, reverse lever and
new shaft o i l seals w i t h petroleum j e l l y .
(4) I n s t a l l shift lever shafts and reverse lever i n
housing bores (Fig. 22).
(5) I n s t a l l n e w o i l seals and seal retainers over
shafts and i n t o housing bores (Fig. 22).
(6) I n s t a l l operating levers o n shift levers a n d
t i g h t e n lever r e t a i n i n g n u t s t o 24 N n n (18 ft-lbs)
torque. B e s u r e t h i r d - o v e r d r i v e l e v e r p o i n t s
downward.
(7) Rotate shift levers t o N e u t r a l position ( s t r a i g h t
up).
(8) I n s t a l l third-overdrive shift fork i n shift lever
and under both interlock levers.
(9) Check installed position o f interlock levers a n d
spring (Fig. 23).
Fig. 23 Gearshift Housing Component Position
(11) Place 1-2 shift fork i n groove o f 1-2 synchro-
nizer sleeve.
(12) Place transmission on r i g h t side.
(13) Coat new gearshift housing gasket w i t h petro-
l e u m j e l l y and position gasket o n transmission. Use
a d d i t i o n a l petroleum j e l l y t o h o l d gasket i n position
i f necessary.
(14) I n s t a l l reverse detent b a l l and detent s p r i n g i n
side o f case (Fig. 16).
(15) I n s t a l l gearshift housing assembly. Guide
t h i r d - o v e r d r i v e shift fork i n t o groove o f synchronizer
sleeve a n d guide shaft o f 1-2 shift fork i n t o bore o f
1-2 shift lever i n housing. H o l d reverse i n t e r l o c k l i n k
against 1-2 shift lever for clearance as housing is
lowered i n t o place.
 • MANUAL TRANSMISSION
(16) Before seating housing on transmission, use a
screwdriver t o l i f t i n t e r l o c k lever t o allow 1-2 shift
fork t o slip under i n t e r l o c k levers.
(17) V e r i f y t h a t reverse detent spring is positioned
i n cover bore. T h e n seat gearshift housing o n case
gasket.
(18) I n s t a l l gearshift housing bolts finger t i g h t and
shift t h r o u g h a l l gears t o insure proper operation.
(19) Check housing bolt i n s t a l l a t i o n before final
t i g h t e n i n g . E i g h t h o u s i n g bolts are shoulder-type
bolts for locating housing on transmission; r e m a i n i n g
bolts are standard. One.bolt has longer shoulder t o
serve as locating dowel. This bolt passes t h r o u g h
cover and i n t o transmission case a t center or rear
flange. T i g h t e n a l l bolts evenly t o 20 N*m (15 ft-lbs)
torque.
(20) L u b r i c a t e end o f reverse shaft and i n s t a l l op-
e r a t i n g lever and n u t . T i g h t e n lever to 24 N*m (18
ft-lbs) torque.
(21) Shift the transmission i n t o each gear to insure
correct shift t r a v e l a n d smooth action.
(22) I n s t a l l speedometer drive p i n i o n gear a n d
adapter b e i n g sure range n u m b e r (representing n u m -
ber o f teeth on p i n i o n gear), is i n 6 o-clock position.
TRANSMISSION INSTALLATION
(1) L u b r i c a t e p i l o t b u s h i n g i n crankshaft w i t h Mo-
p a r h i g h temperature grease, or equivalent. Pilot
b u s h i n g requires grease w h i c h w i l l stay i n place dur-
i n g h i g h temperature operation. Use recommended
grease only.
21-15
(2) A p p l y t h i n coat of Mopar multipurpose, h i g h
temperature grease o n drive p i n i o n splines a n d o n
release bearing slide surface o f front b e a r i n g r e -
tainer. D o n o t l u b r i c a t e e n d o f p i n i o n shaft,
c l u t c h disc splines, o r c l u t c h release levers.
(3) M o u n t transmission on jack and move i t under
vehicle.
(4) Raise transmission a n d center transmission
drive p i n i o n w i t h clutch housing bore.
(5) Roll transmission slowly forward u n t i l drive
p i n i o n enters clutch disc. W i t h transmission i n gear,
t u r n o u t p u t shaft u n t i l splines are aligned..
(6) Push transmission forward, seat i t against
clutch housing a n d i n s t a l l transmission a t t a c h i n g
bolts. T i g h t e n bolts t o 68 N-m (50 ft-lbs) torque.
(7) Remove transmission jack.
(8) A l i g n crossmember bolt holes w i t h d r i f t a n d i n -
s t a l l a t t a c h i n g bolts. Tighten bolts t o 4 1 N*m (30 f t -
lbs) torque.
(9) Remove engine support fixture.
(10) I n s t a l l and t i g h t e n extension housing-to-insu-
l a t o r bolts t o 33 N*m (24 ft-lbs) torque.
(11) I n s t a l l floor gearshift assembly and connect
shift rods.
(12) Connect backup lamp switch wires.
(13) I n s t a l l distance sensor on speedometer adapter
and connect sensor wires.
(14) A l i g n and i n s t a l l propeller shaft.
(15) F i l l transmission w i t h recommended l u b r i c a n t .
(16) Lower vehicle.
(17) I n s t a l l gearshift lever and console, i f equipped.
(18) Verify proper transmission shifting. Adjust
l i n k a g e i f necessary.
21-16 MANUAL TRANSMISSION •
NP2500 MANUAL TRANSMISSION

INDEX
Page Page
General Information . . 16 Service Diagnosis . . 16

GENERAL INFORMATION RECOMMENDED LUBRICANT

COMPONENT DESCRIPTION AND
APPLICATION
The N P 2 5 0 0 (Fig. 1) is a fully-synchronized, five-
speed m a n u a l transmission. T h e transmission is de-
signed p r i m a r i l y for l i g h t d u t y applications a n d
incorporates a n overdrive fifth gear range for i m - SERVICE DIAGNOSIS
proved h i g h w a y fuel economy.
The l i g h t weight, die cast a l u m i n u m case and ex-
tension c o n t a i n a f u l l helical gear set, i n c l u d i n g re- caused b y insufficient l u b r i c a n t , incorrect l u b r i c a n t ,
verse. D u r a b i l i t y improvement items include: tapered
roller bearings o n t h e countershaft gear, caged nee-
dle bearings o n first a n d reverse speed gears, a n d
sealed b a l l bearings o n t h e mainshaft a n d i n p u t
shaft.
A n e w single u n i t t o p mounted shifter a n d three
r a i l shift mechanism optimize shift effort a n d qual-
i t y . Reverse gear is a constant mesh design w h i c h a l -
lows reverse gear t o be located directly behind
overdrive gear i n the shift p a t t e r n . A reverse blocker
is incorporated to prevent accidental shifts from over-
drive t o reverse.
Recommended l u b r i c a n t for t h e NP2500 i s S A E
10W-30 engine oil, A P I classification SG/CD. This l u -
b r i c a n t i s used for improved d u r a b i l i t y and quiet op-
eration.
L u b r i c a n t d r a i n and r e f i l l i n t e r v a l s are outlined i n
Group O, L u b r i c a t i o n and Maintenance.
The m a j o r i t y of transmission malfunctions are
misadjusted or damaged i n t e r n a l components, loose
a t t a c h i n g parts, or improper operation.
HARD SHIFTING
A l o w l u b r i c a n t level, damaged linkage, or w o r n ,
damaged i n t e r n a l shift components are t h e most
common causes of h a r d s h i f t i n g . I f h a r d s h i f t i n g i s
also accompanied by gear clash, synchronizer compo-
nents m a y be w o r n or damaged.
H a r d s h i f t i n g m a y also be caused b y a loose, or
misaligned shift housing. E i t h e r f a u l t can result i n
component b i n d and h i g h shift efforts.

ACCESS COVER NOISY OPERATION

SHIFTER ASSEMBLY
Transmission noise is most often a result of w o r n
or damaged components. Chipped, broken gear or
IDENTIFICATION
synchronizer teeth a n d b r i n n e l l e d , spalled bearings
TAG
a l l cause noise. A b n o r m a l wear a n d damage to i n t e r -
BACK-UP n a l components is frequently the end result of insuf-
LAMP SWITCH ficient l u b r i c a n t , non-recommended lubricants, or
EXTENSION improper operation.

SLIPS OUT OF GEAR

Transmission disengagement m a y be caused b y
misaligned or damaged shift components, or w o r n
synchronizer clutch teeth o n the mainshaft gears. I n -
correct assembly w i l l also contribute t o gear disen-
gagement.

Fig. 1 NP2500 5-Speed Manual Transmission LOW LUBRICANT LEVEL

Insufficient transmission l u b r i c a n t is usually t h e
result o f leaks, or inaccurate fluid level check or re-
f i l l method. Leaks w i l l be evident b y t h e presence o f
 • MANUAL TRANSMISSION 21-17

gear o i l around the leak point. I f leakage i s not evi-
dent, the condition i s probably the result of a n u n -
d e r f i l l condition.
I f a i r powered lubrication equipment is used t o fill
a transmission, be sure t h e equipment is properly
calibrated. E q u i p m e n t out o f c a l i b r a t i o n can lead t o
an u n d e r f i l l condition.
CLUTCH PROBLEMS
W o r n , damaged, or misaligned clutch components
can cause h a r d shifting, gear clash and noise.
A w o r n p i l o t b u s h i n g w i l l cause noise and i n p u t
shaft m i s a l i g n m e n t . The r e s u l t is h a r d s h i f t i n g a n d
noise.
A w o r n or damaged clutch disc, pressure plate, o r
release b e a r i n g c a n cause h a r d shifting a n d gear
clash.
Damaged or w o r n clutch h y d r a u l i c components, o r
leaks i n the f l u i d lines or cylinders w i l l cause h a r d
s h i f t i n g and gear clash. A major failure o f one o f t h e
clutch h y d r a u l i c cylinders w i l l cause incomplete
clutch release o r engagement.
Be sure t h a t t h e clutch components are a l l i n good
condition before r e m o v i n g t h e transmission for r e -
pair.

S E R V I C E IN V E H I C L E

INDEX
Page Page
Extension Housing Yoke Seal Replacement . . . . . 18 Speedometer Pinion And Adapter Service . . . . . . . 17
Gearshift Lever 18 Transmission Wiring Harness 18

SPEEDOMETER PINION AND ADAPTER SERVICE LOCK

RING
Rear axle gear r a t i o and t i r e size determines p i n -
i o n gear usage. I f the gear m u s t be replaced, consult
the parts catalogue for correct application.

ADAPTER AND PINION REMOVAL

(1) Raise t h e vehicle and position a d r a i n pan u n - SPEEDOMETER
PINION
der the speedometer adapter.
GEAR
(2) Disconnect t h e wires f r o m the distance sensor
(Fig. 2). ADAPTER O-RING
(3) Loosen the distance sensor coupling and remove
SPEEDOMETER ADAPTER
the sensor f r o m t h e speedometer adapter (Fig. 2).
(4) Remove t h e bolt a n d retainer securing t h e RETAINER
speedometer p i n i o n adapter i n the extension housing
J9021-73
(Fig. 2). * DISTANCE SENSOR
(5) Carefully w o r k the adapter and p i n i o n out of
the extension housing. Fig. 2 Speedometer Adapter And Pinion
Components
(6) Remove and discard t h e adapter O-ring.
(7) Inspect t h e adapter. I f transmission f l u i d is ADAPTER LOCK RING
found i n the coupling section of the adapter housing,
the o i l seal is l e a k i n g and w i l l require replacement.
Refer t o Adapter O i l Seal Replacement

ADAPTER OIL SEAL REPLACEMENT

(1) Remove t h e C-shaped lock r i n g securing t h e
seal i n the adapter (Fig. 2). TOOL
OIL SEAL
(2) Remove t h e o l d seal f r o m the adapter w i t h a RH263
s m a l l screwdriver or hooked tool.
(3) S t a r t t h e new seal i n the adapter by hand and Fig. 3 Installing Adapter Oil Seal And Lock Ring
insert the lock r i n g i n the adapter.
(4) Seat t h e seal i n the adapter w i t h tool C-4004
(Fig. 3). Press t h e seal and lock r i n g into place u n t i l
the i n s t a l l e r tool bottoms.
21-18 MANUAL TRANSMISSION
ADAPTER AND PINION INSTALLATION
CAUTION: Before installing the pinion and adapter
assembly make sure the adapter flange and the
mating area in the extension housing are perfectly
clean. Dirt, sand, or foreign material will cause mis-
alignment resulting in speedometer pinion gear
damage.
(1) Thoroughly clean t h e adapter flange a n d
adapter m o u n t i n g surface i n t h e extension housing.
These surfaces m u s t be clean for proper adapter
alignment a n d speedometer operation.
(2) I n s t a l l a new O - r i n g on t h e adapter.
(3) Lubricate the adapter o i l seal and O-ring w i t h
transmission fluid.
(4) Count t h e number o f teeth on the p i n i o n gear
and i n s t a l l t h e gear i n t h e adapter. Be sure to count
the gear teeth b e f o r e i n s t a l l i n g the gear.
(5) Note t h e range numbers o n the adapter face
(Fig. 4). These numbers correspond to the number o f
teeth on the speedometer p i n i o n gear.
(6) Insert the adapter i n the extension housing.
(7) Rotate t h e adapter u n t i l t h e required range
numbers are a t a six o-clock position (Fig. 4). Be sure
the adapter range numbers correspond to t h e number
of teeth on the p i n i o n .
(8) L i g h t l y push the adapter a l l the w a y into the
extension housing.
(9) I n s t a l l t h e adapter retainer. T i g h t e n t h e r e -
t a i n e r bolt t o 100 in-lbs (11 N-m) torque.
(10) I n s t a l l t h e distance sensor on t h e adapter.
T i g h t e n the sensor coupling n u t . to 150 in-lbs (17
N-m) torque and i n s t a l l t h e sensor wires.
(11) Check and top o f f t h e transmission l u b r i c a n t
level i f necessary.
Fig. 4 Indexing Speedometer Adapter
EXTENSION HOUSING YOKE SEAL REPLACEMENT
(1) Raise the vehicle a n d position a d r a i n pan u n -
der the extension housing.
(2) M a r k position o f t h e propeller shaft and rear
axle yokes for alignment reference.
•
(3) Disconnect t h e propeller shaft a t the axle yoke
and remove t h e shaft.
(4) Remove t h e o i l seal w i t h tool C-3985 { F i g . 5).
(5) I n s t a l l t h e new seal w i t h tool C-3972 (Fig. 6).
S t a r t the seal i n t h e housing and tap i t i n t o place
u n t i l t h e tool bottoms against the housing.
(6) Check condition o f the slip yoke surface o f t h e
propeller shaft. Reduce m i n o r corrosion, scratches, or
nicks w i t h crocus cloth or 400 g r i t sandpaper. Re-
place the s l i p yoke i f severely scored or rusted t o
m a i n t a i n seal a n d b u s h i n g life.
(7) A l i g n a n d i n s t a l l the propeller shaft.
(8) Check a n d top o f f the transmission l u b r i c a n t
level i f necessary. Correct level is t o the edge o f t h e
f i l l p l u g hole. Refer t o Group O, L u b r i c a t i o n and
Maintenance for lube requirements.
(9) Remove t h e d r a i n pan and lower the vehicle.
Fig. 5 Removing Yoke Seal
SPECIAL TOOL
Fig. 6 Installing Yoke Seal
GEARSHIFT LEVER
The gearshift lever is a two-piece design (Fig. 7).
The upper p a r t o f the lever is threaded to the t r a n s -
mission stub lever. The upper lever can be removed
for service w i t h o u t h a v i n g to remove the entire shift
lever assembly o r the transmission.
I f the upper lever m u s t be serviced, remove t h e
screws a t t a c h i n g the lower boot, support, bezel and
insert for access t o t h e lever lower end. T h e n u n -
thread a n d remove t h e upper lever from the stub le-
ver.
TRANSMISSION WIRING HARNESS
The transmission w i r i n g harness is attached to the
transmission and c l u t c h housing w i t h clips and t i e
straps (Fig. 8). I f the harness must be replaced, be
 • MANUAL TRANSMISSION 21 - 19

KNOB BOOT

Fig. 7 Gearshift Lever Components Fig. 8 Transmission Harness Routing

sure t o route t h e harness as shown i n t h e i l l u s t r a -
tion. Do n o t allow t h e harness t o contact hot or ro-
t a t i n g components. M a k e sure t h e harness is clear of
such components.
21 - 20 MANUAL TRANSMISSION •
S E R V I C E OUT OF V E H I C L E

INDEX

Page Page
Bearing/Seal/Bushing Replacement ............ 30 Transmission Disassembly . . . . . . . . . . . . . . . . . . 20
Cleaning and Inspection 28 Transmission Installation . 35
Transmission Assembly . 33 Transmission Removal 20

TRANSMISSION REMOVAL

(1) Shift t h e transmission i n t o N e u t r a l . Then re-

move t h e upper shift lever. Refer t o procedure i n Ser-
vice I n Vehicle section.
(2) Raise t h e vehicle a n d d r a i n t h e transmission l u -
bricant.
(3) M a r k t h e propeller shaft and rear axle yokes for
assembly alignment.
(4) Disconnect a n d remove t h e propeller shaft.
(5) Disconnect t h e wires f r o m t h e distance sensor.
T h e n loosen t h e sensor coupling and remove t h e sen-
sor from t h e speedometer adapter.
(6) Remove the speedometer adapter a n d p i n i o n
gear.
(7) Disconnect the backup l a m p switch wires.
(8) I n s t a l l engine support fixture C-3487-A or a Fig. 1 Removing/Installing Shifter Bolts
s i m i l a r device to support t h e engine. Be sure t h e sup-
port ends are seated on t h e underside of the o i l p a n
flange.
(9) Raise t h e engine s l i g h t l y w i t h t h e support fix-
ture.
(10) Disconnect t h e i n s u l a t o r from t h e extension
housing.
(11) Support the transmission w i t h a suitable j a c k
and remove t h e center crossmember.
(12) Remove t h e transmission-to-clutch housing
bolts.
(13) Slide t h e transmission r e a r w a r d u n t i l t h e i n -
p u t shaft clears the c l u t c h disc.
(14) P u l l t h e transmission completely away from
the clutch housing and remove t h e transmission from
under t h e vehicle.
(15) Thoroughly clean t h e transmission exterior,
preferably w i t h steam cleaning equipment. Fig. 2 Prying Shifter Plate loose
(6) Remove access cover (Fig. 6).
TRANSMISSION DISASSEMBLY (7) Remove detent springs and bullets w i t h magnet
(Fig. 7).
SHIFTER, EXTENSION HOUSING AND GEAR (8) Remove extension housing bolts (Fig. 8).
SET REMOVAL (9) P r y housing loose (Fig. 9).
(1) Remove shifter a n d stub lever from transmis- (10) Remove extension housing (Fig. 10).
sion (Fig. 1). (11) Note position o f reverse/OD shift r a i l compo-
(2) P r y Shifter plate u p w a r d (Fig. 2). nents (Fig. 11).
(3) Remove shifter ( F i g . 3). (12) Remove shift f o r k pins (Fig. 12).
(4) Remove access cover bolts (Fig. 4). (13) Remove i n t e r l o c k plates and 1-2 shift r a i l ( F i g .
(5) P r y access cover loose (Fig. 5). 13).
• MANUAL TRANSMISSION 21 - 21

Fig. 4 Removing/Installing Access Cover Bolts Fig. 7 Removing/installing Detent Springs And
Bullets
SCREWDRIVER

Fig. 5 Prying Access Cover Loose

Fig. 8 Removing/Installing Extension Housing Bolts
(14) Remove countershaft O D gear snap r i n g (Fig.
(17) Note assembly sequence o f tool C-4982 ( F i g .
14).
(15) Note position o f O D gear k e y w a y (Fig. 15). 17) .
(18) Remove mainshaft O D gear snap r i n g ( F i g .
(16) Remove countershaft O D gear w i t h tool C-
18) .
4982 (Fig. 16).
21 - 22 MANUAL TRANSMISSION •

Fig. 9 Loosening Extension Housing Fig. 12 Removing/installing Shift Fork Pins

Fig. 13 Removing/Installing 1-2 Shift Rail And

Fig. 10 Removing/Installing Extension Housing
Interlock Plates

Fig. 11 Reverse/OD Shift Rail And Blocker Spring

Fig. 14 Removing/Installing Countershaft OD Gear
Position
Snap Ring
(19) Remove t h r u s t washer a n d anti-spin p i n (Fig.
(22) Remove reverse/OD Synchronizer, fork a n d
19). r a i l assembly (Fig. 22).
(20) Remove mainshaft OD gear (Fig. 20). (23) Remove 3-4 shift r a i l and interlock plate (Fig.
(21) Remove reverse/OD hub snap r i n g (Fig. 21). 23).
 MANUAL TRANSMISSION 21 - 23
•

Fig. 15 Overdrive Gear Keyway Position Fig. 18 Removing/Installing Mainshaft OD Gear

Snap Ring

OD GEAR C-4982 BLOCK RN1173

Fig. 16 Removing OD Countershaft Gear

Fig. 19 Removing/installing Thrust Washer And
Anti-Spin Pin

Fig. 17 Tool C-4982 Assembly Sequence

(24) Remove 1-2 and 3-4 shift forks (Fig. 24). Fig. 20 Removing/Installing Mainshaft OD Gear
(25) Note shift r a i l position for assembly reference
(27) Remove reverse gear t h r u s t washer a n d a n t i -
(Fig. 25).
spin p i n (Fig. 27).
(26) Remove reverse gear and caged needle bear- ( 2 8 ) Remove center support bolts (Fig. 28).
ings (Fig. 26). (29) Note gear position prior t o assembly (Fig. 29).
21 - 24 MANUAL TRANSMISSION •

Fig. 21 Removing/Installing Reverse-OD Hub Snap

Ring

Fig. 22 Removing/Installing Reverse-OD

Synchronizer, Fork And Rail

Fig. 26 Removing/Installing Reverse Gear

Fig. 23 Removing/Installing 3-4 Shift Rail And Plate GEAR SET DISASSEMBLY
(1) N o t e gear position for assembly reference (Fig.
(30) Remove center support and gear set (Fig. 30).
32).
(31) Fabricate alignment studs for reassembly (Fig.
31).
• MANUAL TRANSMISSION 21 - 25

SNAP RING CENTER SUPPORT CENTER

PLIERS PLATE SUPPORT
PLATE

AAAINSHAFT
ASSEAABLY

ROUND ALIGNMENT'
HOLE RN1185 STUDS (3) COUNTERSHAFT GEAR

Fig. 27 Removing/Installing Reverse Gear Thrust Fig. 30 Removing/Installing Center Support And
Washer And Anti-Spin Pin Gear Set

CENTER SUPPORT ALIGNMENT

PLATE rSTUDS
(FABRICATE)

BOLT (3) 3 Z i © ^ RN1186

Fig. 28 Removing/Installing Center Support Bolts Fig. 31 Gear Case Alignment Studs
TURN INPUT SHAFT SO THAT 3-4 SYNCHRONIZER SLEEVE 3-4 SYNCHRONIZER 2ND GEAR 1ST GEAR CENTER
CUTAWAY FACES DOWN ASSEMBLY .SUPPORT
c PLATE

4TH SPEED SYNCHRONIZER STOP RING RN1187 COUNTERSHAFT GEAR RN1190

Fig. 29 Gear Set Position Fig. 32 Gear Set Components

(2) Remove center bearing snap r i n g a n d remove (4) Remove snap r i n g securing gear set t o m a i n -
mainshaft a n d gear set from center support plate shaft (Fig. 35).
(Fig. 33). (5) Remove 3-4 synchronizer assembly (Fig. 36).
(3) Remove countershaft (Fig. 34). (6) Remove t h i r d gear (Fig. 37).
21 - 26 MANUAL TRANSMISSION •
1ST SPEED MAINSHAFT CENTER MAINSHAFT CENTER 3-4 SYNCHRONIZER
GEAR BEARING SNAP RING BEARING SNAP RING ASSEMBLY

PLASTIC HAMMER ^O^^fc,, \N^M*N1191 3RD SPEED GEAR RN1194

Fig. 33 Removing/Installing Mainshaft And Gear Set Fig. 36 Removing/Installing 3-4 Synchronizer
Assembly
COUNTERSHAFT REVERSE
GEAR IDLER GEAR RETAINING 3RD SPEED GEAR
2ND SPEED
GEAR RING

CENTER SUPPORT PLATE RN1192 2-3 SPLIT

THRUST WASHER RN1T95
Fig. 34 Removing/Installing Countershaft
Fig. 37 Removing/Installing Third Gear
MAINSHAFT CENTER 3-4 SYNCHRONIZER
BEARING SNAP RING ASSEMBLY 2ND SPEED GEAR RETAINING
RING_

3RD SPEED GEAR RN1194

SPLIT THRUST WASHER RN1196
Fig. 35 Removing/lnstailing Gear Set Retaining
Snap Ring Fig. 38 Removing/Installing Split Thrust Washer,
Retaining Ring And Anti-Spin Pins
(7) Remove s p l i t t h r u s t washer, r e t a i n i n g r i n g and
t w o anti-spin p i n s ( F i g . 38). (9) Remove second speed gear (Fig. 40).
(8) N o t e washer a n d r e t a i n i n g r i n g i n s t a l l a t i o n po- (10) Remove 1-2 synchronizer snap r i n g (Fig. 41).
(11) Remove 1-2 synchronizer assembly (Fig. 42).
s i t i o n for reference ( F i g . 39).
• MANUAL TRANSMISSION 21 - 27

SPLIT THRUST WASHER RETAINING RING AAAINSHAFT 1-2 SYNCHRONIZER

Fig. 39 Thrust Washer And Retaining Installation Fig. 42 Removing/Installing 1-2 Synchronizer
Position Assembly

RING C A G E D NEEDLE BEARINGS RN1201

Fig. 40 Removing/Installing Second Speed Gear Fig. 43 Removing/Installing First Gear And Needle
Bearings
(14) Note synchronizer component l a y o u t for as-
sembly identification (Fig. 44).

INPUT SHAFT REMOVAL

(1) Remove retainer bolts (Fig. 45).
(2) Remove retainer and gasket (Fig. 46).
(3) Remove front bearing locating snap r i n g . T h i s
is largest snap r i n g (Fig. 47).
(4) Remove i n p u t shaft (Fig. 48).
(5) Remove mainshaft p i l o t bearing rollers f r o m i n -
p u t shaft (Fig. 49).

CENTER SUPPORT PLATE/REVERSE IDLER

Fig. 41 Removing/Installing 1-2 Synchronizer Snap
Ring
(12) Remove first speed gear (Fig. 43).
(13) Remove caged needle bearings a n d t h r u s t
washer (Fig. 43).
DISASSEMBLY
(1) Remove idler shaft snap r i n g (Fig. 50).
(2) Remove idler shaft a n d reverse gear compo-
nents (Fig. 51).
(3) Remove center bearing snap r i n g ( F i g . 52).
(4) Remove countershaft center bearing w i t h shop
press a n d suitable tool (Fig. 53).
21 - 28 MANUAL TRANSMISSION •
ENERGIZER SPRINGS
STOP RINGS

REVERSE
STRUT
ETAINER
PLATE
(PLASTIC)

STOP RINGS

SYNCHRONIZER
STRUTS RN1202

Fig. 44 Synchronizer Component Identification

TRANSMISSION
CASE

RETAINER
BOLTS

BEARING RETAINER INPUT SHAFT RN1206 INPUT SHAFT BEARING RNT207

Fig. 45 Removing/Installing Front Bearing Retainer Fig. 46 Removing/Installing Front Bearing Retainer
Bolts
solvent a n d d r y w i t h compressed air. T h e magnetic
CLEANING AND INSPECTION disc, located on bottom of case, can be removed for
cleaning. Wipe t h e disc clean w i t h a cloth a n d r e i n -
s t a l l t h e disc.
Gear Case
Inspect the case for cracks and stripped threads i n
Clean transmission case thoroughly w i t h a suitable
various bolt holes. Inspect t h e machined surfaces for
• MANUAL TRANSMISSION
Fig. 47 Removing/Installing Front Bearing Locating
Snap Ring
Fig. 49 Removing/Installing Mainshaft Pilot Roller
Bearings
burrs, nicks, or any condition t h a t w o u l d render the
case unfit for further service. T h e f r o n t m a t i n g sur-
face should be smooth. I f any b u r r s are present, dress
21 - 29
Fig. 50 Removing/Installing Idler Shaft Snap Ring
t h e m off w i t h a fine m i l l file. I f any case threads are
stripped, i n s t a l l H e l i c o i l , or equivalent t h r e a d i n -
serts.
Bearings
Wash bearings, u s i n g a clean solvent and either a i r
dry t h e m o r wipe d r y w i t h clean shop towels. D o not
use c o m p r e s s e d a i r to d r y t h e b e a r i n g s . C o m -
p r e s s e d a i r a p p l i e d to u n l u b r i c a t e d b e a r i n g s
m a y cause damage t o t h e b e a r i n g races a n d
balls.
Be sure bearings a r e clean. Inspect bearings for
roughness. T h i s can best be determined by slowly
turning by hand.
Inspect a l l b e a r i n g rollers for flat spots or b r i n n e l -
l i n g . Inspect a l l bearing roller spacers for signs of
wear or g a l l i n g . Inspect roller contact surfaces of
gear and shaft. I n s t a l l new parts as required.
Refer t o t h e Bearing/Bushing/Seal Replacement
procedure i n t h i s section for bearing replacement
procedures. L u b r i c a t e the bearings w i t h 10W-30 en-
gine o i l ( A P I class SG/CD) after cleaning, inspection
and/or replacement.
Gears
Inspect countershaft gear a n d a l l gear teeth for
chipped or b r o k e n teeth, or showing signs of exces-
sive wear. S m a l l nicks or burrs must be removed
w i t h a n oilstone.
Inspect t e e t h on i n p u t shaft. I f excessively w o r n ,
broken, or chipped, a new p i n i o n should be installed.
I f the o i l seal contact area on drive p i n i o n shaft is
pitted, rusted, or scratched, a new p i n i o n is recom-
mended for best seal life.
Inspect s h i f t forks for wear on pads and shafts. Re-
place the forks i f w o r n or damaged.
Synchronizer Assemblies
Inspect spline t e e t h on synchronizer clutch gears
and stop r i n g s . I f there is evidence o f chipping or ex-
21 - 30 MANUAL TRANSMISSION •
CENTER SUPPORT PLATE CENTER ARBOR PRESS RAM
SUPPORT
PLATE

SUITABLE
TOOL

W^m^m^^aM NOTE: LETTERED'HUBl

1AFT~^
COUNTERSHAFT »li^ SIDE TOWARD IIIgF COUNTERSHAFT
CENTER BEARING - i SNAP RING RN1216 CENTER BEARING RN1217

Fig. 52 Removing/Installing Countershaft Center Fig. 53 Removing Countershaft Center Bearing

Bearing Snap Ring
BEARING/SEAL/BUSHING REPLACEMENT
REVERSE CENTER
IDLER GEAR SUPPORT
SHAFT PLATE INPUT SHAFT (FRONT) BEARING
REPLACEMENT
(1) Remove f r o n t bearing r e t a i n i n g snap r i n g f r o m
REVERSE i n p u t shaft (Fig. 54).
IDLER GEAR (2) Remove b e a r i n g w i t h shop press and universal
bearing remover (Fig. 55).
(3) I n s t a l l b e a r i n g w i t h tool C-4965 and shop press
(Fig. 56).
INPUT SNAP RING
SNAP RING SHAFT PLIERS

CAGED
ROLLER BEARING 8921-224

Fig. 51 Removing/Installing Reverse Idler Gear

Components
cessively w o r n teeth, i n s t a l l new parts a t reassembly.
Be sure synchronizer sleeves slide freely on the hubs.
Inspect the stop rings for cracks and wear. I f r i n g s
are cracked o r show signs of extreme wear o n SNAP RING
threaded bore, i n s t a l l new stop rings a t reassembly.
Test new rings for good f i t o n gear cones w i t h m i n i - INPUT
SHAFT
m u m wobble. Check synchronizer struts for wear or
BEARING RN1211
breakage.
Synchronizers w i l l be serviced as a n assembly. Fig. 54 Removing/Installing Front Bearing Retaining
Synchronizer p a r t s should n o t be interchanged. Snap Ring
MAINSHAFT CENTER BEARING
Mainshaft REPLACEMENT
Inspect t h e mainshaft gear a n d b e a r i n g m a t i n g (1) Remove b e a r i n g snap r i n g (Fig. 57). »
surfaces. I f gear contact surfaces show signs o f g a l l - (2) Remove b e a r i n g w i t h shop press a n d plates
ing or excessive wear, a new mainshaft should be i n - (Fig. 58).
stalled. (3) I n s t a l l b e a r i n g on mainshaft (Fig. 59). B e s u r e
Inspect the snap r i n g grooves for b u r r e d edges. I f f l a t side o f first g e a r t h r u s t w a s h e r w i l l face
rough or burred, remove b u r r s w i t h a fine file or cro- gear after i n s t a l l a t i o n .
cus cloth. Inspect synchronizer hub splines on shaft (4) I n s t a l l b e a r i n g snap r i n g (Fig. 57).
for b u r r s also.
• MANUAL TRANSMISSION 21 - 31

INPUT SHAFT ARBOR PRESS

RAM ARBOR PRESS

MAINSHAFT

AAAINSHAFT
SPECIAL TOOL
CENTER
INPUT SHAFT (UNIVERSAL JAWS)
BEARING
BEARING

RN1212 RN1204

Fig. 55 Removing Front Bearing From Input Shaft Fig. 58 Removing Center Bearing

ARBOR PRESS
"RAM ARBOR PRESS
RAM

AAAINSHAFT

SPECIAL TOOL
"C-4965 1ST GEAR THRUST
WASHER (FLAT SIDE
FACES GEAR)

AAAINSHAFT
INPUT SHAFT CENTER PLATES (2)
'GEAR BEARING

INPUT SHAFT
BEARING RN1213 RN1205

Fig. 56 Installing Front Bearing On Input Shaft Fig. 59 Installing Center Bearing

AAAINSHAFT J ^ -SH MAINSHAFT

CENTER
BEARING

SEAL INSTALLING
TOOL C-3789

Fig. 60 Installing Bearing Retainer Seal

COUNTERSHAFT GEAR BEARING

REPLACEMENT
SNAP RING (1) Remove b e a r i n g i f n o t removed previously ( F i g .
SNAP RING PUERS RN1203 53).
(2) I n s t a l l new b e a r i n g w i t h tool C-4974 ( F i g . 61).
Fig. 57 Removing/Installing Center Bearing Snap
(3) Note countershaft gear b e a r i n g a n d spacer posi-
Ring
t i o n (Fig. 62).
FRONT BEARING RETAINER SEAL
(4) Remove countershaft f r o n t b e a r i n g cone with
REPLACEMENT
tools C-4983 a n d C-4983-4 ( F i g . 63).
(1) P r y seal out o f r e t a i n e r .
(5) I n s t a l l f r o n t b e a r i n g cone w i t h tool C-4967 ( F i g .
(2) I n s t a l l new seal w i t h tool C-3789 ( F i g . 60).
64).
21 - 32 MANUAL TRANSMISSION •

Fig. 61 Installing Countershaft Gear Center Bearing Fig. 64 Installing Countershaft Gear Front Bearing
Cone
FRONT

Fig. 62 Countershaft Gear Components

Fig. 65 Removing Countershaft Gear Front Bearing
Cup

Fig. 63 Removing Countershaft Gear Front Bearing

Cone
Fig. 66 Installing Countershaft Gear Front Bearing
(6) Remove front bearing cup w i t h shop press and Cup
suitable tool (Fig. 65).
(8) Remove rear b e a r i n g cone w i t h tools C-4983-5
(7) I n s t a l l front bearing cup w i t h tools C-4171 and
and C-4983 (Fig. 67).
C-4968 (Fig. 66).
 • MANUAL TRANSMISSION 21 - 33

Fig. 67 Removing Countershaft Gear Rear Bearing Fig. 69 Removing Countershaft Gear Rear Bearing
Cone Cup
PRESS

RN1225

Fig. 68 Installing Countershaft Gear Rear Bearing Fig. 70 Installing Countershaft Gear Rear Bearing
Cone Cup
(9) I n s t a l l rear bearing cone w i t h tool C-4966 ( F i g .
68).
(10) Remove rear bearing cup w i t h tools L-4454
and L-4518 (Fig. 69).
(11) I n s t a l l rear bearing cup w i t h tools C-4171 a n d
C-4973 (Fig. 70).

MAINSHAFT REAR BEARING REPLACEMENT

(1) Remove bearing snap r i n g (Fig. 71).
(2) Tap bearing o u t of extension housing (Fig. 71).
(3) I n s t a l l new bearing and snap r i n g i n extension
(Fig. 71).

EXTENSION HOUSING BUSHING

REPLACEMENT
(1) Remove seal w i t h tool C-3985.
(2) Remove b u s h i n g w i t h tool C-3996 ( F i g . 72). Fig. 71 Mainshaft Rear Bearing Replacement
(3) I n s t a l l new bushing w i t h tool C-3996 (Fig. 72). TRANSMISSION ASSEMBLY
(4) I n s t a l l new housing seal w i t h tool C-3995.
Lubricate transmission components w i t h fresh
10W-30 engine o i l d u r i n g assembly. Lubricate t h e
21 - 34 MANUAL TRANSMISSION •
(6) Move gear forward and zero indicator.
(7) Move gear r e a r w a r d a n d note d i a l indicator
reading. E n d play should be . 0 3 t o .13 m m ( . 0 0 1 t o
. 0 0 5 inch).
(8) I f necessary, select new s h i m (Fig. 74).
(9) Remove d i a l indicator a n d countershaft gear
and continue w i t h assembly.

Fig. 72 Replacing Extension Housing Bushing

synchronizer components a n d a l l bearings and bear-
i n g contact surfaces b e f o r e assembly a n d i n s t a l l a -
tion.
Assemble t h e transmission o n a clean w o r k sur-
face. D o n o t allow d i r t or foreign m a t e r i a l t o enter
the case or gear components d u r i n g assembly opera-
tions.
V e r i f y t h a t bearings cups a n d cones are correctly
positioned before s t a r t i n g assembly operations.

ASSEMBLING GEAR SET

(1) Assemble 1-2 and 3-4 synchronizers (Fig. 44).
(2) I n s t a l l center b e a r i n g snap r i n g , caged needle
Fig. 73 Measuring Countershaft Gear End Play
bearings a n d first gear o n mainshaft ( F i g . 43). B e
sure t h e c h a m f e r e d side o f t h e snap r i n g faces
Thickness
t h e first g e a r .
(3) I n s t a l l 1-2 synchronizer assembly (Fig. 42) a n d Port No. Millimeters Inches
i n s t a l l assembly r e t a i n i n g snap r i n g (Fig. 41). 4338275 1.37-1.39 .0539
(4) I n s t a l l second gear (Fig. 40). 4338276 1.46-1.48 .0579
(5) I n s t a l l two-piece t h r u s t washer, r e t a i n i n g r i n g 4338277 1.55-1.57 .0614
and a n t i - s p i n pins ( F i g . 38). Note washer and r i n g 4338278 1.64-1.66 .0650
position before i n s t a l l a t i o n (Fig. 39). 4338279 1.73-1.75 .0685
(6) I n s t a l l t h i r d speed gear (Fig. 37) and 3-4 syn- 4338280 1.82-1.84 .0720
chronizer assembly (Fig. 36). 4338281 1.91-1.93 .0756
4338282 2.00-2.02 .0791
(7) I n s t a l l snap r i n g gear set snap r i n g (Fig. 35).
4338283 2.09-2.11 .0827
4338284 2.18-2.20 .0862
CENTER SUPPORT PLATE/REVERSE IDLER
4338285 2.27-2.29 .0898
ASSEMBLY
(1) I n s t a l l countershaft gear center bearing snap J9021-100
r i n g (Fig. 52).
(2) I n s t a l l new O-rings o n reverse i d l e r shaft. T h e n Fig. 74 Countershaft Gear End Play Shim Chart
lubricate, assemble a n d i n s t a l l i d l e r gear, shaft, INPUT SHAFT INSTALLATION
bearings and spacer i n support (Fig. 51). (1) Coat mainshaft p i l o t r o l l e r bearings w i t h petro-
(3) I n s t a l l idler shaft snap r i n g (Fig. 50). l e u m j e l l y and i n s t a l l rollers i n shaft (Fig. 49). E x t r a
petroleum j e l l y can be used t o hold rollers i n place.
ADJUSTING COUNTERSHAFT GEAR END
PLAY (2) Insert i n p u t shaft i n t o f r o n t bearing bore f r o m
(1) I n s t a l l countershaft gear i n support plate ( F i g . inside case (Fig. 48).
73). (3) Seat shaft i n bore and i n s t a l l locating snap r i n g
(2) I n s t a l l support plate and gear i n case. on f r o n t bearing (Fig. 47).
(3) I n s t a l l and t i g h t e n support-to-gear case bolts (4) I n s t a l l new retainer gasket on case a n d i n s t a l l
snug b u t not to final torque. front bearing retainer ( F i g . 46). T i g h t e n r e t a i n e r
(4) I n s t a l l o r i g i n a l countershaft gear end play s h i m bolts t o 28 N-m (21 ft-lbs) torque.
and attach extension t o support and case.
(5) A t t a c h d i a l indicator t o f r o n t o f case and posi- GEAR SET AND SUPPORT PLATE ASSEMBLY
t i o n indicator plunger against countershaft gear (Fig. (1) I n s t a l l countershaft gear i n support plate ( F i g .
34).

(2) I n s t a l l mainshaft a n d gear set assembly i n sup-
port plate (Fig. 33).
(3) Seat mainshaft center bearing snap r i n g (Fig.
33).
CAUTION: T h e center bearing snap ring is cham-
fered. Be sure the chamfered side of the snap ring
is facing the first speed gear.
(4) V e r i f y gear set i n s t a l l a t i o n position (Fig. 32).
INSTALLING GEAR SET IN GEAR CASE
(1) I n s t a l l a l i g n m e n t studs i n case (Fig. 31).
(2) I n s t a l l gear set a n d extension i n gear case
(Figs. 29, 30).
(3) I n s t a l l center support plate bolts ( F i g . 28). cover on case (Fig. 4). T i g h t e n cover bolts t o 28 N»m
T i g h t e n bolts t o 54 N*m (40 ft-lbs) torque.
(4) I n s t a l l square anti-spin p i n and reverse gear
t h r u s t washer (Fig. '27).
SHIFT RAIL AND FORK INSTALLATION
(1) I n s t a l l reverse gear and needle bearings (Fig.
26).
(2) I n s t a l l shift forks (Fig. 24).
(3) I n s t a l l 3-4 shift r a i l and i n t e r l o c k plate (Fig. TRANSMISSION INSTALLATION
23).
(4) Position synchronizer i n reverse/OD shift fork.
T h e n i n s t a l l assembled components (Fig. 22).
(5) I n s t a l l reverse/OD synchronizer snap r i n g (Fig.
21).
OVERDRIVE GEAR INSTALLATION
(1) I n s t a l l mainshaft overdrive gear (Fig. 20).
(2) I n s t a l l overdrive gear t h r u s t washer a n d a n t i -
spin p i n (Fig. 19).
(3) I n s t a l l overdrive gear snap r i n g (Fig. 18).
(4) I n s t a l l overdrive countershaft gear w i t h tools C-
4982, C-4982-2, C-4982-6 and a wood block (Fig. 75).
Refer t o F i g u r e 17 for installer tool components.
Fig. 75 Installing Countershaft Overdrive Gear
MANUAL TRANSMISSION 21 - 35
(5) I n s t a l l countershaft overdrive gear snap r i n g
(Fig. 14).
FINAL ASSEMBLY
(1) I n s t a l l 1-2 shift r a i l and i n t e r l o c k plates (Fig.
13).
(2) I n s t a l l shift fork pins (Fig. 12).
(3) Seat overdrive shift r a i l a n d blocker s p r i n g
(Fig. 11).
(4) A p p l y bead o f sealer t o extension housing and
i n s t a l l housing over gears a n d o n center support
plate (Fig. 10). T i g h t e n a t t a c h i n g bolts to 54 N-m (40
ft-lbs) torque.
(5) I n s t a l l detent springs a n d bullets (Fig. 7).
(6) A p p l y bead o f sealer t o access cover and i n s t a l l
(21 ft-lbs) torque.
(7) I n s t a l l shifter assembly. T i g h t e n shifter bolts to
28 N*m (21 ft-lbs) torque.
(8) I n s t a l l backup lamp switch.
(9) I n s t a l l d r a i n plug.
(10) I n s t a l l countershaft gear O - r i n g and expansion
plug.
(1) L i g h t l y lubricate i n p u t shaft a n d f r o n t bearing
r e t a i n e r w i t h Mopar h i g h temperature grease.
(2) A l i g n i n p u t shaft w i t h clutch disc a n d slide
transmission i n t o place on housing.
(3) I n s t a l l and t i g h t e n transmission-to-clutch hous-
i n g bolts.
(4) I n s t a l l crossmember a n d insulator.
(5) I n s t a l l transfer case, i f equipped.
(6) Remove supports.
(7) I n s t a l l speedometer adapter a n d distance sen-
sor.
(8) Connect backup lamp switch wires.
(9) A l i g n and connect propeller shaft(s).
(10) Refill transmission w i t h 10W-30, A P I SG/CD
engine o i l .
(11) Lower vehicle and i n s t a l l upper p a r t o f shift
lever.
21 - 36 MANUAL TRANSMISSION
NP435 MANUAL TRANSMISSION
INDEX
Page
Component Assembly 38
Component Disassembly 38
General Information 36
Service Diagnosis . 36
GENERAL INFORMATION
The NP435, four-speed m a n u a l transmission used
for heavy service applications (Fig. 1). Second, t h i r d ,
and f o u r t h gears are helical, constant mesh gears
w i t h synchronizers. F i r s t and reverse gears are spur
type a n d n o t synchronized. The reverse idler gear is
serviced as a n assembly complete w i t h i n t e g r a l bear-
ings. T h e countershaft gear is a one-piece design.
A b a l l b e a r i n g supports t h e m a i n drive p i n i o n . A
pilot r o l l e r bearing recessed i n the m a i n drive p i n i o n
supports t h e f r o n t end of themainshaft w i t h t h e rear
end supported by a b a l l bearing.
The f r o n t synchronizer u n i t consists of a s l i d i n g
clutch gear, energizer springs, floating solid pins and
synchronizer cones. The u n i t is serviced only as a n
assembly. T h e stop rings can be serviced separately
but should be used i n sets w i t h the new floating solid
pin type synchronizer.
J902M55
Fig. 1 NP435 Manual Transmission
SERVICE DIAGNOSIS
The m a j o r i t y of transmission malfunctions are
caused by insufficient lubricant, incorrect l u b r i c a n t ,
misadjusted or damaged i n t e r n a l components, loose
a t t a c h i n g parts, or improper operation.
•
Page
Transmission Assembly . . . . . . . . . . . . . . . . . . . . . 41
Transmission Disassembly 37
Transmission Installation . . . . . . . . . . . . . . . . . . . . 42
Transmission Removal . 37
HARD SHIFTING
A l o w l u b r i c a n t level, loose or w o r n shift lever, or
loose, damaged shift housing components are com-
m o n causes of h a r d s h i f t i n g . I f h a r d s h i f t i n g is also
accompanied by gear clash, synchronizer stop r i n g s
or mainshaft clutch gear t e e t h m a y be w o r n or dam-
aged.
H a r d s h i f t i n g m a y also be caused b y a loose, or
misaligned shift housing. E i t h e r f a u l t can r e s u l t i n
component bind and h i g h shift efforts.
NOISY OPERATION
Transmission noise is most often a r e s u l t o f w o r n
or damaged components. Chipped, b r o k e n gear or
synchronizer teeth a n d b r i n n e l l e d , spalled bearings
a l l cause noise. A b n o r m a l wear and damage t o i n t e r -
n a l components i s frequently t h e end result o f insuf-
ficient lubricant, non-recommended l u b r i c a n t s , or
improper operation.
SLIPS OUT OF GEAR
Transmission disengagement m a y be caused b y
misaligned or damaged shift components, or w o r n
synchronizer clutch teeth on t h e mainshaft gears. I n -
correct assembly w i l l also contribute t o gear disen-
gagement.
LOW LUBRICANT LEVEL
Insufficient transmission l u b r i c a n t is u s u a l l y t h e
result of leaks, or inaccurate fluid level check or re-
f i l l method. Leaks w i l l be evident by t h e presence of
gear o i l around t h e leak point. I f leakage is n o t evi-
dent, t h e condition is probably t h e r e s u l t o f a n u n -
d e r f i l l condition.
I f a i r powered l u b r i c a t i o n equipment is used to fill
a transmission, be sure t h e equipment is properly
calibrated. Equipment o u t o f c a l i b r a t i o n can lead to
an u n d e r f i l l condition.
CLUTCH PROBLEMS
W o r n , damaged, or misaligned c l u t c h components
can cause difficult shifting, gear clash and noise.
 • MANUAL TRANSMISSION 21 - 37

A w o r n p i l o t b u s h i n g w i l l cause noise a n d i n p u t RETAINER BOOT

shaft m i s a l i g n m e n t . T h e result is h a r d s h i f t i n g a n d
noise.
A w o r n or damaged clutch disc, pressure plate, or
release bearing can cause h a r d s h i f t i n g a n d gear
clash.
Damaged or w o r n c l u t c h hydraulic components, or
leaks i n t h e fluid lines or cylinders w i l l cause h a r d
s h i f t i n g a n d gear clash. F a i l u r e of one o f t h e clutch
hydraulic cylinders can result i n incomplete clutch
release or engagement.
Be sure t h a t t h e c l u t c h components are a l l i n good
condition before removing t h e transmission for re-
pair.

TRANSMISSION REMOVAL
(1) Remove t h e shift lever retainer b y pressing
down, r o t a t i n g t h e retainer counterclockwise s l i g h t l y
and releasing i t (Fig. 2). Fig. 2 NP435 Gear Shift Lever Components
(2) Remove transfer case ( i f so equipped) as follows: (3) Remove cover screws. Second screw f r o m front
(3) Remove 4 bolts attaching s k i d plate rear cross- on each side is shouldered w i t h s p l i t washer for i n -
member t o underside o f frame, i f so equipped. s t a l l a t i o n alignment.
(4) Remove bolts attaching front end o f s k i d plate (4) W h i l e l i f t i n g cover, rotate s l i g h t l y counterclock-
to transmission crossmember. Remove s k i d plate. wise t o provide clearance to shift forks a n d remove
(5) Disconnect speedometer cable.
cover (Fig. 3).
(6) Disconnect front and rear output shafts (support
(5) Remove extension housing.
each shaft, do n o t allow shafts to hang).
(7) Disconnect shift rods a t transfer case.
(8) W i t h suitable jack, support transfer case. Be
sure transfer case is safely secured i n removing de-
vice.
(9) Remove extension to transfer case m o u n t i n g
bolts.
(10) Move transfer case rearward t o disengage
front i n p u t spline.
(11) Lower transfer case assembly and remove from
under vehicle.
(12) Disconnect back-up lamp switch lead.
(13) I n s t a l l engine support f i x t u r e C-3487A, w i t h
adapter tool DD-1279 f i r m l y over frame r a i l s . Be
sure support ends are u p against underside o f o i l p a n
flange.
(14) Support transmission w i t h a suitable jack.
(15) Remove transmission crossmember. Fig. 3 Transmission Cover Assembly
(16) Remove transmission to clutch housing bolts.
SYNCHRONIZER END PLAY CHECK
Slide transmission t o w a r d rear u n t i l drive p i n i o n
Measure end play between synchronizer outer stop
shaft clears clutch disc, before lowering transmission.
r i n g a n d t h i r d speed gear (Fig. 4). Do t h i s before re-
(17) Lower transmission and remove from under
m o v i n g d r i v e p i n i o n and mainshaft. Use t w o feeler
vehicle. Thoroughly clean exterior of u n i t .
gauges as shown.
TRANSMISSION DISASSEMBLY Correct end play is 1.27 to 1.78 m m (.050 t o .070
inch). Record end play so t h a t correction shims can
be i n s t a l l e d d u r i n g reassembly. T h i c k or t h i n shims
SHIFT COVER AND PARKING BRAKE are available as required.
(1) M o u n t transmission i n holding f i x t u r e .
(2) Shift gears i n t o n e u t r a l by replacing gear shift DRIVE PINION
lever temporarily, or using bar or screwdriver. (1) Remove drive pinion bearing retainer.
21 - 38 MANUAL TRANSMISSION
FEELER
RH196
Fig. 4 Measuring Synchronizer End Play
(2) Rotate t h e drive p i n i o n gear to a l i g n space i n
pinion gear c l u t c h t e e t h w i t h countershaft drive gear
teeth. Remove drive p i n i o n gear a n d b a l l bearing
from transmission. P u l l on p i n i o n shaft a n d tap face
of case w i t h brass h a m m e r to remove.
(3) Remove snap r i n g , washer, a n d p i l o t roller
bearings from recess i n drive p i n i o n gear.
MAINSHAFT
(1) Place a brass d r i f t i n front center o f mainshaft
and drive mainshaft t o rear.
(2) When mainshaft rear bearing has cleared case
remove rear bearing w i t h a suitable puller.
(3) Move mainshaft assembly to rear and t i l t front
of mainshaft up.
(4) Remove roller type t h r u s t bearing.
( 5 ) Remove synchronizer and stop rings separately.
(6) Remove mainshaft assembly.
REVERSE IDLER GEAR
(1) Remove reverse idler lock screw and lock plate.
(2) W i t h brass d r i f t held at angle, drive idler shaft
to rear and p u l l shaft.
( 3 ) L i f t reverse i d l e r gear f r o m case.
COUNTERSHAFT GEAR
(1) I f excessive side play a n d end play are n o t
found and teeth are n o t badly w o r n or chipped, coun-
tershaft gear should n o t require replacement. How-
ever, i f gear is damaged, remove as follows.
(2) Remove bearing retainer a t rear end o f counter-
shaft. The roller bearing assembly a t rear end o f
shaft remains w i t h retainer.
: ^
(3) T i l t countershaft gear assembly and w o r k out o f
case.
(4) U s i n g a suitable driver, remove front bearings
from case.
COMPONENT DISASSEMBLY (Fig. 5)
MAINSHAFT
(1) Remove clutch gear snap r i n g .
(2) Remove clutch gear, synchronizer outer stop
r i n g t o t h i r d speed gear shim(s), a n d t h i r d speed
gear. .
(3) Remove special split lock r i n g w i t h t w o screw-
drivers. Remove second speed gear and synchronizer.
(4) Remove first and reverse s l i d i n g gear.
REVERSE IDLER GEAR
(1) Do not disassemble. I f no longer serviceable re-
place as a n assembly complete w i t h i n t e g r a l bear-
ings.
COVER AND SHIFT FORKS (FIG. 6)
(1) Cover a n d shift forks should be disassembled
only i f r a i l s , poppets, interlock plungers, springs,
shift forks, or cover itself need replacing.
(2) Remove r o l l p i n from first a n d second speed
shift fork. Remove r o l l p i n f r o m gate i n t h e same
manner. A square type or closely w o u n d s p i r a l easy-
out mounted i n a tap handle i s preferable for t h i s op-
eration.
(3) Push shift r a i l out t h r o u g h the front t o force ex-
pansion p l u g o u t of cover. Cover detent b a l l access
hole i n cover w i t h cloth to prevent b a l l a n d spring
from f l y i n g as r a i l clears hole. Remove r a i l , fork, and
gate.
(4) Remove t h i r d a n d f o u r t h speed r a i l s i n t h e
same manner, then remove reverse r a i l .
( 5 ) Compress reverse gear plunger and remove re-
t a i n i n g clip. Remove plunger and spring from gate.
DRIVE PINION AND BEARING RETAINER
(1) Remove b a l l bearing f r o m p i n i o n shaft w i t h
suitable tool.
(2) Remove snap r i n g , washer and p i l o t rollers from
gear bore ( i f not previously removed).
(3) Remove pinion shaft seal, w i t h suitable seal re-
mover.
COMPONENT ASSEMBLY (Fig. 5)
Use new expansion plugs, gaskets and seals d u r i n g
overhaul. Lubricate a l l parts w i t h transmission l u -
b r i c a n t before assembly. Use petroleum j e l l y to hold
parts i n place d u r i n g assembly i n s t a l l a t i o n .
 MANUAL TRANSMISSION 21 - 39

C
OVE
R GASKET

POWERT A
KEO
-FF
C
OVE
RA N
DG ASK
ET
S
ECO
NDS
-P
EED
GE
AR
DRIVE P
I
N I
O N
B
EAR N
IG R E T
AN
IE
R

L
OCK
WAS
HER

L
OCKP
LAT
E

B
RON
Z EB US
HN
IG
C
OUN
TERS
HAF
T U
SED IN P
RODU
CTO
N
T
HRU
ST GEA
R
W
ASH
ER
RN811

Fig, 5 NP435 Transmission Components

21 - 40 MANUAL TRANSMISSION •

CAP RETAINER

EXPANSION
PLUGS

THIRD AND FOURTH

SPEED SHIFT FORK

RETAINING CLIP

FORK SHOES
DETENT BALL
AND SPRING RN807

Fig. 6 Shift Cover Components

 • MANUAL TRANSMISSION
MAINSHAFT
(1) Place mainshaft i n soft-jawed vise w i t h rear end
up.
(2) I n s t a l l first and reverse speed gear. Be sure the
two spline springs ( i f used) a r e i n place inside gear
as i t is placed on shaft.
(3) M o u n t mainshaft i n vise w i t h forward end o f
shaft facing up. Use protective j a w s t o avoid damag-
i n g shaft surfaces.
(4) I n s t a l l second gear synchronizer s p r i n g and syn-
chronizer on gear. Secure w i t h snap ring m a k i n g
sure t h a t snap r i n g tangs are away f r o m gear.
(5) Slide second speed gear onto f r o n t o f o u t p u t
shaft m a k i n g sure t h a t synchronizer is t o w a r d rear.
Secure gear t o shaft w i t h two-piece lock r i n g . I n s t a l l
t h i r d speed gear.
(6) I n s t a l l shim(s) between t h i r d speed gear and
t h i r d and f o u r t h speed synchronizer stop r i n g . Refer
to end play measurement a t disassembly to deter-
m i n e s h i m thickness needed for correct end play of
1.27 - 1.78 m m (.050 to .070 inch). Exact determina-
t i o n of end play m u s t be made after complete assem-
b l y o f mainshaft and m a i n d r i v e p i n i o n is installed
i n the transmission case.
REVERSE IDLER GEAR
No gear assembly required. I f no longer service-
able, replace as a n assembly complete w i t h i n t e g r a l
bearings.
DRIVE PINION AND BEARING RETAINER
(1) Coat roller bearings w i t h petroleum j e l l y (to
hold rollers i n place) and i n s e r t i n pocket o f drive
p i n i o n gear.
(2) I n s t a l l washer and snap r i n g .
(3) Press a new o i l seal i n t o place i n bearing re-
tainer. Make sure l i p of seal i s t o w a r d m o u n t i n g sur-
face (rearward).
COVER AND SHIFT FORKS (FIG. 6)
(1) Assemble s p r i n g on reverse gear plunger and
hold i t i n reverse shift gate. Compress i t i n gate and
i n s t a l l r e t a i n i n g clip.
(2) Enter reverse shift r a i l i n cover and place de-
t e n t spring and b a l l i n position. Depress b a l l a n d
slide r a i l over i t .
(3) I n s t a l l gate and fork on r a i l . I n s t a l l a new r o l l
p i n i n gate and i n fork.
(4) Place reverse fork i n n e u t r a l position.
(5) I n s t a l l the two interlock plungers i n t h e i r bores.
(6) Insert the interlock p i n i n t h e t h i r d and f o u r t h
speed shift r a i l . I n s t a l l r a i l i n t h e same manner as
reverse shift r a i l .
(7) I n s t a l l first and second speed shift r a i l i n the
same manner m a k i n g sure t h e i n t e r l o c k plunger is
i n place.
21 - 41
(8) Check interlocks b y s h i f t i n g reverse shift r a i l
into reverse position. I t should n o t be possible t o
shift the other shift r a i l s w h e n t h i s r a i l is shifted.
(9) I f shift lever is t o be installed a t this point l u -
bricate spherical b a l l seat and place cap i n place.
(10) I n s t a l l back-up lamp switch.
(11) I n s t a l l n e w expansion plugs i n bores o f r a i l
holes.
(12) I n s t a l l r a i l interlock hole plug.
TRANSMISSION ASSEMBLY
COUNTERSHAFT
(1) Press front roller bearing into case u n t i l cage is
flush w i t h front of case. Lubricate roller bearings
w i t h petroleum j e l l y .
(2) Place transmission w i t h front of case facing
down. I f uncaged bearings are reused, hold loose r o l l -
ers i n place i n cap w i t h l i g h t f i l m of grease (not re-
quired w i t h caged type).
(3) Lower countershaft assembly into case placing
t h r u s t washer tangs i n slots i n case, and i n s e r t i n g
front end of shaft into bearing.
(4) Place roller t h r u s t bearing and race on rear end
of countershaft, h o l d i n g i n place w i t h l i g h t coating of
grease.
(5) W h i l e holding gear assembly i n alignment i n -
stall rear bearing retainer gasket, retainer and bear-
i n g assembly. I n s t a l l and t i g h t e n cap screws.
REVERSE IDLER ASSEMBLY
(1) Position reverse gear and bearing assembly i n
case.
(2) A l i g n idler shaft so lock plate groove i n shaft is
i n proper alignment t o i n s t a l l lock plate.
(3) Tap shaft into case far enough to start reverse
gear.
(4) W h i l e holding gear i n position, t a p shaft
t h r o u g h case and gear.
(5) I n s t a l l lock plate, washer, and cap screw.
(6) M a k e sure gear t u r n s freely on shaft.
MAINSHAFT AND DRIVE PINION
(1) Lower rear end o f pre-assembled mainshaft into
case h o l d i n g first speed gear on shaft and maneuver
shaft t h r o u g h rear bearing opening.
(2) W i t h shaft assembly moved to rear of case, be
sure t h i r d and f o u r t h speed synchronizer and prese-
lected shims r e m a i n i n position.
(3) I n s t a l l roller type t h r u s t bearing.
(4) Place a wooden block between front of case and
front o f mainshaft.
(5) I n s t a l l rear bearing on mainshaft by carefully
d r i v i n g bearing onto shaft and into case (snap r i n g
flush against case) using a suitable sleeve against i n -
ner race o f bearing.
21 - 42 MANUAL TRANSMISSION
(6) I n s t a l l d r i v e p i n i o n a n d b a l l bearing assembly
m a k i n g sure p i l o t rollers r e m a i n i n place.
(7) I n s t a l l rear bearing r e t a i n e r and gasket.
(8) I n s t a l l drive p i n i o n b e a r i n g retainer w i t h gas-
ket.
(9) Check synchronizer end play after a l l mainshaft
components are installed a n d tightened. Two sets o f
equal feeler gauges are needed t o check end play
(Fig. 3). E n d play should be 1.27 - 1.78 m m (.050 t o
.070 inch). Keep gauges as close t o both sides o f the
mainshaft as possible for best results. I f necessary,
disassemble mainshaft and change s h i m thickness.
(10) Shift gears and/or synchronizer i n t o a l l speed
positions and check for free r o t a t i o n .
(11) Lubricate transmission parts w i t h gear o i l be-
fore i n s t a l l i n g cover.
(12) Move transmission gears i n t o n e u t r a l position.
(13) Lower cover w i t h n e w gasket o n case, over
transmission.
(14) Carefully engage forks i n t o proper gears and
lower cover i n t o place.
(15) I n s t a l l one shouldered a l i g n m e n t screw and
split washer i n each second-from-front hole o n each
side o f cover and test gears for free r o t a t i o n by shift-
i n g gears t h r o u g h cover tower w i t h long screwdriver.
(16) I n s t a l l r e m a i n i n g cover screws.
•
TRANSMISSION INSTALLATION
(1) Lubricate t h e p i l o t b u s h i n g w i t h Mopar h i g h
temperature wheel b e a r i n g grease.
(2) M o u n t transmission o n suitable j a c k and slide
assembly under vehicle.
(3) Raise transmission u n t i l d r i v e p i n i o n i s cen-
tered i n clutch housing bore.
(4) R o l l transmission slowly f o r w a r d u n t i l p i n i o n
shaft enters c l u t c h disc. T u r n p i n i o n shaft u n t i l
splines are aligned, t h e n w o r k transmission forward
u n t i l seated against c l u t c h housing. D o n o t allow
transmission t o h a n g after p i n i o n shaft has entered
the clutch disc.
(5) I n s t a l l transmission t o c l u t c h housing bolts and
t i g h t e n t o 142 Nnn (105 ft-lbs).
(6) I n s t a l l transmission rear m o u n t assembly o n
crossmember.
(7) I n s t a l l crossmember.
(8) Remove engine support fixture a n d disengage
hooks from t h e frame side r a i l s .
(9) I n s t a l l shift lever.
(10) I n s t a l l transfer case i f equipped.
(11) F i l l transmission w i t h required l u b r i c a n t .
(12) Road test vehicle t o make sure transmission
shifts smoothly a n d operates quietly.
 • AUTOMATIC TRANSMISSION 21 - 43

A-998/999/727 AUTOMATIC TRANSMISSION

GENERAL INFORMATION

INDEX
Page Page
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . 48 Transmission Controls And Components . . . . . . . . 47
Recommended Fluid 47 Transmission Identification 47
Torque Converter . . . 43 Wide Ratio Planetary Gears 43
Transmission Application . 43

TRANSMISSION APPLICATION The converter i m p e l l e r is connected to the engine

Chrysler A998/999 a n d A-727, three-speed auto-
matic transmissions are used i n A D models. A l l are
f u l l y automatic, h y d r a u l i c a l l y operated units w i t h a
compound planetary gear system (Figs. 1 and 2). The
A-998/999 transmission i s used for 3.9L and 5.2L ap-
plications. The A-727 is used for 5.9L applications.
crankshaft t h r o u g h the front cover w h i c h is welded
to t h e impeller. The t u r b i n e is splined to the t r a n s -
mission i n p u t shaft a n d the stator is splined to t h e
transmission reaction shaft.
The torque converter is a welded assembly and is
not a repairable component. The converter is serviced
as a n assembly only.

TORQUE CONVERTER WIDE RATIO PLANETARY GEARS

A three element torque converter is used. A lockup A wide r a t i o planetary gear set is used i n A-998/
torque converter is used w i t h A-998/999 transmis- 999 transmissions (Fig. 3). The wide ratio gears pro-
sions. A-727 transmissions are equipped w i t h a non- vide a 2.74:1 f i r s t gear and a 1.54:1 second gear.
lockup converter. T h i r d gear i s direct w i t h r a t i o of 1.00:1.
 I

45*
FRONT PLANETARY GEAR SET

FLEXIBLE DRIVE PLATE

PR225

Fig. 1 Automatic Transmission—A-998/999)

 •

IMPELLER

Fig. 2 Automatic Transmission—A-727 P R 2 2 6

cn
 DRIVING SHELL

#4

#6 THRUST

WASHER BY150

Fig. 3 Wide Ratio Gear Set-A-998/999

 • AUTOMATIC TRANSMISSION
RECOMMENDED FLUID
Recommended fluid for a l l Chrysler automatic
transmissions i s Mopar A T F Plus, Type 7176, or Mo-
par D e x r o n II™.
Mercon™ transmission fluid should only be used for
topping off the transmission fluid level d u r i n g a nor-
m a l maintenance check. I t i s not recommended for
r e f i l l i n g after scheduled maintenance o r after over-
haul.
TRANSMISSION IDENTIFICATION
The transmission part/identification numbers are
stamped on the left side of the case j u s t above the oil
pan gasket surface. Refer t o t h i s i n f o r m a t i o n when
ordering replacement parts for any Loadflite trans-
mission.
TRANSMISSION CONTROLS AND COMPONENTS
The transmission h y d r a u l i c control system provides
f u l l y automatic operation. T h e system performs five
basic functions, w h i c h are: pressure supply, pressure
r e g u l a t i o n , flow control, clutch/band application, and
lubrication.
Pressure Supply
The o i l p u m p develops fluid pressure for clutch/
band application and for lubrication. T h e pump is
d r i v e n b y the torque converter w h i c h is attached to
the engine crankshaft b y the driveplate.
Pressure Regulation
The pressure regulator valve maintains transmis-
sion l i n e pressure. The amount o f pressure developed
is controlled b y t h r o t t l e pressure w h i c h is dependent
on t h e degree o f t h r o t t l e opening. T h e regulator
valve i s located i n t h e valve body. T h e governor
valve i s operated b y the transmission o u t p u t shaft.
The t h r o t t l e valve determines line pressure and
shift speed. Governor pressure increases i n propor-
t i o n t o vehicle speed.
The t h r o t t l e valve also controls upshift and down-
shift speeds b y r e g u l a t i n g pressure i n conjunction
w i t h t h r o t t l e position.
Flow Control And Lubrication
The m a n u a l valve is operated by the gearshift l i n k -
age a n d provides the operating range selected by the
driver.
The 1-2 shift valve provides automatic 1-2 or 2-1
shifts a n d the 2-3 shift valve provides automatic 2-3
or 3-2 shifts. The k i c k d o w n valve provides forced 3-2
or 3-1 downshifts depending on vehicle speed. Down-
shifts occur w h e n t h e t h r o t t l e is opened beyond
downshift detent position w h i c h is j u s t before wide
open t h r o t t l e .
21 - 47
The 2-3 valve t h r o t t l e pressure p l u g provides 3-2
downshifts w i t h v a r y i n g t h r o t t l e openings a n d de-
pending on vehicle speed. The 1-2 shift control valve
t r a n s m i t s 1-2 s h i f t pressure t o the accumulator pis-
t o n to control k i c k d o w n band capacity on 1-2 upshifts
a n d 3-2 downshifts.
The l i m i t valve determines m a x i m u m speed a t
w h i c h a 3-2 p a r t t h r o t t l e k i c k d o w n can be made.
Some transmissions do n o t have the l i m i t v a l v e and
m a x i m u m speed for a 3-2 k i c k d o w n is a t t h e detent
position.
The shuttle valve has two functions. F i r s t i s fast
front band release and smooth engagement d i n i n g
lift-foot 2-3 upshifts. The second is t o regulate front
c l u t c h and band application d u r i n g 3-2 downshifts.
The lockup valve automatically applies t h e con-
verter lockup c l u t c h w h e n supplied w i t h l i n e pres-
sure t h r o u g h t h e lockup solenoid. The solenoid i s
controlled b y the engine electronics t h r o u g h a n elec-
t r i c a l connector a t the rear of the transmission case.
Electronic control o f torque converter lockup i n -
cludes converter u n l o c k i n g a t closed t h r o t t l e d u r i n g
w a r m u p and d u r i n g p a r t t h r o t t l e acceleration. T h e
non-lockup A-998 used i n California has a threaded
p l u g i n the rear o f t h e transmission case i n place o f
t h e lockup w i r i n g connector.
The f a i l safe v a l v e restricts feed t o the converter
lockup clutch i f f r o n t clutch pressure drops. I t per-
m i t s lockup only i n direct (third) gear and provides
fast lockup release d u r i n g a kickdown.
The switch valve directs apply fluid pressure to the
lockup clutch i n one position and releases i t i n the
opposite position. I t also directs o i l to the cooling and
lube circuits. The switch valve regulates o i l pressure
to t h e torque converter b y l i m i t i n g m a x i m u m o i l
pressure to 130 psi.
Clutch/Band Application
The front/rear c l u t c h pistons and servo pistons are
actuated b y l i n e pressure. When line pressure is r e -
moved, the pistons are released b y spring tension.
O n 2-3 upshifts, the front servo piston i s released
by s p r i n g tension and hydraulic pressure. T h e accu-
m u l a t o r controls h y d r a u l i c pressure on the apply side
of the front servo d u r i n g 1-2 upshifts a t a l l t h r o t t l e
openings.
Gearshift And Parking Lock Controls
The gearshift lever provides six operating posi-
tions: P a r k (P), Reverse (R), N e u t r a l (N), a n d t h e D ,
2 and 1 forward drive ranges.
1 position provides overrun b r a k i n g w h e n t h e
t h r o t t l e is released. However, upshifts are not pro-
vided i n 1 position. 1-2 up shifts w i l l occur i n 2 posi-
t i o n b u t no 2-3 upshift w i l l take place. D position
provides 1-2, 2-3 upshifts and 3-2 and 3-1 downshifts.
21 - 48 AUTOMATIC TRANSMISSION
A n e u t r a l switch controls engine s t a r t i n g . T h e
switch is designed t o allow engine starts only i n
P a r k o r N e u t r a l positions.
The transmission p a r k i n g lock mechanism i s en-
gaged w h e n t h e shift lever i s moved i n t o t h e P a r k
detent. T h e mechanism consists o f a p a w l t h a t en-
gages a gear on the o u t p u t shaft.
OPERATING INSTRUCTIONS
The transmission w i l l automatically upshift a n d
downshift. T h e q u a l i t y o f shifts is i m p o r t a n t . A l l
shifts should be smooth and positive w i t h o u t engine
flare or r u n a w a y .
Gearshift And Parking Lock Controls
The c o l u m n mounted gearshift lever has s i x lever
positions w h i c h are: P (Park); R (Reverse); N (Neu-
t r a l ) ; D (Drive); 2 (Second Gear); and 1 (First Gear).
The p a r k i n g lock is engaged by m o v i n g the shift le-
ver past a gate into the P (Park) position. D o n o t
apply t h e p a r k i n g lock u n t i l t h e vehicle has
stopped. Otherwise a severe r a t c h e t i n g noise
w i l l occur.
Starting The Engine
The engine w i l l s t a r t w i t h the shift lever i n P a r k
or N e u t r a l positions. A s a safety precaution, apply
the service o r p a r k i n g brakes w h e n s t a r t i n g i n Neu-
tral. I f the engine w i l l not start, d o not attempt
•
to start i t b y pushing o r t o w i n g the vehicle. T h e
transmission w i l l not permit engine s t a r t i n g i n
this manner.
Mountain Driving
T r a i l e r t o w i n g or p u l l i n g heavy loads i n m o u n t a i n -
ous t e r r a i n imposes severe loads on the transmission,
torque converter a n d fluid. Shift t h e transmission
i n t o 2 or 1 range o n steep upgrades w h i c h require
heavy t h r o t t l e application for 1/2 m i l e or more. T h i s
w i l l reduce the possibility o f overheating t h e t r a n s -
mission and torque converter.
Vehicle Towing
I f t h e transmission is inoperative, either t o w t h e
vehicle w i t h the rear end raised, or remove t h e pro-
peller shaft and flat-tow the vehicle.
I f t h e transmission is operating properly, shift the
transmission i n t o N e u t r a l . The vehicle can t h e n be
towed w i t h the f r o n t or rear end raised, or i t can be
flat-towed.
T o w i n g speed should not exceed 30 m p h (48 km/h).
I f the vehicle must be towed f o r a n extended
distance, either t o w t h e vehicle w i t h t h e rear
end raised, o r remove t h e propeller shaft a n d
flat-tow the vehicle. Since t r a n s m i s s i o n l u b r i c a -
t i o n o n l y occurs w h e n the engine is r u n n i n g , i t is
good practice t o always t o w a vehicle w i t h t h e
rear e n d raised o r w i t h the propeller shaft re-
moved.
 • AUTOMATIC TRANSMISSION
DIAGNOSIS AND T E S T P R O C E D U R E S
INDEX
Page
Air Pressure Test . . . . . . . . . . . . . .
f 53
Analyzing the Road Test 50
Checking Fluid Level And Condition . . . . . . . . . . . 49
Converter Housing Fluid Leak Diagnosis . . . . . . . . 54
Converter Stall Test 52
Diagnosis Guides And Charts . . . . . . . . . . . . . . . . 57
Gearshift Linkage 50
GENERAL INFORMATION
A u t o m a t i c transmission problems can be a result of
poor engine performance, incorrect fluid level, incor-
rect linkage adjustment, band o r h y d r a u l i c control
pressure adjustments, h y d r a u l i c system malfunctions
or mechanical component malfunctions.
Begin diagnosis by checking t h e easily accessible
items such as fluid lever and condition and linkage
adjustments. A road test w i l l determine i f f u r t h e r d i -
agnosis is necessary.
Procedures o u t l i n e d i n t h i s section should be per-
formed i n t h e f o l l o w i n g sequence t o realize t h e most
accurate results:
• P r e l i m i n a r y diagnosis
• F l u i d Level a n d condition
• Linkage Adjustment
• Road test
• S t a l l test
• H y d r a u l i c pressure test
• A i r pressure tests
• Leak Tests
• Analyze test results and consult diagnosis charts
PRELIMINARY DIAGNOSIS
Two basic procedures are required. One procedure
for vehicles t h a t are driveable a n d a n alternate pro-
cedure for disabled vehicles ( w i l l n o t back u p or
move forward).
Vehicle Is Driveable
(1) Check fluid level and condition.
(2) Adjust t h r o t t l e and gearshift linkage i f com-
p l a i n t was based on delayed, erratic, or h a r s h shifts.
(3) Road test and note transmission operating char-
acteristics.
(4) Perform s t a l l test i f complaint is based on slug-
gish acceleration or i f abnormal t h r o t t l e opening is
needed to m a i n t a i n n o r m a l spieeds w i t h a properly
tuned engine.
(5) Perform h y d r a u l i c pressure tests.
(6) Perform a i r pressure test t o check clutch-band
Operation.
21 - 49
Page
General Information 49
Hydraulic Pressure Test . 51
Lockup Torque Converter Diagnosis Chart . . . . . . 60
Preliminary Diagnosis . . . . . . . . . . . . . . . . . . . . . . 49
Road Test 50
Throttle Valve Linkage 50
Transmission Diagnosis Chart 59
Vehicle Is Disabled
(1) Check fluid level and condition.
(2) Check for broken, disconnected t h r o t t l e l i n k a g e .
(3) Check for cracked, l e a k i n g cooler lines, or loose,
missing pressure port plugs.
(4) Raise vehicle, s t a r t engine, shift transmission
i n t o gear and note following:
(a) I f propeller shafts t u r n b u t wheels do not,
problem is w i t h differential or axle shafts.
(b) I f propeller shafts do not t u r n and t r a n s m i s -
sion i s noisy, stop engine. Remove o i l pan, a n d
check for debris. I f p a n is clear, remove t r a n s m i s -
sion and check for damaged drive plate, converter,
o i l p u m p or i n p u t shaft.
(c) I f propeller shafts do not t u r n and t r a n s m i s -
sion is not noisy, perform h y d r a u l i c pressure test t o
determine i f problem is a h y d r a u l i c or mechanical.
CHECKING FLUID LEVEL AND CONDITION
(1) Place t h e vehicle on a level surface. This is i m -
p o r t a n t for a n accurate reading.
(2) To avoid false readings, w h i c h could produce
under or over fill condition, do not check level u n t i l
fluid is a t n o r m a l operating temperature of 180°F.
(3) Shift transmission i n t o N e u t r a l .
(4) A p p l y p a r k i n g brakes.
(5) Shift t h e transmission m o m e n t a r i l y i n t o a l l
gear ranges. Then shift t h e transmission back t o
Neutral.
(6) Clean the top o f the filler tube and dipstick t o
keep d i r t f r o m e n t e r i n g the tube.
(7) Check the f l u i d level. Correct level is as follows:
(a) I f fluid is a t n o r m a l operating temperature,
t h e correct level is between the " M a x i m u m Level
H o t " and " A d d " m a r k s (crosshatched area) on the
dipstick.
(b) I f the fluid is only w a r m (85 to 125°F), t h e
correct level is between the two dimples on the dip-
stick.
(8) I f the fluid level is low, add only enough fluid t o
correct the level.
 21 - SO AUTOMATIC TRANSMISSION •
CAUTION: Do not overfill the tranmission. Overfill- ROAD TEST
ing may cause leakage out the pump vent which
can be mistaken for a pump seal leak. In addition, Before road testing, be sure the fluid level a n d a l l
overfilling will also cause fluid aeration and foam- l i n k a g e adjustments have been checked a n d adjusted
ing as the excess fluid is picked up and churned by i f necessary.
the gear train. This will reduce the life of the fluid Observe engine performance d u r i n g t h e road test.
significantly. A poorly t u n e d engine w i l l n o t allow a n accurate
analysis o f transmission operation.
(9) Check fluid condition. F l u i d should be d a r k t o Operate t h e transmission i n a l l gear ranges. Check
l i g h t r e d i n color a n d free of d i r t or debris. for slippage a n d shift variations. Note w h e t h e r t h e
(10) I f fluid i s discolored or smells b u r n e d b u t shifts are h a r s h , spongy, delayed, early, o r i f p a r t
transmission operation was O K , flush cooler a n d t h r o t t l e downshifts are sensitive.
lines a n d change fluid a n d filter. Then road test W a t c h closely for slippage or engine flare w h i c h
again t o c o n f i r m proper operation. u s u a l l y indicates clutch, band or o v e r r u n n i n g c l u t c h
problems. I f t h e condition is advanced, a n o v e r h a u l
(11) I f fluid is black or d a r k b r o w n , burned/turned
m a y be necessary to restore n o r m a l operation.
to sludge, contains extensive a m o u n t of metal or fric-
A s l i p p i n g clutch or band can often be d e t e r m i n e d
t i o n m a t e r i a l particles, transmission w i l l probably
by comparing w h i c h i n t e r n a l u n i t s are applied i n t h e
need o v e r h a u l ; Especially i f problems were evident
various gear ranges. T h e C l u t c h and B a n d A p p l i c a -
d u r i n g road test a n d p r e l i m i n a r y diagnosis.
t i o n c h a r t (Fig. 1) provides a basis for a n a l y z i n g r o a d
test results.
Effects Of Incorrect Fluid Level
A l o w fluid level allows t h e pump t o take i n a i r Gearshift Lever Position
along w i t h t h e fluid. A i r i n t h e fluid w i l l cause fluid P
DRIVE R N D 2 1
pressures t o be low a n d develop slower t h a n n o r m a l .
ELEMENTS 1 2 3 1 2
I f t h e transmission is overfilled, t h e gears c h u r n
t h e fluid i n t o foam, a e r a t i n g the fluid and causing FRONT • •
t h e same conditions t h a t occur w i t h a low level. CLUTCH
I n either case, a i r bubbles cause fluid overheating,
FRONT
oxidation a n d v a r n i s h b u i l d u p w h i c h interferes w i t h BAND • •
valve, c l u t c h a n d servo operation. Foaming also (KICKDOWN)
causes fluid expansion w h i c h can result i n fluid over- REAR
flow f r o m t h e transmission vent or f i l l tube. F l u i d CLUTCH
overflow can easily be m i s t a k e n for a leak i f inspec-
REAR
t i o n is not careful. BAND • •
(LOW-REV.)
THROTTLE VALVE LINKAGE OVER-
RUNNING • • •
T h r o t t l e valve l i n k a g e adjustment is i m p o r t a n t to CLUTCH
proper operation. T h i s adjustment positions t h e
t h r o t t l e valve w h i c h controls shift speed, q u a l i t y and J9021-33
p a r t t h r o t t l e downshift sensitivity. I f linkage s e t t i n g
is too short, early shifts and slippage between shifts Fig. 1 Clutch And Band Application Chart
may occur. I f the s e t t i n g is too long, shifts may be ANALYZING THE ROAD TEST
delayed a n d p a r t t h r o t t l e downshifts m a y be very
sensitive. Refer t o t h e In-Vehicle Service section for Refer t o t h e C l u t c h and Band A p p l i c a t i o n c h a r t
adjustment procedure. (Fig. 1) and note w h i c h elements are i n use i n t h e
various gear ranges.
GEARSHIFT LINKAGE The rear c l u t c h is applied i n a l l forward ranges (D,
2, 1). The o v e r r u n n i n g clutch is applied i n first gear
Gearshift l i n k a g e adjustment is i m p o r t a n t because (D and 2 range only).
i t positions the valve body m a n u a l valve. Incorrect The rear band is applied i n 1 and R range only.
adjustment w i l l cause creeping i n N e u t r a l , prema- For example: I f slippage occurs i n f i r s t gear i n D
t u r e c l u t c h wear, delayed engagement i n any gear, or a n d 2 range b u t n o t i n 1 range, t h e o v e r r u n n i n g
a no-start i n P a r k or N e u t r a l . clutch is slipping. S i m i l a r l y , i f slippage occurs i n a n y
Proper operation o f the n e u t r a l switch w i l l provide t w o f o r w a r d gears, the rear clutch is slipping.
a q u i c k check of l i n k a g e adjustment. Refer to the I n - A p p l y i n g the same method o f analysis, note t h a t
Vehicle Service section for adjustment procedure. both clutches are applied i n D range t h i r d gear only.
 • AUTOMATIC TRANSMISSION 21 - 51

I f the transmission slips i n t h i r d gear, either t h e

front clutch or t h e rear clutch i s slipping. B y select-
i n g another gear w h i c h does n o t use one of these
units, t h e s l i p p i n g c l u t c h can be determined. For ex-
ample, i f t h e transmission also slips i n Reverse, the
front clutch is s l i p p i n g . I f the transmission does n o t
slip i n Reverse, t h e r e a r clutch is slipping.
This process o f e l i m i n a t i o n can be used to deter-
mine t h e s l i p p i n g u n i t a n d check operation. Proper
use of the C l u t c h a n d B a n d A p p l i c a t i o n C h a r t is t h e
key.
A l t h o u g h road test analysis w i l l help determine
the s l i p p i n g u n i t , t h e actual cause of a malfunction
usually cannot be determined u n t i l h y d r a u l i c and a i r
pressure tests are performed. Practically a n y condi-
t i o n can be caused b y l e a k i n g hydraulic circuits or APPLY PORT FRONT SERVO RELEASE PORT RH250

sticking valves.
U n l e s s t h e c o n d i t i o n i s o b v i o u s , s u c h as n o Fig. 2 Pressure Test Ports At Side Of Transmission
d r i v e i n D r a n g e , first g e a r o n l y , t h e t r a n s m i s - LUBRICATION
sion s h o u l d n o t b e disassembled u n t i l h y d r a u l i c PRESSURE PORT
(COOLER RETURN G O V E R N O R
a n d a i r pressure tests have been p e r f o r m e d .

HYDRAULIC PRESSURE TEST

H y d r a u l i c test pressures range f r o m a l o w of one
psi (6.895 k P a ) governor pressure, to 300 p s i (2068
kPa) a t t h e rear servo pressure port i n reverse. Use
100 psi test gauge C-3292 to check pressure a t t h e
accumulator, f r o n t servo, governor a n d fluid cooler
line. Use 300 p s i gauge C-3293 t o check pressure a t
the rear servo.
Fig. 3 Pressure Test Ports At Rear Of Transmission
PRESSURE TEST PORT LOCATIONS
(1) Connect test gauges to t h e l i n e pressure a n d
There are pressure test ports a t t h e accumulator,
rear servo ports (Figs. 2, 3). B e s u r e t h e 300 p s i
front servo, rear servo and governor.
gauge is connected t o t h e rear servo port.
Line pressure i s checked a t t h e accumulator port
(2) Disconnect the t h r o t t l e and gearshift rods a t t h e
on the r i g h t side o f t h e case (Fig. 2). The front servo
transmission.
release pressure p o r t is a t t h e r i g h t side o f the case
(3) S t a r t a n d r u n t h e engine a t 1000 r p m .
j u s t behind t h e filler tube opening (Fig. 2).
(4) Move t h e valve body selector lever a l l t h e w a y
The rear servo pressure port is a t t h e r i g h t rear of
f o r w a r d i n t o 1 range.
the transmission case (Fig. 3). The governor pressure
(5) Read pressures on both gauges as t h e transmis-
port is a t t h e left side of case a t t h e transmission
sion t h r o t t l e lever is i s moved f r o m f u l l forward t o
rear (Fig. 3).
f u l l r e a r w a r d position.
PRESSURE TEST PROCEDURE (6) L i n e pressure should be 54-60 psi (372-414 kPa)
Connect a tachometer to t h e engine. Position t h e w i t h t h r o t t l e lever f o r w a r d and g r a d u a l l y increase t o
tachometer so i t can be observed f r o m under t h e ve- 90-96 p s i (621-662 kPa) as lever is moved r e a r w a r d .
hicle. Raise t h e vehicle on a hoist t h a t w i l l allow the (7) Rear servo pressure should be t h e same as l i n e
wheels to rotate freely. pressure w i t h i n 3 psi.

Test One-Transmission In 1 Range Test Two-Transmission In 2 Range

This test checks p u m p o u t p u t , pressure regula- T h i s test checks p u m p o u t p u t a n d pressure
tion, a n d condition o f the rear clutch a n d rear regulation.
servo c i r c u i t s . (1) Connect a test gauge to t h e l i n e pressure port
(Fig. 2).
21 - 52 AUTOMATIC TRANSMISSION •
(2) S t a r t a n d r u n the engine a t 1000 r p m . (4) A p p l y brakes t o stop wheels. S t a r t and r u n t h e
(3) Move t h e valve body selector lever one detent engine a t c u r b idle speed a n d note pressure. A t idle,
rearward f r o m f u l l f o r w a r d position. T h i s is 2 range. pressure should be zero t o 1-1/2 p s i m a x i m u m . I f
(4) Move t h e transmission t h r o t t l e lever f r o m f u l l pressure exceeds t h i s figure, the governor valve or
forward t o f u l l r e a r w a r d position and read pressure weights are s t i c k i n g open.
at both gauges. (5) S l o w l y increase engine speed a n d observe speed-
(5) L i n e pressure should be 54-60 psi 372-414 kPa) ometer a n d pressure test gauge. Governor pressure
w i t h t h r o t t l e lever f o r w a r d and g r a d u a l l y increase t o should increase i n p r o p o r t i o n to vehicle speed. Or ap-
90-96 psi ( 621-662 kPa) as the lever i s moved rear- p r o x i m a t e l y 1 psi for every 1 m p h .
ward.
(6) Pressure rise should be smooth a n d drop back t o
0 t o 1-1/2 psi w h e n wheels are stopped.
Test Three-Transmission In D Range
(7) Compare results o f t h e pressure tests w i t h t h e
T h i s test c h e c k s p r e s s u r e r e g u l a t i o n a n d c o n -
analysis c h a r t (Fig. 4).
dition o f the front a n d r e a r c l u t c h c i r c u i t s .
(1) Connect test gauges t o the l i n e pressure and
TEST CONDITION INDICATION
front servo ports (Fig. 2).
(2) S t a r t a n d r u n the engine a t 1600 r p m for this line pressure OK during Pump and regulator valve OK
test. any one test
(3) Move t h e selector lever two detents r e a r w a r d
Line Pressure OK in R Leakage in rear dutch area (servo,
from f u l l f o r w a r d position. This is D range.
but bw in D, 2, 1 dutch seals, governor support
(4) Read pressures on b o t h gauges as transmission seal rings)
throttle lever i s moved f r o m f u l l forward to f u l l rear-
ward position. Pressure OK in 1, 2 but Leakage in front dutch area (servo,
bw in D3 and R dutch seals, retainer bore, pump
(5) L i n e pressure should be 54-60 psi (372-414 kPa) seal rings)
w i t h t h r o t t l e lever forward and g r a d u a l l y increase as
lever is moved r e a r w a r d . Pressure OK in 2 but bw in Leakage in rear servo
R and 1
(6) F r o n t servo is pressurized only i n D range and
should be t h e same as l i n e pressure w i t h i n 3 psi (21 Front servo pressure in 2 Leakage in servo; broken servo
kPa) u p t o downshift p o i n t . ring or cracked servo piston

Pressure bw in all positions Clogged filter, stuck pressure

Test Four-Transmission In Reverse regulator valve, worn or
T h i s test c h e c k s p u m p output, p r e s s u r e r e g u l a - defective pump
tion a n d the front c l u t c h a n d r e a r s e r v o c i r c u i t s .
Governor pressure too high at Governor valve sticking open
(1) Connect t h e 300 psi gauge to the rear servo port idle speed:
(Fig. 3).
Governor pressure bw at all Governor valve sticking dosed
(2) S t a r t a n d r u n the engine a t 1600 r p m for test.
mph figures
(3) Move t h e valve body selector lever four detents
rearward f r o m the f u l l forward position. This is Re- Lubrication pressure low at all Clogged oil cooler or lines, seal
verse range. throttle positions rings leaking, output shaft
plugged with debris, worn
(4) Move t h e t h r o t t l e lever a l l t h e w a y forward bushings in pump or dutch
then a l l the way r e a r w a r d and note the gauge read- retainer J9021-34
ings.
(5) Pressure should be 145 - 175 p s i (1000-1207 Fig. 4 Pressure Test Analysis Chart
kPa) w i t h lever forward and increase to 230 - 280 psi
(1586-1931 kPa) as lever is moved r e a r w a r d . CONVERTER STALL TEST
Test Five-Governor Pressure S t a l l t e s t i n g involves d e t e r m i n i n g m a x i m u m en-
(1) This test checks governor operation b y measur- gine r p m obtainable a t f u l l t h r o t t l e w i t h the rear
ing governor pressure response t o changes i n engine wheels locked and t h e transmission i n D range. T h i s
speed. I t is u s u a l l y not necessary t o check governor test checks t h e h o l d i n g a b i l i t y o f t h e the converter
operation unless shift speeds are incorrect or i f the o v e r r u n n i n g clutch a n d b o t h o f t h e transmission
transmission w i l l not downshift. clutches. W h e n s t a l l t e s t i n g is completed, refer to the
(2) Connect a test gauge t o the governor pressure S t a l l Speed Specifications c ha rt and S t a l l Speed D i -
port (Fig. 3). agnosis guides.
(3) Move t h e selector lever to D range.
 • AUTOMATIC TRANSMISSION 21 - 53

WARNING: NEVER ALLOW ANYONE TO STAND IN
FRONT OF THE VEHICLE DURING A STALL TEST.
ALWAYS BLOCK THE FRONT WHEELS AND APPLY
THE SERVICE AND PARKING BRAKES DURING
THE TEST.
STALL TEST PROCEDURE
(1) Connect a tachometer t o t h e engine.
(2) Check and adjust transmission fluid level.
(3) Start a n d r u n t h e engine u n t i l transmission
fluid reaches n o r m a l operating temperature.
(4) Block the front wheels.
(5) F u l l y apply the service a n d p a r k i n g brakes.
(6) Open t h e t h r o t t l e completely for no more t h a n
five seconds and record m a x i m u m engine r p m regis-
tered on the tachometer.
CAUTION: Stall testing causes a rapid increase in
transmission fluid temperature. Do not hold the
throttle open any longer than five seconds. If more
than one stall test is required, run the engine at
1000 rpm with the transmission in Neutral for at
least 20 seconds to cool the fluid.
converter o v e r r u n n i n g c l u t c h is seized and the torque
converter m u s t be replaced.
Converter Noise During Test
A w h i n i n g noise caused b y fluid flow is n o r m a l
d u r i n g a s t a l l test. However, loud metallic noises i n -
dicate a damaged converter. To confirm t h a t noise is
o r i g i n a t i n g from the converter, operate the vehicle at
l i g h t t h r o t t l e i n D r i v e a n d N e u t r a l o n a hoist a n d lis-
t e n for noise coming from t h e converter housing.
AIR PRESSURE TEST
A i r pressure t e s t i n g can be used t o check clutch
and band operation w i t h t h e transmission either i n
the vehicle, or o n t h e w o r k bench as a final check af-
ter overhaul.
A i r pressure t e s t i n g requires t h a t t h e o i l p a n and
valve body be removed from t h e transmission. The
servo a n d c l u t c h apply passages are shown i n Figure
5. '" • •
FRONT SERVO APPLY, FRONT
REAR SERVO APPLY SERVO
.RELEASE

(7) I f engine speed exceeds m a x i m u m shown i n the PUMP

LINE PRESSURE TO!
SUCTION
s t a l l speed chart, release t h e accelerator i m m e d i - ACCUMULATOR
ately. This indicates t h a t transmission c l u t c h slip- PUMP
PRESSURE
page is occurring.
(8) Shift t h e transmission i n t o N e u t r a l . Operate FRONT
t h e engine for 20 seconds. Stop t h e engine, shift t h e CLUTCH
transmission i n t o P a r k and release t h e brakes. APPLY

(9) Stall speeds should be: 1800-2100 r p m w i t h REAR

CLUTCH
3.9L engine a n d 1700-2000 r p m w i t h 5.2L/5.9L en- APPLY
gines.
TO TORQUE
(10) Refer t o S t a l l Test Diagnosis. GOVERNOR CONVERTOR
PRESSURE /
FROM TORQUE
STALL TEST DIAGNOSIS CONVERTER
TO
GOVERNOR TO COOLER
Stall Speed Too High
I f the stall speed exceeds specifications b y more Fig. 5 Air Pressure Test Passages
t h a n 200 r p m , transmission c l u t c h slippage i s i n d i -
Front Clutch Test
cated.
Place one or t w o fingers on the clutch housing and
Stall Speed Too Low
apply a i r pressure t h r o u g h front clutch apply passage
Low stall speeds w i t h a properly t u n e d engine i n - (Fig. 5). Piston movement can be felt and a soft t h u d
dicate a torque converter o v e r r u n n i n g c l u t c h prob- heard as t h e c l u t c h applies.
l e m . The condition should be confirmed b y road
t e s t i n g prior to converter replacement. Rear Clutch Test
The converter o v e r r u n n i n g c l u t c h is s l i p p i n g when: Place one or t w o fingers on the clutch housing and
S t a l l speeds are 250 t o 350 r p m below specified m i n - apply a i r pressure t h r o u g h rear clutch apply passage
i m u m and t h e vehicle operates properly a t h i g h w a y (Fig. 5). P i s t o n movement can be felt and a soft t h u d
speeds but has poor l o w speed acceleration. heard as t h e c l u t c h applies.

Stall Speed Normal Front Servo Test

I f stall speeds are n o r m a l b u t a b n o r m a l t h r o t t l e A p p l y a i r pressure t o the front servo apply passage.
opening is required t o m a i n t a i n h i g h w a y speeds, t h e The servo r o d should extend and cause t h e band to
21 - 54 AUTOMATIC TRANSMISSION
t i g h t e n a r o u n d the d r u m . S p r i n g tension should r e -
lease the servo w h e n a i r pressure is removed.
Rear Servo Test
A p p l y a i r pressure t o t h e rear servo apply passage.
The servo rod should extend a n d cause t h e band t o
t i g h t e n around the d r u m . S p r i n g tension should r e -
lease the servo w h e n a i r pressure is removed.
CONVERTER HOUSING FLUID LEAK DIAGNOSIS
W h e n diagnosing converter h o u s i n g fluid leaks,
t w o items m u s t be established before repair. F i r s t , i t
m u s t be verified t h a t a leak condition a c t u a l l y exists.
A n d second, t h e t r u e source o f t h e leak m u s t be de-
termined.
Some suspected converter h o u s i n g fluid leaks m a y
not be leaks a t a l l . They m a y only be t h e r e s u l t o f
residual fluid i n t h e converter housing, o r excess
fluid spilled d u r i n g factory fill or r e f i l l after repair.
Converter h o u s i n g leaks have several p o t e n t i a l
sources. T h r o u g h careful observation, a leak source
can be identified before r e m o v i n g t h e transmission
for repair.
Pump seal leaks t e n d t o move along t h e d r i v e h u b
and onto the rear o f t h e converter. P u m p O-ring or
p u m p body leaks follow the same p a t h as a seal leak
(Fig. 6).
Pump vent or p u m p a t t a c h i n g b o l t leaks are gener-
a l l y deposited on the inside o f t h e converter housing
and not on t h e converter i t s e l f (Fig. 6).
Pump seal or gasket leaks u s u a l l y t r a v e l down the
inside of t h e converter housing.
F r o n t band lever p i n p l u g leaks are generally de-
posited on t h e housing and not on the converter.
PUMP PUMP PUMP
Fig. 6 Converter Housing Leak Paths
LEAK DIAGNOSIS PROCEDURE
(1) Raise the rear o f the vehicle and a l l o w accumu-
lated fluid t o d r a i n o u t o f the converter housing.
(2) Check and adjust the t r a n s m i s s i o n fluid level.
•
(3) Raise t h e vehicle. Remove t h e converter hous-
i n g dust cover a n d wipe as m u c h fluid as possible
from the converter housing.
(4) Fabricate a test probe (Fig. 7). T h e n attach t h e
probe t o t h e converter housing w i t h one o f the dust
shield bolts (Fig. 7).
(5) Have a helper r u n the engine a t 2500 r p m ( w i t h
the transmission i n N e u t r a l ) for t w o m i n u t e s ; t h e n
stop the engine.
(6) Inspect t h e test probe and converter housing. I f
a leak is evident, note the color o f the fluid. Trans-
mission fluid i s red. E n g i n e o i l ranges i n color from
b r o w n t o green, or t o black w h e n t h e o i l is d i r t y .
(7) I f t h e probe upper surface i s dry, the converter
and seal are not a t f a u l t . A p a t h o f fluid across t h e
probe upper surface indicates a converter or seal
leak. F l u i d l e a k i n g under the probe is coming f r o m
the p u m p housing area (Fig. 8).
(8) F l u i d l e a k i n g under t h e probe could be f r o m
the: p u m p seal and/or bushing, p u m p vent, k i c k d o w n
lever shaft access p l u g , pump bolts, or porous spots
i n the p u m p body or transmission case (Fig. 8).
(9) I f porous spots i n the transmission case or p u m p
body are t h e suspected leak source, pressurize t h e
transmission as described i n L e a k Testing W i t h A i r
Pressure.
SHIELD MATERIAL: 5-1/2" X 1-1/2" X 1/32"
BOLT SHEET METAL RN778
Fig. 7 Leak Test Probe
TORQUE CONVERTER LEAK POINTS
Possible sources o f converter leaks are:
(a) Leaks a t t h e weld j o i n t around the outside
diameter w e l d (Fig. 9).
(b) Leaks a t t h e converter h u b weld (Fig. 9).
LEAK TESTING WITH AIR PRESSURE
This test involves closing o f f t h e transmission
openings and pressurizing the transmission to 8 psi
w i t h a i r p u m p tool C-4080.
A soapy water s o l u t i o n is applied to suspected leak
points before and d u r i n g the pressure test. Leaks w i l l
be indicated b y t h e presence o f a i r bubbles coming
t h r o u g h the solution.
 + _ AUTOMATIC TRANSMISSION 21 - 5i

WELD OR BREAK EDGE

OUTSIDE OF OPEN
END FOR THIS
MATERIAL: 1-7/8 INCH O.D.
DISTANCE ON TUBE
THIN WALLED STEEL TUBING
AND 1/8 INCH STEEL DISC RN779

Fig. 10 Converter Hub Seal Cup—A-727

RH253 WELD BREAK EDGE 1/16" MIN.

OR BRAZE
Fig. 8 Pump Area Inspection Points
OUTSIDE TORQUE CONVERTER
DIAMETER HUB WELD
WELD
POLISH
OUTSIDE
OF OPEN
"END FOR 1.498
THIS DISTANCE
ON TUBE
MATERIAL: 1-1/2 INCH O.D. THIN
WALLED STEEL TUBING AND
1/8 INCH STEEL DISC RN780

'LUG Fig. 11 Converter Hub Seal Cup—A-998/999

STARTER RING GEAR RH254
15/32 INCH DRILL 4 HOLES
Fig. 9 Converter Leak Points (Nonlockup Shown)
Some transmission openings such as t h e f i l l tube
a n d f r o n t cooler line f i t t i n g can be closed o f f w i t h a
r u b b e r p l u g or s i m i l a r device. Plugs can secured w i t h
w i r e or duct tape.
The transmission rear o u t p u t shaft opening is
closed off simply by leaving t h e transfer case bolted
i n place. However, i f the transfer case has been re-
moved, a shipping p l u g can used t o close off t h i s
opening.
The torque converter h u b opening i n t h e p u m p a n d MATERIAL: 1/4 INCH STEEL STOCK
1-1/4 INCH WIDE RN781
t h e p u m p vent require special tools to close t h e m off.
The converter h u b seal cap is made f r o m t h i n w a l l
Fig. 12 Seal Cup Retaining Strap
tube a n d a 1/8 inch t h i c k disc (Figs. 10, 11). A r e -
t a i n i n g strap is needed to secure t h e seal cup for AIR PRESSURE LEAK TEST PROCEDURE
testing. The strap can be made from 1-1/4 i n c h wide (1) I n s t a l l t h e vent p l u g , converter h u b seal cup
stock (Fig. 12). The strap a t t a c h i n g hole positions a r e and cup r e t a i n i n g strap (Fig. 15).
approximate only. Measure hole position o n t h e con- (2) Close off t h e r e m a i n i n g transmission openings
w i t h rubber plugs, or stoppers. D o n o t c l o s e o f f t h e
v e r t e r housing before d r i l l i n g .
rear cooler line fitting. T h e a i r p u m p w i l l be at-
The pump vent tool is made from 1/4 i n c h rod a n d
tached to this fitting.
3/16 plate (Figs. 13, 14).
(3) A t t a c h a i r p u m p C-4080 t o t h e rear cooler line
The fabricated tools can a l l be made f r o m m i l d
fitting. Connect a l e n g t h of copper tube to the fitting.
steel or a l u m i n u m stock.
T h e n attach t h e a i r p u m p hose to t h e tube w i t h a
hose clamp (Fig. 16).
21 - 56 AUTOMATIC TRANSMISSION •
3/8" DRILL VENT PLUG RETAINER
2 HOLES RETAINER

1/4" ROD

4-21/32" RADIUS

5" RADIUS

TORQUE
SPRING CONVERTER
HUB SEAL CUP
PLUG - MADE FROi
OLD FILLER TUBE RH255
MATERIAL: 3/16 INCH STEEL STOCK RN782

Fig. 15 Vent Plug And Hub Seal Cup Installation

Fig. 13 Pump Vent Plug-A-727
FLARE C A P _
13/32" DRILL 2 HOLES HOSE CLAMP

AIR PUMP
WELD O R
BRAZE

3-3/4"
RADIUS

1/4" ROD FLARED TUBE O N

COOLER LINE FITTING RY254

Fig. 16 Pressurizing Transmission

CONVERTER HOUSING AREA LEAK
CORRECTION
(1) Remove t h e converter.
R N 7 8 3
(2) T i g h t e n t h e front band adjusting screw u n t i l
MATERIAL: 3/16 INCH STEEL STOCK
t h e band is t i g h t around t h e f r o n t clutch retainer.
Fig. 14 Pump Vent Plug-A-998/999 T h i s prevents t h e front clutch f r o m coming out w h e n
t h e o i l p u m p is removed.
(4) A p p l y a t h i c k soapy w a t e r solution t o t h e sus-
(3) Remove t h e o i l pump a n d seal. Inspect t h e
pected leak areas.
p u m p housing drainback and v e n t holes for obstruc-
CAUTION: The recommended test pressure is 8 psi. tions. Clear t h e holes w i t h solvent and w i r e .
The maximum allowable test pressure is 10 psi. Do (4) Inspect t h e pump b u s h i n g a n d converter h u b . I f
not exceed specified pressure. t h e bushing is scored, replace i t . I f the converter h u b
is scored, either polish i t w i t h crocus cloth o r replace
(5) Pressurize the transmission t o 8 psi w i t h t h e a i r t h e converter i f scoring is severe.
pump. (5) I n s t a l l a new p u m p seal, O-ring, gasket, bush-
(6) Observe t h e suspected leak areas. A i r bubbles i n g . Replace t h e o i l p u m p i f cracked, porous or dam-
appearing i n t h e soapy water solution indicate leak aged i n a n y way.
points. (6) Loosen t h e k i c k d o w n lever p i n p l u g t w o t u r n s .
(7) Remove the test tools a n d plugs after test com- A p p l y Permatex No. 2 or equivalent t o t h e p l u g
pletion a n d make necessary repairs as described i n threads a n d t i g h t e n t h e p l u g t o 17 N*m (150 in-lbs)
the Leak Correction procedure. torque.
(7) Adjust t h e front (kickdown) band.
• AUTOMATIC TRANSMISSION 21 - 57

(8) L u b r i c a t e t h e p u m p seal a n d converter h u b DIAGNOSIS GUIDES AND CHARTS

w i t h t r a n s m i s s i o n fluid or p e t r o l e u m j e l l y a n d i n s t a l l
T h e diagnosis guides a n d charts provide a d d i t i o n a l
t h e converter.
reference a for transmission diagnosis.
(9) I n s t a l l t h e transmission a n d converter h o u s i n g
T h e guides provide basic procedures for conditions
d u s t shield
i n v o l v i n g , abnormal noise, fluid leaks, or i f t h e v e h i -
(10) L o w e r t h e vehicle. cle w i l l n o t move forward or i n reverse.
T h e diagnosis chart provides general i n f o r m a t i o n
o n a v a r i e t y o f transmission f a u l t conditions.
T h e h y d r a u l i c flow charts o u t l i n e fluid flow a n d
h y d r a u l i c c i r c u i t r y . C i r c u i t operation is p r o v i d e d for
a l l gear ranges. N o r m a l w o r k i n g pressures a r e also
supplied for each of t h e various gear ranges.

VEHICLE WILL NOT MOVE

CHECK THE TRANSMISSION FLUID LEVEL
BEFORE STARTING THE ENGINE IF NO
FLUID IS VISIBLE ON THE DIP STICK, ADD
FLUID TO THE "L" MARK BEFORE
STARTING THE ENGINE. THEN START THE
ENGINE WITH THE TRANSMISSION IN

ABNORMAL NOISE.
N O ABNORMAL NOISE,
STOP ENGINE IMMEDIATELY.
MOVE THE SELECTOR TO A FORWARD REMOVE TRANSMISSION
DRIVE RANGE AND OBSERVE THE AND CONVERTER AS AN ASSEMBLY-
DISASSEMBLE, CLEAN AND INSPECT ALL
PROPELLER SHAFT FOR TURNING. PARTS; CLEAN THE VALVE BODY, INSTALL
ALL NEW SEALS, RINGS, AND GASKETS;
REPLACE WORN OR DEFECTIVE PARTS.
PROPELLER SHAFT TURNS] PROPELLER SHAFT DOES
NOT TURN.
BUT REAR WHEELS REMOVE THE
DO NOT TURN, INSPECT TRANSMISSION OIL PAN.
FOR BROKEN REAR INSPECT FOR DEBRIS.
AXLE PARTS.
1 DEBRIS IS PRESENT.
NO DEBRIS REMOVE THETRANSMISSION AND
CONVERTER AS AN ASSEMBLY.
REMOVE VALVE BODY. DISASSEMBLE, CLEAN AND INSPECT
DISASSEMBLE CLEAN AND ALL PARTS. CLEAN VALVE BODY;
INSPECT ALL PARTS. INSTALL ALL NEW SEALS, RINGS
REASSEMBLE, INSTALL AND AND GASKETS; REPLACE WORN OR
CHECK PRESSURES AND DEFECTIVE PARTS. PV567
OPERATION.
21 - 58 AUTOMATIC TRANSMISSION •

DIAGNOSIS GUIDE—
FLUID LEAKS
VISUALLY INSPECT FOR SOURCE OF
LEAK. IF THE SOURCE OF LEAK
CANNOT BE READILY DETERMINED,
CLEAN THE EXTERIOR OF THE
TRANSMISSION. CHECK TRANSMISSION
FLUIO LEVEL CORRECT IF NECESSARY.

THE FOLLOWING LEAKS MAY BE CORRECTED THE FOLLOWING LEAKS

WITHOUT REMOVING THE TRANSMISSION: REQUIRE REMOVAL OF THE TRANSMISSION
AAANUAL LEVER SHAFT OIL SEAL AND TORQUE CONVERTER FOR
FILLER TUBE 'O RING
7 CORRECTION.
PRESSURE GAUGE PLUG TRANSMISSION FLUID LEAKING FROM THE LOWER
NEUTRAL START SWITCH EDGE OF THE CONVERTER HOUSING; CAUSED BY
PAN GASKET FRONT PIJMP SEAL, PUMP TO CASE SEAL, OR TORQUE
OIL COOLER FITTINGS CONVERTER WELD.
EXTENSION HOUSING TO CASE GASKET CRACKED OR
EXTENSION HOUSING TO CASE BOLTS POROUS TRANSMISSION CASE.
EXTENSION HOUSING YOKE SEAL
SPEEDOMETER ADAPTER 'O RING
FRONT BAND ADJUSTING SCREW PU568

DIAGNOSIS GUIDE-ABNORMAL NOISE 1

INSPECT AND CORRECT THE TRANSMISSION
FLUID LEVEL, ROAD TEST TO VERIFY THAT
AN ABNORMAL NOISE EXISTS, IDENTIFY
THE TYPE OF NOISE, DRIVING RANGES, AND
CONDITIONS WHEN THE NOISE OCCURS.

GEAR NOISE WHINE OR KNOCK, CLICK OR

OR GRINDING BUZZ NOISE SCRAPE NOISE

REMOVE THE
TRANSMISSION AND REMOVE TORQUE
CONVERTER ASSEMBLY; LISTEN TO TRANSMISSION
CONVERTER AND INSPECT
DISASSEMBLE, CLEAN AND FOR LOOSE OR CRACKED
INSPECT ALL PARTS; CLEAN AND
CONVERTER DRIVE PLATE;
THE VALVE BODY INSTALL CONVERTER FOR SOURCE INSPECT FOR CONTACT OF
ALL NEW SEALS, RINGS, THE STARTER DRIVE WITH
AND GASKETS; REPLACE OF NOISE. THE STARTING RING GEAR.
WORN OR
DEFECTIVE PARTS.

1
TRANSMISSION HAS
CONVERTER HAS LOUD
BUZZ OR
BUZZ OR WHINE.
WHINE
REMOVE THE
TRANSMISSION PAN; REPLACE TORQUE
T INSPECT FOR DEBRIS
INDICATING WORN OR CONVERTER DEBRIS PRESENT
N O DEBRIS PRESENT FAILED PARTS.
REMOVE TRANSMISSION
REMOVE VALVE BODY, AND CONVERTER AS AN
DISASSEMBLE, CLEAN AND ASSEMBLY; DISASSEMBLE,
INSPECT PARTS. CLEAN AND INSPECT ALL
REASSEMBLE, INSTALL, PARTS. CLEAN THE VALVE
CHECK OPERATION AND BODY INSTALL ALL NEW
PRESSURES. SEALS, RINGS AND
GASKETS; REPLACE WORN
OR DEFECTIVE PARTS.
PU566"
• AUTOMATIC TRANSMISSION 21 - 59

TRANSMISSION DIAGNOSIS CHART

POSSIBLE CAUSE

Faulty lockup clutch

Overrunning clutch inner race
damaged.
Overrunning clutch worn, broken
or seized.
Planetary gear sets broken or
seized.
Rear clutch dragging.
Worn or faulty rear clutch.
insufficient cutch plate clearance.
Faulty cooling system.
Kickdown band adjustment too
tight.
Hydraulic pressure too high.
Breather clogged.
High fluid level.
Worn or faulty front clutch.
Kickdown servo band or linkage
malfunction.
Governor malfunction.
Worn or broken reaction shaft
support seal rings.
Governor support seal rings broken
or worn.
Output shaft bearing and/or
bushing damaged.
Overrunning clutch not holding.
Kickdown band out of adjustment.
Incorrect throttle linkage
adjustment.
Engine idle speed too low.
Aerated fluid.
Worn or broken input shaft seal
rings.
Faulty oil pump.
Oil filter clogged.
Incorrect gearshift control linkage
adjustment.
Low fluid level.
Low-reverse servo, band or linkage
malfunction.
Valve body malfunction or
leakage.
Low-reverse band out of
adjustment.
Hydraulic pressure too bw.
Engine idle speed too high.
Stuck lockup valve.
Stuck switch valve.

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21 - 60 AUTOMATIC TRANSMISSION •
LOCKUP TORQUE CONVERTER DIAGNOSIS CHART

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 LOCKUP VALVE X X X
STUCK FAIL-SAFE VALVE X X x X
STUCK LOCKUP SOLENOID X X
SOLENOID WIRING DISCONNECTED X
FAILED LOCKUP SOLENOID X
FAILED LOCKUP RELAY X X
FAULTY TORQUE CONVERTER: X X X X X
OUT OF BALANCE X
FAILED LOCKING CLUTCH X X X
LEAKING TURBINE HUB SEAL X X
ALIGN EXHAUST SYSTEM X X
TUNE ENGINE X X X
FAULTY INPUT SHAFT OR SEAL RING X X
THROTTLE LINKAGE MISADJUSTED X X
DURING LOCKUP ENGAGEMENT
LOCKUP ENGAGEMENT—(COLD)

OVERHEATING: OIL BLOWING

OUT DIPSTICK OR PUMP SEAL
VIBRATION WHEN "REVED"
STALLS OR IS SLUGGISH IN
STAYS LOCKED UP TO TOO

SHUDDER AFTER LOCKUP

VIBRATION OR SHUDDER
LOW A SPEED IN DIRECT
LOCKS UP OR DRAGS IN

LOUD CHATTER DURING

LOCKUP ENGAGEMENT
WILL NOT UNLOCK

VIBRATIONS AFTER
LOW OR SECOND
CONDITION

ENGAGEMENT
IN NEUTRAL
NO LOCKUP

REVERSE

J9021-62
 TO
LUBRICATION

THROTTLE VALVE KICKDOWN VALVE I

FRONT
CLUTCH
i UBRICATION

^ ^ ^ ^ ^ ^

OIL PRESSURES •

LINE 57-63 PSI CONVERTER 57-63 PSI

PUMP SUCTION Fx?r LUBRICATION 5-30 PSI

SELECTOR LEVER IN THROTTLE 0-10 PSI HH TORQUE CONVERTER

NEUTRAL
OIL FILTER ENGINE RUNNING

O
OIL PRESSURES 2
>
LINE 0-30 PSI H
0

PUMP SUCTION \y//A •H

SELECTOR LEVER IN
>
CO
PARK
ENGINE RUNNING 1
CO

OIL FILTER
J902M60 2
!1 - 62 AUTOMATIC TRANSMISSION •
AUTOMATIC TRANSMISSION 21 - 63
GOVERNOR VALVE IS*
REAR SERVO FRONT m SERVO
ACCUMULATOR
r
CD

>
CZ

30
>
Z
co
CO
CO

TO
LUBRICATION

FRONT
CLUTCH
1UBRICATION

J902M63
21 - 66 AUTOMATIC TRANSMISSION •
O
o
• AUTOMATIC TRANSMISSION 21 -
GOVERNOR VALVE REAR SERVO FRONT SERVO
REAR CLUTCH FRONT CLUTCH ACCUMULATOR
r

SELECTOR LEVER IN
TWO (MANUAL SECOND)
CLOSED THROTTLE J902M67
GOVERNOR VALVE REAR SERVO FRONT SERVO
REAR CLUTCH FRONT CLUTCH ACCUMULATOR
r

TO
1LUBRICATION

FRONT
CLUTCH
[LUBRICATION

SELECTOR LEVER IN
ONE (MANUAL LOW)
CLOSED THROTTLE M902M68
21 - 70 AUTOMATIC TRANSMISSION
 • AUTOMATIC TRANSMISSION
MAINTENANCE A N D ADJUSTMENTS
Page
Fluid And Filter Change
Fluid And Filter Replacement
Fluid Level Check
Front (Kickdown) Band Adjustment
FLUID LEVEL CHECK
Transmission fluid level should be checked a t least
twice a year under n o r m a l operation. I f t h e vehicle is
used for t r a i l e r t o w i n g or heavy load h a u l i n g , check
f l u i d level a n d c o n d i t i o n four o r more times each
year.
FLUID CHECK PROCEDURE
(1) Position the vehicle on a level surface. This is
necessary for a n accurate check.
(2) Start and r u n t h e engine a t curb idle speed.
(3) Shift t h e transmission i n t o N e u t r a l a n d apply
the p a r k i n g brakes.
(4) Clean the top o f the f i l l e r tube and dipstick to
keep d i r t f r o m e n t e r i n g the tube.
(5) F l u i d level should be:
(a) Between t h e " A D D " a n d " M A X I M U M
L E V E L H O T " m a r k s w h e n t h e f l u i d i s a t normal
operating temperature of approximately 180° F (82°
C).
(b) Between t h e two dimples on the dipstick i f
fluid is o n l y w a r m (85°-125°F).
FLUID AND FILTER CHANGE
NORMAL CHANGE INTERVAL
The fluid a n d filter should be changed (and t h e
bands adjusted) a t recommended maintenance inter-
vals, or whenever t h e transmission has been disas-
sembled for any reason.
Refer t o t h e D r i v e l i n e section i n L u b r i c a t i o n and
Maintenance Group O a t the f r o n t o f t h i s m a n u a l for
recommended change i n t e r v a l s . Refer to t h e fluid/fil-
ter replacement a n d band adjustment procedures i n
this section.
SEVERE USAGE CHANGE INTERVAL
Under severe usage, the fluid and f i l t e r should be
changed a n d the bands adjusted a t 12,000 m i l e (19
000 K m ) i n t e r v a l s .
Severe usage is defined as:
(a) More t h a n h a l f o f vehicle operation occurs
i n heavy city traffic d u r i n g h o t weather (above 90°
F).
21 - 71
INDEX
Page
71 Gearshift Linkage Adjustment . . . . . . . . . . . . . . . . 71
71 Rear (Low-Reverse) Band Adjustment 72
71 Throttle Linkage Adjustment . . . . . . . . . . . . . . . . . 72
72 Valve Body Control Pressure Adjustments . . . . . . 73
(b) Vehicle is used for T a x i , Police, Limousine,
or s i m i l i a r commercial operations.
(c) Vehicle is used for t r a i l e r t o w i n g or heavy
load h a u l i n g .
W h e n t h e factory fluid is drained, r e f i l l t h e
transmission w i t h Mopar A T F Plus, type 7176, o r
Dexron II™ automatic transmission fluid.
FLUID AND FILTER REPLACEMENT
(1) Raise, the vehicle.
(2) Remove the o i l pan and d r a i n the fluid.
(3) Remove the three filter screws and remove t h e
filter.
(4) Position the new filter o n the valve body a n d
i n s t a l l t h e f i l t e r screws finger t i g h t .
(5) T i g h t e n the filter screws to 35 in-lbs (4 N»m)
w i t h a torque wrench.
(6) Position a new gasket on the o i l pan and i n s t a l l
the p a n o n t h e transmission. T i g h t e n pan bolts t o
150 in-lbs (17 N n n ) torque.
(7) Lower t h e vehicle and r e f i l l t h e transmission
w i t h Mopar A T F Plus type 7176, or Dexron II™ fluid.
GEARSHIFT LINKAGE ADJUSTMENT
Check l i n k a g e adjustment b y s t a r t i n g t h e engine
i n P a r k a n d N e u t r a l . Adjustment is O K i f the engine
starts only i n p a r k and N e u t r a l . Adjustment is incor-
rect i f the engine starts i n one b u t not both positions.
I f the engine starts i n any position other t h a n P a r k
or N e u t r a l , or i f the engine w i l l not start a t a l l , t h e
n e u t r a l s w i t c h may be faulty.
LINKAGE ADJUSTMENT PROCEDURE
Do not attempt linkage adjustment i f any com-
ponents a r e w o r n o r damaged. I n a d d i t i o n , i f ei-
ther l i n k a g e r o d must b e disconnected, t h e
plastic grommet securing the r o d i n the lever
m u s t be replaced. Disconnect the r o d w i t h a p r y
tool. P r y only where the grommet and r o d at-
t a c h a n d n o t o n t h e r o d itself. T h e n c u t a w a y t h e
o l d g r o m m e t . Use pliers t o snap the new g r o m -
m e t i n t o the lever a n d t o snap the r o d into t h e
grommet.
(1) Shift the transmission into Park.
(2) Raise t h e vehicle.
21 - 72 AUTOMATIC TRANSMISSION
(3) Check condition o f the s h i f t rods, control lever,
bushings, washers and torque shaft (Fig. 1). Tighten,
repair, or replace w o r n or damaged parts.
(4) Loosen t h e shift r o d adjusting swivel lock screw.
Be sure t h e swivel t u r n s freely o n t h e rod.
(5) V e r i f y t h a t the valve body shift control lever is
i n P a r k detent. Move t h e lever a l l the w a y r e a r w a r d
to check.
(6) A d j u s t swivel position (on t h e shift rod) to a ob-
t a i n free p i n fit i n t h e torque shaft lever (Fig. 1).
Then t i g h t e n t h e swivel lock screw to 90 in-lbs
torque.
(7) Check adjustment b y s t a r t i n g t h e engine i n
P a r k and N e u t r a l . E n g i n e should start i n these posi-
tions only. I f e n g i n e s t a r t s i n a n y p o s i t i o n o t h e r
than P a r k o r Neutral, adjustment is incorrect o r
neutral switch is faulty.
GROMMET
FRONT ROD
ASSEMBLY
BRACKET
ASSEMBLY
REAR
ROD
^> LOCK SCREW |r
RBAfKFT GEARSHIFT
BRACKET CONTROL
WASHER LEVER
- RETAINER PU500
Fig. 1 Column Gearshift Linkage
THROTTLE LINKAGE ADJUSTMENT
(1) Retract ISC actuator w i t h D R B I I , or w i t h
j u m p e r wires as follows:
(a) I f D R B I I is used, connect tester to diagnos-
tic connector i n engine compartment (connector is
located near SBEC connector). Start engine a n d
place D R B I I i n i n " T h r o t t l e Body M i n i m u m A i r
F l o w Test". Disconnect electrical connector o n ISC
actuator. T h e n s h u t engine off and disconnect D R B
I I tester. A c t u a t o r i s now f u l l y retracted.
(b) I f j u m p e r wires are used, shut engine off
and disconnect electrical connector a t ISC actuator.
Connect p a i r of j u m p e r wires to battery. Connect
negative j u m p e r to top p i n o f ISC actuator and pos-
i t i v e j u m p e r to second p i n o f actuator. Leave j u m p -
ers connected for no more t h a n five seconds t h e n
disconnect them. A c t u a t o r is now f u l l y retracted.
(2) Raise vehicle to make adjustment at transmis-
sion t h r o t t l e lever.
•
(3) Loosen adjustable swivel lock screw (Fig. 2). B e
sure swivel slides freely on t h r o t t l e r o d so t h a t r e -
t u r n spring action i s not restricted.
(4) Disassemble a n d clean linkage parts i f b i n d i n g
was encountered i n step (3). Clean l i n k a g e p a r t s as
necessary.
(5) H o l d transmission t h r o t t l e lever firmly f o r w a r d
against i t s i n t e r n a l stop a n d t i g h t e n swivel lock
screw to 90 in-lbs (10 Nnn) torque.
(6) Lower vehicle
(7) Check l i n k a g e freedom o f operation. V e r i f y t h a t
l i n k a g e backlash is removed b y r e t u r n spring. Press
t h r o t t l e r o d r e a r w a r d a n d release i t slowly. Rod
should r e t u r n t o f u l l forward position w h e n released.
(8) Reconnect ISC actuator.
(9) Reposition ISC actuator for n o r m a l operation as
follows. T u r n i g n i t i o n key to O N position for a m i n -
i m u m o f five seconds. D o n o t s t a r t t h e e n g i n e .
T h e n t u r n key t o O F F position. A c t u a t o r is n o w po-
sitioned for n o r m a l operation.
FRONT (KICKDOWN) BAND ADJUSTMENT
The front (kickdown) band adjusting screw is lo-
cated on t h e left side of the transmission case above
t h e m a n u a l valve and t h r o t t l e valve levers.
(1) Raise t h e vehicle.
(2) Loosen t h e band adjusting screw l o c k n u t . T h e n
back t h e l o c k n u t off 4-5 t u r n s . Be sure t h e adjusting
screw t u r n s freely i n t h e case.
(3) T i g h t e n t h e band adjusting screw t o 72 i n c h -
pounds (8 N n n ) torque. However, i f adapter extension
C-3705 is used o n t h e torque wrench, t i g h t e n t h e
screw to only 47-50 i n c h pounds (5 N n n ) torque ( F i g .
3).
(4) Back off the band adjusting screw 2-1/2 t u r n s .
(5) H o l d t h e adjuster screw i n position and t i g h t e n
the locknut to 30 ft-lbs (41 Nnn) torque.
(6) Lower t h e vehicle.
REAR (LOW-REVERSE) BAND ADJUSTMENT
The transmission o i l p a n m u s t be removed for ac-
cess to t h e rear band adjusting screw.
(1) Raise t h e vehicle.
(2) Remove t h e transmission o i l p a n and d r a i n t h e
fluid.
(3) Loosen t h e band adjusting screw l o c k n u t 5-6
t u r n s . Be sure the adjusting screw t u r n s freely i n t h e
lever.
(4) T i g h t e n the adjusting screw to 8 N n n (72 in-lbs)
torque (Fig. 4).
(5) O n A-998/999 transmissions, back off t h e a d -
j u s t i n g screw f o u r t u r n s . O n A-727 transmissions,
back off the adjusting screw t w o t u r n s .
 • AUTOMATIC TRANSMISSION 21 - 73

THROTTLE
BODY

THROTTLE
BODY

CLIP

WASHER
THROTTLE
VALVE
ROD

THROTTLE
ROD

THROTTLE VALVE SHIFT

LEVER J902M45
LEVER

Fig. 2 Throttle Rod And Linkage

TO COOLER KICKDOWN BAND ADJUSTING SCREW LOW-REVERSE BAND ADJUSTMENT

GEARSHIFT CONTROL LEVER RH256

Fig. 3 Front Band Adjustment Screw Location
(6) Hold t h e adjusting screw i n place and t i g h t e n
t h e locknut t o 34 N n n (25 ft-lbs) torque.
(7) Position a new gasket on the o i l p a n and i n s t a l l
t h e pan on t h e transmission. T i g h t e n the pan bolts to
17 N n n (150 in-lbs) torque.
(8) Lower t h e vehicle a n d r e f i l l t h e transmission
w i t h Mopar A T F Plus, type 7176, or Dexron II™
fluid.
Fig. 4 Rear Band Adjustment Screw Location
VALVE BODY CONTROL PRESSURE
ADJUSTMENTS
There are t w o control pressure adjustments on t h e
valve body w h i c h are: L i n e pressure a n d t h r o t t l e
pressure.
Because line and t h r o t t l e pressures are interdepen-
dent (each affects the shift q u a l i t y and t i m i n g ) , both
adjustments m u s t be performed properly and i n t h e
correct sequence, t h e line pressure adjustment first,
the t h r o t t l e pressure adjustment last.
21 - 74 AUTOMATIC TRANSMISSION
LINE PRESSURE ADJUSTMENT
Measure distance from the valve body t o the i n n e r
edge of the adjusting screw w i t h a n accurate steel
scale (Fig. 5).
Distance should be 33.4 m m (1-5/16 inch).
I f adjustment is required, t u r n t h e adjusting screw
i n , or out, to obtain required distance setting.
T h e 33.4 m m (1-5/16 i n c h ) s e t t i n g i s a n a p p r o x -
imate setting. Because o f m a n u f a c t u r i n g toler-
ances, i t m a y b e n e c e s s a r y t o v a r y from t h i s
dimension t o o b t a i n desired pressure. One com-
plete t u r n o f the adjusting screw changes line
p r e s s u r e a p p r o x i m a t e l y 9 k P a (1-2/3 p s i ) . T u r n -
ing t h e adjusting screw counterclockwise i n -
creases p r e s s u r e while t u r n i n g t h e screw
c l o c k w i s e decreases p r e s s u r e .
Fig. 5 Line Pressure Adjustment
+
THROTTLE PRESSURE ADJUSTMENT
I n s e r t gauge tool C-3763 between the t h r o t t l e lever
cam a n d k i c k d o w n valve (Fig. 6).
Push the gauge tool i n w a r d t o compress the k i c k -
down valve against the s p r i n g and bottom the t h r o t -
tle valve.
M a i n t a i n pressure against k i c k d o w n valve spring.
T u r n t h r o t t l e lever stop screw u n t i l the screw head
touches t h r o t t l e lever t a n g and the t h r o t t l e lever cam
touches gauge tool.
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 be fully c o m -
p r e s s e d a n d the k i c k d o w n v a l v e completely bot-
tomed to obtain c o r r e c t adjustment.
Fig. 6 Throttle Pressure Adjustment
 • AUTOMATIC TRANSMISSION 21 - 75

IN-VEHICLE S E R V I C E

INDEX
Page Page
Aluminum Thread Repair . 86 Speedometer Pinion And Adapter Service 75
Extension Housing Bushing And Output Transmission Cooler Service 85
Shaft Bearing 77 Valve Body Assembly 83
Extension Housing Yoke Seal . . . . . . . . . . . . . . . . 76 Valve Body Disassembly 79
Governor And Park Gear 78 Valve Body Installation 84
Neutral Start And Backup Lamp Switch 75 Valve Body Removal 79
Parking Lock Components . . . . . . . . . . . . . . . . . . 79

SPEEDOMETER PINION AND ADAPTER SERVICE
Rear axle gear r a t i o a n d t i r e size determine p i n i o n
gear requirements. I f t h e gear m u s t be replaced, re-
fer to the p a r t s catalogue i n f o r m a t i o n for the correct
gear.
(7) Remove t h e adapter o i l seal i f necessary. S t a r t
a new seal i n t h e adapter by hand. Then press t h e
seal i n t o t h e adapter w i t h tool C-4004 u n t i l the tool
bottoms (Fig. 2).
CAUTION: Before installing the pinion and adapter
assembly, make sure adapter flange and mating
area on the extension housing are clean. Dirt or
sand will cause misalignment resulting in speedom-
eter pinion gear damage.

(8) T h o r o u g h l y clean t h e adapter flange a n d

adapter m o u n t i n g surface i n t h e extension housing.
These surfaces m u s t be clean for proper adapter
a l i g n m e n t and speedometer operation.
(9) L u b r i c a t e t h e adapter o i l seal and O-ring w i t h
transmission f l u i d .
(10) Count t h e number of teeth o n the p i n i o n gear
before i n s t a l l i n g the gear i n the adapter.
(11) Note t h e range numbers on t h e adapter face
(Fig. 3). These numbers correspond to the number of
teeth o n t h e p i n i o n .
(12) I n s t a l l t h e adapter i n the extension housing.
(13) Rotate t h e adapter u n t i l t h e required range
Fig. 1 Speedometer Components numbers are a t a six o-clock position (Fig. 3). Be sure
ADAPTER AND PINION the adapter range numbers correspond to the n u m b e r
REMOVAL/INSTALLA TION of t e e t h on t h e p i n i o n .
(1) Raise t h e vehicle. (14) L i g h t l y push or tap t h e adapter a l l t h e w a y
(2) Remove t h e distance sensor f r o m the speedome- into t h e extension housing.
t e r adapter (Fig. 1). O n A-500/518, remove the sensor (15) I n s t a l l t h e adapter retainer. T i g h t e n t h e r e -
adapter as w e l l . tainer b o l t to 11 N»m (100 in-lbs) torque.
(3) Check t h e distance sensor m o u n t i n g area i n the (16) I n s t a l l t h e distance sensor. T i g h t e n the sensor
p i n i o n adapter. I f t r a n s m i s s i o n f l u i d is found i n t h i s coupling n u t t o 17 N*m (150 in-lbs) torque a n d i n -
area, the adapter o i l seal is l e a k i n g and w i l l have to stall t h e sensor wires.
be replaced. (17) Lower t h e vehicle and top off the transmission
f l u i d level.
(4) Remove t h e bolt a n d r e t a i n e r securing the p i n -
i o n gear adapter to t h e extension housing.
NEUTRAL START AND BACK-UP LAMP SWITCH
(5) Carefully w o r k t h e adapter a n d gear out of the
housing. The center t e r m i n a l of the n e u t r a l start a n d
(6) Remove a n d discard t h e adapter O-ring i f dam- backup l a m p s w i t c h is the starter circuit t e r m i n a l . I t
aged (Fig. 1). provides t h e g r o u n d for the starter solenoid c i r c u i t
21 - 76 AUTOMATIC TRANSMISSION •
ADAPTER LOCK RING

Fig. 2 Replacing Speedometer Adapter Seal

SWITCH
RH266

Fig. 4 Neutral Start Switch Contacts

EXTENSION HOUSING YOKE SEAL

ADAPTER YOKE SEAL REPLACEMENT

6 O'CLOCK POSITION RH260
Fig. 3 Indexing Speedometer Adapter
t h r o u g h the selector lever i n P a r k and N e u t r a l posi-
tions only. The outer t e r m i n a l s on the switch are for
the backup l a m p c i r c u i t .
SWITCH TEST
To test t h e switch, remove t h e w i r i n g connector.
Then test c o n t i n u i t y between t h e center t e r m i n a l
and t h e transmission case. C o n t i n u i t y should exist
only when the transmission is i n P a r k or N e u t r a l .
Shift the transmission into reverse and test conti-
n u i t y a t t h e switch outer terminals. C o n t i n u i t y
should exist only w h e n t h e transmission is i n Re-
(1) Raise t h e vehicle.
(2) M a r k propeller a n d axle yokes for alignment
reference. T h e n disconnect the shaft a t the yoke and
remove the shaft.
(3) Remove t h e old seal w i t h tool C-3985 (Fig. 5).
(4) I n s t a l l t h e new seal. Position the seal i n the ex-
tension opening. Then t a p t h e seal i n t o place w i t h
tool C-3995 or C-3972 (Fig. 6).
(5) Carefully guide front universal j o i n t yoke i n t o
extension housing a n d on t h e mainshaft splines.
A l i g n m a r k s made a t removal and connect propeller
shaft t o rear axle p i n i o n shaft yoke.
SPECIAL
TOOL

verse. C o n t i n u i t y should not exist between the outer

terminals and the case.
Check gearshift linkage adjustment before replac-
i n g a switch t h a t tests bad.

SWITCH REPLACEMENT
(1) Raise the vehicle and position a d r a i n pan u n -
der t h e switch. SEAL RH77
(2) Disconnect the switch wires.
(3) Remove the s w i t c h from the case. Fig. 5 Removing Extension Housing Yoke Seal
(4) Move t h e shift lever to P a r k and N e u t r a l posi-
SPECIAL TOOL
tions. Verify t h a t the switch operating lever fingers
are centered i n the switch opening i n the case (Fig.
4).
(5) I n s t a l l a new seal on the switch and i n s t a l l the
switch i n the case. T i g h t e n the switch to 34 N*m (25
ft-lbs) torque.
(6) Test c o n t i n u i t y o f the new switch w i t h the test RH78
lamp.
Fig. 6 Installing Extension Housing Yoke Seal
(7) Connect the switch wires and lower the vehicle.
(8) Top off the transmission f l u i d level.
 • AUTOMATIC TRANSMISSION 21 - 77

EXTENSION HOUSING BUSHING AND OUTPUT

SHAFT BEARING

EXTENSION HOUSING REMOVAL

(1) S h i f t t h e transmission i n t o 1 (first gear) posi-
tion.
(2) Raise t h e vehicle.
(3) M a r k t h e propeller shaft and axle yokes for
a l i g n m e n t reference. Then disconnect t h e shaft from
t h e yoke a n d remove the shaft.
(4) Remove t h e distance sensor, speedometer
adapter and speedometer p i n i o n gear (Fig. 1).
(5) Remove the bolts attaching t h e extension hous-
i n g t o t h e crossmember.
(6) Raise the transmission s l i g h t l y w i t h a service
jack.
(7) Remove the center crossmember and support as- Fig. 7 Removing/Installing Output Shaft Bearing
sembly. Snap Ring
(8) Remove the extension housing-to-transmission
bolts.
(9) V e r i f y t h a t the transmission is i n 1 position.
The p a r k lock rod can only be disengaged/engaged
w i t h t h e sprag i n t h i s position.
(10) Remove the access plate and gasket from the
underside o f the extension housing m o u n t i n g pad.
(11) Spread the large snap r i n g on the o u t p u t shaft
bearing outer race (Fig. 7).
(12) H o l d the snap r i n g i n a spread position and
carefully t a p t h e extension housing off t h e shaft Fig. 8 Output Shaft Bearing Position
bearing.
(13) Carefully p u l l the extension housing r e a r w a r d
to move the b a l l on t h e park lock control rod past the
sprag.
(14) Remove the housing.

OUTPUT SHAFT REAR BEARING

REPLACEMENT
(1) U s i n g heavy d u t y snap r i n g pliers, remove the
rear snap r i n g t h a t retains the bearing on the shaft.
(2) Remove the bearing from t h e o u t p u t shaft. Note Fig. 9 Extension Housing Bushing Replacement
t h a t A-727 transmissions have a second snap r i n g a t (2) O n A-998/999, remove t h e housing b u s h i n g
the f r o n t o f the shaft bearing. A-998/999 transmis- w i t h tool C-3996. O n A-727, remove t h e b u s h i n g
sions do not have t h i s second snap r i n g . w i t h tool C-3974 (Fig. 9).
(3) I n s t a l l the new bearing o n the shaft. Be sure
(3) O n A-998/A-999, slide the new bushing o n the
the large snap r i n g groove i n the outer circumference
i n s t a l l i n g end o f tool C-3996. O n A-727, slide t h e
of the b e a r i n g i s facing forward (Fig. 8).
b u s h i n g on i n s t a l l i n g end o f tool C-3974 (Fig. 9).
(4) I n s t a l l the rear snap r i n g to secure t h e bearing
(4) A l i g n the b u s h i n g o i l hole w i t h the o i l slot i n
on the shaft (Fig. 8). However, d o n o t i n s t a l l t h e
t h e extension housing. T h e n press or drive the bush-
large snap r i n g on the bearing. The large snap r i n g
i n g i n t o place (Fig. 9).
w i l l be installed i n t h e extension housing a t assem-
bly. (5) I n s t a l l a new o i l seal i n the housing. O n A-998/
A-999 use seal i n s t a l l e r C-3995. On A-727, use tool
EXTENSION HOUSING BUSHING C-3972 (Fig. 6).
REPLACEMENT
(1) Remove the housing o i l seal w i t h Tool C-3985 EXTENSION HOUSING INSTALLATION
(Fig. 5). (1) Position a new gasket on t h e extension housing.
21 - 78 AUTOMATIC TRANSMISSION •
(2) I n s t a l l t h e large snap r i n g (for shaft bearing) i n GOVERNOR SUPPORT
the extension housing. AND PARKING GEAR
(3) Slide t h e extension h o u s i n g onto t h e o u t p u t
shaft. W o r k t h e b a l l on the p a r k r o d past t h e sprag
w h i l e m a n u e v e r i n g the housing onto the shaft.
(4) Spread the large snap r i n g ( i n t h e housing) as
far as possible (Fig. 7).
(5) C a r e f u l l y tap the housing i n t o place and release
the snap r i n g . Be very sure t h e snap r i n g is f u l l y
seated i n t h e bearing outer race.
(6) I n s t a l l and t i g h t e n the housing-to-transmission
bolts t o 43 N - m (32 ft-lbs) torque.
GOVERNOR BODY
(7) I n s t a l l t h e gasket and access plate o n the u n -
derside o f t h e housing. LOCKING BOLTS (4)
(8) I n s t a l l t h e center crossmember and rear m o u n t
assembly. RH269
(9) Remove t h e supporting j a c k a n d lower t h e
transmission.
Fig. 10 Governor Snap Rings
(10) Install and tighten t h e housing- SPRING
to-crossmember bolts to 68 N*m (50 ft-lbs) torque. OUTER WEIGHT
(11) I n s t a l l the speedometer p i n i o n and adapter.
BODY
(12) A l i g n and i n s t a l l the propeller shaft.
(13) Lower the vehicle.
VALVE SHAFT
(14) Top off the transmission f l u i d level.

GOVERNOR AND PARK GEAR VALVE

GOVERNOR AND PARK GEAR REMOVAL

(1) Remove the extension housing and o u t p u t shaft
bearing as described i n this section.
(2) C a r e f u l l y pry the snap r i n g f r o m the w e i g h t end
of the governor valve shaft (Fig. 10).
(3) Slide t h e valve and shaft assembly out o f the
governor body.
(4) Remove t h e large snap r i n g f r o m t h e w e i g h t
end of the governor body and l i f t the governor valve
and w e i g h t assembly out of the body.
(5) Remove the snap r i n g f r o m inside the governor
weight a n d remove the inner w e i g h t and s p r i n g f r o m
the outer w e i g h t (Fig. 11).
(6) Remove t h e snap r i n g r e t a i n i n g t h e governor
and gear o n the output shaft (Fig. 10).
(7) Slide t h e governor and p a r k gear assembly o f f
the output shaft.
(8) Remove the bolts a t t a c h i n g t h e governor body
to the gear and separate the t w o components.
(9) Remove t h e filter screen f r o m t h e governor
body.
CLEANING AND INSPECTION
Thoroughly clean a l l the governor parts i n a s u i t -
able cleaning solution b u t do n o t use a n y type o f
caustic cleaning agents. The weights a n d valves
should slide freely i n the bores w h e n clean a n d d r y .
M i n o r surface scratches and b u r r s can be removed
w i t h crocus cloth. Inspect the governor w e i g h t s p r i n g
for distortion. Replace the spring, i f damaged. Clean
FILTER SCREEN SNAP RING RH270
Fig. 11 Governor Components
the f i l t e r i n solvent a n d d r y i t w i t h compressed a i r .
Replace t h e filter, i f damaged. Inspect the p a r k gear
for chipped or w o r n gear t e e t h or damaged r i n g
grooves. Replace the gear, i f damaged.
GOVERNOR AND PARK GEAR ASSEMBLY AND
INSTALLATION
(1) Assemble t h e governor body, screen a n d p a r k
gear. T i g h t e n the gear to governor bolts finger t i g h t .
M a k e sure the o i l passage i n t h e governor body
aligns w i t h m a t c h i n g passage i n the gear.
(2) I n s t a l l t h e assembled governor body a n d gear
on the o u t p u t shaft.
(3) Position the assembly so the valve shaft hole i n
the governor body aligns w i t h t h e hole i n t h e o u t p u t
shaft. T h e n slide the the assembly i n t o place.
(4) I n s t a l l the snap r i n g securing the governor and
p a r k gear t o the o u t p u t shaft (Fig. 10).
(5) T i g h t e n the bolts a t t a c h i n g the governor body
to the p a r k gear to 11 N»m (95 in-lbs) torque. The at-
taching bolts have a self-locking n y l o n patch a n d can
be reused.
(6) Assemble the governor weights and spring. Se-
cure the i n n e r weight and spring i n the outer w e i g h t
w i t h the snap r i n g (Fig. 11).
 • AUTOMATIC TRANSMISSION
(7) I n s t a l l t h e weight assembly i n t h e governor
body and i n s t a l l the r e t a i n i n g snap r i n g (Fig. 11).
(8) Place t h e governor valve on t h e valve shaft a n d
insert valve an<d shaft i n the body and t h r o u g h t h e
governor weights and o u t p u t shaft.
(9) Secure t h e valve shaft w i t h t h e s m a l l snap r i n g .
(10) I n s t a l l t h e o u t p u t shaft bearing a n d extension
housing as described i n t h i s section.
PARKING LOCK COMPONENTS
PARKING LOCK COMPONENT REMOVAL
(1) Remove t h e extension housing as described i n
t h i s section.
(2) Slide the sprag shaft out of t h e extension hous-
i n g and remove the p a r k i n g sprag and s p r i n g (Fig.
12).
(3) Remove t h e snap r i n g and slide t h e reaction
p l u g and p i n assembly out o f the housing.
(4) To replace the p a r k i n g lock control r o d , refer t o
V a l v e Body Removal and I n s t a l l a t i o n .
Fig. 12 Parking Lock Components
COMPONENT INSPECTION
Inspect t h e sprag shaft for scores and free move-
ment i n the housing and sprag. Inspect t h e sprag and
control rod springs for distortion and loss o f tension.
Inspect the square l u g on the sprag for b r o k e n edges.
Check the lugs on the p a r k gear for damage. Inspect
the b a l l on t h e end of the control rod for nicks a n d
burrs. Also be sure the b a l l rotates freely.
PARKING LOCK COMPONENT INSTALLATION
(1) I n s t a l l t h e reaction p l u g and p i n assembly i n
the housing a n d secure w i t h a new snap r i n g (Fig.
12).
(2) Position t h e sprag and spring i n t h e housing
and insert the sprag shaft. M a k e sure the square l u g
on t h e sprag i s t o w a r d the p a r k gear. Also be sure
the s p r i n g is positioned so i t moves the sprag away
from t h e gear.
(3) Replace t h e p a r k i n g lock control rod i f neces-
sary.,
(4) I n s t a l l t h e extension housing as described i n
t h i s section.
21 - 79
VALVE BODY REMOVAL
(1) Raise the vehicle.
(2) Remove the o i l pan and d r a i n t h e fluid.
(3) Loosen the clamp bolts and remove the t h r o t t l e
and m a n u a l valve levers f r o m t h e m a n u a l valve
shaft.
(4) Remove t h e n e u t r a l s t a r t a n d backup l a m p
switch (Fig. 4).
(5) Remove the filter from the valve body.
(6) Remove the valve body a t t a c h i n g screws.
(7) Lower a n d remove t h e valve body. P u l l t h e
valve body forward t o disengage t h e p a r k lock r o d
and remove valve body. I f necessary, rotate t h e pro-
peller shaft so the p a r k lock r o d w i l l clear the sprag.
(8) Remove the accumulator piston and spring from
the transmission case (Fig. 13).
FRONT/REAR SERVO
The front and rear servos are accessible and can be
Fig. 13 Accumulator Piston And Spring
serviced after valve body removal. Refer to the servo
overhaul procedures i n t h e Transmission O v e r h a u l
section
VALVE BODY DISASSEMBLY
CAUTION: Tag all valve body springs for reference
as they are removed. Do not clamp any part of the
valve body in a vise. This practice will distort the
valve body and transfer plate and result in valve
bind. When removing the valves and plugs, slide
them out carefully. Do not use force at any time.
The valves and valve body will both be damaged if
force is used.
TRANSFER PLATE/CHECK BALL REMOVAL
(1) M o u n t valve body on repair stand (Fig. 14).
(2) Remove lock r o d E-clip (Fig. 12) and remove
p a r k lock rod f r o m valve body.
(3) Remove top and bottom screws f r o m s p r i n g re-
t a i n e r a n d adjusting screw bracket ( F i g . 15).Hold
spring retainer firmly against spring force w h i l e re-
m o v i n g last screw.
(4) Remove spring retainer and bracket and l i n e
pressure adjusting screw assembly. D o n o t d i s t u r b
a d j u s t i n g screw settings.
21 - 80 AUTOMATIC TRANSMISSION

TRANSFER PLATE SPRING RETAINER LOCKUP MODULE REMOVAL

AND LINE PRESSURE (1) Remove lockup module (or stiffener plate o n
ADJUSTING SCREW
BRACKET
nonlockup models) (Fig. 16).
(2) Remove lockup module e n d plate a n d remove
lockup a n d failsafe valves a n d springs. O n n o n -
FLUID l o c k u p C a l i f o r n i a A-998 m o d e l s , a n e m p t y
FILTER
l o c k u p module is used instead o f a stiffener
plate.
(3) Remove lockup module connecting t u b e ( F i g .
SCREW 16).
07)
TRANSFER PLATE/SEPARATOR PLATE/
VALVE BODY CHECK BALL REMOVAL
(1) Remove transfer plate screws and remove t r a n s -
fer plate and separator plate (Fig. 17).
REPAIR STAND LINE PRESSURE
ADJUSTING SCREW
(2) Remove lockup module solenoid r e t a i n i n g screw
THROTTLE LEVER" MANUAL and p u l l solenoid out of transfer plate.
AND SHAFT LEVER ASSEMBLY
PUS (3) Remove screws a t t a c h i n g transfer a n d separator
plates a n d remove t h e separator plate f r o m t h e
Fig. 14 Valve Body Mounted On Repair Stand transfer plate (Fig. 17).
(5) Remove s w i t c h valve, pressure regulator valve (4) O n 999 models, remove a n d r e t a i n rear (low-re-
and valve springs (Fig. 15). verse) servo check b a l l (Fig. 17).
(5) Remove rear clutch check b a l l (Fig. 17).
(6) Remove and inspect the f i l t e r screen i n t h e sep-
arator plate (Fig. 17). Replace t h e screen i f damaged.

DETENT BALL AND SPRING MANUAL LEVER WASHER " E " CLIP
ASSEMBLY

SEAL

MANUAL VALVE
THROTTLE LEVER
ASSEMBLY
SWITCH VALVE

SWITCH VALVE SPRING

LINE PRESSURE
REGULATOR VALVE
LINE PRESSURE ADJUSTING
SCREW ASSEMBLY
LINE PRESSURE
REGULATOR SPRING
THROTTLE PRESSURE
ADJUSTING SCREW

SPRING RETAINER AND

ADJUSTING SCREW BRACKET

PU8A

Fig. 15 Pressure Regulators And Manual Controls

 • AUTOMATIC TRANSMISSION 21 - 81

TUBE

LONG END MUST BE TOWARD

LOCK-UP MODULE

LOCK-UP MODULE

FAIL-SAFE SPRING

FAIL-SAFE VALVE

SCREW®
LOCK-UP VALVE"

LOCK-UP SPRING'

END PLATE

PU9B

Fig. 16 Lockup Module Components

PRESSURE REGULATOR LOW-REVERSE SERVO 1/4 INCH DIAMETERp?\
FILTER SCREEN BALL CHECK
(NOT USED ON A-727) BALLS l&J ) SMALL ORIFICE INTO
1-2 SHIFT CONTROL BORE

SEPARATOR PLATE

REAR CLUTCH BALL

CHECK VALVE
1/4 INCH DIAMETER BALLS
TRANSFER PLATE p u i o c
11/32 INCH DIAMETER BALL PU11

Fig. 17 Transfer And Separator Plates Fig. 18 Valve Body Check Balls
(7) Remove t h e valve body check balls (Fig. 18). (5) Remove t h e E-clip and remove the shuttle valve
Note check b a l l sizes and location for assembly refer- secondary spring and guides (Fig. 19).
ence.
MANUAL VALVE/THROTTLE LEVER REMOVAL
SHUTTLE VALVE/GOVERNOR PLUG REMOVAL (1) Remove m a n u a l lever E-clip, washer and seal
(FIG. 19) (Fig. 15).
(1) T u r n t h e v a l v e body over. (2) Remove a n y burrs f r o m t h r o t t l e valve shaft b y
(2) Remove the s h u t t l e valve end plate (Fig. 19). polishing w i t h crocus cloth o r very fine g r i t paper.
(3) Remove t h e governor p l u g end plate (Fig. 19). (3) Secure detent b a l l and s p r i n g (Fig. 14) w i t h tool
(4) Remove the s h u t t l e valve, plug, s p r i n g a n d gov- C-3765 a n d slide m a n u a l lever off t h r o t t l e shaft (Fig.
ernor plugs (Fig. 19). 14).
21 - 82 AUTOMATIC TRANSMISSION •
SHUTTLE VALVE
CLIP
SPRING
GUIDESC2)*

SHUTTLE
VALVE
SECONDARY
SPRING

1-2 SHIFT VALVE

GOVERNOR PLUG

SHUTTLE VALVE

GOVERNOR PLUG
END PLATE 2-3 SHIFT VALVE
GOVERNOR PLUG

SHUTTLE VALVE PRIMARY SPRING

SHUTTLE VALVE THROTTLE PLUG

SCREWS)

PU12

Fig. 19 Shuttle Valve And Governor Plugs

(4) Remove and r e t a i n detent b a l l and s p r i n g (Fig.
15).
(5) Remove t h r o t t l e lever assembly (Fig. 15).
(6) Remove m a n u a l valve, k i c k d o w n valve a n d de-
tent, and t h r o t t l e valve components (Fig. 15).
SHIFT VALVES/PRESSURE REGULATOR PLUG
REMOVAL
(1) Remove the l i n e pressure end plate and remove
the line pressure p l u g and sleeve a n d t h e t h r o t t l e
pressure p l u g and s p r i n g (Fig. 20).
(2) Remove t h e l i m i t valve end plate a n d l i m i t
valve housing i f equipped (Fig. 20).
(3) Remove the t h r o t t l e p l u g from the housing (Fig.
20).
(4) Slide t h e retainer from the housing and remove
the l i m i t valve and s p r i n g (Fig. 20).
(5) Remove the 1-2 a n d 2-3 shift valves and springs
from the valve body (Fig. 20).
VALVE BODY CLEANING AND INSPECTION
Clean t h e valve body components i n clean solvent.
D r y t h e parts w i t h compressed air. M a k e sure a l l
passages are clean and free from obstructions.
Inspect t h e t h r o t t l e a n d m a n u a l valve levers a n d
shafts. D o n o t a t t e m p t t o s t r a i g h t e n a b e n t s h a f t
or c o r r e c t a loose lever. R e p l a c e these c o m p o -
n e n t s i f w o r n , bent, loose o r d a m a g e d i n a n y
way.
Inspect a l l o f the valve body m a t i n g surfaces for
scratches, n i c k s , burrs, or distortion. Use a s t r a i g h t -
edge t o check surface flatness. M i n o r scratches m a y
be removed w i t h crocus cloth using only very l i g h t
pressure. M i n o r d i s t o r t i o n o f a m a t i n g surface m a y
be corrected b y smoothing t h e surface w i t h a sheet o f
crocus c l o t h placed on a surface plate (or equally f l a t
surface). I f d i s t o r t i o n is severe or a n y surfaces are
h e a v i l y scored, t h e valve body w i l l have to be r e -
placed.
V e r i f y t h a t the 1-2 shift orifice is clear. Check t h e
orifice b y i n s e r t i n g a .79 m m (1/32 inch) diameter
d r i l l b i t t h r o u g h t h e orifice and i n t o t h e 1-2 shift
bore.
Inspect t h e valves and plugs for scratches, b u r r s ,
nicks, o r scores. M i n o r surface scratches can be r e -
moved w i t h crocus cloth b u t do not r o u n d off the
edges o f the v a l v e o r p l u g lands. M a i n t a i n i n g t h e
 # — : — AUTOMATIC TRANSMISSION 21 - 83

2-3 SHIFT VALVE

1-2 SHIFT
CONTROL
VALVE

REGULATOR VALVE
THROTTLE PRESSURE
PLUG SPRING END PLATE

3-2 DOWNSHIFT
AND LIMIT
VALVE ASSEMBLY
(USED ON SOME
V-8 MODELS)
REGULATOR VALVE / SLEEVE^
THROTTLE PRESSURE
PLUG END PLATE RY151A

Fig. 20 Shift And Pressure Regulator Valves/Plugs

sharpness of these edges i s v i t a l l y i m p o r t a n t . These SHIFT VALVE/PRESSURE REGULATOR PLUG
edges prevent foreign m a t t e r from lodging between INSTALLATION (FIG. 20)
the valves and plugs a n d t h e bore. (1) I n s t a l l 1-2 and 2-3 shift valves and t h r o t t l e and
Inspect a l l the valve a n d p l u g bores i n the valve pressure r e g u l a t i n g plugs and springs.
body. Use a p e n l i g h t to v i e w t h e bore i n t e r i o r s . Re- (2) O n models so equipped, i n s t a l l l i m i t valve and
place t h e valve body i f a n y bores are distorted or s p r i n g a n d t h r o t t l e p l u g i n l i m i t valve housing. T h e n
scored. Inspect a l l o f t h e valve body springs. The secure l i m i t valve a n d spring w i t h retainer.
springs m u s t be free of distortion, warpage or broken (3) I n s t a l l pressure plugs, sleeve and spring.
coils.
(4) I n s t a l l s m a l l end plate.
T r i a l f i t each valve a n d p l u g i n its bore t o check
(5) I n s t a l l l i m i t valve housing and end plate.
freedom of operation. W h e n clean and dry, t h e valves
and plugs should slide freely i n t h e bores. V a l v e body SHUTTLE VALVE/GOVERNOR PLUG
bores do not change dimensionally w i t h use. I f the INSTALLATION (FIG. 19)
valve body functioned correctly when new, i t w i l l
(1) I n s t a l l 1-2 a n d 2-3 shift valve governor plugs i n
continue t o operate properly after repair. I t should
t h e i r respective bores.
not be necessary t o replace a valve body assembly
(2) I n s t a l l s h u t t l e valve and hold i t i n place w i t h
unless i t is damaged i n h a n d l i n g .
index finger w h i l e i n s t a l l i n g secondary spring,
guides a n d E-clip.
VALVE BODY ASSEMBLY
(3) I n s t a l l p r i m a r y shuttle valve spring a n d t h r o t -
tle plug.
CAUTION: Do not force any valves or plugs into (4) I n s t a l l governor p l u g end plate and shuttle
place during reassembly. If the valves, plugs and valve cover plate. T i g h t e n plate r e t a i n i n g screws to 4
bores are free of distortion or burrs, they should N - m 35 in-lbs (4 N n n ) torque.
slide into place easily. In addition, do not over-
tighten the valve body screws during reassembly. MANUAL VALVE/THROTTLE LEVER
Overtightening will distort the valve body resulting INSTALLATION
in valve sticking, cross leakage and unsatisfactory (1) I n s t a l l t h r o t t l e valve and spring, k i c k d o w n
operation. Tighten the screws alternately and valve a n d valve detent i n valve body (Fig. 15).
evenly to 4 N«m (35 in-lbs) torque.
21 - 84 AUTOMATIC TRANSMISSION
(2) I n s t a l l t h e m a n u a l valve (Fig. 15).
(3) I n s t a l l t h r o t t l e lever i n valve body (Fig. 15).
(4) Insert detent b a l l a n d s p r i n g i n bore. Compress
spring w i t h t o o l C-3765 and a n d slide m a n u a l lever
onto t h r o t t l e lever shaft (Fig. 21).
(5) I n s t a l l seal, r e t a i n i n g washer and E-clip o n t o
secure m a n u a l lever o n t h r o t t l e lever shaft (Fig. 15).
Fig. 21 Installing Detent Ball And Spring
INSTALLING FILTER/TRANSFER PLATE/
LOCKUP SOLENOID/PRESSURE
REGULATORS/CHECK BALL
(1) I n s t a l l check balls i n valve body (Fig. 18).
(2) I n s t a l l rear c l u t c h check b a l l i n transfer plate
(Fig. 17).
(3) I n s t a l l low-reverse servo b a l l check i n transfer
plate. T h i s b a l l c h e c k i s o n l y u s e d i n A-998/999
transmissions.
(4) I n s t a l l pressure r e g u l a t o r f i l t e r screen i n sepa-
r a t o r plate (Fig. 17).
(5) Assemble transfer and separator plates and i n -
stall three a t t a c h i n g screws i n transfer plate.
(6) Position transfer plate o n valve body. A l i g n
pressure r e g u l a t o r f i l t e r screen a n d i n s t a l l transfer
plate screws finger t i g h t . T h e short screws are for
the transfer plate a n d valve body. The three long
screws are f o r the f l u i d filter.
(7) T i g h t e n transfer plate screws evenly to 4 N T H
(35 in-lbs) torque. T i g h t e n screws s t a r t i n g a t center
and w o r k i n g o u t w a r d .
(8) I n s t a l l s w i t c h valve, l i n e pressure valve a n d
valve springs i n valve body bore (Fig. 15).
(9) Assemble a n d i n s t a l l l i n e pressure adjusting
screw a n d t h r o t t l e pressure adjusting screw a n d
bracket assembly ( F i g . 15). Secure t h e components
w i t h one screw for t h e t i m e being. Use t h e screw
t h a t goes i n t o t h e side o f the valve body.
(10) I n s t a l l lockup valve a n d spring. T h e n i n s t a l l
fail safe s p r i n g and valve i n lockup module (Fig. 16).
(11) I n s t a l l lockup module 9or stiffener plate) on
•
transfer a n d separator plates. B e sure connecting
tube is properly seated i n valve body a n d lockup
module. T h e n i n s t a l l and t i g h t e n module a t t a c h i n g
screws t o 4 N m (35 in-lbs) torque.
#
(12) I n s t a l l n e w O-ring o n lockup solenoid nozzle.
T h e n i n s t a l l nozzle i n transfer plate bore and t i g h t e n
r e t a i n i n g screw t o 35 in-lbs) torque.
(13) Route lockup solenoid w i r e between solenoid
and l i m i t valve housing cover and under edge o f f l u i d
filter. S o l e n o i d w i r e r o u t i n g i s e x t r e m e l y i m p o r -
t a n t . T h e w i r e m u s t b e r o u t e d a w a y from t h e
low-reverse b a n d lever.
(14) Secure pressure adjusting screw bracket t o
valve body w i t h r e m a i n i n g a t t a c h i n g screw.
(15) Check and adjust valve body pressure settings
i f necessary. Refer t o procedure i n Maintenance A n d
Adjustments section.
(16) Secure p a r k lock control r o d to valve body
w i t h n e w E-clip (Fig. 12).
MANUAL LEVER SHAFT SEAL
I f the lever shaft seal m u s t be replaced, t a p i t out
of the transmission case w i t h a punch. T h e n i n s t a l l
the new seal w i t h a 15/16 socket (Fig. 22).
Fig. 22 Installing Manual Lever Shaft Seal
VALVE BODY INSTALLATION
(1) V e r i f y t h a t n e u t r a l start s w i t c h has N O T been
installed i n the case. Valve body cannot be i n s t a l l e d
w i t h s w i t c h i n place. Remove the switch i f necessary.
(2) I n s t a l l n e w seals on accumulator piston and i n -
stall piston i n case.
(3) Place valve body m a n u a l lever i n l o w (1 posi-
tion) so b a l l o n p a r k lock r o d can be i n s t a l l e d i n
sprag.
(4) Use screwdriver to push p a r k sprag i n t o e n -
gagement w i t h p a r k gear. This allows b a l l o n p a r k
lock r o d t o move past sprag w h e n valve body is i n -
stalled. Rotate output to verify sprag engagement.
(5) Position accumulator spring between piston a n d
valve body.
(6) Position valve body on transmission a n d w o r k
b a l l on p a r k lock rod past the sprag.
 • AUTOMATIC TRANSMISSION
(7) H o l d t h e valve body i n position a n d i n s t a l l t h e
valve body attaching bolts finger t i g h t only.
(8) I n s t a l l n e u t r a l start a n d backup l a m p switch i n
case.
(9) Move m a n u a l lever t o N e u t r a l position.
(10) Move valve body as needed t o a l i g n n e u t r a l
finger of m a n u a l lever w i t h plunger o f n e u t r a l s t a r t
switch.
(11) T i g h t e n valve body a t t a c h i n g screws alter-
nately and evenly t o 11 N n n (100 in-lbs) torque.
(12) I n s t a l l new fluid f i l t e r o n valve body. I n s t a l l
and t i g h t e n the three, long f i l t e r screws t o 4 N n n (35
in-lbs) torque.
(13) I n s t a l l m a n u a l a n d t h r o t t l e levers on t h r o t t l e
lever shaft. T i g h t e n lever clamp screws and check for
free operation. Shaft a n d levers m u s t operate freely
w i t h o u t any b i n d .
(14) I n s t a l l o i l p a n a n d n e w gasket. Tighten p a n
bolts to 17 N n n (150 in-lbs) torque.
(15) Connect n e u t r a l s w i t c h a n d lockup solenoid
wires.
(16) I n s t a l l t h e speedometer p i n i o n gear, adapter
and distance sensor.
(17) Lower t h e vehicle.
(18) F i l l transmission w i t h Mopar A T F Plus, type
7176, or Dexron II™ f l u i d .
(19) Adjust gearshift a n d t h r o t t l e linkage.
TRANSMISSION COOLER SERVICE
FLUSHING COOLERS AND LINES
I f a transmission m a l f u n c t i o n contaminates t h e
f l u i d , t h e cooler a n d lines m u s t be reverse flushed
thoroughly. This is necessary t o prevent sludge a n d
particles from flowing back i n t o t h e transmission af-
t e r repair. The f l u s h i n g procedure applies to stan-
dard a n d a u x i l i a r y coolers.
Pressure equipment is preferred for cooler reverse
flushing. However, reverse f l u s h i n g can be performed
w i t h hand operated equipment as follows.
Flushing Procedure
(1) Identify a n d disconnect t h e cooler pressure a n d
r e t u r n lines a t t h e transmission.
(2) Position a d r a i n p a n under t h e cooler pressure
l i n e t o catch m a t e r i a l flushed t h r o u g h t h e cooler and
lines.
(3) Reverse flush t h e cooler u s i n g a h a n d operated
suction g u n f i l l e d w i t h m i n e r a l spirits. Insert t h e
g u n nozzle (or hose) into t h e cooler r e t u r n line. Then
force m i n e r a l spirits i n t o t h e line a n d t h r o u g h t h e
cooler.
(4) Continue reverse f l u s h i n g u n t i l t h e f l u i d e x i t i n g
t h e cooler pressure line is clear and free from debris.
Replace t h e cooler i f f l u i d cannot be pumped
through it.
21 - 85
(5) Clear t h e f l u s h i n g materials f r o m t h e cooler
and lines w i t h short pulses o f compressed air. Insert
the a i r g u n nozzle i n t o t h e cooler r e t u r n l i n e a n d
continue the short a i r pulses u n t i l a l l fluid is cleared
from t h e cooler a n d lines.
(6) P u m p one q u a r t o f automatic transmission fluid
t h r o u g h t h e cooler a n d lines before reconnecting t h e
lines.
CHECKING COOLER FLUID FLOW
Cooler flow is checked, b y measuring the amount o f
f l u i d pumped t h r o u g h t h e cooler i n a specified t i m e
by t h e transmission o i l p u m p .
(1) Disconnect t h e cooler r e t u r n line from t h e
transmission a n d place i t i n a one q u a r t test con-
tainer.
(2) A d d extra q u a r t of fluid t o transmission.
(3) Use stopwatch t o check test t i m e .
(4) Shift into N e u t r a l .
(5) S t a r t a n d r u n engine a t curb idle speed a n d
note cooler flow. A m i n i m u m o f one q u a r t (0.9 l i t e r )
of fluid should flow i n t o test container i n 20 seconds.
(6) I f fluid flow i s i n t e r m i t t e n t , flows less t h a n one
quart i n 20 seconds, or fails t o flow a t a l l , cooler i s
plugged or damaged and should be replaced.
I f a transmission malfunction contaminates t h e
fluid, the fluid coolers a n d lines m u s t be flushed
thoroughly. T h i s is necessary t o prevent sludge a n d
particles from flowing back i n t o t h e transmission af-
ter repair. T h e flushing procedure applies t o stan-
dard and a u x i l i a r y coolers.
MAIN COOLER REPLACEMENT
The m a i n transmission cooler is located i n t h e r a -
diator lower t a n k . T h e cooler is n o t a serviceable
component. I f the cooler i s damaged i n any w a y , t h e
radiator w i l l have t o be replaced.
AUXILIARY COOLER REPLACEMENT
(1) Remove g r i l l e .
(2) Remove brackets securing cooler to radiator a n d
raditor support ( F i g . 23).
(3) T a g cooler hoses for i n s t a l l a t i o n reference ( F i g .
23).
(4) Position d r a i n p a n under cooler lines.
(5) Loosen cooler connecting hose clamps a n d dis-
connect t h e hoses.
(6) Remove t h e cooler
(7) Connect cooler t o hoses.
(8) Position cooler on r a d i a t o r a n d i n s t a l l cooler
support brackets a n d a t t a c h i n g fasteners.
(9) T i g h t e n cooler hose clamps securely.
(10) I n s t a l l g r i l l e .
(11) Check a n d adjust transmission fluid level.
21 - 86 AUTOMATIC TRANSMISSION
Fig. 23 Au
ALUMINUM THREAD REPAIR
Damaged or w o r n threads i n the a l u m i n u m trans-
mission case and i n t h e valve body can be repaired
w i t h Heli-Coil or equivalent q u a l i t y t h r e a d inserts.
Essentially, repair, consists o f d r i l l i n g out the w o r n
•
ary Cooler
or damaged threads, t a p p i n g the hole w i t h a special
tap and i n s t a l l i n g a t h r e a d insert i n t o t h e tapped
hole. T h i s procedure r e t u r n s the hole threads t o orig-
i n a l size. H e l i - C o i l , or equivalent, tools and inserts
are r e a d i l y available f r o m most automotive parts
suppliers.
 • AUTOMATIC TRANSMISSION 21 - 87

TRANSMISSION AND TORQUE CONVERTER REMOVAL/INSTALLATION

INDEX
Page Page
Converter And Drive Plate Service 88 Transmission And Converter Installation . . . . . . . . 89
Pump Oil Sea! 88 Transmission And Converter Removal 87
Starter Ring Gear Replacement 87

TRANSMISSION AND CONVERTER REMOVAL (15) I n s t a l l engine support f i x t u r e Tool C-3487-A

w i t h frame hooks (or a suitable substitute) t o support
The transmission a n d torque converter must rear o f engine (Fig. 1).
be r e m o v e d as a n assembly; o t h e r w i s e , the con- (16) Raise transmission s l i g h t l y w i t h service j a c k
v e r t e r d r i v e p l a t e , p u m p b u s h i n g , o r o i l seal m a y to relieve load on the supports.
be damaged. T h e drive plate w i l l n o t support (17) Remove bolts securing transmission m o u n t t o
transmission weight. D o not allow t h e plate t o crossmember and crossmember t o frame a n d remove
support transmission weight a t any time during crossmember.
removal. (18) Remove a l l converter h o u s i n g bolts.
(1) Disconnect the battery negative cable. (19) Carefully w o r k transmission and torque con-
(2) Disconnect and lower or remove necessary ex- verter assembly rearward o f f engine block dowels
haust components. Refer to Group 11 f o r procedures. and disengage torque converter h u b from end of
crankshaft. A t t a c h a small C-clamp to edge o f bell
(3) Remove engine-to-transmission struts, i f so
housing t o hold torque converter i n place d u r i n g
equipped.
transmission removal.
(4) Remove fluid cooler lines a t transmission.
(20) Lower transmission a n d remove assembly from
(5) Remove starter motor and cooler l i n e bracket.
under the vehicle.
(6) Remove torque converter access cover.
(21) To remove torque converter, remove C-clamp
(7) Loosen o i l pan bolts and t a p p a n t o break i t
from edge o f bell housing and carefully slide torque
loose a l l o w i n g fluid to d r a i n . T h e n r e i n s t a l l pan. converter out of the transmission.
(8) M a r k torque converter and d r i v e plate for as-
sembly alignment. The crankshaft flange bolt circle,
i n n e r a n d outer circle o f holes i n t h e d r i v e plate and
t h e tapped holes i n t h e front face o f t h e torque con-
verter a l l have one hole offset. T h i s ensures t h a t
these parts are i n s t a l l e d i n the o r i g i n a l position t o
m a i n t a i n balance of the engine a n d torque converter.
(9) Rotate engine i n clockwise direction ( w i t h
socket w r e n c h on v i b r a t i o n dampener bolt) u n t i l con-
verter bolts are accessible. Then remove t h e bolts.
(10) M a r k propeller shaft U-joint a n d axle yoke
parts for assembly alignment. T h e n disconnect and
remove popeller shaft.
(11) Disconnect wires from n e u t r a l s t a r t switch and
lockup solenoid, i f so equipped.
(12) Disconnect gearshift rod and torque shaft as-
sembly f r o m transmission. W h e n necessary to discon-
nect l i n k a g e rods f r o m levers t h a t use plastic
grommets as retainers, grommets should be replaced Fig. 1 Typical Engine Support Fixture
w i t h n e w ones. Use p r y tool t o remove r o d from STARTER RING GEAR REPLACEMENT
g r o m m e t a n d cut away old grommet. Use pliers to
snap n e w grommet i n t o lever a n d t o snap rod r o d The starter r i n g gear on nonlockup torque convert-
i n t o grommet a t assembly. ers can be removed and a new gear welded i n place.
(13) Disconnect t h r o t t l e rod f r o m lever a t the left However, lockup torque converters w i t h a damaged
side o f transmission. Remove l i n k a g e b e l l c r a n k from starter r i n g gear m u s t be replaced as a n assembly.
transmission, i f so equipped. The heat from welding w o u l d damage the converter
(14) Remove oil f i l l e r tube and speedometer cable. lockup clutch friction m a t e r i a l .
21 - 88 AUTOMATIC TRANSMISSION
The starter ring gear is mounted directly on the
outer diameter of the torque converter front cover.
Gear replacement is as follows:
RING GEAR REMOVAL
(1) C u t through weld material at rear side of ring
gear w i t h a hack saw or grinding wheel. B e careful
not to cut or grind into front cover stamping.
(2) Scribe heavy line on front cover next to front
face of ring gear. L i n e is needed to properly locate
new gear on converter.
(3) Support torque converter on front cover with
blocks of wood (Fig. 2) Position blocks adjacent to
converter lugs to avoid altering lug position. T h e
torque c o n v e r t e r m u s t n o t r e s t o n t h e front
c o v e r h u b d u r i n g this operation.
(4) U s i n g blunt chisel or drift and a hammer, tap
downward on ring gear near welded areas to break
any remaining weld material (Fig. 2).
(5) T a p around ring gear until it comes off the
torque converter.
(6) Smooth off weld areas on the cover with a file.
Fig. 2 Removing Starter Ring Gear
RING GEAR INSTALLATION
(1) Heat and expand the new starter ring gear for
installation on the converter. A n y of the following
methods are acceptable:
(a) Oven: Place gear i n oven and set tempera-
ture at 200° F (93° C) Allow ring gear to remain i n
oven for 15 to 20 minutes.
(b) Boiling Water: Place ring gear i n shallow
container. Add water and heat for approximately
eight minutes after water has come to a boil.
(c) Steam: Place ring gear on a flat surface and
direct a steam flow around gear for approximately
2 minutes.
(d) Flame: Place ring gear squarely on a flat
surface. Using a medium size tip, direct a slow
flame evenly around inner r i m of the gear. Do not
apply flame to the gear teeth. Place a few drops of
•
water on face of gear at intervals during heating
process. When gear is hot enough to just boil the
water, gear is ready for installation.
(2) After ring gear is expanded by heating, imme-
diately place gear i n position on converter front
cover.
(3) Quickly tap gear onto cover evenly with plastic
or rawhide mallet. Continue tapping gear until face
of gear is even with scribe line (made during r e -
moval) on the front cover.
(4) Before proceeding, make sure gear is even with
scribed line around full circumference of the front
cover.
(5) The following suggestions are offered as a n aid
in welding the new ring gear to the converter. D o
not g a s w e l d w i t h o x y - a c e t y l e n e equipment. U s e
a D.C. welder set at straight polarity, or use an A . C .
welder i f the proper electrode i s available. U s e a 3
mm (1/8 inch) diameter welding rod and a welding
current of 80 to 125 amps. Direct the arc at the i n -
tersection of the gear and front cover from a n angle
of 45 degrees from the rear face of the gear.
(6) Weld new ring gear to torque converter front
cover. Take care to place same amount of weld mate-
rial (or as nearly as possible) i n original weld loca-
tions. This is essential i n maintaining converter
balance. Position welds alternately on opposite sides
of converter and ring gear to minimize distortion.
(7) Inspect gear teeth and remove a l l nicks where
metal is raised, weld metal splatter, etc., i n order to
ensure quiet starter operation.
PUMP OIL SEAL
SEAL REPLACEMENT
The pump oil seal can be replaced without remov-
ing pump and reaction shaft support assembly from
the transmission case.
To remove the seal use remover tool C-3981 on A -
998/999 transmission, or tool C-3861 on A-727 trans-
mission. Thread the seal remover tool into the seal.
Then tighten the tool puller screw to withdraw the
seal (Fig. 3).
To install the seal, use driver handle C-4171 and
installer tool C-4193 (A-998/999) or installer tool C -
3860-A (A-727). Place the new seal i n the pump
opening with the seal lip facing inward. Then tap the
seal into place with the driver handle and installer
tool (Fig. 4).
CONVERTER AND DRIVE PLATE SERVICE
After the transmission has been removed, the drive
plate and torque converter can replaced or removed
for service access.
The torque converter is not a serviceable part. I f
the converter is contaminated or damaged i n any
way, it must be replaced as a n assembly. D o n o t a t -
 • AUTOMATIC TRANSMISSION
Fig. 3 Pump Seal Removal
Fig. 4 Pump Seal Installation
t e m p t t o flush a c o n v e r t e r c o n t a m i n a t e d b y
metal o r c l u t c h facing particles. F l u s h i n g w i l l
n o t r e m o v e these c o n t a m i n a n t s .
TRANSMISSION AND CONVERTER INSTALLATION
(1) I f the torque converter was removed, a l i g n the
p u m p gears before i n s t a l l i n g the converter.
(2) Rotate converter u n t i l drive slots i n converter
h u b are aligned w i t h rotor lugs. Then remove a l i g n -
i n g tool a n d carefully insert converter h u b i n t o
p u m p . Be sure converter is fully seated i n p u m p
gears.
(3) Check converter seating w i t h a scale a n d
straightedge ( F i g . 5). Surface of converter lugs
should be 1/2 i n c h to rear of straightedge w h e n con-
v e r t e r is f u l l y seated.
(4) T e m p o r a r i l y secure converter w i t h C-clamp a t -
tached to housing or w i t h metal strap attached
across converter housing.
(5) Position transmission on jack and secure i t w i t h
chains.
21 - 89
Fig. 5 Checking Torque Converter Seating
(6) Check condition of converter driveplate. Replace
the plate i f cracked, distorted or damaged. I f d r i v e -
plate r e p l a c e m e n t was necessary, b e sure trans-
m i s s i o n d o w e l pins a r e seated i n engine b l o c k
and protrude far enough to held transmission i n
alignment.
(7) Coat p i l o t hub of torque converter w i t h Mopar
h i g h temperature grease.
(8) Raise transmission a n d a l i g n converter w i t h
drive plate.
(9) Move transmission forward. T h e n raise, lower
or t i l t transmission to a l i g n converter housing w i t h
engine block dowels.
(10) Rotate converter so a l i g n m e n t m a r k s scribed
on converter are aligned w i t h m a r k o n driveplate.
The offset holes i n plate are n e x t t o 1/8 i n c h hole i n
i n n e r circle o f plate (Fig. 6).
(11) Carefully w o r k transmission f o r w a r d and over
engine block dowels u n t i l converter h u b is seated i n
crankshaft.
(12) I n s t a l l bolts attaching converter housing to en-
gine. T i g h t e n bolts to 4 1 N T H (30 ft-lbs) torque.
(13) I n s t a l l crossmember. T h e n lower transmission
onto crossmember and i n s t a l l bolts a t t a c h i n g trans-
mission m o u n t to crossmember.
(14) Remove engine support f i x t u r e .
(15) I n s t a l l distance sensor a n d speedometer.
(16) Connect gearshift a n d t h r o t t l e l i n k a g e to
transmission. I f a n y l i n k a g e r o d s w e r e d i s c o n -
n e c t e d , r e p l a c e t h e p l a s t i c g r o m m e t s t h a t se-
c u r e d the linkage r o d t o the lever.
(17) Connect the wires to the n e u t r a l s t a r t switch,
lockup solenoid a n d oxygen sensor. Be sure t h e
transmission harnesses are properly routed (Figs. 7-
8).
(18) I n s t a l l torque converter-to-driveplate bolts.
T i g h t e n bolts to 31 N-m (23 ft-lbs) torque.
 21 - 90 AUTOMATIC TRANSMISSION
4
ENGINE

Fig. 6 Torque Converter And Driveplate Markings

J9021-75

Fig. 8 Transmission Wire Routing—A-500/518

SENSOR

NEUTRAL START AND

BACKUP LAMP SWITCH
J9021-76

Fig. 7 Transmission Wire Routing—A-998/999/727

(19) I n s t a l l converter housing access cover.
(20) I n s t a l l starter motor and cooler l i n e bracket.
(21) Connect cooler lines to transmission.
(22) I n s t a l l transmission f i l l tube ( F i g . 9). I n s t a l l
new seal on tube before i n s t a l l a t i o n .
(23) Install engine-to-transmission struts, i f Fig. 9 Strut And Fill Tube Mounting
equipped (Fig. 9). T i g h t e n strut-to-transmission bolts (25) A l i g n a n d i n s t a l l propeller shaft.
first and to 17 N m (150 in-lbs) torque. T i g h t e n s t r u t -
#
(26) Adjust gearshift and t h r o t t l e linkages.
to-engine bolts last and to 41 N m (30 ft-lbs) torque.
#
(27) F i l l transmission w i t h Mopar A T F Plus, type
(24) I n s t a l l exhaust components. 7176, or Dexron n™ fluid.
 • AUTOMATIC TRANSMISSION 21 - 91

TRANSMISSION OVERHAUL

TRANSMISSION DISASSEMBLY
(1) Clean transmission exterior w i t h a steam
cleaner or w i t h solvent. Cleanliness d u r i n g overhaul
is extremely i m p o r t a n t . Clean a l l parts w i t h solvent
a n d d r y w i t h compressed a i r only. D o not u s e s h o p
towels to d r y t r a n s m i s s i o n p a r t s . S h o p towels
w i l l leave lint p a r t i c l e s o n t r a n s m i s s i o n p a r t s
w h i c h c a n p l u g fluid p a s s a g e s o r interfere w i t h
v a l v e operation.
(2) Place transmission i n a repair stand (Fig. 1).

Fig. 2 Measuring Input Shaft End Play

(2) Loosen clamp bolts and remove t h r o t t l e a n d
m a n u a l valve levers from m a n u a l shaft.
(3) Remove n e u t r a l switch.
(4) Remove valve body bolts a n d p a r k lock rod E-
clip. L i f t valve up and off transmission and remove
lock rod from valve body.
(5) Remove accumulator s p r i n g a n d piston.

Fig. 2 Transmission Mounted On Repair Stand
(3) Measure i n p u t shaft end play before disassem-
b l y to determine i f a t h r u s t washer change is needed
(Fig. 2).
(4) A t t a c h d i a l indicator to converter housing (Fig.
1). Position indicator plunger against i n p u t shaft and
zero indicator. Move i n p u t shaft i n a n d o u t a n d
record reading. E n d play should be.56 - 2.31 m m
(.022 - .091 i n c h o n 998/999 models and .86 - 2.13
m m (.034 - .084 inch) on 727 models.
Oil Pan And Valve Body
(1) Remove o i l pan bolts and remove pan and gas-
ket.
Extension Housing
(1) P u l l p a r k i n g lock rod out o f case.
(2) Remove distance sensor a n d speedometer and
gear i f not previously removed.
(3) Remove plate and gasket f r o m underside of
housing.
(4) Spread o u t p u t shaft bearing snap r i n g as far as
possible and w o r k housing off transmission and out-
p u t shaft.
(5) Remove snap r i n g securing o u t p u t shaft bearing
to shaft. Use heavy d u t y snap r i n g pliers for t h i s
task.
(6) Remove the bearing from t h e shaft.
(7) O n 727, remove the second snap r i n g used to
position the bearing on the o u t p u t shaft (998/999 do
not have t h i s second snap r i n g ) .
Governor And Park Gear
(1) Remove snap r i n g t h a t r e t a i n s governor and
p a r k gear on o u t p u t shaft.
(2) Remove governor valve shaft snap r i n g s and re-
move governor valve and shaft f r o m governor body.
21 - 92 AUTOMATIC TRANSMISSION •
SEAL .RING PISTON S N A P R I N G

S N A P R I N G S P R I N G RETAINER

Fig. 5 Rear Servo Components

Front Clutch
(1) Loosen the band adjusting screw.
(2) Remove band s t r u t and a n d remove s t r u t an-
chor o n 727 models.
(3) Slide front clutch out o f case.

Input Shaft And Rear Clutch

(1) P u l l i n p u t shaft and rear c l u t c h assembly out of
case.
Fig. 3 Removing Oil Pump
: (2) O n 998/999 models, remove and r e t a i n t h r u s t
washer located between i n p u t a n d o u t p u t shafts.

Planetary Gears-Sun Gear-Driving Shell

(1) L i f t a n d support output shaft and d r i v i n g shell.
(2) Carefully slide assembly f o r w a r d and o u t of
case. Be careful w i t h the finely machined surfaces of
the o u t p u t shaft. Do not allow these surfaces to be-
come n i c k e d or damaged d u r i n g removal.

Rear Band-Low Reverse Drum

(1) Remove low-reverse d r u m .
(2) Loosen rear band adjusting screw.
(3) Remove snap r i n g r e t a i n i n g d r u m .
(4) O n 727, remove band s t r u t and l i n k t h e n re-
move rear band.
(5) O n 998/999, loosen band adjuster screw.
(6) Remove band and d r u m as assembly.

Overrunning Clutch
Remove only t h e o v e r r u n n i n g c l u t c h rollers a n d
springs as a n assembly. T h e c l u t c h cam w i l l be re-
moved d u r i n g subassembly overhaul i f replacement
Fig. 4 Removing Front Servo Components is necessary.
(3) Slide governor body and p a r k gear off o u t p u t
Kickdown (Front) Servo
shaft.
(1) Remove p l u g from front servo test port.
Oil Pump And Reaction Shaft Support (2) Compress servo piston and s p r i n g w i t h tool C-
3422A (Fig. 4).
(1) T i g h t e n front band adjusting screw u n t i l band
(3) Remove servo piston snap r i n g and remove the
is t i g h t o n front clutch retainer. This prevents re-
compressor tool.
tainer f r o m coming out w i t h pump and causing unec- (4) Refnove servo piston.
essary damage to clutch components.
(2) Remove oil pump bolts. Rear Servo
(3) Remove oil pump and reaction shaft support as- (1) Compress servo piston and remove snap r i n g
sembly w i t h two slide hammer tools C-3752 (Fig. 3). (Fig. 5 ) .
Thread slide hammers into threaded holes i n p u m p (2) Remove servo retainer, springs, piston p l u g and
body flange. spring and piston.
 • AUTOMATIC TRANSMISSION 21 - 93

SUBASSEMBLY OVERHAUL

INDEX
Page Page
Front CIutch-A-727 99 Planetary Gear Train—A-998/999 . . . . . . . . . . . . 104
Front Clutch-A-998/999 97 Rear Clutch-A-727 . . . . . . 102
Front (Kickdown) Servo And Band—All . . . . . . . . 106 Rear Clutch-A-998/999 101
Oil Pump And Reaction Shaft Support—A-727 . . . 95 Rear (Low-Reverse) Servo And Band-All . . . . . . 107
Oil Pump And Reaction Shaft Support—A-998/999 . 93 Transmission Assembly . 107
Overrunning Clutch 106 Transmission Case 106
Planetary Gear Train—A-727 . ...... 105

OIL PUMP AND REACTION SHAFT SUPP0RT-A- I n s t a l l the gears i n the pump body and measure
998/999 end clearance w i t h a feeler gauge and straightedge
(Fig. 7). Clearance should be .010 - .063 m m (.0004 -
.0025 i n ) .
PUMP AND SUPPORT DISASSEMBLY
(1) Remove the support bolts and separate the sup-
port and p u m p body (Fig. 6).
(2) Remove the O - r i n g seal from pump body.
(3) Remove the p u m p seal w i t h punch.

REACTION SHAFT
SUPPORT

INNER G E A R

OUTER GEAR

RN31
"O" RING PUMP HOUSING

Fig. 6 Oil Pump And Reaction Shaft Support Components—A-998/999

(4) M a r k t h e p u m p gears for assembly reference STRAIGHTEDGE

and remove the gears.

(5) Remove the seal rings from the reaction shaft
support (Fig. 6).
(6) Clean the p u m p and support components w i t h
solvent and d r y t h e m w i t h compressed air.

PUMP AND SUPPORT INSPECTION

Inspect the p u m p a n d support components. Replace
the pump or support i f the seal r i n g grooves or ma- FEELER

chined surfaces are w o r n , scored, pitted, or damaged. G A U G E

Replace the p u m p gears i f p i t t e d , w o r n chipped, or

damaged. Inspect the No. 1 t h r u s t washer for dam-
age. Then check the support-to-front clutch retainer
PUMP
t h r u s t washer. Replace the washer i f worn. G E A R S J9021-53
Replace the p u m p b u s h i n g and the reaction shaft
support bushing i f scored, w o r n or damaged. Fig. 7 Measuring Pump Gear End Clearance—Ail
21 - 94 AUTOMATIC TRANSMISSION
J8921-388
Fig. 8 Measuring Pump Gear Clearances—All
Measure gear tooth clearance w i t h a feeler gauge.
A l i g n one t o o t h of the outer gear w i t h one tooth of
the inner gear and measure clearance (Fig. 8). Clear-
ance should be .089 - 1.90 m m (.0035 - .0075 inch).
Measure clearance between the outer gear and the
pump body (Fig. 8). Clearance should be .089 - 1.90
m m (.0035 - .0075 inch),
REPLACING OIL PUMP BUSHING-A-998/999
(1) Remove the pump bushing w i t h driver handle
C-4171 a n d remover tool SP 3551 (Fig. 9).
(2) I n s t a l l t h e new p u m p b u s h i n g w i t h driver han-
dle C-4171 a n d installer tool SP 5117 (Fig. 9). Bush-
i n g should be flush w i t h pump body bore.
•
RN32
Fig. 9 Replacing Oil Pump Bushing—A-998/999
Fig. 10 Staking Oil Pump Bushing—A-998/999
(3) Stake t h e new p u m p bushing i n two places w i t h
a b l u n t punch. Then remove b u r r s from t h e stake
points w i t h a knife blade (Fig. 10).
REPLACING REACTION SHAFT SUPPORT
BUSHING-A-998/999
(1) Assemble the bushing remover tools SP 1 1 9 1 ,
3633 and 5324 (Fig. 11). D o not clamp a n y p a r t of
the r e a c t i o n shaft o r s u p p o r t i n a vise.
(2) H o l d cup tool SP-3633 f i r m l y against reaction
shaft and t h r e a d remover SP-5324 into b u s h i n g as
far as possible by hand. Then thread remover tool an
additional 3-4 t u r n s i n t o bushing w i t h wrench.
(3) T u r n tool hex n u t down against cup t o p u l l
bushing f r o m reaction shaft. Clean a l l chips f r o m
shaft after bushing removal.
(4) L i g h t l y grip old bushing i n a vise or w i t h pliers
and back remover tool out of bushing.
 • AUTOMATIC TRANSMISSION 21 - 95

(5) Assemble b u s h i n g i n s t a l l e r tools C-4171 a n d (12) I n s t a l l a n e w O-ring o n t h e pump body ( F i g .

SP-5325 (Fig. 11). 6).
(6) Slide t h e n e w b u s h i n g onto i n s t a l l e r tool SP- (13) Lubricate the O-ring and the l i p o f the p u m p
5325. seal w i t h transmission fluid o r petroleum j e l l y .
(7) Position the reaction shaft support u p r i g h t on a (14) Set the assembled p u m p and support aside f o r
clean smooth surface. assembly i n s t a l l a t i o n .
(8) A l i g n t h e b u s h i n g i n t h e bore. T h e n t a p t h e
bushing i n t o place i n s t a l l e r tool SP-5325 bottoms.:
(9) Clean reaction t h e shaft support t h o r o u g h l y af-
ter i n s t a l l i n g the b u s h i n g .

P
UMPG
EAR
S RH283

Fig. 12 Assembling Oil Pump And Reaction Shaft

Support—A-998/999
OIL PUMP AND REACTION SHAFT SUPPORT-A-
Bushing—A-998/999
727
ASSEMBLING OIL PUMP AND REACTION
SHAFT SUPPORT-A-998/999
PUMP AND SUPPORT DISASSEMBLY
(1) Lubricate t h e p u m p gears w i t h transmission
(1) Remove the support bolts and separate the sup-
fluid and i n s t a l l t h e m i n the p u m p body.
port and pump body (Fig. 13).
(2) I n s t a l l a n e w t h r u s t washer a n d seal rings on
(2) Remove the O-ring seal f r o m the pump body.
the reaction shaft support. Lubricate t h e washer and
(3) Remove the p u m p seal w i t h a b l u n t punch.
seal rings w i t h transmission fluid.
(4) M a r k t h e p u m p gears for assembly reference
(3) Place t h e reaction shaft support i n assembly
and remove the gears.
tool C-3759. T h e shaft h u b and assembly tool should
(5) Remove the seal rings and t h r u s t washer f r o m
be positioned on a clean smooth w o r k surface.
the reaction shaft support (Fig. 13).
(4) Thread t w o p i l o t s t u d tools C-3283-A into t h e
(6) Clean t h e p u m p and support components w i t h
threaded holes o f the reaction shaft support flange
(Fig. 12). ' solvent and d r y t h e m w i t h compressed air.
(5) A l i g n and lower t h e p u m p body onto t h e pilot
INSPECTING PUMP AND SUPPORT
studs (Fig. 12).
Inspect the p u m p and support components. Replace
(6) Insert a l i g n i n g tool C-3756 t h r o u g h t h e pump
the p u m p or support i f the seal r i n g grooves or ma-
body and engage the p u m p i n n e r gear.
chined surfaces are w o r n , scored, p i t t e d , or damaged.
(7) Rotate t h e p u m p gears w i t h t h e tool to center
t h e m i n the p u m p body. Replace the p u m p gears i f p i t t e d , w o r n chipped, or
(8) T i g h t e n t h e c l a m p i n g tool securely when t h e damaged. Inspect t h e No. 1 t h r u s t washer. Replace
gears are centered a n d t h e p u m p body is firmly the washer i f w o r n or damaged.
seated against the reaction shaft support. Replace t h e p u m p bushing and t h e reaction shaft
(9) T u r n the assembly tool, p u m p a n d support over. support b u s h i n g d u r i n g overhaul. Do n o t reuse t h e
T h e n i n s t a l l and t i g h t e n the support-to-pump bolts to o r i g i n a l bushings even i f they look O K .
20 N*m (175 in-lbs) torque. I n s t a l l t h e gears i n t h e p u m p body and measure
(10) Remove the assembly tool f r o m t h e pump and end clearance w i t h a feeler gauge and straightedge
support. (Fig. 7). Clearance should be .025 - .076 m m (.001 -
(11) I n s t a l l a new p u m p seal w i t h t o o l C-4193 and .003 i n ) .
handle C-4171. Be sure t h e seal l i p faces i n w a r d .
21 - 96 AUTOMATIC TRANSMISSION •

OIL PUMP B O D Y

V E N T BAFFLE

"O" RING
INNER GEAR
#1 THRUST W A S H E R >

(SELECTIVE)

BOLTS (6)-
RH284

Fig. 13 Oil Pump And Reaction Shaft Support Components—A-727

Clearance between t h e p u m p outer gear and t h e
T O O L HANDLE C-4171 REMOVAL
pump body should be .089 - 1.90 m m (.0035 to .0075
inch). REMOVING HEAD
SP-3550
OIL PUMP BUSHING REPLACEMENT-A-727 F R O N T PUMP HOUSING
(1) Position t h e p u m p housing on a clean, smooth
surface w i t h the gear cavity facing down.
(2) Remove t h e b u s h i n g w i t h handle C-4171 a n d
remover tool SP-3550 (Fig. 14).
(3) Assemble handle C-4171 and bushing installer
tool SP-5118 (Fig. 14).
(4) Place the new b u s h i n g on the installer tool and T O O L HANDLE C-4171

start the b u s h i n g i n t o the shaft (Fig. 14).

(5) T a p t h e bushing i n t o place u n t i l tool SP-5118
bottoms i n t h e pump cavity (Fig. 14). Keep the tool
and b u s h i n g square w i t h the bore. Do not allow t h e
bushing to become cocked d u r i n g i n s t a l l a t i o n .
(6) Stake t h e pump b u s h i n g i n t w o places w i t h a
b l u n t punch. Then remove b u r r s from t h e stake RN35
points w i t h k n i f e blade (Fig. 15).
Fig. 14 Replacing Oil Pump Bushing—A-727
REPLACING REACTION SHAFT SUPPORT
(3) U s i n g a wrench, t h r e a d the remover tool a n ad-
BUSHING-A-727
d i t i o n a l 3-4 t u r n s i n t o t h e b u s h i n g to f i r m l y engage
(1) Assemble cup tool SP-3633, n u t SP-1191 and re-
the tool i n t h e b u s h i n g .
mover SP-5301 (Fig. 16).
(4) T i g h t e n the tool h e x n u t against the cup tool t o
(2) H o l d t h e cup tool f i r m l y against t h e reaction
p u l l the b u s h i n g f r o m t h e shaft. Clean a l l chips f r o m
shaft. Thread t h e remover tool into t h e bushing as
the shaft a n d support after b u s h i n g removal.
far as possible by hand.
 • AUTOMATIC TRANSMISSION 21 - 97

(4) I n s t a l l t h e bolts a t t a c h i n g t h e reaction shaft

support to t h e pump. T i g h t e n the bolts to 175 in-lbs
(20 N-m) torque.
(5) I n s t a l l a new seal i n the o i l pump w i t h installer
C-3860-A and driver handle C-4171.
(6) I n s t a l l a new O - r i n g o n the pump body. L u b r i -
cate the o i l seal and O - r i n g w i t h .transmission fluid
or petroleum j e l l y .
(7) Set the assembled p u m p and support aside for
assembly i n s t a l l a t i o n .

FRONT CLUTCH-A-998/999

FRONT CLUTCH DISASSEMBLY

RH285
(1) Remove t h e waved snap r i n g and remove t h e
Fig. 15 Staking Pump Bushing—A-727 pressure plate, clutch plates and d r i v i n g discs (Fig.
17).
(5) Place t h e reaction shaft support u p r i g h t o n a
(2) Compress the r e t u r n spring and spring retainer
clean, smooth surface.
w i t h compressor tool C-3575-A (Fig. 18).
(6) Assemble bushing installer tools C-4171 a n d
(3) Remove t h e piston snap r i n g a n d spring re-
SP-5302 (Fig. 16). T h e n slide the new bushing on the
tainer. Then remove the compressor tool.
installer tool.
(4) Remove t h e clutch piston and piston retainer
(7) Start the bushing i n t o the shaft. Then t a p t h e
(Fig. 17).
bushing into the shaft u n t i l the installer tool bottoms
(5) Remove and discard the piston inner and outer
against the support flange (Fig. 16).
seals. Also discard the retainer snap r i n g .
(8) Clean the reaction shaft support thoroughly af-
ter bushing replacement. CLUTCH INSPECTION
HEX NUT Clean and inspect the f r o n t clutch components. Re-
SP-1191 TOOL HANDLE place the c l u t c h discs i f warped, worn, scored, burned
C-4171
or charred, t h e lugs are damaged, or i f the facing is
INSTALLING flaking off. Replace the steel plates i f heavily scored,
HEAD
SP-5302 warped, or broken. Be sure t h e d r i v i n g lugs on t h e
CUP SP-3633 discs and plate are also i n good condition. The lugs
must not be bent, cracked or damaged i n any way.
REMOVER SP-5301 Replace the r e t u r n spring and spring retainer i f ei-
BUSHING
ther is distorted, warped or broken.
Check t h e l u g grooves i n the clutch piston retainer.
The steel plates should slide freely i n the slots. Re-
place the piston retainer i f the grooves are w o r n or
REACTION damaged. Also check action o f the check b a l l i n the
REACTION SHAFT
SHAFT SUPPORT
piston retainer. The b a l l m u s t move freely and not
stick.
REMOVAL
INSTALLATION *N37 Replace t h e retainer b u s h i n g i f w o r n , scored, or
there is any doubt about b u s h i n g condition.
Fig. 16 Replacing Reaction Shaft Support Inspect t h e piston a n d retainer seal surfaces for
Bushing—A-727 nicks or scratches. M i n o r scratches can be removed
ASSEMBLING OIL PUMP AND REACTION w i t h crocus cloth. However, replace the piston and/or
SHAFT SUPPORT-A-727 retainer i f the seal surfaces are seriously scored.
(1) Lubricate t h e pump gears w i t h transmission
fluid and i n s t a l l t h e m i n pump body. REPLACING FRONT CLUTCH RETAINER
(2) I n s t a l l a new t h r u s t washer and seal rings on BUSHING—A-998/999
the reaction shaft support. Lubricate t h e seal r i n g s (1) Assemble driver handle C-4171 and bushing re-
w i t h transmission fluid. mover SP-3627 (Fig. 19).
(3) A l i g n and i n s t a l l the reaction shaft support o n (2) Insert t h e remover tool i n t h e bushing a n d
the pump body. drive the old bushing out of the retainer (Fig. 19).
21 - 98 AUTOMATIC TRANSMISSION •
PISTON SEAL (INNER)
PRESSURE
DRIVING DISCS PLATE

SNAP RING
(WAVED)

PISTON RETAINER
ASSEMBLY

PISTON SEAL (OUTER)

CLUTCH PLATES RH286

Fig. 17 Front Clutch Components—A-998/999

TOOL HANDLE C-4171 TOOL HANDLE
SPECIAL TOOL
C-3575A C-4171 INSTALLING
REMOVING HEAD HEAD
FRONT SP-3627 SP-3626
CLUTCH
RETAINER FRONT CLUTCH
RETAINER

SPRING
RETAINER
REMOVAL INSTALLATION RN34

SNAP RING
RH287
Fig. 18 Removing Front Clutch Spring Retainer
Snap Ring—A-998/999
(3) M o u n t bushing installer tool SP-3626 o n t h e
driver handle. Then slide the new b u s h i n g onto the
installer tool.
(4) A l i g n a n d i n s t a l l t h e new bushing. T a p t h e
bushing into the retainer u n t i l the i n s t a l l e r tool bot-
toms against the retainer (Fig. 19).
(5) Remove t h e installer tools a n d clean t h e r e -
tainer thoroughly.
FRONT CLUTCH ASSEMBLY-A-998/999
(1) Lubricate the clutch plates and soak the clutch
discs w i t h transmission f l u i d .
(2) Lubricate the new inner and outer piston seals
w i t h Door Ease, or petroleum j e l l y .
(3) I n s t a l l the new seals on the c l u t c h piston. Be
sure the seal lips face the inside o f the retainer.
(4) I n s t a l l the clutch piston i n the retainer. Use a
t w i s t i n g motion to seat the piston a t the retainer bot-
Fig. 19 Clutch Retainer Bushing Replacement—A-
998/999
torn. D o n o t a t t e m p t t o f o r c e t h e p i s t o n s t r a i g h t
i n . T h i s w i l l f o l d t h e seals o v e r c a u s i n g l e a k a g e
and clutch slip.
(5) I n s t a l l t h e r e t u r n spring and spring retainer.
(6) Compress the r e t u r n spring and spring retainer
w i t h compressor tool C-3575-A. Then i n s t a l l a new
snap r i n g to secure the spring retainer (Fig. 18).
(7) I n s t a l l t h e clutch plates a n d discs (Fig. 17). I n -
stall a steel plate t h e n disc u n t i l a l l plates and discs
are installed.
(8) I n s t a l l the pressure plate and waved snap r i n g
(Fig. 17).
(9) Check c l u t c h plate clearance (Fig. 20). Clear-
ance should be 1.70 - 3.40 m m (.067 to .134 inch)
w i t h a 4-disc c l u t c h and 1.90 - 3.86 m m (.075 to .152
inch) w i t h a 5-disc clutch. I f clearance is incorrect,
clutch plates, discs and/or pressure plate w i l l have to
be changed.
• AUTOMATIC TRANSMISSION 21 - 99

(2) Compress the clutch piston retainer and springs

w i t h compressor tool C-3863-A (Fig. 22).
(3) Remove t h e piston snap r i n g a n d spring re-
tainer (Fig. 21).
(4) Remove the piston springs. N o t e t h e n u m b e r
a n d position o f the piston springs f o r assembly
reference.
(5) Remove the compressor tool.
(6) Remove the clutch piston from the retainer.
(7) Remove a n d discard t h e clutch piston seals.
Also discard the spring retainer snap r i n g .

Clutch Inspection
Clean and inspect the front clutch components. Re-
place the clutch discs i f warped, w o r n , scored, burned
or charred, the lugs are damaged, or i f t h e facing is
f l a k i n g off. Replace the steel plates i f heavily scored,
warped, or broken. Be sure the d r i v i n g lugs on t h e
discs and plates are also i n good condition. The lugs
must not be bent, cracked or damaged i n any way.
Replace the piston springs and spring retainer i f ei-
ther are distorted, warped or broken.
Check the l u g grooves i n the clutch piston retainer.
FEELER GAUGE RH288 The steel plates should slide freely i n t h e slots. Re-
place the piston retainer i f the grooves a r e w o r n or
Fig. 20 Measuring Front Clutch Pack Clearance damaged. Also check action o f the check b a l l i n the
(Typical) piston retainer. T h e b a l l m u s t move freely and not
FRONT CLUTCH—A-727 stick.
Replace t h e retainer b u s h i n g i f w o r n , scored, o r
Clutch Disassembly there is any doubt about b u s h i n g condition.
(1) Remove t h e waved snap r i n g a n d remove t h e Inspect t h e piston and retainer seal surfaces for
pressure plate, clutch plates a n d d r i v i n g discs (Fig. nicks or scratches. M i n o r scratches can be removed
21).

PISTON SEAL
(INNER) PISTON CLUTCH
PLATES
SPRING RETAINER SNAP RING
(WAVED)

PISTON
RETAINER ASSEMBLY
PISTON SEAL
(OUTER)

DRIVING DISCS
PRESSURE PLATE
RH289

Fig. 21 Front Clutch Components—A-727

21-100 AUTOMATIC TRANSMISSION •

Fig. 22 Removing Front Clutch Spring Retainer

Snap Ring—A-727
w i t h crocus cloth. However, replace the piston and/or
retainer i f the seal surfaces are seriously scored.

REPLACING FRONT CLUTCH RETAINER

BUSHING-A 727
(1) Assemble driver handle C-4171 and b u s h i n g re-
mover head SP-3629 (Fig. 23).
(2) Insert t h e remover head i n t h e b u s h i n g and
drive the bushing s t r a i g h t out o f the piston retainer.
(3) M o u n t bushing installer head SP-5511 on t h e
driver handle (Fig. 23).
(4) Slide the new bushing onto the installer head
and s t a r t the bushing i n the retainer.
(5) I n s t a l l the new bushing u n t i l the installer head
bottoms against the retainer (Fig. 23).
(6) Remove t h e installer tools and clean t h e re-
tainer thoroughly.

ASSEMBLING A-727 FRONT CLUTCH
(1) Lubricate the clutch plates and soak the clutch
discs w i t h transmission fluid.
(2) Lubricate the new inner and outer piston seals
w i t h Door Ease, or petroleum j e l l y .
(3) I n s t a l l the new seals on the clutch piston. Be
sure the seal lips face the inside of the retainer.
(4) I n s t a l l the clutch piston i n the retainer. Use a
t w i s t i n g m o t i o n to seat the piston at the retainer bot-
tom. D o n o t a t t e m p t t o f o r c e t h e p i s t o n s t r a i g h t
i n . T h i s w i l l f o l d t h e seals o v e r c a u s i n g l e a k a g e
and clutch slip.
(5) I n s t a l l the clutch piston springs.
(a) On a 9 spring clutch, position the springs as
shown (Fig. 24).
(b) On a n 11 or 13 spring clutch, position t h e
Fig. 24 Front Clutch Spring Location—9 Spring
springs as shown (Fig. 25).
(6) I n s t a l l the piston spring retainer on the springs.
(7) Compress the spring retainer and piston springs
w i t h tool C-3863-A (Fig. 22).
(8) I n s t a l l a new spring retainer snap r i n g (Fig.
22). Then remove the compressor tool.
(9) I n s t a l l the clutch plates and discs (Fig. 21). I n -
stall a steel plate t h e n a disc u n t i l four plates and
discs are installed.
(10) I n s t a l l the pressure plate and waved snap r i n g
(Fig. 21).
(11) Check front clutch pack clearance (Fig. 20).
Clearance between the waved s p r i n g and the pres-
sure plate should be 2.08 - 3.83 m m (.082 to .151
• AUTOMATIC TRANSMISSION
Fig. 25 Front Clutch Spring Location—11 or 13
Spring
inch). I f clearance is incorrect, t h e clutch plates, discs
and/or pressure plate w i l l have t o be changed.
(12) Set front d u t c h aside for assembly i n s t a l l a -
tion.
REAR CLUTCH—A-998/999
CLUTCH DISASSEMBLY
(1) Remove the selective snap r i n g (Fig. 26).
(2) Remove pressure plate and the clutch discs and
steel plates (Fig. 26).
(3) Remove the wave spring a n d piston spring (Fig.
26).
(4) Remove t h e # 2 t h r u s t washer (Fig. 26).
(5) T u r n t h e clutch retainer over and t a p i t o n
wood block t o dislodge the c l u t c h piston.
(6) Remove a n d discard the piston seals.
(7) Remove the i n p u t shaft snap r i n g and press the
i n p u t shaft o u t of the retainer. Discard t h e shaft
snap r i n g . Use a new r i n g a t assembly.
Fig. 26 Rear Clutch
21-101
(8) Remove the seal r i n g f r o m t h e clutch r e t a i n e r
b u t leave the i n p u t shaft seal r i n g s i n place for i n -
spection.
Clutch Inspection
Clean the clutch components w i t h solvent.
Replace t h e clutch discs i f warped, w o r n , scored,
burned/charred, t h e lugs are damaged, or i f t h e fac-
i n g is f l a k i n g off. Replace t h e steel plates a n d t h e
pressure plate i f h e a v i l y scored, warped, or broken.
Be sure the d r i v i n g lugs on t h e discs and plates are
also i n good condition. T h e lugs m u s t n o t be bent,
cracked or damaged i n any way.
Replace the piston spring and wave s p r i n g i f p a r t
is distorted, warped or broken.
Check the l u g grooves i n t h e clutch piston r e t a i n e r .
The steel plates should slide freely i n t h e slots. Re-
place the piston r e t a i n e r i f t h e grooves are w o r n or
damaged. Also check action o f the check b a l l i n the
piston retainer. T h e b a l l m u s t move freely a n d not
stick.
Replace t h e r e t a i n e r b u s h i n g i f w o r n , scored, or
there is any doubt about b u s h i n g condition.
Inspect t h e piston and r e t a i n e r seal surfaces for
nicks or scratches. M i n o r scratches can be removed
w i t h crocus cloth. However, replace the piston and/or
retainer i f the seal surfaces are seriously scored.
Check condition of the # 2 t h r u s t washer. Replace
the washer i f w o r n or damaged. Washer thickness
should be .061 t o .063 inch.
Check condition of the teflon or cast i r o n seal r i n g s
on the i n p u t shaft. Replace these seal r i n g s o n l y i f
they are obviously damaged. I f new r i n g s are re-
quired, service replacement r i n g s w i l l be cast i r o n
hooked-joint type.
Check the i n p u t shaft for wear, or damage. Replace
the shaft i f w o r n , scored or damaged i n a n y way.
Components—A-998/999
21-102 AUTOMATIC TRANSMISSION
ASSEMBLING REAR CLUTCH-A-938/999
(1) Lubricate the steel plates a n d soak t h e d r i v e
discs w i t h transmission f l u i d .
(2) I n s t a l l new seal rings i n the c l u t c h r e t a i n e r a n d
on t h e i n p u t shaft i f necessary.
(3) Press t h e i n p u t shaft i n t o t h e clutch r e t a i n e r
a n d secure t h e shaft w i t h a new snap r i n g .
(4) I n s t a l l new seals on t h e clutch piston. T h e n l u -
bricate t h e seals w i t h Door Ease or petroleum j e l l y t o
ease piston installation.
(5) I n s t a l l t h e clutch piston i n t h e retainer. Use a
t w i s t i n g m o t i o n to seat the piston a t the r e t a i n e r bot-
tom. D o n o t force t h e piston s t r a i g h t i n . T h i s
c o u l d c u t o r f o l d t h e seals o v e r c a u s i n g l e a k a g e
a n d slip.
(6) I n s t a l l t h e piston spring and wave s p r i n g ( F i g .
27). D o n o t i n s t a l l a s p a c e r r i n g i n t h e 999 r e a r
c l u t c h . T h e s p a c e r r i n g i s o n l y u s e d i n t h e 727
r e a r c l u t c h ( F i g . 27).
PISTON SPRING WAVE SPRING
SPACER RING
(A-727
ONLY)
RH294
Fig. 27 Piston Spring And Wave Spring
Position—AH
(7) I n s t a l l t h e first pressure plate i n t h e r e t a i n e r .
T h e n i n s t a l l a clutch disc followed by a steel plate
u n t i l a l l discs and plates are installed (Fig. 26).
(8) I n s t a l l the r e m a i n i n g pressure plate and t h e se-
lective snap r i n g (Fig. 26).
(9) Measure clutch pack clearance (Fig. 28). Clear-
ance should be .81 - 1.39 m m (.032 - .055 inch). I f
clearance is incorrect, change t h e selective snap r i n g
(see specifications section). However, i f a t h i c k e r or
t h i n n e r snap r i n g does not provide proper clearance,
the steel plates, discs and pressure plates m a y have
to be changed.
(10) Coat the # 2 t h r u s t washer w i t h p e t r o l e u m
j e l l y and i n s t a l l i t over t h e i n p u t shaft a n d i n t o t h e
piston retainer. Use enough petroleum j e l l y t o h o l d
the washer i n place i n the retainer.
•
SELECTIVE
SNAP RING
FEELER
GAUGE
RH295
Fig. 28 Measuring Rear Clutch Pack Clearance—All
REAR CLUTCH-A-727
CLUTCH DISASSEMBLY
(1) Remove t h e selective snap r i n g ( F i g . 29).
(2) Remove t h e outer pressure plate a n d t h e steel
plates and discs ( F i g . 29).
(3) Remove t h e i n n e r pressure plate, wave spring,
spacer r i n g a n d piston^ s p r i n g ( F i g . 29).
(4) Remove t h e clutch piston a n d piston r e t a i n e r
f r o m t h e clutch retainer. B u m p t h e clutch retainer
on a wood block t o dislodge t h e piston a n d retainer.
(5) Remove t h e # 2 t h r u s t washer.
(6) Remove t h e i n p u t shaft snap r i n g and press t h e
shaft o u t of the clutch retainer.
(7) Remove and discard t h e clutch piston seals ( F i g .
29).
(8) Do not remove the i n p u t shaft seal rings unless
they are obviously damaged (broken, cracked).
Clutch Inspection
Clean t h e clutch components w i t h solvent.
Replace t h e clutch discs i f warped, w o r n , scored,
burned/charred, t h e lugs are damaged, or i f the fac-
i n g is f l a k i n g off. Replace t h e steel plates a n d t h e
pressure plate i f heavily scored, warped, or broken.
Be sure t h e d r i v i n g lugs o n t h e discs a n d plates are
also i n good condition. T h e lugs m u s t n o t be bent,
cracked or damaged i n a n y way.
Replace the piston spring a n d wave s p r i n g i f p a r t
is distorted, warped or broken.
Check the l u g grooves i n t h e clutch piston retainer.
The steel plates should slide freely i n t h e slots. Re-
place t h e piston retainer i f t h e grooves are w o r n or
damaged. Also check action o f t h e check b a l l i n t h e
 • AUTOMATIC TRANSMISSION 21 - 103

Fig. 29 Rear Clutch omponents—A-727

piston retainer. T h e b a l l m u s t move freely and not
stick.
Replace the i n p u t shaft bushing ( i n t h e retainer) i f
w o r n , scored, o r there is any doubt about bushing
condition.
Inspect t h e piston and retainer seal surfaces for
nicks or scratches. M i n o r scratches can be removed
w i t h crocus cloth. However, replace t h e piston and/or
retainer i f the seal surfaces are seriously scored.
Check condition o f t h e # 2 t h r u s t washer. Replace
the washer i f w o r n or damaged. Refer to Specifica-
tions for washer thickness.
Check condition of t h e seal rings on the i n p u t shaft
and piston retainer. Replace these seal rings i f w o r n
or damaged.
Check the i n p u t shaft for wear, or damage. Replace
the shaft i f w o r n , scored or damaged i n any way.
(6) Clean t h e i n p u t shaft thoroughly to remove
chips. Be sure t h e small l u b r i c a t i o n hole next to the
shaft b a l l is not plugged. Also be sure the b a l l i t s e l f
is not restricted b y any chips.
(7) Assemble tool handle C-4171 and b u s h i n g i n -
staller head SP-3636 (Fig. 30). Then slide the n e w
bushing on the i n s t a l l e r head.
(8) A l i g n the b u s h i n g i n the shaft. Tap t h e bushing
into place u n t i l the installer head bottoms.
(9) Remove t h e bushing i n s t a l l e r tools and clean
the c l u t c h retainer and shaft a second t i m e .

INPUT SHAFT BUSHING REPLACEMENT-A-

727
(1) Clamp t h e i n p u t shaft i n a vise w i t h protective
jaws. Do not clamp t h e seal r i n g lands or bearing
journals.
(2) Assemble remover tool SP-3630, cup tool SP-
3633 and hex n u t SP-1191 (Fig. 30).
(3) H o l d t h e cup tool f i r m l y against the clutch pis- RN38
t o n retainer. T h e n t h r e a d the remover tool i n t o the
Fig. 30 Replacing Input Shaft Bushing—A-727
b u s h i n g as far as possible b y hand.
(4) Thread t h e b u s h i n g remover a n additional 3-4 ASSEMBLING REAR CLUTCH-A-727
t u r n s u s i n g a w r e n c h to f i r m l y engage the tool i n the (1) L u b r i c a t e the clutch plates and soak the discs
bushing. w i t h transmission fluid.
(5) T i g h t e n t h e hex n u t w i t h a wrench to p u l l the (2) I n s t a l l new seal rings on the i n p u t shaft and
b u s h i n g out o f t h e i n p u t shaft (Fig. 30). piston r e t a i n e r (Fig. 29).
(3) Press the i n p u t shaft into the clutch retainer.
21 - 104 AUTOMATIC TRANSMISSION
Secure t h e shaft w i t h a new snap r i n g .
(4) I n s t a l l n e w seals o n the clutch piston. Lubricate
the piston seals w i t h Door Ease or petroleum j e l l y t o
ease i n s t a l l a t i o n . Be sure the seal lips face the i n p u t
shaft.
(5) I n s t a l l t h e clutch piston i n t h e piston retainer.
Use a t w i s t i n g m o t i o n t o seat t h e piston a t t h e bot-
t o m of t h e retainer. D o n o t attempt to p u s h t h e
p i s t o n s t r a i g h t i n . T h i s c o u l d fold the seals over
c a u s i n g l e a k a g e a n d c l u t c h slip.
(6) I n s t a l l t h e # 2 t h r u s t washer on t h e piston r e -
tainer ( F i g . 29). Use petroleum j e l l y t o hold t h e
t h r u s t washer i n place.
(7) I n s t a l l t h e assembled piston r e t a i n e r i n t h e
clutch r e t a i n e r (Fig. 29).
(8) I n s t a l l t h e piston spring, spacer s p r i n g a n d
wave s p r i n g i n t h e clutch retainer (Fig. 27). Be sure
the wave s p r i n g is f u l l y seated. T a p t h e spring i n t o
place i f necessary.
(9) I n s t a l l t h e i n n e r pressure plate. T h e n i n s t a l l
the first disc followed b y a steel plate u n t i l a l l t h e
discs and plates are installed.
(10) I n s t a l l t h e outer pressure plate a n d t h e selec-
tive snap r i n g .
(11) Check clutch pack clearance w i t h a feeler
gauge ( F i g . 28). Clearance should be .63 - 1.14 m m
(.025 - .045 inch).
(12) I f clutch pack clearance is incorrect, change
the selective snap r i n g as needed. See t h e specifica-
tions section for available snap r i n g thicknesses.
PLANETARY GEAR TRAIN-A-998/999
GEARTRAIN END PL A Y MEASUREMENT
(1) Measure planetary gear t r a i n e n d play before
disassembly (Fig. 31).
(2) Stand t h e assembly u p r i g h t w i t h t h e forward
end of t h e output shaft on a wood block. T h i s is nec-
essary for accurate measurement, i t causes the plan-
etary components to move forward against t h e snap
r i n g a t f r o n t o f the shaft (Fig. 31).
(3) Measure end play w i t h a feeler gauge. Insert
the gauge between t h e shoulder on t h e output shaft
and t h e rear annulus gear support h u b (Fig. 31).
(4) E n d play should be .12 - 1.21 m m (.005 - .048
inch). I f end play is incorrect, the snap r i n g or t h r u s t
washer m a y have to be replaced.
PLANETERY GEARTRAIN DISASSEMBLY-A-
998/999
(1) Remove selective snap r i n g a n d # 3 t h r u s t
washer f r o m front end of output shaft (Fig. 32).
(2) Remove planetary gear components f r o m o u t p u t
shaft (Fig. 32).
(3) Remove snap r i n g and # 4 t h r u s t washer ( F i g .
32).
•
Fig. 32 Measuring Planetary End Play—All
(4) Remove annulus support, annulus gear, # 5
t h r u s t washer, front planetary, # 6 t h r u s t washer,
sun gear, spacer and # 7 t h r u s t plate (Fig. 32).
(5) Remove d r i v i n g shell, # 8 t h r u s t plate, snap
r i n g rear p l a n e t a r y and # 1 0 t h r u s t washer (Fig. 32).
(6) Remove and dissassemble rear annulus gear,
support, low-reverse d r u m and output shaft (Fig. 32).
Geartrain Inspection
Clean t h e planetary components i n solvent and d r y
t h e m w i t h compressed air.
Check s u n gear a n d d r i v i n g shell condition. Re-
place t h e gear i f damaged or i f t h e bushings are
scored o r w o r n (bushings are n o t serviceable). Re-
place t h e d r i v i n g shell i f w o r n , cracked or damaged.
Replace planetary gear sets i f gears, p i n i o n pins, or
c a r r i e r a r e damaged i n any way. Replace t h e a n n u -
lus gear a n d support i f either component is w o r n or
damaged. Inspect machined surfaces of output shaft.
Replace t h e output shaft i f scored, pitted, or dam-
aged i n a n y way. Replace t h e t h r u s t washers a n d
plates i f w o r n or damaged.
ASSEMBLING PLANETARY GEARTRAIN-A-
998/999
(1) L u b r i c a t e planetary components w i t h t r a n s m i s -
sion f l u i d d u r i n g assembly. Petroleum j e l l y can be
used t o l u b r i c a t e and hold t h r u s t washers and plates
i n position.
(2) Assemble low-reverse d r u m , annulus gear a n d
support a n d output shaft.
(3) I n s t a l l # 1 0 t h r u s t washer on rear planetary
gear a n d i n s t a l l gear i n rear annulus.
(4) I n s t a l l # 9 t h r u s t washer and snap r i n g on out-
p u t shaft a n d seat washer against rear planetary.
(5) Assemble # 8 and # 7 t h r u s t plates, spacer, sun
gear a n d d r i v i n g shell (Fig. 32). I n s t a l l assembled
components on output shaft.
 • AUTOMATIC TRANSMISSION 21-105

Fig. 32 Planetary C \r Train—A-998/999

(6) Assemble # 6 t h r u s t washer, front planetary annulus a n d low-reverse d r u m (Fig. 33).
gear and a n n u l u s gear a n d support (Fig. 32). I n s t a l l
assembled components o n o u t p u t shaft.
Geartrain Inspection
(7) Verify t h a t a l l p l a n e t a r y components are prop- Clean t h e g e a r t r a i n components i n solvent and dry
erly seated a n d properly meshed. t h e m w i t h compressed air.
(8) I n s t a l l f i n a l snap r i n g a n d check end play Check s u n gear a n d d r i v i n g shell condition. Re-
again. I f end play is n o t correct, i t can be adjusted place t h e s u n gear as a n assembly i f t h e gear or
w i t h a different thickness snap r i n g . Select f i t snap bushings a r e scored or w o r n (the sun gear bushings
rings are available i n 1.07, 1.63, and 2.13 m m (.042, are not serviceable). Replace the d r i v i n g shell i f dam-
.064 and .084 inch) thicknesses. aged i n a n y way.
Replace t h r u s t washers and plates i f cracked,
PLANETARY GEAR TRAIN-A-727 scored or w o r n .
Inspect t h e planetary gear sets. Replace t h e gear
GEARTRAIN END PLAY MEASUREMENT sets i f the gears, p i n i o n pins, or carrier are damaged
(1) Measure gear t r a i n end play before disassembly i n any way.
(Fig. 31). Check condition o f the annulus gear a n d support.
(2) Stand assembly u p r i g h t w i t h f o r w a r d end of Replace t h e a n n u l u s gear and support i f either com-
output shaft o n wood block so a l l parts w i l l move for- ponent is w o r n or damaged.
w a r d against snap r i n g a t front of shaft (Fig. 31). Inspect t h e machined surfaces of the output shaft.
This is necessary for a n accurate measurement. Replace t h e shaft i f scored, pitted, or damaged i n any
(3) Insert feeler gauge between shoulder on output way.
shaft a n d r e a r a n n u l u s gear support h u b (Fig. 31). Inspect t h e low-reverse d r u m a n d annulus gears.
E n d play should be .15 - 1.21 m m (.006 - .048 inch). Replace t h e a n n u l u s gears and the low reverse d r u m
(4) I f end play is incorrect, t h e selective snap r i n g i f worn, cracked or damaged i n any fashion.
or t h r u s t washer m a y need replacement.
ASSEMBLING PLANETARY GEARTRAIN—A-
PLANETARY GEARTRAIN DISASSEMBLY-A- 727
727 (1) L u b r i c a t e planetary components w i t h transmis-
(1) Remove select f i t snap r i n g (Fig. 33). sion f l u i d d u r i n g assembly. Petroleum j e l l y can be
(2) Remove front p l a n e t a r y gear, # 4 t h r u s t washer, used to l u b r i c a t e and hold t h r u s t washers and plates
front annulus gear and # 5 t h r u s t washer (Fig. 33). i n position.
(3) Remove snap r i n g and remove s un gear, d r i v i n g (2) Assemble low-reverse d r u m , rear annulus gear,
shell and # 6 t h r u s t plate (Fig. 33). # 8 t h r u s t plate and rear planetary gear (Fig. 33). I n -
(4) Remove snap r i n g a n d remove # 7 t h r u s t stall t h e assembled components on the output shaft.
washer, rear planetary gear, # 8 t h r u s t plate, rear (3) I n s t a l l # 7 t h r u s t washer on rear planetary gear
21-106 AUTOMATIC TRANSMISSION
Fig. 33 Planetary
and i n s t a l l snap r i n g on o u t p u t shaft (Fig. 33).
(4) Assemble sun gear, # 6 t h r u s t plate, and d r i v i n g
shell. I n s t a l l assembled components on o u t p u t shaft
and i n s t a l l r e t a i n i n g snap r i n g .
(5) I n s t a l l #5 t h r u s t washer f r o n t annulus gear, # 4
t h r u s t washer and f r o n t planetary gear (Fig. 33).
(6) I n s t a l l select f i t snap r i n g on o u t p u t shaft and
check end play again. I f end play is not correct, i t
can be adjusted w i t h a different thickness snap r i n g .
Select f i t snap r i n g s are available i n 1.22, 1.40 and
1.57 m m (.048, .055 and .062 inch) thicknesses.
(7) Set gear t r a i n aside for final assembly.
TRANSMISSION CASE
Clean t h e case t h o r o u g h l y w i t h solvent and d r y
w i t h compressed a i r . A p p l y a i r t h r o u g h a l l case
channels and passages to be sure they are clear and
to remove cleaning residue.
Inspect t h e case for cracks, stripped threads, or
other damage. Stripped threads i n case bolts holes
can be repaired w i t h steel t h r e a d inserts. However,
do not a t t e m p t to r e p a i r cracks or porous spots i n the
case.
Inspect t h e band levers, pins, l i n k s and adjusting
levers. Replace a n y component e x h i b i t i n g wear or
damage.
OVERRUNNING CLUTCH
Inspect t h e o v e r r u n n i n g c l u t c h cam, rollers a n d
spring retainer. Replace the cam as a n assembly i f
the rollers are w o r n , chipped, flat spotted, or any of
the roller or cam surfaces are brinneled or damaged.
The c l u t c h rollers, springs and retainer are ser-
viced as a n assembly. Do not attempt t o remove or
disassemble the rollers and springs.
= •
ear Train—A-727
The c l u t c h cam is attached t o the case w i t h bolts.
The cam a n d shaft support m u s t both be indexed t o
each other a n d t o the case.
The support has a n a l i g n m e n t arrow on i t indicat-
i n g correct i n s t a l l a t i o n position.
The c l u t c h cam has one hole t h a t is not threaded.
This hole does not a l i g n w i t h any of the bolt holes i n
the case. I t aligns w i t h a flat surface on the case i n -
stead.
T i g h t e n t h e cam bolts alternately and evenly w h e n
i n s t a l l i n g t h e cam. This is necessary to seat the cam
properly a n d avoid distortion or cocking.
FRONT (KICKDOWN) SERVO AND BAND-All
FRONT SERVO DISASSEMBLY
(1) Remove the small snap r i n g from the servo pis-
ton.
(2) Remove the piston, rod, springs and guide (Fig.
34).
(3) Remove and discard the servo piston r i n g s and
O-ring.
Front Band And Servo Inspection
Clean t h e servo components w i t h solvent and d r y
t h e m w i t h compressed air.
Inspect t h e servo components. Replace the springs
i f collapsed, distorted or broken. Replace the guide,
rod and piston i f cracked, bent, or w o r n . Discard the
servo snap r i n g i f distorted or warped.
Replace t h e front band i f distorted, t h e l i n i n g i s
burned or f l a k i n g off, or w o r n (grooves no longer vis-
ible a t any p o i n t on band).
Check t h e servo piston bore for wear. Replace the
piston a n d r o d as an assembly i f either p a r t is w o r n
or damaged.
Replace any servo component i f doubt exists about
its condition. Do not reuse suspect parts.
 • AUTOMATIC TRANSMISSION
SNAP RING SPRING RETAINER RH308
Fig. 35 Rear (Low-Reverse) Servo Components—All
FRONT SERVO ASSEMBLY
(1) Lubricate the seal rings and O-rings w i t h petro-
l e u m j e l l y . Lubricate t h e other servo parts w i t h
transmission fluid.
(2) I n s t a l l a new O - r i n g on t h e piston rod.
(3) I n s t a l l a new seal on the piston rod guide and
i n s t a l l new seal r i n g s on the the piston.
(4) Assemble the rod, piston, servo springs, washer
(727 only) and the snap r i n g (Fig. 34).
REAR (LOW-REVERSE) SERVO AND BAND—All
(1) Dissassemble the servo piston, plug, spring and
retainer (Fig. 35).
(2) Remove and discard the servo piston seal r i n g .
Rear Servo And Band Inspection
Clean t h e servo components w i t h solvent and dry
t h e m w i t h compressed a i r .
Inspect the servo components. Replace the spring i f
collapsed, distorted or broken. Replace the p l u g and
piston i f cracked, bent, or w o r n . Discard t h e servo
snap r i n g i f distorted or warped.
Check rear band condition. Replace the band i f dis-
torted, the l i n i n g is b u r n e d or flaking off, or the l i n -
i n g is w o r n (grooves no longer visible at any point on
band).
I f doubt exists about t h e condition of any servo
component, replace i t . Do not reuse suspect parts.
21-107
ASSEMBLING LOW-REVERSE SERVO
(1) L u b r i c a t e the piston and guide seals w i t h petro-
l e u m j e l l y . L u b r i c a t e t h e other servo parts w i t h
transmission fluid.
(2) I n s t a l l a new seal r i n g on the piston (Fig. 35).
(3) Assemble the piston, p l u g and snap r i n g (Fig.
35) .
TRANSMISSION ASSEMBLY
FRONT/REAR SERVO INSTALLATION
(1) L u b r i c a t e the f r o n t servo bore i n the transmis-
sion case w i t h transmission fluid. T h e n i n s t a l l t h e
front servo assembly i n the bore w i t h a t w i s t i n g mo-
t i o n . Compress the servo w i t h tool C-3422-A. Secure
the servo w i t h a new snap r i n g and remove t h e com-
pressor tool.
(2) L u b r i c a t e the rear servo bore i n t h e t r a n s m i s -
sion case w i t h transmission fluid. T h e n i n s t a l l t h e
rear servo assembly i n t h e case bore w i t h a t w i s t i n g
motion. Compress the servo w i t h tool C-3422-A. Se-
cure the servo w i t h a new snap r i n g and remove t h e
compressor tool.
OVERRUNNING CLUTCH INSTALLATION
(1) Place t h e transmission case i n a n u p r i g h t posi-
tion.
(2) I n s t a l l t h e o v e r r u n n i n g clutch h u b , rollers and
springs. L u b r i c a t e the h u b , rollers and springs w i t h
transmission fluid.
REAR BAND AND LINKAGE
INSTALLATION-A-727
(1) Assemble t h e lever, p i n and l i n k and anchor
(Fig. 36).
(2) I n s t a l l a new O-ring on the rear band p i n (Fig.
36) .
(3) Position the rear band i n the case.
(4) I n s t a l l t h e short s t r u t . Then connect t h e l i n k
and anchor t o the band. Be sure the l i n k and anchor
are i n s t a l l e d as shown i n Figure 36.
(5) T i g h t e n t h e band adjuster screw j u s t enough to
hold the s t r u t i n place.
(6) I n s t a l l t h e low-reverse d r u m . Then verify t h a t
the l i n k does not touch the d r u m ( i f i t does, l i n k and
anchor are i m p r o p e r l y installed).
DOUBLE WRAP REAR BAND
INSTALLA TION-A-998/999
(1) I n s t a l l a new O-ring on the band reaction p i n
and l u b r i c a t e t h e p i n w i t h transmission fluid ( F i g .
37) .
(2) Push t h e reaction p i n into the case u n t i l i t is
flush w i t h t h e gasket surface.
(3) Position t h e double wrap band i n t h e case so
t h e band lugs are r e s t i n g against the reaction p i n
(Fig. 38).
21 - 108 AUTOMATIC TRANSMISSION •
ADJUSTING SCREW . LOCKNUT

Fig. 38 Low-Reverse Band Installation—A998/999

Fig. 36 Low-Reverse (Rear) Band And Linkage—A-
727
(4) I n s t a l l the low-reverse d r u m into the band and
o v e r r u n n i n g clutch.
(5) L u b r i c a t e t h e adjuster lever pivot p i n w i t h
transmission fluid.
(6) I n s t a l l the adjuster lever.
(7) Position the adjuster lever so the lever pivot p i n
is flush w i t h t h e case and t h e adjusting screw is
touching t h e center l u g of the band.
(3) Carefully w o r k the shaft and g e a r t r a i n assem-
b l y r e a r w a r d . Continue rearward movement u n t i l the
rear p l a n e t a r y gears are f u l l y engaged i n t h e low-re-
verse d r u m slots.
POSITIONING TRANSMISSION CASE FOR
FINAL ASSEMBLY
The r e m a i n i n g transmission components (clutches,
front band, o i l pump/reaction shaft support), are
much easier t o i n s t a l l i f the transmission case is i n
an u p r i g h t position.
Two methods can be used to hold the transmission
case u p r i g h t . T h e f i r s t method involves u s i n g a C-
clamp style transmission h o l d i n g tool. T h e second
(and simpler) method only requires modifying a shop
workbench.
Workbench modification involves d r i l l i n g or cut-
t i n g a 8.89 c m (3-1/2 inch) diameter m o u n t i n g hole
i n the bench; t h e n c u t t i n g notches at the hole sides
large enough to clear t h e output shaft support
flanges. B e s u r e t h e m o u n t i n g h o l e w i l l b e l o -
cated a t a convenient location o n the bench be-
fore cutting/drilling.
After p r e p a r i n g t h e workbench m o u n t i n g hole,
carefully lower t h e transmission o u t p u t shaft
t h r o u g h t h e hole u n t i l the shaft support and case are
resting on the bench surface.

Fig. 37 Low-Reverse Band Components—A-998/999 ASSEMBLING/INSTALLING FRONT AND REAR

INSTALLING PLANETARY GEARS, SUN GEAR CLUTCHES
AND DRIVING SHELL (1) Coat No. 3 t h r u s t washer w i t h petroleum j e l l y
(1) Lubricate the o u t p u t shaft and g e a r t r a i n w i t h and insert washer i n end of i n p u t shaft (Fig. 39). Use
transmission fluid. enough petroleum j e l l y to hold i t i n place.
(2) Insert the o u t p u t shaft t h r o u g h t h e rear sup- (2) Coat o u t p u t shaft t h r u s t plate w i t h petroleum
port. j e l l y and i n s t a l l plate on forward end of o u t p u t shaft
(Fig. 39).
 • AUTOMATIC TRANSMISSION
THRUST
WASHER.
THRUST
PLATE
OUTPUT
INPUT SHAFT
J9021-116
SHAFT
Fig. 39 No. 3 Thrust Washer And Output Shaft
Thrust Plate Position
(3) A l i g n front clutch plate i n n e r splines. T h e n i n -
s t a l l front clutch o n rear clutch. B e s u r e front
c l u t c h plate s p l i n e s a r e fully e n g a g e d i n r e a r
clutch hub.
(4) Lower front/rear clutch assembly i n t o case.
(5) Carefully w o r k assembled clutches i n a c i r c u l a r
m o t i o n to engage rear clutch splines over splines o f
front annulus gear. Be sure t h e front c l u t c h drive
lugs are f u l l y engaged i n slots o f d r i v i n g shell.
FRONT (KICKDOWN) BAND INSTALLATION
(1) Slide t h e front band over t h e front c l u t c h .
(2) I n s t a l l t h e band lever and shaft (Fig. 40).
(3) I n s t a l l t h e band s t r u t (Fig. 40).
(4) I n s t a l l the band adjusting screw. O n A-727, also
i n s t a l l t h e adjusting screw anchor.
(5) Coat the lever shaft p l u g w i t h a non-hardening
sealer such as Permatex No. 2 and i n s t a l l t h e p l u g i n
the case.
OIL PUMP AND REACTION SHAFT SUPPORT
INSTALLATION
(1) I f the o i l p u m p was a n extremely t i g h t fit a n d
difficult to remove a t the start o f overhaul, w a r m the
p u m p m o u n t i n g area of the case w i t h a heat l a m p . A
few minutes of heat application should expand t h e
case enough ease pump i n s t a l l a t i o n . Leave t h e heat
l a m p o n u n t i l t h e pump is ready for i n s t a l l a t i o n .
(2) O n A-998/999, i n s t a l l t h e # 1 t h r u s t washer o n
the reaction shaft support h u b ( F i g . 6). Use petro-
l e u m j e l l y to hold t h e washer i n place.
(3) O n A-727, i f i n p u t shaft end play measured d u r -
i n g disassembly was incorrect, i n s t a l l a n e w t h r u s t
washer t h a t w i l l provide correct end play. Select fit
washers are available for t h i s purpose. Refer t o t h e
specifications section for select fit washer t h i c k -
nesses.
(4) I n s t a l l t w o pilot stud tools C-3288-B i n t h e
p u m p m o u n t i n g holes (Fig. 41).
(5) I n s t a l l a new pump gasket over t h e studs a n d
21 - 109
PLUG
STRUT ANCHOR (A-727 ONLY)
LEVER SHAFT
ADJUSTING
SCREW
AND LOCKNUT
RH312
Fig. 40 Front (Kickdown) Band And Linkage
seat t h e gasket i n t h e case.
(6) Coat the p u m p O-ring w i t h Door Ease or petro-
l e u m j e l l y t o a i d i n s t a l l a t i o n . A p p l y either o f t h e
same lubricants t o t h e l i p o f t h e p u m p o i l seal.
(7) Remove t h e heat lamp ( i f used).
(8) Position t h e p u m p a n d reaction shaft support
assembly on t h e p i l o t studs. T h e n slide the p u m p and
shaft assembly i n t o the case (Fig. 40). Gently tap the
p u m p body w i t h a rubber m a l l e t t o f u l l y seat i t .
(9) Remove t h e p i l o t stud tools a n d i n s t a l l t h e
p u m p bolts. T i g h t e n the bolts snugly b u t not t o final
torque a t t h i s t i m e .
(10) Check for correct component i n s t a l l a t i o n as
follows:
(a) Rotate t h e i n p u t and o u t p u t shafts and ob-
serve shaft operation.
(b) I f both shafts rotate freely, proceed t o t h e
next assembly step.
(c) I f either shaft binds, t h e clutches, planetary
gears or t h r u s t washers are misassembled. Remove
and reassemble transmission components as neces-
sary to eliminate t h e b i n d condition.
(11) F i n a l - t i g h t e n pump bolts t o 20 N n n (175 i n -
lbs) torque.
(12) Check i n p u t a n d o u t p u t shaft r o t a t i o n one
more t i m e .
GOVERNOR AND SUPPORT INSTALLATION
(1) Lubricate the governor valve, weights, body and
shaft w i t h transmission fluid.
(2) I n s t a l l t h e filter screen i n t h e governor body.
(3) Position t h e governor body o n t h e p a r k gear
and i n s t a l l t h e body a t t a c h i n g bolts finger t i g h t .
(4) I n s t a l l t h e assembled p a r k gear a n d governor
body o n t h e o u t p u t shaft (Fig. 42).
(5) A l i g n the governor valve shaft holes i n the gov-
ernor body and output shaft.
(6) I n s t a l l t h e governor r e t a i n i n g snap r i n g on t h e
output shaft.
21-110 AUTOMATIC TRANSMISSION •

Fig. 41 Installing Oil Pump And Reaction Shaft

Support
(7) T i g h t e n the bolts a t t a c h i n g t h e governor body
to t h e p a r k gear to 11 N n n (95 in-lbs) torque.
(8) Assemble the governor weights and spring. Use
a n e w snap r i n g to secure t h e i n n e r w e i g h t a n d
spring i n the outer weight.
(9) I n s t a l l t h e weights i n the governor body and i n -
Fig. 43 Accumulator Piston And Spring
stall t h e r e t a i n i n g snap r i n g (Fig. 42).
(10) Assemble the governor valve, valve shaft and (2) I n s t a l l new seal rings o n t h e accumulator piston
snap r i n g . Then insert the shaft i n t o the governor (Fig. 43).
body a n d t h r o u g h t h e output shaft a n d governor (3) Lubricate the accumulator piston, seals and the
weights. Secure the shaft to the weights w i t h a new accumulator bore ( i n t h e case) w i t h transmission
snap r i n g . fluid.
(11) Verify t h a t t h e governor valve and weights (4) I n s t a l l the accumulator piston and s p r i n g (Fig.
move freely i n the governor body. 43) i n t h e case.
(5) Place t h e valve body m a n u a l lever i n l o w to
REAR BEARING AND EXTENSION HOUSING
move the p a r k lock rod r e a r w a r d .
INSTALLATION
(6) Position the valve body o n the case. W o r k the
(1) Position a new housing gasket on the t r a n s m i s -
park lock rod past the sprag and i n s t a l l t h e valve
sion case.
body bolts finger-tight.
(2) I n s t a l l a new o i l seal i n the extension housing.
(7) I n s t a l l the n e u t r a l s t a r t switch i n t h e case and
(3) I n s t a l l the rear bearing on the o u t p u t shaft. Se-
move the p a r k lock rod to N e u t r a l position.
cure t h e bearing w i t h one new snap r i n g (A-998/999)
(8) A l i g n the valve body o n t h e transmission case
or two new snap rings (A-727).
(4) I n s t a l l the output shaft snap r i n g i n the exten- and i n s t a l l the valve body bolts. T i g h t e n the bolts a l -
sion housing. Then spread t h e snap r i n g and w o r k ternately and evenly t o 35 in-lbs (4 N n n ) torque.
the housing onto the bearing and transmission case. Start a t t h e center and w o r k o u t w a r d w h e n t i g h t e n -
Be sure the shaft bearing snap r i n g is seated. i n g the bolts.
(5) I n s t a l l the snap r i n g access plate i n t h e hous- (9) I n s t a l l a new f i l t e r o n t h e valve body. T i g h t e n
ing. the filter bolts evenly t o 35 in-lbs (4 Nnn) torque.
(6) T i g h t e n the housing a t t a c h i n g bolts t o 33 N n n (10) I n s t a l l a new m a n u a l lever shaft seal the i n
(24 ft-lbs) torque. case. T h e n install t h e t h r o t t l e valve a n d m a n u a l
valve levers on the shaft.
VALVE BODY, ACCUMULATOR AND OIL PAN (11) Position a new o i l p a n gasket on the case.
INSTALLATION
(12) I n s t a l l the o i l pan a n d t i g h t e n the p a n bolts to
(1) M a k e sure the n e u t r a l s w i t c h has n o t been i n -
17 N n n (150 ft-lbs) torque.
stalled i n the case ( i t w i l l interfere w i t h valve body
i n s t a l l a t i o n i f mounted i n the case).
 • AUTOMATIC TRANSMISSION
A-500/A-518 AUTOMATIC TRANSMISSION
INDEX
" Page
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . 122
General Information • 111
Overdrive Geartrain Assembly and Adjustment . . 124
Overdrive Geartrain Disassembly .121
Overdrive Unit Assembly and Adjustment . . . . . 127
Overdrive Unit Disassembly . . . . . . . . . . . . . . . . 117
GENERAL INFORMATION
DESCRIPTION/APPLICATION
The A-500/518, four speed automatic transmissions
are a unique two-section design. They consist o f a
modified Chrysler three speed automatic t r a n s m i s -
sion w i t h a n overdrive u n i t attached to t h e rear o f
the transmission (Fig. 1).
TRANSMISSION
Fig. 1 A-500/518 Transmission And Overdrive Unit
The f r o n t section of the A-500 overdrive automatic
transmission is a modified A-999, three speed t r a n s -
mission. The f r o n t section of the A-518 overdrive au-
t o m a t i c transmission is a modified A-727 three speed
transmission.
T h e overdrive u n i t is mounted a t the rear of the
t r a n s m i s s i o n case i n place o f the n o r m a l extension
housing. The overdrive u n i t is connected to the f r o n t
section intermediate shaft. T h e overdrive u n i t pro-
vides a f o u r t h gear r a t i o of 0.69 to 1 (Fig. 1). T h e
f i r s t three gear ratios o f the A-500/518 transmission
are t h e same as those i n the applicable three speed
a u t o m a t i c transmission.
T h e A-500 is used for 3.9L and 5.2L applications.
The A-518 transmission is used for 5.2 and 5.9 L gas
engine applications.
21 - 111
Page.
Overdrive Unit Installation 128
Overdrive Unit Removal 116
Overdrive Unit Service Diagnosis 115
Overdrive Valve Body Service 116
Service Diagnosis 113
OVERDRIVE COMPONENTS
The components i n the front section o f t h e A-500/
518 transmission are basically t h e same as those i n
the applicable Chrysler transmission. However, dif-
ferent components are needed t o a t t a c h t h e overdrive
unit.
The three speed transmission has a n i n t e r m e d i a t e
shaft instead of the usual o u t p u t shaft. I t serves as
the front section o u t p u t shaft a n d connects the over-
drive u n i t to the front section.
The governor and speedometer drive are relocated
to t h e rear o f the overdrive u n i t o u t p u t shaft. T w o
bearings are used t o support t h e overdrive o u t p u t
shaft. A longer p a r k lock r o d assembly i s also r e -
quired.
R o t a t i n g seal r i n g s and pressurized o i l for the over-
drive and direct clutches i n t h e overdrive u n i t are
not required. The governor is t h e only component re-
ceiving pressurized o i l (through s l i p f i t tubes). Pres-
surized o i l for t h e overdrive l u b r i c a t i o n circuit i s
supplied t h r o u g h the intermediate shaft.
Governor pressure and overdrive pressure taps are
provided i n t h e rear o f the transmission case for i n -
vehicle pressure testing.
The overdrive f o u r t h gear range is provided b y a
t h i r d planetary gear set, a direct clutch, an overdrive
clutch and a n o v e r r u n n i n g clutch. A h i g h tension
spring t h a t exerts u p to 800 pounds (5,516 k P a )
force, holds the sun gear t o t h e a n n u l u s for direct
drive. For coasting or reverse gear, power flows only
t h r o u g h the direct clutch.
The lockup t i m i n g valve releases the torque con-
verter to n o r m a l operation p r i o r to the 4-3 downshift.
21 - 112 AUTOMATIC TRANSMISSION
T h e standard valve body is modified b y adding sev-
e r a l new components t o a lower housing (Figs. 2 and
3). The new components include: a n overdrive sole-
noid, a lockup solenoid (A-500 only), a 3-4 shift
valve, a 3-4 t i m i n g valve, a 3-4 accumulator, and a
3-4 s h u t t l e valve.
I n f o u r t h gear overdrive, t h e A-500 converter
lockup solenoid, lockup valve, a n d lockup t i m i n g
v a l v e are actuated. A t lockup, t h e converter t u r b i n e
is locked t o t h e converter housing b y t h e converter
lockup clutch.
•
Converter lockup i n overdrive f o u r t h gear i s con-
t r o l l e d b y sensor i n p u t s t o t h e engine controller. I n
t h i r d gear above 25 m p h , sensor i n p u t s to t h e con-
t r o l l e r t h a t determine lockup a n d s h i f t t i m i n g are:
coolant temperature (verifies t e m p e r a t u r e m i n i m u m
of 60° F ) , engine speed, vehicle speed, t h r o t t l e posi-
t i o n and manifold v a c u u m t h r o u g h t h e map sensor.
The c o l u m n gear shift m e c h a n i s m provides t h e
same s h i f t positions used w i t h t h r e e speed automatic
transmissions (P-R-N-D-2-1). T h e s h i f t i n t o overdrive
f o u r t h gear range occurs o n l y after t h e transmission

3-4 ACCUMULATOR PISTON 3-4 ACCUMULATOR HOUSING

LOWER VALVE
BODY HOUSING
3-4 TIMING
VALVE PLUG

END
COVER
PLATE

SPRING
RETAINER

OVERDRIVE LOCKUP TIMING

SOLENOID VALVE
(BLACK WIRE)

LOCKUP SOLENOID STEEL J9021-143

(WHITE WIRE) SEPARATOR PLATE

Fig. 2 A-500 Valve Body Lower Housing

OVERDRIVE CONTROL AND OPERATION
F o u r t h gear overdrive i s electronically controlled
and h y d r a u l i c a l l y activated. A variety o f sensor i n -
puts are supplied to t h e engine controller w h i c h op-
erates t h e valve body solenoids. T h e solenoids
energize a n d close a vent allowing a 3-4 upshift. The
engine electronic module also controls operation of
the lockup torque converter using m a n y of the same
sensor inputs.
Closed t h r o t t l e 3-4 upshifts occur a t 25-28 m p h , re-
gardless o f axle ratio. Closed t h r o t t l e 4-3 downshifts
occur a t approximately 25 m p h , regardless o f axle r a -
tio.
A 3-4 u p s h i f t w i l l n o t occur i f t h r o t t l e opening is
greater t h a n approximately 70 percent.
has completed the shift i n t o D t h i r d gear range. T h e
shift t o overdrive f o u r t h gear occurs automatically
and is determined b y sensor i n p u t t o the engine con-
troller.
The overdrive control s w i t c h i s located i n t h e i n -
s t r u m e n t panel. I n t h e O n position, automatic shifts
i n t o f o u r t h gear overdrive w i l l occur. I n the O f f posi-
t i o n , t h e s w i t c h overrides t h e electronic control mod-
ule p r e v e n t i n g a shift to f o u r t h gear.
The control switch has a n i n d i c a t o r l i g h t t h a t i l l u -
minates w h e n overdrive i s t u r n e d off. T h e switch
also resets when the i g n i t i o n k e y is t u r n e d to the O f f
position so the overdrive feature is restored.
F a u l t codes are employed t o help diagnose elec-
tronic components t h a t operate t h e overdrive u n i t
and lockup converter.
 • AUTOMATIC TRANSMISSION
Fig. 3 A-518 Valve
TORQUE CONVERTER APPLICATION
Lockup a n d nonlockup torque converters are used.
A lockup converter is used w i t h t h e A-500. A-518
models are equipped w i t h a nonlockup converter.
RECOMMENDED FLUID
Recommended fluid for use i n A-500/518 overdrive
transmissions is Mopar A T F Plus, Type 7176. Mopar
Dexron II™ can be used i f A T F Plus is not available.
Mercon™ fluid is not recommended for use i n A -
500/518 transmissions for r e f i l l i n g after filter/fluid
changes, or after overhaul. I t can only be used for
topping off t h e fluid level d u r i n g periodic checks.
SERVICE DIAGNOSIS
GENERAL DIAGNOSIS INFORMATION
A-500/518 automatic transmission problems can be
a result of: poor engine performance; incorrect fluid
level; incorrect linkage adjustment; electronic compo-
nent shorts-grounds-opens; band or h y d r a u l i c control
pressure adjustments; h y d r a u l i c system malfunc-
tions; or mechanical component malfunctions.
Begin diagnosis by checking the easily accessible
items such as fluid level and condition, l i n k a g e ad-
j u s t m e n t s a n d overdrive fuse, solenoid and w i r e con-
d i t i o n . A road test w i l l determine i f f u r t h e r diagnosis
21 - 113
>dy Lower Housing
is necessary. The overdrive u n i t should not be r e -
moved unless diagnosis reveals a n actual overdrive
fault.
ROAD TESTING
Before road testing, be sure fluid level and linkage
adjustments are correct and t h a t t h e overdrive cir-
cuit fuse and electrical connections are O K .
Observe engine performance d u r i n g the road test.
A poorly t u n e d engine w i l l not allow a n accurate
analysis o f transmission operation.
Operate the transmission i n a l l gear ranges. Check
for slippage and shift variations. Note whether t h e
shifts are h a r s h , spongy, delayed, early, or i f down-
shifts are sensitive.
W a t c h closely for slippage or engine flare w h i c h
u s u a l l y indicates clutch, band or o v e r r u n n i n g c l u t c h
problems. I f the condition is advanced, a n overhaul
m a y be necessary to restore n o r m a l operation.
A s l i p p i n g clutch or band can often be determined
by comparing w h i c h i n t e r n a l u n i t s are applied i n the
various gear ranges. The clutch and band application
chart (Fig. 1) provides a basis for analyzing road test
results.
For example: I f slippage occurs d u r i n g the 3-4 shift
or i n f o u r t h gear, t h e overdrive clutch is slipping.
S i m i l a r l y , i f the direct clutch were t o f a i l , the t r a n s -
mission w o u l d lose reverse gear and overrun b r a k i n g
21-114 AUTOMATIC TRANSMISSION •

TRANSMISSION FRONT SECTION OVERDRIVE UNIT

A500/
CLUTCHES BANDS CLUTCHES
A518
LEVER OVER- START MRKMG K/D
POSITION DMVE SAFETY SPRAG FRONT REAR OWN LOCKUP FRONT REVERSE/REAR O/D O'RUNNWG DRECT

P-Poric X X

2.21 X X X

O-0rive
Fht 274 X X X X
Second 1.54 X X X X
Third 1.00 X X X X X
O/D .69 X X X X

2-Secood
First 274 X X X X
Second 1.54 X X X X

1-Low 274 X X X X X
J9021-80

Fig. 1 Elements In Use In All Gear Ranges

i n 2 ( m a n u a l second gear) position. I f t h e t r a n s m i s - mission f r o n t section rear clutch m a y be s l i p p i n g ,
sion slips i n any other two forward gears, t h e t r a n s -
• AUTOMATIC TRANSMISSION 21-115

OVERDRIVE UNIT SERVICE DIAGNOSIS

Condition Possible Cause

(1) N o reverse o r slips in reverse (1) Failed direct clutch
(a) Overdrive spring lost load.
(b) W r o n g overdrive piston bearing spacer
selected.

(2) N o overdrive shift. (2) Blown fuse

(a) Faulty overdrive solenoid.
(b) Faulty wiring o r connectors.
(c) Faulty overdrive off switch.
(d) Faulty engine controller.
(e) Failed overdrive clutch.
-— W r o n g overdrive piston bearing spacer
selected.
— Low overdrive pressure.

(3) Runaway overdrive shift. (3) Failed overdrive overrunning clutch.

(4) Overdrive shift occurs immediately after (4) Faulty overdrive solenoid — not venting.
2-3 shift. (a) Lower valve body malfunction.
(b) Faulty wiring.
(c) Faulty engine controller.

(5) Excessively delayed overdrive shift. (5) Incorrect overdrive piston bearing spacer,
(a) Faulty sensor.

(6) N o 4-3 downshift. (6) Faulty lockup solenoid — not venting.

(a) Lower valve body malfunction.
(b) Faulty wiring.
(C) Faulty engine controller.

(7) N o 4-3 downshift with overdrive off switch. (7) Faulty overdrive off switch.
(a) Faulty engine controller.
(b) Faulty lockup solenoid — not venting.
(c) Faulty wiring.

(8) Torque converter locks up in 2nd and (8) Faulty lockup solenoid — not venting.
3rd gears.

(9) Harsh shifts 1-2, 2-3, & 3-2. (9) Faulty lockup solenoid — not venting.

(10) Low governor pressure. (10) Leaking governor tubes:

(a) Bent.
(b) Loose fit.
(c) Governor seal rings broken or w o r n .

(11) Noisy. (11) Failed overdrive piston bearing.

(a) Failed gear train needle thrust bearings.
(b) Failed overdrive planetary.
(c) Failed overdrive overrunning clutch.

J9021-81
21-116 AUTOMATIC TRANSMISSION
OVERDRIVE UNIT REMOVAL
The overdrive removal a n d i n s t a l l a t i o n procedures
i n t h i s section apply to the overdrive u n i t only. I f t h e
complete transmission assembly must be removed for
service, refer t o the procedures i n the three speed
transmission section.
(1) Shift t h e transmission i n t o Park.
(2) Raise t h e vehicle.
(3) Remove the transmission o i l pan and gasket
and d r a i n t h e fluid. T h e n r e i n s t a l l the o i l pan plus a
new gasket.
(4) I f the malfunction involved an overdrive clutch
or governor problem, remove only the overdrive u n i t .
However, i f the failure generated m e t a l particles, or
i f the fluid is contaminated w i t h friction m a t e r i a l , re-
move t h e e n t i r e transmission.
(5) M a r k propeller shaft universal j o i n t and axle
p i n i o n yoke for a l i g n m e n t reference (Fig. 1).
Fig. 1 Mark Propeller Shaft And Yoke For Alignment
Reference
(6) Disconnect and remove the propeller shaft, or
shafts on four wheel drive models.
(7) O n four wheel drive models, remove the trans-
fer case f r o m the overdrive u n i t .
(8) Support the transmission w i t h a transmission
jack.
(9) Remove t h e crossmember. M a r k position o f
crossmember for reassembly.
(10) Remove the distance sensor and speedometer
adapter.
(11) Remove the bolts a t t a c h i n g the overdrive u n i t
to the t r a n s m i s s i o n (Fig. 2).
CAUTION: Support the overdrive unit during re-
moval. Do not allow the front section intermediate
shaft to support the entire weight of the overdrive
unit.
(12) C a r e f u l l y slide the overdrive u n i t off the i n t e r -
mediate shaft. Retain t h e bearing a n d select fit
•
Fig. 2 Removing/Installing Overdrive Unit Attaching
Bolts
spacer t h a t m a y r e m a i n on the overdrive piston, rear
of the t r a n s m i s s i o n case, s l i d i n g h u b , or i n t e r m e d i a t e
shaft.
(13) Place several clean shop towels o n the w o r k -
bench.
(14) T i l t t h e overdrive u n i t t o d r a i n a n y fluid r e -
m a i n i n g i n t h e case. E x a m i n e the fluid for clutch
m a t e r i a l or m e t a l fragments. I f the fluid contains
these items, a n overhaul w i l l be necessary.
OVERDRIVE VALVE BODY SERVICE
GENERAL SERVICE INFORMATION
The upper p a r t o f the overdrive valve body is sim-
i l a r t o t h e three speed automatic transmission valve
body (Fig. 3). I t contains the t h r o t t l e valves, gover-
nor plugs, pressure regulators, 1-2 shift valves, pres-
sure adjustment components and the m a n u a l valve
and lever. Refer to the Loadflite transmission section
for service procedures.
The lower section o f the overdrive valve body (Fig.
3) contains the f o u r t h gear shift components. These
include t h e 3-4 shift valve, 3-4 accumulator, 3-4 t i m -
i n g valve, lockup and t i m i n g valves, 3-4 shuttle and
t i m i n g valves and the dual overdrive/lockup solenoid
assembly (Fig. 3).
VALVE BODY REMOVAL/INSTALLATION
Removal a n d i n s t a l l a t i o n procedures f o r the over-
drive valve body are the same as for t h e three speed
valve body. Refer t o t h e procedures i n t h e three
speed t r a n s m i s s i o n section.
VALVE BODY OVERHAUL AND ADJUSTMENT
The overdrive valve body overhaul procedures v a r y
f r o m t h e three speed procedures only i n regard t o
lower h o u s i n g components (Fig. 4). C l e a n i n g and i n -
spection methods are the same except for the d u a l so-
lenoid assembly a n d solenoid connector. These
 AUTOMATIC TRANSMISSION 21-117

PRESSURE ADJUSTING Maintenance a n d Adjustments i n t h e three speed

SCREW BRACKET transmission section for procedures.
SWITCH VALVE
VALVE BODY OVERDRIVE UNIT DISASSEMBLY
ASSEMBLY
(1) Remove overdrive clutch w i r e r e t a i n i n g r i n g
(Fig. 5).
DUAL SOLENOID
MANUAL ASSEMBLY WIRE
OVERDRIVE
LEVER RETAINING
CLUTCH
SHAFT RING
PACK
SEALf

SOLENOID
CONNECTOR

J9021-84
Fig. 3 A-500/518 Valve Body
components m u s t not be immersed i n solvent. Wipe
t h e m d r y w i t h l i n t free shop towels for inspection
and test purposes.
Overdrive valve body screw t i g h t e n i n g torques are
unchanged and r e m a i n a t 4 N n n (35 in-lbs) torque.
Screw t i g h t e n i n g sequence also remains t h e same
(start at center and w o r k outward).
The h y d r a u l i c pressure adjustments for t h e over-
drive valve body are t h e same as for Chrysler auto-
matic transmission valve bodies. Refer to
8921-229
Fig. 5 Remove Clutch Pack Retaining Ring
(2) Remove overdrive clutch pack plates and discs
(Fig. 6. Thickest plate is t h e clutch pressure plate.
T h i s plate i s positioned a t front o f clutch pack.
(3) Remove overdrive clutch wave r i n g ( F i g . 7).
T h i s special r i n g acts as a cushion to absorb shock
w h e n the overdrive clutch engages.
(4) Remove large f l a t snap r i n g from same groove
as wave r i n g was i n s t a l l e d i n (Fig. 8).

LOCKUP SOLENOID LOWER VALVE BODY

OVERDRIVE SOLENOID

3-4 ACCUMULATOR

3-PRONG SOLENOID
CONNECTOR

TRANSFER PLATE 8921-270

Fig. 4 Valve Body

21-118 AUTOMATIC TRANSMISSION •

Fig. 9 Removing/Installing Access Cover

(6) Insert a l i g n m e n t Tool C-6277-2 i n t o sun gear
(Fig. 10). Be sure tool is firmly seated as i t w i l l be
used t o remove e n t i r e gear t r a i n as a n assembly.
(7) A f t e r seating the a l i g n m e n t tool C-6227-2, t u r n
overdrive u n i t over a n d position i t on the a l i g n m e n t
tool (Fig. 11).
(8) E x p a n d t h e o u t p u t shaft bearing snap r i n g w i t h
expandable snap r i n g pliers (Fig. 11). Then l i f t t h e
overdrive case off the g e a r t r a i n .

8921-231

Fig. 7 Removing/Installing Overdrive Clutch Wave

Ring

Fig. 10 Installing Alignment Tool C-6227-2

(9) Remove the governor r e t a i n i n g snap r i n g a n d
remove t h e governor and shaft key (Fig. 12). T h i s
prevents damaging t h e governor when t h e direct
clutch s p r i n g is compressed i n an arbor press.
(10) Set gear t r a i n aside for overhaul operations
and continue disassembly of case components.
(11) Remove t h e output shaft front bearing snap
r i n g (Fig. 13). T h e n remove t h e governor support
Fig. 8 Removing/Installing Overdrive Clutch Flat
Snap Ring snap r i n g .
(12) Remove the governor support and the slip fit
(5) Remove access cover (Fig. 9). Cover provides ac-
pressure tubes f r o m the case (Fig. 14).
cess t o snap r i n g t h a t holds o u t p u t shaft front bear- (13) Remove o u t p u t shaft rear bearing snap r i n g
i n g i n place. w i t h locking-type snap r i n g pliers (Fig. 15).
• AUTOMATIC TRANSMISSION 21 -119

Fig. 14 Removing Governor Support And Pressure

Fig. 11 Expanding Output Shaft Bearing Snap Ring Tubes
(To Remove Case From Geartrain)
GOVERNOR

Fig. 15 Removing Output Shaft Rear Bearing And

Snap Ring

8921-237

Fig. 13 Removing Output Shaft Front Bearing Snap

Ring Fig. 16 Removing Reaction Plug And Snap Ring
(14) Tap overdrive case downward on wood block t o (15) Remove the reaction p l u g snap r i n g and the
remove the rear bearing. reaction p l u g . Compress snap r i n g j u s t enough to a l -
low removal (Fig. 16).
21 - 120 AUTOMATIC TRANSMISSION -— •

PARKING REACTION
PAWL PLUG

RETAINING PAWL
BOLT 8921-241 SPRING SHAFT J9021-93

Fig. 17 Removing Parking Pawl Shaft Retainer Bolt Fig. 18 Parking Pawl Components

(16) Remove the bolt securing t h e p a r k p a w l shaft (18) Remove t h e seal and damper weight from t h e
i n the case (Fig. 17). overdrive case (Fig. 19).
(17) Tap the case l i g h t l y o n a wood block to dis- (19) Remove t h e p a r k lock r o d f r o m the valve body
lodge the p a w l shaft, p a w l and s p r i n g (Fig. 18). i f the r o d or b a l l end are w o r n o r damaged (Fig. 19).

SEAL ACCESS PLATE CASE GASKET

SPRING PLUG AND SNAP RING PARK LOCK ROD J9021-85

Fig. 19 Overdrive Case Components

 • AUTOMATIC TRANSMISSION 21-121

OVERDRIVE GEARTRAIN DISASSEMBLY

WARNING: THE FIRST STEP IN GEARTRAIN DISAS-

SEMBLY INVOLVES COMPRESSING THE DIRECT
CLUTCH SPRING. BECAUSE THE SPRING E X E R T S
OVER 800 POUNDS FORCE ON THE SLIDING HUB,
IT IS EXTREMELY IMPORTANT THAT PROPER
EQUIPMENT BE USED FOR THIS PURPOSE.
SPRING COMPRESSOR TOOL C-6227-1 AND A
SHOP PRESS WITH A MINIMUM PRESS RAM
TRAVEL OF THREE INCHES ARE REQUIRED TO
COMPRESS THE SPRING SAFELY. SPRING TEN-
SION MUST ALSO BE RELEASED SLOWLY AND
COMPLETELY TO AVOID PERSONAL INJURY. DO
NOT ATTEMPT TO COMPRESS THE SPRING WITH
ANYTHING OTHER THAN THE COMPRESSOR TOOL
AND SHOP PRESS.

(1) M o u n t t h e g e a r t r a i n assembly i n a shop press

w i t h t h e output shaft facing downward. Position t h e
o u t p u t shaft i n a f i x t u r e t h a t w i l l support t h e o u t p u t
shaft flange.
(2) W i t h t h e g e a r t r a i n assembly properly supported
i n t h e press, i n s t a l l spring compressor tool C-6227-1
i n t h e sliding h u b (Fig. 20).

Fig. 22 Removing Safety Ring From Sun Gear

Fig. 20 Installing Clutch Spring Compressor Tool

(3) A l i g n t h e press r a m w i t h t h e compressor tool
a n d have a helper operate t h e press t o compress t h e
direct clutch spring.
(4) When t h e spring a n d h u b are compressed, r e -
move the large load r e t a i n i n g r i n g ( F i g . 21) a n d t h e
s m a l l load r e t a i n i n g safety r i n g ( F i g . 22).
HUB 8921-246
(5) Release t h e press load o n t h e clutch s p r i n g
s l o w l y . Then remove t h e compressor tool a n d Fig. 23 Removing Sliding Hub And Direct Clutch
g e a r t r a i n from t h e press. Pack
(6) Remove t h e s l i d i n g h u b a n d direct clutch pack
(8) T u r n the output shaft over.
as a n assembly (Fig. 23).
(9) Remove the overrunning clutch as a n assembly
(7) Remove direct clutch spring, s u n gear a n d
w i t h expanding snap r i n g pliers (Fig. 25). Reach into
c l u t c h spring t h r u s t plate, needle t h r u s t bearing, a n d
the inner splines of the clutch and engage t h e pliers.
planetary gear assembly (Fig. 24).
 21 - 122 AUTOMATIC TRANSMISSION

DIRECT SUN DIRECT

CLUTCH GEAR CLUTCH
SPRING DRUM

CLUTCH
SPRING
THRUST
PLATE
GEAR NEEDLE THRUST BEARING
ASSEMBLY J9021-91 PUNCH 8921-249

Fig. 24 Planet Carrier, Sun Gear And Clutch Spring Fig. 26 Marking Direct Clutch Drum And Annulus
T h e n remove the o v e r r u n n i n g clutch assembly w i t h a For Assembly Alignment
q u i c k counterclockwise t w i s t i n g motion. REAR DIRECT
(10) Remove t h e needle t h r u s t bearing from t h e RETAINING CLUTCH
c l u t c h h u b (Fig. 25). RING DRUM

OVERRUNNING
CLUTCH

8921-250

Fig. 27 Removing Clutch Drum Rear Retaining Ring

8921-248

Fig. 25 Removing/Installing Overrunning Clutch

(11) M a r k t h e direct clutch d r u m and a n n u l u s for
reassembly (Fig. 26).
(12) Two w i r e r e t a i n i n g rings secure t h e direct
c l u t c h d r u m to t h e annulus. Remove the rear i n n e r
r i n g f i r s t (Fig. 27). T h e n remove the front outer re-
t a i n i n g r i n g a t t h e rear of the d r u m (Fig. 28).
(13) Slide t h e c l u t c h d r u m off the annulus.
(14) M a r k a n n u l u s gear and output shaft for a l i g n -
m e n t a t assembly (Fig. 29).
(15) Remove t h e annulus gear snap r i n g . T h e n
l i g h t l y tap the gear w i t h a plastic mallet t o remove i f
FRONT RETAINING
f r o m t h e shaft (Fig. 30). RING 8921-251
(16) Remove t h e o u t p u t shaft front bearing.
Fig. 28 Removing/Installing Clutch Drum Front
CLEANING AND INSPECTION Retaining Ring
shop towels for w i p i n g parts d r y unless t h e towels
Clean t h e g e a r t r a i n and case components w i t h sol-
are a lint-free type. L i n t f r o m shop towels can p l u g
vent. T h e n d r y a l l parts except the bearings w i t h
compressed air. A l l o w bearings to air dry. Do n o t use the transmission filters and o i l passages.
 • AUTOMATIC TRANSMISSION 21-123

PUNCH 8921-252 SNAP RING J9021-88

Fig. 29 Marking Annulus And Output Shaft For
Assembly Reference
Discard o l d gaskets and seals. Do n o t a t t e m p t t o
salvage these parts. Replace a n y o f t h e overdrive
u n i t snap rings i f distorted or damaged. I f i n doubt
about the condition o f a p a r t i c u l a r snap r i n g , replace
i t . Refer to Figure 31 for snap r i n g i d e n t i f i c a t i o n .
M i n o r nicks or scratches on components c a n be
smoothed w i t h crocus cloth. However, do not a t t e m p t
to reduce severe scoring on a n y components w i t h
Fig. 30 Removing Annulus Gear
abrasive materials. Replace severely scored compo-
nents; do not t r y t o salvage t h e m .
E x a m i n e the overdrive and direct clutch discs and
plates ( F i g . 31). Replace t h e discs i f t h e facing is
w o r n , severely scored, or b u r n e d and f l a k i n g off. Re-
place t h e clutch plates i f w o r n , heavily scored, or
cracked. Check t h e lugs on t h e clutch plates for
wear. The plates should slide freely i n the d r u m . Re-
place the plates or d r u m i f b i n d i n g occurs.

SLIDING HUB DIRECT THRUST SUN PLANETARY GEAR ASSEMBLY OVERRUNNING CLUTCH
SNAP RING CLUTCH BEARING GEAR ASSEMBLY
OVERRUNNING
DIRECT CLUTCH V SPRING CLUTCH
OVERDRIVE WAVE SPRING SNAP RING
RACE ANNULUS GEAR
CLUTCH
PISTON REACTION" SNAP RING
RETAINER PLATE (CLUTCH DRUM)
DIRECT CLUTCH
DRUM

OVERDRIVE
CLUTCH PISTON

PISTON SNAP RING

THRUST / (SAFETY RING)
PLATE DORECT
(SELECTIVE) CLUTCH
SPRING

OVERDRIVE SNAP RING

CLUTCH PACK REACTION
PLATE (CLUTCH) J9021-87

Fig. 31 Overdrive Geartrain Components

21 - 124 AUTOMATIC TRANSMISSION
Check condition o f t h e a n n u l u s gear, s l i d i n g h u b ,
clutch d r u m and clutch s p r i n g (Fig. 31). Replace t h e
spring i f collapsed, distorted, or cracked. Be sure the
splines a n d lugs on the gear, d r u m and h u b are i n
good condition. The clutch plates a n d discs should
slide freely i n and on these components.
Inspect the t h r u s t bearings and plate (Fig. 31). Re-
place t h e plate i f w o r n or scored, replace the bearings
i f r o u g h , noisy, brinneled, or w o r n .
Inspect t h e planetery gear assembly and t h e su n
gear a n d bushings (Fig. 31). I f either the sun gear or
the bushings are damaged, replace t h e gear a n d
bushings as a n assembly. The gear and bushings are
not serviced separately. The p l a n e t a r y carrier a n d
pinions m u s t be i n good condition. Also be sure t h e
p i n i o n pins are secure and i n good condition.
Inspect the o v e r r u n n i n g clutch and race (Fig. 31).
The race surface should be smooth and free o f scores.
Replace t h e o v e r r u n n i n g clutch assembly or the race
i f either assembly is w o r n or damaged i n any way.
Inspect the output shaft and governor components
(Fig. 32). Replace the shaft p i l o t b u s h i n g and i n n e r
b u s h i n g i f damaged. Replace either shaft b e a r i n g i f
rough or noisy. Replace the b e a r i n g snap rings i f dis-
torted o r cracked.
Check t h e machined surfaces o n the o u t p u t shaft.
These surfaces should be clean a n d smooth. V e r y m i -
GOVERNOR PRESURE
BUSHING BUSHING
Fig. 32 Output Shaft And Governor
•
nor nicks or scratches can be smoothed w i t h crocus
cloth. Replace t h e shaft i f w o r n , scored or damaged
i n any way.
Check condition o f the governor components. Re-
place the governor drive seal r i n g s i f damaged. Also
be sure the seal r i n g grooves are i n good condition.
Check operation o f t h e governor valve, weights and
shaft. The valves a n d weights should slide freely i n
t h e governor body (Fig. 32).
Inspect t h e governor o i l pressure tubes (Fig. 32).
The tubes m u s t not be pinched, k i n k e d , collapsed, or
distorted. Blow t h e m out w i t h compressed a i r to be
sure they are clear. T h e tubes are designed to be a
slip f i t . Do not modify the tube ends i n a n effort to
make t h e m f i t t i g h t e r .
Check condition o f the governor valve a n d weight
snap rings. Replace any snap r i n g t h a t appears bent
or distorted. Replace any snap r i n g i f i t s condition is
doubtful.
OVERDRIVE GEARTRAIN ASSEMBLY AND
ADJUSTMENT
(1) D u r i n g assembly operations, lubricate t h e over-
drive components w i t h Mopar A T F Plus, Type 7176
transmission f l u i d . T h e clutch discs can be immersed
SNAP RING OUTPUT SHAFT
KEY SHAFT J9021-86
Components
 • AUTOMATIC TRANSMISSION 21 - 125

i n fluid for a t i m e before i n s t a l l a t i o n i f desired. Use
Door Ease o r p e t r o l e u m j e l l y t o lubricate seals and
ease seal i n s t a l l a t i o n .
(2) I n s t a l l t h e front b e a r i n g and bearing snap r i n g
on the o u t p u t shaft.
(3) A l i g n a n d i n s t a l l t h e output shaft i n the a n n u -
lus gear. I n s t a l l t h e large snap r i n g t o secure t h e
gear t o the shaft (Fig. 33).
Then i n s t a l l the assembly into the annulus gear and
clutch d r u m w i t h a counterclockwise t w i s t i n g m o t i o n
(Fig. 25).
(10) Carefully i n s t a l l planetary gear assembly i n
annulus gear (Fig. 35).
(11) A l i g n planetary gear i n annulus w i t h a l i g n -
ment tool C-6227-2 (Fig. 36).
(12) I n s t a l l needle t h r u s t bearing i n p l a n e t a r y gear
assembly.
(13) Remove the alignment tool.

Fig. 33 Installing Annulus Gear And Snap Ring

(4) A l i g n a n d i n s t a l l the clutch d r u m on the a n n u -
lus gear (Fig. 34). Be sure the d r u m is engaged w i t h
the lugs on t h e a n n u l u s gear.
(5) Slide t h e clutch d r u m forward t o expose t h e
snap r i n g groove and i n s t a l l the front r e t a i n i n g r i n g
(Fig. 28).
(6) I n s t a l l t h e c l u t c h d r u m rear r e t a i n i n g r i n g (Fig.
34).

Fig. 36 Aligning Planetary Gear Assembly

Fig. 34 Installing Clutch Drum And Rear Snap
(7) I n s t a l l the o v e r r u n n i n g clutch on the race.
(8) I n s t a l l the needle t h r u s t bearing o n the over-
r u n n i n g clutch race (Fig. 25).
(9) I n s t a l l the o v e r r u n n i n g clutch assembly. H o l d
the assembly w i t h expanding type snap r i n g pliers.
(14) I n s t a l l t h e assembled sun gear a n d clutch
spring t h r u s t plate (Fig. 37). Be sure the sun gear is
f u l l y seated.
(15) I n s t a l l and position the direct clutch spring on
the clutch spring t h r u s t plate (Fig. 37).
Ring (16) I n s t a l l the sliding hub over and onto the direct
clutch spring.
(17) Reinstall the alignment tool t h r o u g h the s u n
gear and i n t o the planetary gears.
(18) I n s t a l l t h e direct clutch pack on t h e s l i d i n g
hub as follows (Fig. 38).
21 - 126 AUTOMATIC TRANSMISSION •
(20) M o u n t t h e g e a r t r a i n assembly i n a shop press.
Use a fixture t h a t w i l l support the assembly on t h e
output shaft and annulus gear.
(21) I n s t a l l compressor t o o l C-6227-1 and compress
the clutch s p r i n g (Fig. 39).
(22) I n s t a l l the load r e t a i n i n g snap r i n g (Fig. 39).
(23) I n s t a l l the safety snap r i n g (Fig. 40).
(24) Release the press r a m slowly and remove the
compressor tool.
(25) Remove t h e g e a r t r a i n f r o m the shop press.

Fig. 37 Installing Sun Gear And Clutch Spring

Thrust Plate
(a) I n s t a l l t h e wave spring and reaction plate
(Fig. 31).
(b) I n s t a l l a clutch disc followed by a steel plate
u n t i l t h e r e q u i r e d number of discs and plates a r e
installed. A-500 requires six discs. A-518 requires 8
discs.
(c) I n s t a l l t h e pressure plate last (Fig. 31).
(19) Remove t h e a l i g n m e n t tool.

DIRECT
CLUTCH
PACK

Fig. 38 Direct Clutch Pack Installation 8921-261

WARNING: THE DIRECT CLUTCH SPRING EXERTS
Fig. 40 Installing Safety Ring
OVER 800 POUNDS FORCE ON THE SLIDING HUB.
FOR SAFETY REASONS, IT IS EXTREMELY IMPOR- (26) I n s t a l l the large b e a r i n g on the output shaft
TANT THAT PROPER EQUIPMENT BE USED TO (Fig. 32).
(27) I n s t a l l the governor drive key i n the o u t p u t
COMPRESS THE SPRING. USE SPRING COMPRES-
shaft (Fig. 32).
SOR TOOL C-6227-1 AND A SHOP PRESS WITH A
(28) Assemble the governor drive and body on the
MINIMUM P R E S S RAM TRAVEL OF THREE INCHES
output shaft (Fig. 32). Be sure the filter is properly
FOR THIS PURPOSE. TO AVOID PERSONAL IN-
seated and positioned i n the governor body before as-
JURY, DO NOT ATTEMPT TO COMPRESS THE
sembly.
SPRING WITH ANYTHING OTHER THAN THE COM- (29) I n s t a l l t h e assembled governor drive and body
PRESSOR TOOL AND SHOP PRESS. on the o u t p u t shaft. Be sure the drive is engaged i n
the shaft key.
 • AUTOMATIC TRANSMISSION 21 - 127

(30) I n s t a l l t h e governor valves and weights i n t h e REAR

governor body (Fig. 32) BEARING
(31) Reinstall a l i g n m e n t tool C-6227-2 a n d set t h e
g e a r t r a i n aside for final assembly.

OVERDRIVE UNIT ASSEMBLY AND ADJUSTMENT

(1) I n s t a l l t h e p a r k i n g p a w l a n d spring i n t h e case
(Fig. 41).
PARKING OVERDRIVE
PAWL CASE
SNAP
GROOVE
TOWARD
FRONT OF
CASE 8921-263

Fig. 43 Installing Output Shaft Rear Bearing

GOVERNOR
SUPPORT

8921-262 SUP-FIT
TUBES
Fig. 41 Installing Parking Pawl And Spring
(2) I n s t a l l t h e pawl shaft and shaft r e t a i n i n g bolt
(Fig. 19). T i g h t e n t h e bolt t o 27 N * m (20 ft-lbs)
torque.
(3) I n s t a l l t h e reaction p l u g a n d snap r i n g ( F i g .
42). Compress t h e snap r i n g only enough to i n s t a l l i t .
8921-238
(4) I n s t a l l t h e o u t p u t shaft rear bearing i n t h e
REACTION Fig. 44 Installing Governor Support And Oil
PLUG SNAP Pressure Tubes
RING
SNAP SCREWDRIVER
RING

SNAP RING
PLIERS 8921-240

Fig. 42 Installing Reaction Plug And Snap Ring

8921-264
case. M a k e sure the snap r i n g groove i n t h e bearing
outer race is facing t h e front of the case (Fig. 43). Fig. 45 Installing Governor Support Snap Ring
(5) I n s t a l l t h e governor support a n d t h e governor (7) I n s t a l l t h e o u t p u t shaft front bearing snap r i n g
pressure tubes i n the case (Fig. 44). T h e tubes are i n t h e case.
designed to be a slip fit.
(6) I n s t a l l t h e governor support snap r i n g (Fig. 45).
21 - 128 AUTOMATIC TRANSMISSION •
(8) M a k e sure the a l i g n m e n t tool i s i n s t a l l e d i n t h e
Moasuramonfls Spacer Spocw Tfucknoss
gear t r a i n . T h e n i n v e r t t h e gear t r a i n a n d slip t h e
(Inches) Part Number (Inches)
case over o u t p u t shaft.
(9) E x p a n d t h e b e a r i n g snap r i n g a n d slide the case .7336-.7505 4431916 .159-. 158
downward u n t i l t h e snap r i n g locks i n t h e bearing .7506-7675 4431917 .176-.175
groove. Release t h e snap r i n g . .7676-7855 4431918 .194-. 193
(10) I n s t a l l t h e gasket a n d access plate a t t h e u n - .7856-.8011 4431919 .212-.211
derside o f the case.
(11) I n s t a l l t h e overdrive clutch components as fol-
lows:
Fig. 49 Intermediate Shaft Selective Spacer Chart
(a) I n s t a l l the flat r i n g (Fig. 46) followed b y the
wave r i n g (Fig. 7). T h e r i n g s fit i n t h e same r i n g (a) Position Tool C-6311 across t h e face o f t h e
groove. Use a large screwdriver t o seat each r i n g . overdrive case (Fig. 50).
(b) I n s t a l l t h e reaction plate (Fig. 31). (b) Position d i a l caliper C-4962 over tool C-
(c) I n s t a l l a c l u t c h disc followed b y a c l u t c h 6311 (Fig. 50).
plate u n t i l the r e q u i r e d n u m b e r o f discs and plates (c) Measure distance to the s l i d i n g h u b b e a r i n g
have been installed. A-500 requires three discs. A - seat a t four points 90 degrees apart. Average t h e
518 requires 4 discs for standard engine applica- measurements b y adding t h e m a n d d i v i d i n g b y
tions and five discs for diesel engine applications. four.
(d) I n s t a l l t h e pressure plate ( F i g . 47). T h e (d) Select t h e required t h r u s t plate f r o m t h e
pressure plate is t h e thickest plate i n t h e clutch chart (Fig. 51).
pack.
(12) M o u n t t h e overdrive u n i t i n a vise i n a v e r t i -
cal position.
(13) Determine t h e proper intermediate shaft
spacer thickness as follows:
(a) I n s e r t tool C-6312 t h r o u g h the s u n gear. Be
sure t h e tool bottoms against t h e carrier spline
shoulder.
(b) Position tool C-6311 across t h e face o f t h e
overdrive case (Fig. 48).
(c) Position d i a l caliper C-4962 over tool C-6311
and measure distance t o t h e top o f tool C-6312
(Fig. 48).
(d) Select t h e proper thickness end play spacer
from t h e c h a r t ( F i g . 49) based o n distance mea-
sured.
Fig. 50 Overdrive Piston Thrust Plate Measurement
OVERDRIVE UNIT INSTALLATION
(1) Before i n s t a l l i n g t h e overdrive u n i t , i t w i l l be
necessary t o t r i m t h e new case gasket t o size. U s i n g
a sharp k n i f e , cut out t h e old gasket around t h e pis-
t o n (Fig. 52). T h e n remove and place t h e old gasket
on t h e n e w gasket for a template and t r i m t h e new
gasket to fit.
(2) Place t h e new gasket on t h e overdrive case.
(3) I n s t a l l t h e selective spacer on t h e intermediate
shaft. T h e spacer goes i n t h e groove j u s t r e a r w a r d o f
the shaft rear splines (Fig. 53).
(4) I n s t a l l t h e overdrive piston t h r u s t plate on t h e
piston h u b . Use petroleum j e l l y t o hold the plate i n
position.
Fig. 48 Intermediate Shaft Spacer Measurement
(5) I n s t a l l t h e t h r u s t bearing i n t h e s l i d i n g h u b .
(14) Determine t h e proper thickness t h r u s t plate Use p e t r o l e u m j e l l y to hold the bearing i n position.
for the overdrive piston as follows:
 AUTOMATIC TRANSMISSION 21-129

SPACER
Measurement Spacer Spacer Thickness GROOVE
(Inches) Part Number (Inches) SELECTIVE SPACER

1.7500-1.7649 4431730 - .i08-.no

1.7650-1.7799 4431585 .123-125
1.7800-1.7949 4431731 .138-.140
1.7950-1.8099 4431586 .153-.155
1.8100-1.8249 4431732 .168-.170
1.8250-1.8399 4431587 .183-.185
INTERMEDIATE
1.8400-1.8549 4431733 .198-.200 SHAFT J9021-96
1.8550-1.8699 4431588 .213-.215
1.8700-1.8849 4431734 .228-.230 Fig. 53 Intermediate Shaft Selective Spacer Location
1.8850-1.8999 4431590 .243-.245 CAUTION: Do not tilt the unit during installation.
J9021-95 Tilting the unit could cause the planetary gear and
and overrunning clutch splines to rotate out of
Fig. 51 Overdrive Piston Selective Thrust Plate alignment. If this happens, it will be necessary to
Chart remove the overdrive unit and realign the compo-
SHARP KNIFE nents with tool C-6227-2.
GASKET

(7) A l i g n t h e slip-fit governor tubes and push t h e

overdrive u n i t f o r w a r d u n t i l i t touches the t r a n s m i s -
sion case.
(8) I n s t a l l t h e overdrive u n i t attaching bolts.
T i g h t e n t h e bolts i n a crisscross pattern t o 34 N m #

(25 ft-lbs).
(9) I n s t a l l t h e crossmember.
(10) O n four wheel drive models, install t h e t r a n s -
fer case.
(11) I n s t a l l t h e distance sensor and speedometer
adapter. Be sure t o index t h e adapter .
(12) Connect t h e distance sensor a n d overdrive
8921-269 wires.
(13) A l i g n and i n s t a l l t h e propeller shaft, or shafts
Fig. 52 Trimming Overdrive Case Gasket on four wheel drive models.
CAUTION: Be sure the shoulder on the inside diam- (14) I f the valve body was also removed, adjust t h e
eter of the bearing is facing forward. bands, i n s t a l l t h e v a l v e body a n d install t h e trans-
mission o i l pan.
(6) Carefully raise t h e overdrive u n i t a n d slide i t (15) Lower t h e vehicle and r e f i l l t h e transmission
straight onto the transmission intermediate shaft. I n - w i t h Mopar A T F Plus, Type 7176 transmission f l u i d .
sert t h e b a l l o n t h e p a r k i n g r o d i n t o t h e reaction
p l u g a t the same t i m e .
21 - 130 TRANSFER CASE
NP205 T R A N S F E R C A S E
Page
General Information
Service Diagnosis . . . . . . . . . . . . . . . . . . . . . . . .
Shift Linkage Adjustment
Speedometer Service .
Transfer Case Assembly .
GENERAL INFORMATION
The NP205 transfer case is a gear drive u n i t w i t h
a one-piece, cast i r o n gear case. The N P 205 provides
four operating ranges w h i c h are: four-wheel drive
h i g h , n e u t r a l , two-wheel drive h i g h and four-wheel
drive l o w (Fig. 1). T h e NP205 i s used i n W-250/350
models.
The transfer case g e a r t r a i n consists o f constant
mesh, helical gears. T h e gears rotate on shafts sup-
ported b y b a l l a n d r o l l e r bearings. S l i d i n g clutch
sleeves and shift forks are used to engage or disen-
gage the transfer case drive gears.
The NP205 g e a r t r a i n provides h i g h and low ranges
i n four-wheel mode. T h e h i g h range has a 1:1 r a t i o
for n o r m a l operation and a l o w range w i t h a reduc-
t i o n r a t i o o f 1.96:1 for off road or heavy operation. I n
two-wheel drive range, the transfer case front o u t p u t
shaft drive gear is disengaged. Torque is not t r a n s -
m i t t e d t o the front propeller shaft.
Fig. 1 NP205 Transfer case
TRANSFER CASE LUBRICANTS
Recommended lubricants for t h e NP205 transfer
case include m u l t i purpose gear oils a n d single
weight engine oils.
•
INDEX
Page
130 Transfer Case Disassembly 135
130 Transfer Case Identification 130
132 Transfer Case Lubricants 130
132 Transfer Case Removal 132
136
Engine o i l should be A P I classification SF/CC or
SF/CD. Use S A E 30 a t a m b i e n t temperatures below
0° C ( + 32° F) a n d S A E 50 a t temperatures above
t h i s point.
SAE multipurpose gear oils o f A P I , G L 5 q u a l i t y
can be used w h e n heavy d u t y operation i s a n t i c i -
pated. S A E 80, 90 and 140 are a l l acceptable. Use
SAE 80 w h e n ambient temperatures are below -23° C
(-10° F) or S A E 90 w h e n temperature is above t h e
stated range. S A E 140 can be used w h e n severe ser-
vice is anticipated, or w h e n a m b i e n t temperatures
are expected t o exceed +32° C (90° F)
The transfer case shift l i n k a g e pivot and contact
surfaces should be l u b r i c a t e d w i t h engine o i l a t rec-
ommended intervals. L u b r i c a t i o n frequency for t h e
linkage is described i n Group O, L u b r i c a t i o n A n d
Maintenance.
TRANSFER CASE IDENTIFICATION
The NP205 i d e n t i f i c a t i o n t a g is attached t o t h e
PTO cover on t h e d r i v e r side o f the transfer case.
The tag contains transfer case m a n u f a c t u r i n g and as-
sembly p a r t numbers. Refer to t h i s i n f o r m a t i o n w h e n
ordering service replacement parts.
SERVICE DIAGNOSIS
The most frequent causes of transfer case malfunc-
tions are improper operation, insufficient l u b r i c a n t ,
non-recommended l u b r i c a n t , misadjusted shift l i n k -
age, or improper assembly after repair.
The general problems a n d causes of transfer case
malfunctions are o u t l i n e d below.
LOW LUBRICANT LEVEL
A low l u b r i c a n t level is u s u a l l y the result of loose
components, leakage, o r improper checking and/or
filling techniques.
L u b r i c a n t leaks can occur a t the shaft seals, case
vent, or gasket j o i n t s . Most leaks w i l l be evident by
the presence o f l u b r i c a n t around the leakage point.
However, be sure t h e leakage is actually from a
transfer case component. Leakage from other sources
 • TRANSFER CASE
(engine, transmission, etc.) can be b l o w n back onto
the transfer case b y a i r flow under t h e vehicle. A
blocked transfer case v e n t can also cause leakage a t
the shaft seals due t o i n t e r n a l pressure b u i l d up.
O v e r f i l l i n g the transfer case can force fluid out the
vent and be m i s t a k e n for a leak. Correct fluid level
checking methods should prevent o v e r f i l l problems.
Checking Fluid Level
The correct method o f checking transfer case fluid
level requires t h a t the vehicle be level. I f fluid level
is checked w i t h the vehicle parked o n t h e shop floor,
be sure the floor area used is level. I f a hoist is used,
a drive-on, or swivel a r m type i s preferred.
A l l o w t h e transfer case fluid t o settle for a m i n u t e
or so before checking. Correct fluid level is t o t h e
bottom edge o f the fill p l u g hole.
HARD SHIFTING
H a r d s h i f t i n g is generally caused b y misadjusted
linkage, loose linkage or d r i v e l i n e components, drive-
l i n e torque loads caused b y operation o n h a r d paved
surfaces i n 4 W D , improper s h i f t i n g techniques, or a
lack o f l u b r i c a n t w h i c h caused i n t e r n a l wear a n d
damage.
Loose l i n k a g e or d r i v e l i n e components are a result
of improperly tightened, stripped, or m i s s i n g fasten-
ers. Remember t h a t loose crossmember a n d m o u n t i n g
parts can also generate a h a r d shift condition.
Torque loads i n t h e transfer case can cause h a r d
s h i f t i n g or even prevent s h i f t i n g . Such loads are gen-
erally a product o f extensive operation o n h a r d ,
paved surfaces i n 4 W D range, u n e q u a l size tires, or
by mismatched front/rear axle gear ratios.
L i n k a g e adjustment should be performed as de-
scribed i n the service section. Improper shift and op-
e r a t i n g techniques can be corrected b y i n s t r u c t i n g
the driver. I n t e r n a l component damage w i l l require
overhaul t o correct.
NOISE
Some transfer case operating noise i s n o r m a l . The
r o t a t i n g gear t r a i n can produce sounds t h a t may be-
come audible a t higher speeds a n d loads. However,
unusual noise is a n indicator t h a t i n t e r n a l compo-
nents may be w o r n or damaged.
Low l u b r i c a n t levels are a frequent cause o f noisy
operation. Insufficient l u b r i c a n t w i l l lead t o over-
heating, subsequent damage t o b e a r i n g a n d gear sur-
faces and h a r d shifting.
Transfer case bearing noise is h i g h e r i n p i t c h t h a n
gear noise. I f the u n i t is noisy i n 4 W D range only,
the front shaft bearings are probably a t fault. I f the
u n i t is noisy i n a l l ranges, a n overhaul w i l l be nec-
essary t o locate the f a u l t y bearing.
Gear noise is lower i n p i t c h and u s u a l l y most no-
ticeable w h e n engaged and under load. Gear noise i n
4 W D drive range only is a n indicator t h a t the front
21-131
shaft gears are damaged. Noise i n a l l ranges could be
the idler or drive gears. A n o v e r h a u l w i l l be neces-
sary t o determine w h i c h is a t f a u l t .
Frequently, suspected transfer case noise may actu-
a l l y originate from another d r i v e l i n e component. The
p r o x i m i t y o f other d r i v e l i n e components can some-
times make i t difficult t o p i n p o i n t t h e noise source.
TRANSFER CASE OPERATIONAL CHECK
The transfer case should n o t be removed u n t i l d i -
agnosis indicates t h e u n i t has actually malfunc-
tioned. I f a transfer case problem i s suspected, check
and verify operation before a t t e m p t i n g repair. A
transfer case operational check m a y reveal t h a t a
problem is actually r e l a t e d t o another driveline com-
ponent.
(1) Raise the vehicle o n a hoist t h a t w i l l allow a l l
four wheels to rotate.
(2) Check l u b r i c a n t level. I f l u b r i c a n t level is low,
check for leaks a t t h e b e a r i n g a n d seal retainers,
yokes, drain/fill plugs, P T O cover and vent.
(3) I f the vehicle i s equipped w i t h l o c k i n g hubs, en-
gage the hubs.
(4) S t a r t t h e engine, shift t h e transmission i n t o
gear and operate t h e transfer case i n a l l ranges. Ob-
serve propeller shaft action, shift efforts and opera-
t i o n a l sound levels as follows:
(a) Only the r e a r propeller shaft should rotate
i n two-wheel drive. B o t h propeller shafts should
both rotate i n four-wheel drive h i g h a n d l o w
ranges.
(b) I f the front propeller shaft d i d not rotate i n
either four-wheel d r i v e range, t h e transfer case
shift components m a y be w o r n or damaged. O r , i f
the front shaft d i d rotate b u t t h e f r o n t wheels d i d
not, check the f r o n t axle shift mechanism and t h e
locking hubs ( i f equipped).
(c) I f both propeller shafts rotate i n four-wheel
drive b u t the wheels on one axle d i d not rotate, the
problem is i n the axle.
(d) I f neither propeller shaft rotates i n any
range, the problem is i n the transmission or t r a n s -
fer case. To determine w h i c h component is a t fault,
proceed t o next step.
(5) Determine i f f a u l t is w i t h transfer case or
transmission as follows:
(a) Raise vehicle and disconnect b o t h propeller
shafts a t the transfer case.
(b) Position supports under t h e transmission.
(c) Remove the bolts/nuts a t t a c h i n g the transfer
case adapter to t h e crossmember and transmission.
(d) Support t h e transfer case w i t h a transmis-
sion j a c k and slide t h e transfer case and adapter
clear o f the transmission o u t p u t shaft.
(e) Have helper s t a r t engine and shift transmis-
sion i n t o gear. I f transmission o u t p u t shaft rotates,
21 - 132 TRANSFER CASE
problem is w i t h transfer case. I f transmission shaft
does not rotate, problem is w i t h transmission or re-
lated component.
SHIFT LINKAGE ADJUSTMENT
Two adjustment procedures a r e provided. T h e pro-
cedure described i n F i g u r e 2 i s used w h e n t h e l i n k -
age has been removed and r e i n s t a l l e d (or replaced)
d u r i n g service operations. The second procedure out-
l i n e d below i s used w h e n the l i n k a g e i s i n place a n d
has not been removed f r o m t h e vehicle.
ADJUSTMENT WITH LINKAGE IN PLACE
(1) Shift transfer case into n e u t r a l .
(2) Move shift rod boot u p w a r d for access.
(3) Loosen shift bracket bolts.
(4) Move bracket forward as f a r as possible a n d
t i g h t e n bolts.
(5) Shift the transfer case i n t o a l l ranges t o check
operation.
SPEEDOMETER SERVICE
The speedometer driven gear, adapter and distance
sensor can be serviced w i t h t h e transfer case i n t h e
vehicle.
•
SPEEDOMETER COMPONENT REMOVAL/
INSTALLATION
(1) Shift the transfer case i n t o N e u t r a l .
(2) Raise t h e vehicle.
(3) Disconnect the w i r e s a t t h e distance sensor.
(4) Loosen and disconnect t h e coupling n u t s attach-
i n g t h e sensor to t h e adapter a n d the adapter t o the
d r i v e n gear.
(5) Remove the sensor a n d adapter.
(6) Loosen and remove t h e d r i v e n gear.
(7) Lubricate the d r i v e n gear w i t h engine or gear
oil and i n s t a l l the gear i n the transfer case. T i g h t e n
the gear t o 11 N«m (100 in-lbs) torque.
(8) I n s t a l l the adapter and distance sensor. T i g h t e n
the coupling nuts t o 17 N»m (150 in-lbs) torque.
(9) Connect the w i r e s t o the distance sensor.
(10) Lower the vehicle.
TRANSFER CASE REMOVAL
(1) Raise vehicle.
(2) Remove d r a i n p l u g and d r a i n transfer case l u -
bricant.
(3) Disconnect distance sensor wires.
(4) M a r k front/rear propeller shafts and yokes for
i n s t a l l a t i o n reference.

BOLT KNOB
SHIFT LINKAGE ADJUSTMENT PROCEDURE •JAM NUTySs,
1. INSTALL LOWER SHIFT LEVER (5)
TO BRACKET ( j > ' UPPER SHIFT LEVER
2 MOUNT BRACKET © LOOSE TO ADAPTER.
3. INSTALL SHIFT ROD 0 .
4. POSITION BRACKET Q) AS FAR FORWARD -NUT
AS POSSIBLE AND TIGHTEN BRACKET
SCREW®. ^
5. CYCLE SHIFT LEVER (3) TO CHECK FOR
PROPER FUNCTION.

SPRING WASHER

FRONT

SPRING WASHER

TORQUE
NEWTON
LET. POUNDS
METERS
FRAME RAIL
A 30 FT. 41

A 55 IN. 6
TRANSFER CASE WASHER RH1437

Fig. 2 NP205 Shift Linkage

 DRIVEN
GEAR J9021-151

Fig. 3 NP205 Speedometer Components.

(5) Disconnect propeller shafts a t transfer case.
Move shafts aside for w o r k i n g clearance and secure
t h e m t o frame r a i l s w i t h wire.
(6) Disconnect shift r o d from shift lever on transfer
case.
(7) Support transfer case w i t h transmission jack.
(8) Remove bolts/nuts a t t a c h i n g transfer case t o
transmission adapter.
(9) Lower transfer case and move i t f r o m under ve-
hicle.

YOKE NUT GASKET CASE MAGNET AND CLIP

WASHER IDLER SHAFT FILL PLUG
SEAL WASHER IDLER GEAR BEARINGS PTO COVER AND GASKET
REAR YOKE BEARING RACES GEAR CASE
OIL SEAL BEARING SPACER SHIFT RAIL DETENT BALLS
REAR SEAL RETAINER IDLER GEAR AND SPRINGS
GASKET IDLER GEAR BEARING SHIMS 4WD INDICATOR LIGHT
SNAP RING WASHER SWITCH AND GASKET
REAR OUTPUT SHAFT BEARING IDLER SHAFT LOCK NUT © SHIFT FORK AND RAIL - REAR
SPEEDOMETER GEAR THRUST WASHER PIN WHEEL
BEARING RETAINER - REAR FRONT OUTPUT SHAFT ® INTERLOCK PINS (2)
VENT TUBE CONNECTOR SLIDING CLUTCH FORK-TO-RAIL LOCK PIN
GASKET HIGH GEAR ® SHIFT RAIL OIL SEALS
REAR OUTPUT SHAFT SUPPORT THRUST WASHER ® SHIFT RAIL LINK
BEARING FRONT OUTPUT SHAFT FRONT ® RETAINING CLIP (2J
LOW GEAR RETAINING RING BEARING ® LINK-TO-RAIL RETAINING PIN
THRUST WASHER (3/16" THICK) BEARING SNAP RING
THRUST WASHER ll/16" THICK) FRONT OUTPUT SHAFT REAR © HIFT FORK AND RAIL -
LOW GEAR ROLLER BEARINGS BEARING FRONT WHEEL
BEARING RETAINER - FRONT © INTERLOCK HOLE PLUGS (4)
liEARING SPACER GASKET ® FRONT OUTPUT SHAFT
LOW GEAR - REAR SHAFT RETAINING RING BEARING
THRUST WASHER (1/16" THICK) THRUST WASHER (3/16" THICK) © BEARING SNAP RING
REAR OUTPUT SHAFT LOW GEAR - FRONT SHAFT © INPUT SHAFT SNAP RING
THRUST WASHER PIN LOW GEAR ROLLER BEARINGS • © ADAPTER OIL SEAL (2)
SLIDING CLUTCH GASKET
PILOT BEARING ROLLERS (15) BERING SPAC€R © TRANSFER CASE ADAPTER
PILOT BEARING THRUST FLANGE ® ADAPTER SLEEVE
WASHER OIL SEAL ® SLEEVE RETAINING RING
LOCK RING FRONT SEAL RETAINER ® GASKET
INPUT GEAR GASKET © TRANSMISSION ADAPTER
IDLER SHAFT COVER DRAIN PLUG
J9021-149
 • TRANSFER CASE 21 - 135

TRANSFER CASE DISASSEMBLY

REAR RETAINER AND OUTPUT SHAFT

REMOVAL/DISASSEMBLY
(1) Loosen rear yoke n u t u n t i l only 2-3 threads are
h o l d i n g n u t on shaft.
(2) Remove bolts a t t a c h i n g rear bearing r e t a i n e r t o
case.
(3) P u l l yoke r e a r w a r d t o s t a r t rear o u t p t shaft out
of clutch.
(4) Remove yoke n u t , washer, seal washer a n d
yoke.
(5) Remove rear retainer, rear o u t p u t shaft a n d
gears as assembly.
(6) Remove rear seal retainer from b e a r i n g r e -
tainer.
(7) Remove snap r i n g . Fig. 5 Removing/Installing Front Output Shaft
(8) Remove rear bearing retainer.
(9) Remove rear bearing, speedometer gear, shaft
support bearings, t h r u s t washer p i n a n d l o w gear
f r o m rear o u t p u t shaft ( F i g . 4).
(10) Remove lock r i n g , t h r u s t washer a n d p i l o t
b e a r i n g rollers from rear o u t p u t shaft ( F i g . 4).

FRONT OUTPUT SHAFT RETAINER REMOVAL

(1) Remove front yoke n u t , washer and flange ( F i g .
4).
(2) Remove front seal retainer and gasket.
(3) Remove P T O cover a n d gasket.
(4) Remove detent p l u g a n d 4 W D indicator l i g h t
s w i t c h from case (Fig. 4).
(5) Remove shift r a i l detent springs and balls ( F i g .
4) . Use pencil magnet t o remove these components.
(6) Remove bolts a t t a c h i n g front bearing r e t a i n e r
to case.
(7) T a p front o u t p u t shaft w i t h plastic m a l l e t t o
loosen i t . Then remove shaft, retainer and gears ( F i g .
5) .
(8) Remove shaft snap r i n g (Fig. 6).
(9) Remove t h r u s t washer, gear, bearings a n d
spacer.

SHIFT RAIL-IDLER GEAR-INPUT

GEAR-FRONT SHAFT REMOVAL
(1) Remove adapter a n d gasket.
(2) Remove idler shaft n u t and washer.
(3) Remove i d l e r shaft cover plate a n d gasket.
(4) Remove cup plugs a t top of case for access t o
shift fork lock pins. Use s m a l l punch t o remove
plugs.
(5) Place shift r a i l s i n N e u t r a l position.
(6) Remove lock pins f r o m shift forks w i t h l o n g
handle easy-out tool ( F i g . 7). Fig. 7 Removing/Installing Shift Fork Lock Pins
(7) Remove pins a t t a c h i n g shift r a i l l i n k a n d re-
(9) Remove snap r i n g , t h r u s t washer a n d bearing
move l i n k .
from front shaft.
(8) Remove shift forks a n d sliding clutches.
21 - 136 TRANSFER CASE •
(10) Remove front shaft and h i g h gear.
(11) Remove i n p u t gear, bearing, seals and washer.
(12) Loosen a n d remove idler shaft w i t h plastic
m a l l e t (Fig. 8).

Fig. 8 Idler Shaft Removal Fig. 9 Assembling/Adjusting Idler Gear And

(13) T i l t case, r o l l i d l e r gear t o w a r d front shaft Bearings
opening i n case and remove gear t h r o u g h t h i s open-
ing.
(14) Remove a n d r e t a i n idler shaft shims. T i e
shims together to avoid losing them.
(15) Remove b e a r i n g cups and bearings from i d l e r
gear.
(16) Remove i n t e r l o c k pins from inside case. Re-
move pins t h r o u g h P T O cover opening.
(17) I f f r o n t o u t p u t shaft rear bearing m u s t be re-
placed, replace the b e a r i n g and retainer as a n assem-
b l y only.

TRANSFER CASE ASSEMBLY

L u b r i c a t e t h e transfer case gears a n d shafts w i t h
gear o i l d u r i n g assembly. Use petroleum j e l l y t o pre-
lubricate a n d h o l d bearings i n place d u r i n g i n s t a l l a -
t i o n . Use n e w gaskets and seals throughout. Do n o t
reuse these components. Replace snap rings i f dis-
torted or damaged and use new yoke locknuts t o se-
cure t h e yoke and flange.
(1) I n s t a l l bearing cups i n idler gear w i t h shop
press (Fig. 9).
(2) Assemble idler gear, gear bearing cones, bear-
i n g spacer a n d shims o n shaft tool DD1272 (Fig. 9).
T h e n check end play (Fig. 9). E n d play should be
.000 t o .002 i n c h . A d d or remove shims as needed to
adjust end play. * ers, snap r i n g and retainer on front o u t p u t shaft.
(3) Press shift r a i l seals into case. Seals are wiper-
type and should be installed w i t h seal l i p o u t w a r d .
(4) I n s t a l l idler gear assembly a n d shaft tool i n
case t h r o u g h front bore (large end first). T i l t case a t
45 degree angle to ease bearing i n s t a l l a t i o n a t boss
(Fig. 10).
(5) I n s t a l l idler shaft. Insert shaft from large bore
side a n d d r i v e shaft into gear and bearings w i t h
Fig. 10 Installing Idler Gear
heavy, soft face hammer. Remove shaft a l i g n m e n t
tool as idler shaft pushes i t out of gear and case.
(6) I n s t a l l i d l e r shaft washer a n d n e w l o c k n u t .
Check end play and free rotation. T i g h t e n l o c k n u t t o
203 N - m (150 ft-lbs).
(7) I n s t a l l f r o n t bearing and snap r i n g on i n p u t
gear.
(8) Assemble front output shaft. I n s t a l l gears, slid-
i n g clutch, bearings, t h r u s t washer p i n , t h r u s t wash-
(9) I n s t a l l interlock pins t h r o u g h large case bore or
PTO opening.
(10) I n s t a l l i n p u t gear i n case. T h e n i n s t a l l s l i d i n g
c l u t c h on i n p u t gear and position shift fork i n c l u t c h .
(11) I n s t a l l rear wheel shift r a i l into case (from
back), w i t h slotted end first and detent notches fac-
i n g up (Fig. 7). Then push r a i l t h r o u g h shift fork a n d
i n t o opposite end of case.
 • TRANSFER CASE 21-137

(12) I n s t a l l front o u t p u t shaft i n case.

(13) I n s t a l l front wheel shift fork i n sliding c l u t c h
on front shaft. T h e n i n s t a l l f r o n t wheel shift r a i l i n t o
case and t h r o u g h shift fork.
(14) Secure shift forks to shift r a i l s w i t h new lock
pins. I n s t a l l pins t h r o u g h s m a l l bores at top of case.
(15) I n s t a l l f r o n t o u t p u t shaft bearing retainers. B e
s u r e oil d r a i n slot i n b e a r i n g r e t a i n e r i s a l i g n e d
w i t h d r a i n hole i n c a s e before tightening bolts.
Use new gaskets and apply sealer to bolt threads be-
fore i n s t a l l a t i o n . Use e x t r a gasket on retainers i f
necessary.
(16) I n s t a l l flange on f r o n t shaft. I n s t a l l seal
washer on shaft and i n s t a l l flange locknut finger
tight.
(17) I n s t a l l washer, seals gasket and adapter on i n -
p u t shaft (Fig. 4).
(18) I n s t a l l shift l i n k and l i n k r e t a i n i n g pins, clips. Fig. 11 Assembling Rear Retainer And Output Shaft
(19) Assemble rear o u t p u t shaft. I n s t a l l gears,
bearings a n d spacers (Fig. 4). pending on clearance. Tighten retainer bolts to 54
(20) I n s t a l l new snap r i n g . Tap r i n g to seat i t and N*m (40 ft-lbs).
check end play. E n d play should be .05 to .68 m m (25) I n s t a l l seals i n front and rear seal retainers.
(.002 to .027 i n ) . Position gaskets on case and i n s t a l l retainers over
(21) I n s t a l l p i l o t bearing rollers i n rear o u t p u t shafts and against case. Tighten bolts to 54 N n n (40
shaft. Use as m u c h petroleum j e l l y as needed to hold ft-lbs).
bearing rollers i n place. (26) I n s t a l l yoke and flange. T i g h t e n yoke a n d
(22) I n s t a l l p i l o t bearing t h r u s t washer and new flange nuts to 176 N* (130 ft-lbs).
snap r i n g . (27) I n s t a l l detent balls, springs, plugs, cup plugs
(23) I n s t a l l retainer on rear o u t p u t shaft i n s t a l l and 4 W D indicator l i g h t switch.
speedometer gear and spacer, i n s t a l l bearing (Fig. (28) I n s t a l l d r a i n plug.
11). (29) F i l l transfer case w i t h proper l u b r i c a n t to bot-
(24) I n s t a l l r e t a i n e r and shaft assembly. B e s u r e t o m of fill p l u g hole.
oil d r a i n s l o t i n r e t a i n e r i s a l i g n e d w i t h d r a i n (30) I n s t a l l fill p l u g .
hole i n c a s e . Use one or t w o retainer gaskets de-
21-138 TRANSFER CASE
NP241 T R A N S F E R C A S E
INDEX
Page
General Information 138
Recommended Lubricant 138
GENERAL INFORMATION
The NP241 is a p a r t - t i m e transfer case w i t h a low-
range gear system. I t has three operating ranges
plus a N e u t r a l position. T h e l o w range system pro-
vides a gear reduction r a t i o for increased low speed
torque capability.
The NP241 has three operating ranges w h i c h are:
Two-wheel drive h i g h , four-wheel drive h i g h and four
wheel-drive l o w . T h e four-wheel drive operating
ranges are undifferentiated.
A f r o n t axle disconnect system is used to achieve
two-wheel drive mode. T h e axle disconnect v a c u u m
motor i s actuated by a v a c u u m switch on the transfer
case. The switch is operated b y t h e transfer case
range rod.
Two-wheel drive range is used for on road, h i g h -
way operation. T h e four-wheel drive ranges are for
off road operation or w h e n the vehicle is d r i v e n o n
paved road surfaces covered b y snow, ice or s i m i l a r
low t r a c t i o n elements.
Fig. 1 NP 241 Transfer Case
•
Page
Service Diagnosis . 138
Transfer Case Identification . . . . . . . . . . . . . . . . . 138
TRANSFER CASE IDENTIFICATION
A c i r c u l a r identification t a g (Fig. 1) is attached to
the rear case o f each Model 241 transfer case. T h e
i d e n t i f i c a t i o n t a g provides t h e transfer case model
number, assembly number, serial number, a n d l o w
range r a t i o .
The transfer case serial number also represents the
date o f b u i l d . For example, a serial n u m b e r o f 9-9-89
w o u l d represent September 9, 1989.
Transfer case operating ranges are selected w i t h a
floor-mounted shift lever. The shift lever is connected
to t h e transfer case range lever b y a n adjustable
linkage r o d (Fig. 2). A s t r a i g h t l i n e shift p a t t e r n is
used. Range positions are m a r k e d on t h e gearshift le-
ver knob.
A synchronizer assembly i n t h e transfer case a l -
lows t h e u n i t to be shifted between t h e t w o a n d four-
wheel h i g h ranges w h i l e the vehicle is i n m o t i o n .
RECOMMENDED LUBRICANT
Recommended l u b r i c a n t for t h e N P 2 4 1 is Mopar
A T F Plus, type 7176, or Dexron II™ automatic trans-
mission f l u i d . Use t h i s f l u i d for t o p p i n g off t h e f l u i d
level, or r e f i l l i n g after f l u i d change or service.
Do not use a n t i f r i c t i o n additives or s i m i l a r m a t e r i -
als i n t h e NP241 transfer case. Use t h e recom-
mended f l u i d only.
N P 2 4 1 transfer case l u b r i c a n t should be changed
at t h e i n t e r v a l s specified i n the Maintenance Sched-
ule or after service repairs.
SERVICE DIAGNOSIS
Before a t t e m p t i n g t o repair a suspected transfer
case m a l f u n c t i o n , check a l l other d r i v e l i n e compo-
nents beforehand. The actual cause o f a problem may
be related t o such items as: front hubs, axles, propel-
ler shafts, wheels and tires, transmission, or clutch
instead. I f a l l other driveline components are i n good
condition and operating properly, refer to the Service
Diagnosis chart for f u r t h e r i n f o r m a t i o n .
 TRANSFER CASE 21-139

SERVICE DIAGNOSIS
Condition Possible C a u s e Correction
TRANSFER CASE (a) Vehicle speed too great to permit (a) Stop vehicle and shift into desired
DIFFICULT TO SHIFT shifting. range. Or reduce speed to 3-4 km/h
OR WILL NOT 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
MOPAR 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 IN ALL MOPAR ATF PLUS (Type 7176) or
DRIVE MODES 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 IN—OR (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 OR 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 WEAR surface {paved) roads in 4H range.

J9021-152
21 - 140 TRANSFER CASE •
IN-VEHICLE S E R V I C E

INDEX
Page Page
Fluid Drain/Refill . 140
140 Speedometer Gear/Shaft Seal/Bearing/Retainer
Fluid Level . . 140
140 Service . 140
Shift Linkage Adjustment 141

FLUID LEVEL (6) Remove transfer case yoke.

(7) Remove r e t a i n e r seal ( i f seal or b u s h i n g i s t o be
Correct fluid level for t h e NP241 transfer case is t o replaced) u s i n g suitable tool.
the bottom edge o f the fill p l u g hole. (8) I n s t a l l a new seal, i f old seal was removed.
A correct method of checking fluid level is impor- (9) Remove speedometer gear f r o m rear r e t a i n e r .
t a n t . A n accurate check requires t h a t the vehicle be (10) M a r k rear r e t a i n e r for assembly a l i g n m e n t
perfectly level. I f fluid level is checked w i t h the ve- reference.
hicle parked on the shop floor, be sure the floor area (11) Remove r e t a i n e r a t t a c h i n g bolts a n d remove
used i s level. I f fluid level is checked w i t h the vehicle retainer. Pry retainer w i t h screwdrivers t o remove i t
raised, use either a swivel a r m or drive-on type hoist (Fig. 2).
to be sure the vehicle i s level. (12) Remove rear retainer (Fig. 3). Remove speed-
ometer drive gear, i f necessary.
FLUID DRAIN/REFILL (13) Completely clean off old sealant.
(14) I f the r e t a i n e r or bearing are t o be replaced,
(1) Raise vehicle. remove bearing r e t a i n e r snap r i n g f r o m rear r e t a i n e r
(2) Position d r a i n p a n under transfer case. and remove bearing.
(3) Remove d r a i n and fill plugs and d r a i n l u b r i c a n t
completely.
(4) I n s t a l l d r a i n p l u g . T i g h t e n p l u g to 54 N»m (40
ft-lbs).
(5) Remove d r a i n pan.
(6) F i l l transfer case t o bottom edge of fill p l u g
opening w i t h Mopar A T F Plus, type 7176, or Dexron
II™ automatic transmission fluid.
(7) I n s t a l l fill p l u g . T i g h t e n p l u g to 54 N n n (40 ft-
lbs).
(8) Lower vehicle.
The front a n d rear yokes, output shaft seals, r e -
t a i n e r s and bearings, and speedometer drive gear can
a l l be serviced w i t h t h e transfer case i n the vehicle.
The following combined procedure outlines removal
and i n s t a l l a t i o n of these components:

SPEEDOMETER GEAR/SHAFT SEAL/BEARING/ Fig. 2 Loosening Rear Retainer

RETAINER SERVICE COMPONENT INSTALLATION
(1) I n s t a l l rear o u t p u t bearing i n rear r e t a i n e r a n d
COMPONENT REMOVAL i n s t a l l snap r i n g .
(1) Raise vehicle. (2) A p p l y a 3.17 m m (1/8 i n ) wide bead of M o p a r
(2) Remove fill and d r a i n plugs a n d d r a i n o i l f r o m Gasket M a k e r or Loctite 515 sealant t o m a t i n g sur-
transfer case. face o f rear retainer.
(3) M a r k propeller shaft and transfer case yoke for (3) A l i g n retainer case reference m a r k s and i n s t a l l
a l i g n m e n t reference. rear retainer o n case.
(4) Disconnect propeller shaft. Secure shaft to u n - (4) I n s t a l l and t i g h t e n rear retainer a t t a c h i n g bolts
derside of vehicle. to 24 N*m (18 ft-lbs).
(5) Remove transfer case yoke r e t a i n i n g n u t a n d (5) I n s t a l l o u t p u t shaft seal ( i f required).
seal washer. Use tool C-3281 t o hold yoke w h i l e r e - (6) I n s t a l l yoke, a new yoke seal washer and yoke
moving nut. n u t . T i g h t e n n u t to 149 N«m (110 ft-lbs).
 • TRANSFER CASE 21 - 141

REAR w i t h Mopar A T F Plus, type 7176 or D e x r o n II™ au-

RETAINER tomatic transmission fluid.
(10) I n s t a l l fill p l u g . T i g h t e n p l u g t o 54 N n n (40 ft-
lbs).
(11) Connect propeller shaft. T i g h t e n a t t a c h i n g
bolts t o 19 N n n (170 in-lbs).
(12) Lower vehicle.

SHIFT LINKAGE ADJUSTMENT

(1) Move transfer case shift lever boot aside for v i -
sual access to shift lever and gate.
(2) Move shift lever i n t o 4 H position. Be sure lever
is against 4 H gate (Fig. 4).
(3) Raise the vehicle.
(4) Loosen shift r o d clamp screw u n t i l shift rod is
free t o slide i n s w i v e l (Fig. 4).
Fig. 3 Removing/Installing Rear Retainer
(5) V e r i f y t h a t range lever i s i n 4 H position (verti-
(7) I n s t a l l speedometer d r i v e n gear. cal). Move lever i f necessary.
(8) I n s t a l l d r a i n p l u g . T i g h t e n p l u g t o 54 N n n (40 (6) T i g h t e n shaft r o d clamp screw to (90 in-lbs)
ft-lbs). torque.
(9) F i l l transfer case t o edge o f fill p l u g opening (7) Lower vehicle.
(8) Check l i n k a g e operation.

SHIFT LINKAGE ADJUSTMENT PROCEDURE _

A o u n KNOB
ARM2HT1
1. POSITION SHIFT ARM AGAINST 4H GATE. 4HV1
2. PLACE RANGE LEVER IN 4H POSITION (VERTICAL). JAM NUT A
3. INSTALL SHIFT ROD AND TIGHTEN CLAMP BOLT.
4. CYCLE SHIFT LEVER TO CHECK FOR PROPER FUNCTION

SHIFT LEVER

SHIFT
ROD
CLAMP
PREFERRED TORQUE
NEWTON CLAMP A
LET. POUNDS METERS BOLT &

A 35 FT-LBS 47
A 30 FT-LBS 41
90 IN-LBS 10 SHIFT
A FRAME RAIL J9021-153
ROD

Fig. 4 NP241 Shift Linkage

21 - 142 TRANSFER CASE •
OUT-OF V E H I C L E S E R V I C E

INDEX
Page Page
Bearing Replacement . . . . . . . . . . . . . . . . . . . . . 146 Transfer Case Assembly 148
Cleaning And Inspection 144 Transfer Case Disassembly 142
NP241 Specifications . . . . . . . . . . . . . . . . . . . . . 151 Transfer Case Installation . . . . . . . . . . . . . . . . . . 142
Tightening Reference 154 Transfer Case Removal 142

TRANSFER CASE REMOVAL (8) F i l l transfer case w i t h M o p a r A T F Plus, type

7176, or D e x r o n II™ fluid.
(1) Raise vehicle. (9) I n s t a l l fill p l u g .
(2) D r a i n l u b r i c a n t from transfer case. (10) Lower vehicle.
(3) M a r k transfer case f r o n t and rear o u t p u t shaft
yokes a n d propeller shafts for assembly a l i g n m e n t TRANSFER CASE DISASSEMBLY
reference.
(4) Disconnect speedometer cable a n d v a c u u m
RETAINER AND REAR CASE REMOVAL
switch hoses.
(1) Remove indicator s w i t c h f r o m f r o n t case.
(5) Disconnect shift lever l i n k from operating lever. (2) Remove rear r e t a i n e r (Figs. 2-3). Remove a n d
(6) Place support stand under transmission a n d re- discard r e t a i n e r seal.
move rear crossmember. (3) Remove speedometer gear upper snap r i n g and
(7) M a r k transfer case f r o n t a n d rear o u t p u t shaft remove speedometer gear (Fig. 5).
yokes a n d propeller shafts for assembly a l i g n m e n t
reference. MAINSHAFT SNAP RING
(8) Disconnect front a n d rear propeller shafts a t PUERS
transfer case yokes. Secure shafts to frame r a i l s w i t h
wire.
(9) Remove transfer case-to-transmission nuts.
(10) Move transfer case assembly r e a r w a r d u n t i l SPEEDOMETER
free of transmission output shaft and remove assem- DRIVE GEAR
bly.
(11) Remove a l l gasket m a t e r i a l f r o m rear o f t r a n s -
mission adapter housing.

TRANSFER CASE INSTALLATION

(1) A p p l y Permatex No. 3 sealer, or equivalent t o
both sides of transfer case-to-transmission gasket. RR21F35
Then position gasket on transmission.
(2) A l i g n a n d i n s t a l l transfer case assembly o n Fig. 5 Upper Snap Ring And Speedometer Gear
Removal/Installation
transmission. Be sure transfer case i n p u t gear
splines are aligned w i t h transmission o u t p u t shaft. (4) Remove lower snap r i n g (Fig. 6)
A l i g n splines b y r o t a t i n g transfer case rear o u t p u t (5) Remove o i l pump. Remove a n d discard o i l p u m p
shaft yoke i f necessary. D o n o t i n s t a l l a n y t r a n s f e r seal.
case a t t a c h i n g n u t s u n t i l t h e t r a n s f e r case i s (6) Loosen rear case b y p r y i n g corners loose to
c o m p l e t e l y seated a g a i n s t t h e t r a n s m i s s i o n . break sealant bead (Fig. 7).
(3) A l i g n and i n s t a l l transfer case a t t a c h i n g nuts. (7) Remove rear case f r o m f r o n t case (Fig. 8)
Tighten nuts to 47 N n n (35 ft-lbs). (8) Remove o i l pickup screen, tube a n d magnet
(4) I n s t a l l rear crossmember and remove t r a n s m i s - from rear case.
sion support stand.
DRIVE CHAIN, SPROCKET, SHIFT FORK AND
(5) A l i g n and connect propeller shafts.
MAINSHAFT SHAFT REMOVAL
(6) Connect speedometer cable and v a c u u m switch
(1) Remove mode s p r i n g f r o m shift r a i l (Fig. 9).
hoses.
(2) Remove d r i v e n sprocket snap r i n g (Fig. 10).
(7) Connect shift lever to operating lever. T i g h t e n
locknut to 10 N n n (90 in-lbs).
 TRANSFER CASE 21 - 143

MAINSHAFT SNAP RING MAINSHAFT MODE

PLIERS SPRING

DRIVE CHAIN RR21F39

Fig. 6 Removing/Installing Shaft Lower Snap Ring Fig. 9 Removing/Installing Mode Spring

SCREWDRIVER ^ REAR CASE DRIVEN SPROCKET

RETAINING SNAP RING

OIL
PUMP

RR21F37 SCREWDRIVER'

Fig. 7 Loosening Rear Case

RY716

Fig. 10 Removing/Installing Sprocket Snap Ring

MAINSHAFT FRONT
OUTPUT
SHAFT

DRIVE
CHAIN ^RR21F38
Fig. 8 Removing/installing Rear Case
(3) Remove sprocket a n d drive chain ( F i g . 11). T i l t
mainshaft for clearance i f necessary. RR21F40
(4) Remove mainshaft, mode f o r k a n d shift r a i l as DRIVE CHAIN
assembly. Fig. 11 Removing/Installing Drive Chain And
(5) Remove front output shaft (Fig. 11). Sprocket
21 - 144 TRANSFER CASE •

Fig. 12 Removing/Installing Front Output Shaft Fig. 14 Removing/Installing Input Gear Bearing
Retainer

Fig. 13 Removing/Installing Range Fork And Hub

(6) Remove range f o r k and h u b (Fig. 12). Fig. 15 Removing/Installing Input Gear Snap Ring

INPUT GEAR LOW, RANGE GEAR, RETAINER

AND SECTOR REMOVAL
(1) Remove i n p u t gear bearing retainer ( F i g . 14).
(2) Remove i n p u t gear snap r i n g (Fig. 15).
(3) Remove low range gear a n d i n p u t gear as as-
sembly (Fig. 16).
(4) Remove low range gear snap r i n g (Fig. 17).
(5) Remove i n p u t gear and t h r u s t washer f r o m l o w
range gear.
(6) Remove shift detent p l u g , s p r i n g a n d plunger.
Replace O-ring on p l u g i f w o r n or cut.
(7) Remove shift sector and sector seals (Fig. 18).

MAINSHAFT DISASSEMBLY
(1) Remove Synchronizer snap r i n g (Fig. 19).
(2) Remove synchronizer sleeve and h u b as assem-
b l y ( F i g . 20). I t is n o t necessary to disassemble t h e
synchronizer components unless wear or damage is
evident.
(3) Remove stop r i n g (Fig. 20).
(4) Remove drive sprocket f r o m mainshaft (Fig. 21)
Fig. 16 Removing/Installing Low Range Gear And
Input Shaft
CLEANING AND INSPECTION
Wash a l l parts t h o r o u g h l y i n clean solvent. Be sure
a l l old lubricant, sealant, m e t a l particles, d i r t and
 • TRANSFER CASE
Fig. 19 Removing/Installing
foreign m a t e r i a l are removed from the surfaces of ev-
ery p a r t .
21 - 145
Fig. 20 Removing/Installing Synchronizer Sleeve,
Hub And Stop Ring
Fig. 21 Removing/Installing Mainshaft Drive
Sprocket
A p p l y compressed a i r to each o i l feed p o r t a n d
channel i n both case halves t o remove a n y foreign
m a t e r i a l or cleaning solvent residue.
Inspect t h e spline teeth o n synchronizer sleeve,
h u b , and stop r i n g . I f there is evidence of c h i p p i n g or
excessive wear, i n s t a l l new parts a t reassembly. Be
sure the clutch sleeve slides easily on the c l u t c h h u b .
Synchronizer springs should be i n place w i t h the
t a n g inside the cavity o f one s t r u t . The r i n g s should
not exhibit any evidence of interference w i t h t h e pol-
ished gear cone or inside diameters of the c l u t c h h u b .
Inspect the stop r i n g for cracks and wear. Replace
t h e r i n g i f cracked or excessively w o r n o n t h e
threaded bore. Check new r i n g s for proper fit on the
cone w i t h a m i n i m u m o f wobble. Also check t h e syn-
Synchronizer Snap Ring chronizer struts for wear or damage.
Inspect a l l gear teeth for excessive wear or damage
and check a l l gear splines for b u r r s , nicks, wear, or
damage. Remove minor nicks or scratches w i t h a n o i l
stone. Replace any p a r t e x h i b i t i n g excessive wear or
damage.
21 - 146 TRANSFER CASE •
Inspect a l l snap r i n g s and t h r u s t washers for exces-
sive wear, distortion or damage. Replace w o r n o r
damaged parts.
Inspect t h e two case halves for cracks, porosity,
damaged m a t i n g surfaces, stripped bolt threads, o r
d i s t o r t i o n . Replace either case h a l f i f necessary.
Inspect condition o f a l l needle, roller, b a l l , a n d
t h r u s t bearings i n t h e front and rear case halves a n d
t h e i n p u t gear. Also check condition o f the b e a r i n g
bores i n b o t h cases a n d i n the i n p u t gear, rear o u t p u t
shaft, side gear, and rear retainer. Replace any com-
ponent e x h i b i t i n g excessive wear or damage. I f t h e
case or i n p u t gear bearings require replacement, re-
fer t o t h e Transfer Case B e a r i n g Replacement proce-
dures.

BEARING REPLACEMENT

CAUTION: The bearing bores in most of the transfer

case components contain oil feed holes. Be sure re-
placement bearings do not block these feed holes.

REPLACING DRIVE SPROCKET BEARINGS

(1) Remove the t w o drive sprocket bearings s i m u l -
taneously i n a shop press w i t h tool handle C-4171
a n d remover/installer tool C-4697-1 (Fig. 22).
(2) Clean the sprocket bearing bore after r e m o v i n g
the old bearings. RR21F32

(3) Before proceeding, note t h a t the sprocket bear-

ings are positioned differently (Fig. 23). The f r o n t
b e a r i n g is installed flush w i t h the end of t h e bore.
However, the rear bearing i s recessed s l i g h t l y . B e
sure to i n s t a l l the bearings as shown i n F i g u r e 23.
(4) I n s t a l l the new sprocket bearings one a t a t i m e
s t a r t i n g w i t h the f r o n t bearing. Press the f r o n t bear-
i n g f l u s h w i t h the end of the bore as shown (Fig. 23).
T h e n press the rear bearing i n t o the sprocket u n t i l i t
is 4.6 m m (11/64 in) below the edge of the bore.
Fig. 23 Drive Sprocket Bearing Installation
REPLACING MAINSHAFT PILOT BEARING
The m a i n s h a f t p i l o t b e a r i n g is located i n t h e i n p u t
shaft. The bearing is removed from shaft bore w i t h
tool MD-998346 and t w o appropriate size backup
wrenches (Fig. 24).
The new bearing is i n s t a l l e d w i t h tool handle C-
4171 and i n s t a l l e r tool 5065 (Fig. 25). A shop press is
recommended to press t h e b e a r i n g i n t o place. The
bearing is seated w h e n t h e i n s t a l l e r tool contacts the
i n p u t shaft.

REPLACING MAINSHAFT REAR (OUTPUT)

BEARING
The mainshaft rear (output) bearing i s located i n
the rear retainer. The seal m u s t be removed before
the b e a r i n g can be replaced.
(1) Remove the seal w i t h tool C-4613 (Fig. 26).
(2) Remove the b e a r i n g w i t h tool handle C-4171
and remover tool C-4610 (Fig. 27).
(3) Clean t h e bearing bore thoroughly.
(4) I n s t a l l the new b e a r i n g w i t h handle C-4171 and
installer tool C-4609 (Fig. 28).
(5) I n s t a l l a new seal i n t h e rear retainer.

Fig. 22 Removing Drive Sprocket Bearings

• TRANSFER CASE 21-147

Fig. 24 Removing Mainshaft Pilot Bearing

SPECIAL TOOL M I* ARBOR PRESS RAM

HANDLE G4171 Ifef Fig. 27 Removing Mainshaft Rear (Output) Bearing

Fig. 25 Installing Mainshaft Pilot Bearing

Fig. 28 Installing Mainshaft Rear (Output) Bearing

REPLACING FRONT OUTPUT SHAFT FRONT
BEARING
(1) Remove t h e bearing f r o m t h e front case bore
w i t h t o o l handle C-4171, remover tool C-4610 and a
shop press (Fig. 29).
(2) Clean the bearing bore thoroughly.
(3) I n s t a l l t h e new bearing w i t h installer tool C-
4210, tool handle C-4171 and a shop press (Fig. 30).

REPLACING FRONT OUTPUT SHAFT REAR

BEARING
Fig. 26 Removing Rear Retainer Seal (1) Remove t h e bearing from t h e rear case bore
w i t h tools L-4518-1 and L-4454-1 (Fig. 31).
(2) Clean the bearing bore thoroughly.
21 - 148 TRANSFER CASE •

Fig. 29 Removing Front Output Shaft Front Bearing

Fig. 32 Installing Front Output Shaft Rear Bearing

TRANSFER CASE ASSEMBLY

(1) L u b r i c a t e transfer case components w i t h M o p a r
A T F Plus, type 7176 d u r i n g assembly.
(2) I f t r a n s f e r case b e a r i n g s w e r e r e p l a c e d ,
verify that n e w bearings do n o t block a n y o i l
feed h o l e s .
(3) Assemble i n p u t gear, t h r u s t washer a n d l o w
range gear. Be sure low range snap r i n g i s f u l l y
seated.
(4) I n s t a l l i n p u t a n d low range gear assembly i n
front case. Secure i n p u t gear w i t h snap r i n g ( F i g .
15).
(5) I n s t a l l shift sector and new sector shaft seals.
Fig. 30 Installing Front Output Shaft Front Bearing I n s t a l l range lever o n sector shaft a n d t i g h t e n a t -
t a c h i n g l o c k n u t to 10 N n n (90) in-lbs).
(6) I n s t a l l range fork and h u b (Fig. 13).
(7) I n s t a l l front output shaft i n case (Fig. 12).
(8) Assemble mainshaft, stop r i n g , synchronizer
a n d m a i n s h a f t drive sprocket (Figs. 18, 19, 20).
(9) I n s e r t mode fork i n synchronizer sleeve. T h e n
i n s t a l l m a i n s h a f t and fork as assembly. Be sure shift
r a i l i s aligned i n range f o r k t a n d i s seated i n case
bore.
(10) I n s t a l l drive chain a n d front shaft sprocket
(Fig. 11). - " ^ J
(11) I n s t a l l snap r i n g t h a t secures d r i v e n sprocket
to front o u t p u t shaft (Fig. 10).
(12) I n s t a l l detent plunger, spring a n d p l u g . Re-
place O - r i n g on p l u g i f necessary. D o n o t reuse o l d
O - r i n g i f damaged.
(13) I n s t a l l mode spring on shift r a i l (Fig. 9).
Fig. 31 Removing Front Output Shaft Rear Bearing (14) I n s t a l l o i l pump, pickup tube a n d screen i n
rear case. - •. . ., . ]••;;.
(3) I n s t a l l t h e new b e a r i n g w i t h tool handle C-4171
(15) A p p l y 3 m m (1/8 i n ) wide bead of Mopar gas-
and i n s t a l l e r tool C-4608 (Fig. 32).
k e t m a k e r , or Loctite 515 to front case sealing sur-
face.
• TRANSFER CASE 21-149

(16) A l i g n a n d i n s t a l l rear case o n front case. I n -
s t a l l and t i g h t e n r e a r case-to-front case bolts -to 3 1
N n n (23 ft-lbs).
(17) I n s t a l l lower snap r i n g on mainshaft (Fig. 6).
(18) I n s t a l l speedometer gear and upper snap r i n g
(Fig. 5).
(19) I n s t a l l new seals i n retainers i f necessary.
(20) A p p l y 3 m m (1/8 in) wide bead o f Mopar gas-
k e t m a k e r or Loctite 515 t o sealing surface o f r e a r
retainer. T h e n i n s t a l l retainer and t i g h t e n r e t a i n e r
bolts t o 3 1 N - m (23 ft-lbs).
(21) I n s t a l l yokes, seal washers and r e t a i n i n g n u t s .
T i g h t e n yoke n u t s t o 163 N n n (120 ft-lbs).
(22) I n s t a l l indicator switch. T i g h t e n s w i t c h t o 2 4
N-m (18 ft-lbs).
(23) F i l l transfer case w i t h Mopar A T F Plus, type
7176 t r a n s m i s s i o n fluid.

MANUAL OVERDRIVE 4 GENERAL SPECIFICATIONS

Gsar Ratio:
First . 3.09
Second 1.67
Third 1.00
Overdrive 0.71
Reverse 3.00
Tolerances:
Clutch Housing Face Squareness. .006 inch Max.
Clutch Housing Bore Runout .008 inch Max.
Countershaft Gear End Play .015 to .029 inch
Countershaft to Case Bore F i t . . . .005 to .0065 inch Loose
Lubricant — Capacity 7 pints (3.3 liters)
Type ATF PLUS, Type 7176 OR
"DEXRON I I " Automatic Transmission Fluid
Downshift Speed Limits:
Overdrive to 3rd . . . 50 to 25 mph 80 to 40 km/h;
3rd to 2nd 25 to 15 mph 40 to 24 km/h
2nd to 1st 15 to 0 mph 24 to Okm/h

TIGHTENING REFERENCE
Ft. Lbs. Nut Ft. Lbs. N-m
Back-Up Lamp Switch 15 20 Shift Lever Nuts 18 24
Drive Pinion Bearing Retainer B o l t s . . 30 41 Transmission to Clutch Housing Bolts 50 68
Extension Mousing to Case Bolts 50 68 Transmission Drain Plug 25 34
Gearshift to Mounting Plate 24 33
Gearshift Mounting Plate to Extension 12 16

J9021-102
21 -150 TRANSMISSION—TRANSFER CASE

NP 2500 GENERAL SPECIFICATIONS

Gear Ratio:
First 3.79
Second 2.29
Third 1.48
Fourth........................................... 1.00.
Overdrive.... 0.79
Reverse 3.90
Tolerances:
Clutch Housing Face Squareness.. . . . . . . . i... v .• .006 inch Max.
Clutch Housing lore R u n o u t . . . . . . . . . . . . . . . . . . . . . — . . .008 inch Max.
Countershaft Gear End P l a y . . . . . . . . . . . . . . . . . . . . . . . . . . . .(Wl to .005 inch
Lubricant — Capacity .. 4 pints (1.9 liters)
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAE10W-30 Engine Oil,
API GRADE SG/CD

TIGHTENING REFERENCE
Ft. Lbs. Nm Ft. Lbs. Nm
Access Cover Bolts . . . . . . . . . . . . . . . . . . . . . . . 21 28 Shift Assembly to Extension B o l t s . . . . . . . . . . . . . 21 28
Back-Up Lamp Switch . . .. ......... 15 20 Speedometer Adapter Screw 8 11
Center Support to Case . . . 4 0 54 Transmission to Clutch Housing Bolts 50 68
Extension Housing to Case Bolts . . . . . . . . . . . . . 40 54 Transmission Drain Plug 30 41
Gearshift Lever 30 41 Transmission Fill P l u g . . . . . . . . . . . . . . . . 30 41
Input Shaft Bearing Retaining Bolts.... i . . . . . . 21 28

J9021-103
+ _ TRANSMISSION -TRANSFER CASE 21-151

NP241 SPECIFICATIONS

Transfer Case Type . . Part-time, dual range with low range reduction. Four-wheel-drive range is undifferentiated.

Torque Transfer Mode. . Output shaft and sprocket driven by interconnecting drive chain.

Operating Ranges . . . 2H, 4H, 4L, and Neutral. Low range reduction ratio is 2.72:1.

Case Configuration. . . . . . . . . . . Two-piece aluminum with removable extension and rear retainer housings.

Required Lubricant. . . . . . .MOPAR automatic transmission fluid. ATF Plus,Type 7176 or DEXRON* II

Transfer Case Fill Level To bottom edge of fill plug hole.

TORQUE SPECIFICATIONS

Component Service Set-To Torque Service Recheck Torque

Oil Pump Screws 1.6 N-m (14 in-lbs) 1.4-1.8 Nnn (12-15 in-lbs)

Yoke Nut 149 NITI (110 ft-lbs) 122-176 N-m (90-130 ft-lbs)

Vacuum Switch 27 Nnn (20 ft-lbs) 20-34 Nnn (15-25 ft-lbs)

Range Lever Nut 30 N-m (22 ft-lbs) 27-34 Nnn (20-25 ft-lbs)

Front Case-to-Rear Case Bolts 41 Nnn (30 ft-lbs) 35-46 Nnn (26-34 ft-lbs)

Rear Retainer Bolts 24 N«m (18 ft-lbs) 20-27 Nnn (15-20 ft-lbs)

Extension Housing Bolts 41 N-m (30 ft-lbs) 35-46 Nnn (26-34 ft-lbs)

Drain/Fill Plugs 47 N*m (35 ft-lbs) 41-54 Nnn (30-40 ft-lbs)

Detent Plug 20 Nhm (15 ft-lbs) 16-24 Nnn (12-18 ft-lbs)

Front Bearing Retainer Bolts 21 N-m (16 ft-lbs) 16-27 Nnn (12-20 ft-lbs)

J9021-147
21 - 152 TRANSMISSION—TRANSFER CASE •

GENERAL SPECIFICATIONS
Transmission M o d e l s A-998/A-999/A-500 A-727/A-51S

TYPE..... Automatic with Torque Converter

TORQUE CONVERTER DIAMETER 10-3/4 inches 10-3/4 inches

U.S. Metric U.S. Metric

Measure Measure Measure Measure
OIL CAPACITY — TRANSMISSION AND
TORQUE CONVERTER .Lockup 17.1 Pts. 8.1 Liter 16.7 Pts. 7.9 Liter
NonLockup — — 17.1 Pts. 8.1 Liter
A-500/A-518 20.4 Pts. 9.6 Liter

Use MOPAR ATF PLUS Automatic Transmission

Fluid, Type 7176
COOLING METHOD Water-Heat Exchanger
LUBRICATION Pump (Gear Type)
GEAR R A T I O S : . . . . . . . . . . . . First Second Third Reverse
A-727/A-518 2.45 1.45 1 to 1 2.21 overdrive
A-998/A-999/A-500 2.74 1.54 1 to I 2.21 0.69
PUMP CLEARANCES:
.0035 to .0075 inch
.0004 to .0025 inch .001 to .003 inch
GEAR TRAIN END PLAY .005 to .048 inch .006 to .048 inch
INPUT SHAFT END PLAY .022 to .091 inch .034 to .084 inch

SNAP RINGS
.060 to .062 inch .060 to .062 inch
.068 to .070 inch .074 to .076 inch
.076 to .078 inch .088 to .090 inch
.098 to .100 inch .106 to .108 inch
.040 to .044 inch .048 to .052 inch
.062 to .066 inch .055 to .059 inch
.082 to .086 inch .062 to .066 inch

CLUTCH PLATE CLEARANCE

4 Disc. .067 to .134 inch 4 Disc. .082 to .151 inch
5 Disc. .075 to .152 inch
4 Disc. .032 to .055 inch 4 Disc. .025 to .045 inch

CLUTCHES
A-998 A-500 A-999 A-727 A-518
3.9L 3.9L/5.2L 5.2L 5.2L/5.9L 5.2L/5.9L
4 5 5 4
4 4 4 4
6 8
3 4 (Gas)/
5 (diesel)

BAND ADJUSTMENTS
2-1/2 2-1/2 2-1/2 2-1/2 2-1/2
4 4 4 2 2

* Backed off from 72 inch-pounds (5 N-m)

J9021 -77
 TRANSMISSION-TRANSFER CASE 21 - 153

THRUST WASHERS
A-727/A-518

Reaction Shaft Support Thrust Washer . . . . . . . . . . . . . . . . . . . . # 1 .061 to .063 inch # 1 Selective

.016 to .063 inch (Natural)
.084 to .086 inch (Red)
.102 to .104 inch (Yellow)
Rear Clutch Retainer Thrust W a s h e r . . . . . . . . . . . . . . . . . . . . . . . # 2 .061 to .063 inch # 2 .061 to .063 inch (Natural)
Output Shaft Thrust Washer # 3 Selective # 3 Selective
.068 to .070 inch .052 to .054 inch (Tin)
.068 to .070 inch (Red)
.083 to .085 inch (Green)
Output/Input Shaft Thrust Plate .060 to .063 inch (All)
Front Annulus Thrust Washer # 4 .121 to .125 inch
Front Carrier (To Annulus) T h r u s t . . . . . . . . . ........... # 5 .048 to .050 inch # 4 .059 to .062 inch
Drive Shell (To Front Annulus) Thrust Washer . . . . . . . . . . . — # 5 .059 to .062 inch
Front Carrier (To Drive Shell) Thrust W a s h e r . . . . . . . . . . . . . . . . # 6 .048 to .050 inch
Sun Gear Drive Shell Thrust Plate # 7 .050 to .052 inch
# 8 .050 to .052 inch # 6 .034 to .036 inch
Rear Carrier (To Drive Shell) Thrust Washer . . . ...... # 9 .048 to .050 inch # 7 .059 to .062 inch
Rear Carrier (To Annulus) Thrust Plate — # 8.034 to .036 inch
Rear Carrier (To Annulus) Thrust Washer. #10 .048 to .050 inch

TIGHTENING REFERENCE
Ft. Lbs. Nm ft. Lbs. Nm

Cooler Line Fitting . . .................. 155* 18 Neutral Starter Switch. 25 34

Cooler Line Nut 85* Oil Pan Bolt 150* 17
10
Converter Drive Plate To Oil Pump Housing to Transmission
Cranksaft Bolt 55 Case Bolt . . . . . . . . . . . . . . . . . . 175* 20
75
Converter Drive Plate to Torque Output Shaft Support Bolt 150* 17
Converter Bolt . . . . . . . . . . . . . . . . . . . . . . . . . 270* Overrunning Clutch Cam Set Screw . . 40* 5
31
Extension Housing to Transmission Pressure Test Take-Off Plug 120* 14
Case Bolt ........ 32 43
Reaction Shaft Support to Oil
Extension Housing to Insulator Pump Bolt 175* 20
Mounting Bolt 50 68
Reverse Band Adjusting Screw
Governor Body to Support B o l t . . . . . . . . . . . . . . 95* 11 Lock Nut 25 34
Kickdown Band Adjusting Screw Speedometer Drive Clamp Screw . . . 100* 11
Lock Nut ............................ 30 41 30 41
Transmission to Engine Bolt
Kickdown Lever Shaft Plug . . . . . . . . . . . . . . . . . 150* 17 35* 4
Valve Body S c r e w . . . . . . .
Lockup Solenoid Wiring Connector . . . . . . . . . . . 150* 17 105* 12
Valve Body to Transmission Case Bolt
*lnch Pounds 'Inch Pounds

J9021-78
21-154 TRANSMISSION-TRANSFER CASE

TIGHTENING REFERENCE
NP2500 5-Speed Ft. lbs. N « m Ft. Lbs. N*m
Access Cover Bolts . . . . . . . ....... 21 28 Shift Assembly to
Back-Up Lamp Switch 15 20 Extension B o l t s . . . . . . . . ........ 21 28
Center Support to Case 40 54 Speedometer Drive Clamp Screw ... B 11
Extension Housing to Case Bolts . . . . . . . . 40 54 Transmission to Clutch
Gearshift Lever 30 41 Housing Bolts 50 68
Input Shaft Bearing Transmission Drain Plug 30 41
Retaining Bolts 21 28 Transmission Fill Plug 30 41

A833 4-Speed Ft. lbs. N*m Ft. Lbs. N « m

Back-Up Light Switch . . . . . . . . . . . . 15 20 Shift Lever Nuts 18 24
Drive Pinion Bearing Transmission to Clutch
Retaining Bolts 30 41 Housing Bolts 50 68
Extension Housing to Case Bolts . . . . . . . . 50 68 Transmission Drain Plug 25 34
Gearshift to Mounting Plate 24 33
Gearshift Mounting Plate to
Extension 12 16
NP435 4-Speed Ft. L b s . N « m Ft. Lbs. N*m
Cover Screw 30 41 Mainshaft Rear Retainer Screw . . . . . . . . . 20 27
Drive Gear Retainer Screw 20 27 Rear Countershaft Retainer Screw . . 20 27
Front Countershaft Retainer Screw . . . . . . . 20 27 PTO Cover Screw 10 14
Front Countershaft Bearing Filler and Drain Plug 35 47
Washer Screw 17 23 Reverse Idle Shaft Lock Screw . . . . . . 30 41
Flange Nut 125 169 Brake Link Shoulder Screw 40 41
Transmission-To-Clutch
Housing Bolts 50 68
Automatic Transmission:
A-998fA-999fA-500fA727/A518 Ft. Lbs. N » m Ft. Lbs. N*m
Cooler Line Fitting 155* 18 Neutral Starter Switch . 25 34
Cooler Line Nut 85* 10 Oil Pan Bolt . . . . . . . . . . . . . . . . . . . . . . . 150* 17
Converter Drive Plate to Oil Pump Housing to Transmission
Crankshaft Bolt 55 75 Case B o l t . . . . . . . . . . . . . . . . . 175* 20
Converter Drive Plate to Torque Output Shaft Support Bolt 150* 17
Converter Bolt 270* 31 Overrunning Clutch Cam Set Screw 40* 5
Extension Housing to Transmission Pressure Test Take-Off Plug 120* 14
Case Bolt 32 43 Reaction Shaft Support to Oil
Extension Housing to Insulator Pump Bolt 175* 20
Mounting Bolt 50 68 Reverse Band Adjusting Screw
Governor Body to Support Bolt 95 11 Locknut 25 34
Kickdown Band Adjusting Screw Speedometer Drive Clamp Screw . . . . . . . 100* 11
Locknut 30 41 Transmission to Engine Bolt 30 41
Kickdown Lever Shaft Plug 150* 17 Valve Body Screw 35* 4
Lockup Solenoid Wiring Valve Body to Transmission
Connector 150* 17 Case Bolt 105* 12
*lnch Pounds •Inch Pounds

NP20S Transfer Cose Ft. Lbs. N*m Ft. Lbs. N*m

Bearing Preload 5-30* 7-41 Detent Screw 20 27
Drain and Fill Plugs 40 54 PTO to Case 35 47
Front Adaptor Screws 30 41 PTO Cover Screws. . . . . . . . ....... 35 47
Front Output Flange Nut 110 149 Rear Output Yoke Nut 138 187
Front Output Rear Brg. Retainer . . . . . . . . 30 41 Rear Retainer Assy 30 41
Front Output Seal Retainer 30 41 Rear Seal Retainer 30 41
Idler Shaft Cover 20 27 Transfer Case to Extension 35 47
Idler Shaft Nut . 138 187
NP241 Transfer Case Ft. Lbs. N « m Ft. Lbs. N « m
Detent Bolt 23 31 Operating Lever Locknut . 90* 10
Drain and Fill Plugs . ........ 40 54 Rear Case-to-Front Case Bolts (All) 23 31
Front and Rear Yoke Nuts . 120 163 Rear Retainer Bolt . . . . . . . . . . ... . . . 23 31
Indicator Switch . 18 24 Transfer Case to Extension 40 54
*lnch Pounds
J9021-154
 • TIRES AND WHEELS 22 - 1

TIRES AND WHEELS

CONTENTS
Page Page

GENERAL INFORMATION . . . . . . . . . . . . . . . . . 1 TIRE SERVICE 9

SPECIFICATIONS 20 WHEEL SERVICE 17

GENERAL INFORMATION

INDEX
Page Page
Tires 1 Wheels .. .... 7

TIRES

CONSTRUCTION

BIAS-PLY TIRES
Bias-ply tires (Fig. 1) have plies o f cords t h a t ex-
t e n d a t a n angle f r o m bead-to-bead across the center
l i n e o f the tread. The even n u m b e r plies (i.e., second,
f o u r t h , s i x t h , etc.) cross t h e odd n u m b e r plies (i.e.,
first, t h i r d , fifth, etc.) a t 90 degree angles.

RADIAL-PLY TIRES
Radial-ply tires (Fig. 1) have belts under the tread
t h a t encircle t h e t i r e a n d extend f r o m t h e tread
shoulder-to-tread shoulder. Radial-ply t i r e s are also
constructed w i t h t h e carcass cord plies a t a r i g h t an-
gle (perpendicular) t o t h e tread centerline (Fig. 1).
The cord plies cross the centerline a t a n angle o f ap-
proximately 90 degrees. Because t h e carcass cord
plies radiate f r o m t h e centerline o f the tread, t h i s
type of t i r e carcass design was designated radial-ply.
Performance-type r a d i a l tires also have a n y -
lon-belt overlay o n the c o r d plies t o provide i n -
Fig. 1 Tire construction
creased dimensional stability d u r i n g high-speed
operation. Radial-ply tires are identified b y the code letter R
(e.g., P225/75R15) t h a t appears i n the t i r e identifica-
IDENTIFICATION t i o n i m p r i n t e d o n the t i r e sidewall.
Bias-ply tires are identified b y the n u m e r i c a l des- As a result o f t h e i r u n i q u e carcass design, r a -
ignations of the t r e a d w i d t h ( i n inches) and the bead/ dial-ply tires have a h i g h l y flexible sidewall.
r i m diameter ( i n inches), a n d t h e code letter(s) This flexibility allows the characteristic sidewall
designation for t h e t i r e type (e.g., 7.50-16LT). " b u l g e " t h a t causes t h e t i r e t o a p p e a r t o b e u n -
The example (above) identifies a " l i g h t " t r u c k d e r - i n f l a t e d . T h i s i s a n o r m a l c o n d i t i o n for r a d i -
al-ply tires. D o n o t attempt t o reduce t h e
( L T ) t i r e w i t h a s e v e n a n d o n e - h a l f i n c h (7.50)
" b u l g e " b y over-inflating a tire. T o ensure t h a t a
t r e a d w i d t h a n d s i x t e e n i n c h (16) b e a d / r i m d i a m -
t i r e is p r o p e r l y inflated, use a n accurate a n d r e -
eter.
liable t i r e pressure gauge. Test a n d adjust t i r e
22-2 TIRES AND WHEELS
i n f l a t i o n pressure i n accordance w i t h the infor-
m a t i o n listed o n the tire i n f l a t i o n pressure decal
affixed t o the i n t e r i o r surface o f the driver-side
door pillar-
Size, Aspect Ratio And Speed Rating
The t i r e type, size, aspect r a t i o a n d speed r a t i n g
are encoded i n the combination o f letters and n u m -
bers i m p r i n t e d on t h e t i r e sidewall (e.g., P225/
75SR15).
The f i r s t letter-number combination, indicates t h e
tire type and size:
• t h e letter P indicates the t i r e is designed fpr pas-
senger vehicles, L T for " l i g h t - t r u c k " vehicles and T
for temporary spare; and
• 2 2 5 is t h e section w i d t h ( i n c l u d i n g t h e 24-hour
growth) of the t i r e w h e n new (Fig. 2).
T h e section w i d t h (Fig. 2 ) t h a t i s i m p r i n t e d o n
a t i r e s i d e w a l l (e.g., 2 2 5 ) i s o n l y v a l i d w h e n t h e
tire i s mounted o n a wheel t h a t has a r i m w i d t h
t h a t conforms t o the tire's design specifications.
A f t e r the slash, the aspect r a t i o (Fig. 2):
• 7 5 i s the aspect r a t i o (i.e., t h e section height of the
tire equals 75 percent of t h e section w i d t h ) .
WIDTH
75-SERIES
SIZES
"75" A S P E C T RATIO
•
• Z for speeds exceeding 149 m p h (238 km/h)—con-
sult t h e t i r e m a n u f a c t u r e r for t h e specific speed
range.
The speed r a t i n g is n o t always i m p r i n t e d o n
the tire.
The r i m size:
'• 1 5 is the t i r e bead/wheel r i m diameter i n inches.
Tread Life, Traction And Heat Resistance Ratings
The t r e a d wear/traction/heat (temperature) resis-
tance ratings are also i m p r i n t e d on t h e t i r e sidewall
(e.g., 250 A B ) .
The t r e a d wear r a t i n g i s expressed as a 3-digit
number a n d is a comparative value based o n t h e
wear rate of a t i r e w h e n tested under controlled con-
ditions o n a U.S. Government designated test course.
For example, i n theory, a t i r e w i t h a tread wear r a t -
i n g o f 300 w o u l d have a 50 percent better t r e a d life
t h a n a t i r e w i t h a r a t i n g o f 200. I n r e a l i t y , the rela-
tive tread wear performance o f the various tires also
greatly depends upon the d r i v i n g habits of the owner
and upon the a c t u a l d r i v i n g conditions, i n c l u d i n g t i r e
service a t t e n t i o n , the climate a n d the road/street sur-
faces t h a t the t i r e s u s u a l l y encounter.
T i r e t r e a d wear (and vehicle stability) are affected
greatly b y t i r e size, i n f l a t i o n pressures, wheel r i m
size, d i s t r i b u t i o n o f the load w i t h i n a vehicle, wheel
alignment, road surface conditions, a n d i n d i v i d u a l
d r i v i n g habits.
A b r a s i v e r o a d surfaces accelerate t i r e t r e a d
wear.
Tires t h a t are operated a t l o w speeds, i n cool cli-
mates, and w i t h l i g h t loads, w i l l have a longer t r e a d
life t h a n tires operated a t high-speeds, i n h o t cli-
mates, and w i t h heavy loads.

o
I n d i v i d u a l d r i v i n g habits have more effect o n t i r e
WIDTH tread life t h a n any other factor. Careful/steady d r i v -
ers w i l l obtain, i n most instances, f a r greater t i r e
HEIGHT tread life t h a n w i l l intense or careless drivers. Rapid
IS acceleration and deceleration, h a r d application of the
70%
OF brakes, high-speed d r i v i n g , excessive t u r n i n g speeds,
WIDTH contacting street curbs and other obstacles are j u s t a
few o f the d r i v i n g habits t h a t w i l l shorten the tread
70-SERIES life of any t i r e .
SIZES
" 7 0 " A S P E C T RATIO J9022-7 The t i r e t r a c t i o n and the heat (temperature) resis-
tance r a t i n g s follow t h e t r e a d wear r a t i n g . They are
Fig. 2 Tire Aspect Ratio encoded either A , B o r C. A n A code represents the
The speed r a t i n g : best r a t i n g i n either category.
• the letter S indicates t h a t the t i r e is "speed-rated" The t r a c t i o n r a t i n g s are based upon a tires's a b i l i t y
up t o 112 m p h , to stop a vehicle on wet pavement w h e n tested under
• Q u p to 100 m p h , controlled conditions on U.S. Government designated
asphalt and concrete test surfaces.
• T u p to 118 m p h ,
T h e t r a c t i o n r a t i n g a s s i g n e d t o a specific t i r e
• U u p to 124 m p h ,
is b a s e d o n s t r a i g h t - a h e a d b r a k i n g t r a c t i o n tests
• H u p to 130 m p h ,
a n d does n o t i n c l u d e c o r n e r i n g / t u r n i n g t r a c t i o n .
• V u p to 149 m p h , and
The heat (temperature) resistance r a t i n g repre-
sents a tire's resistance t o temperature increases
 • TIRES AND WHEELS
from r o l l i n g friction and i t s a b i l i t y to dissipate heat
u n d e r controlled conditions on a specified indoor lab-
oratory test wheel. Sustained h i g h t i r e temperature
can cause t h e construction m a t e r i a l of a t i r e to de-
generate a n d t h i s w i l l greatly reduce t h e life o f t h e
t i r e . A C r a t i n g represents t h e m i n i m u m acceptable
heat (temperature) resistance performance for a t i r e
i n accordance w i t h F M V S S N u m b e r 109.
T h e h e a t ( t e m p e r a t u r e ) r e s i s t a n c e r a t i n g as-
signed t o a specific t i r e is based o n t h e t i r e be-
i n g properly inflated a n d n o t overloaded.
E x c e s s i v e s p e e d , u n d e r - i n f l a t i o n a n d a n exces-
sive load, either separately o r combined, c a n
cause t h e t e m p e r a t u r e o f a t i r e t o increase w e l l
a b o v e n o r m a l a n d p o t e n t i a l l y cause t i r e f a i l u r e .
A L L SEASON TIRES
A n " A l l Season" t i r e w i l l have either M + S , M &
S o r M - S (i.e., m u d a n d snow) i m p r i n t e d on t h e t i r e
sidewall.
LOAD RANGE/PLY RATING
To obtain m a x i m u m vehicle stability and t i r e t r e a d
life, a vehicle m u s t be equipped w i t h t h e recom-
mended suspension "package", i n c l u d i n g t h e correct
t i r e size a n d load range r a t i n g . The recommended
full-load capacity (load range) r a t i n g should never be
exceeded. T h e load range/ply r a t i n g indicates t h e
load capacity (i.e., t h e supporting a b i l i t y ) of a t i r e .
Radial-ply tires s h o u l d always be installed i n
sets o f f o u r a n d s h o u l d n e v e r b e i n s t a l l e d o n t h e
f r o n t only. M i x i n g r a d i a l - p l y a n d bias-ply tires is
n o t r e c o m m e n d e d . M i x e d t i r e types c a n cause
unpredictable vehicle handling.
LOAD RANGE-TO-PL Y RA TING
Load Replaces
Range Pty Rating
A L i g h t - t r u c k type (i.e., L T type) tires m u s t be i n -
2
B 4
XL 4 plus a n a d d i t i o n a l 10 p s i (69 kPa) i f sustained v e h i -
C 6
D 8
E 10
F 12
J9022-2
The gross (i.e., combined) weight of a vehicle can
best be determined by w e i g h i n g i t after i t has been
loaded a n d is ready for t r a v e l . The vehicle should
f i r s t be weighed v i a a commercial scale to ensure
t h a t t h e g r o s s v e h i c l e w e i g h t r a t i n g ( G V W R ) has
n o t been exceeded. T h e weight being supported b y
t h e front and the rear tires should t h e n be separately
determined to ensure t h a t the load is properly dis-
t r i b u t e d . T h e a i r i n f l a t i o n pressures should t h e n be
22 - 3
adjusted, i f necessary, t o compensate for a d d i t i o n a l
weight. Refer t o I n f l a t i o n P r e s s u r e s .
INFLATION PRESSURES
The o r i g i n a l equipment tires i n s t a l l e d o n R a m
T r u c k a n d Ramcharger vehicles are selected a n d
tested for conformance w i t h t h e operating conditions
n o r m a l l y encountered b y these vehicles a n d for t h e
t i r e load capacity. T h e recommended c o l d i n f l a t i o n
pressures for different load conditions (i.e., l i g h t a n d
full) are listed on t h e T i r e I n f l a t i o n Pressures c h a r t
and o n a decal affixed t o t h e i n t e r i o r surface o f t h e
door p i l l a r .
L o a d conditions:
• l i g h t l o a d — m a x i m u m of t w o passengers plus 200
lbs. (90 k g ) cargo; a n d
• f u l l load—heavier t h a n a l i g h t load a n d u p to t h e
gross vehicle w e i g h t ( G V W ) specified for t h e vehicle.
The lower cold i n f l a t i o n pressures i n t h e c h a r t t h a t
are designated for tires involved w i t h l i g h t l o a d ve-
hicle operation are intended to improve t h e q u a l i t y of
the "vehicle r i d e " and t o decrease t i r e wear for v e h i -
cles t h a t are n o r m a l l y operated either a t or w i t h less
load w e i g h t t h a n t h a t specified for a l i g h t load.
The tire inflation pressures m u s t be increased
to those designated f o r full load operation f o r a l l
vehicle l o a d c o n d i t i o n s t h a t exceed t h e w e i g h t o f
a l i g h t l o a d (as s p e c i f i e d a b o v e ) .
T i r e i n f l a t i o n pressure adjustments are n o t neces-
sary for sustained, Interstate H i g h w a y operation u p
to 65 m p h (104 km/h), however (where legal) passen-
ger car type (i.e., P type) tires can be i n f l a t e d t o t h e
recommended cold i n f l a t i o n pressure plus a n addi-
t i o n a l 4 psi (27 kPa) i f sustained vehicle operation
exceeding 75 m p h (120 km/h) is anticipated. T h e i n -
f l a t i o n pressure m u s t never exceed t h e m a x i -
mum recommended air inflation pressure
imprinted o n the tire sidewall.
flated to t h e recommended cold i n f l a t i o n pressure
cle operation exceeding 65 m p h (104 km/h) is a n t i c i -
pated. T h e i n f l a t i o n p r e s s u r e m u s t n e v e r e x c e e d
the m a x i m u m recommended a i r i n f l a t i o n pres-
sure i m p r i n t e d o n t h e tire sidewall.
For special vehicle operation w i t h light-truck
t y p e t i r e s (e.g., e q u i p p e d w i t h a c a m p e r o r a s i m -
ilar " h i g h center o f g r a v i t y " vehicle application),
the inflation pressure o f t h e tires m a y be i n -
c r e a s e d u p t o 10 p s i (69 k P a ) g r e a t e r t h a n t h e
recommended cold inflation pressure.
The t i r e a i r i n f l a t i o n pressure should be measured
and, i f necessary, adjusted to t h e recommended a i r
i n f l a t i o n pressure (cold) on a weekly basis. T h i s is es-
pecially i m p o r t a n t i f an extreme change (20°F/7°C or
more) i n t h e average seasonal temperature occurs.
22 - 4 TIRES AND WHEELS •
MAXIMUM LOAD CAPACITY

P A S S E N G E R G A R TYPE TIRES
MAX. LOAD CAPACITY AT VARIOUS COLD INFLATION PRESSURES PSI * KILOPASCALS (PER PAIR)
MAX. MAX. PSI kPa PSI kPa PSi kPa PSI kPa PSI kPa PSI kPa
TIRE CAP. CAP.
SIZE (IBS.) 26 (180) 29 (200) 32 (230) 35 (240) 38 (260) 41 (283)
P195/75R15 2685 (1218) 2325 (1055) 2445 (1109) 2565 (1163) 2685 (1218) - -
P205/75R15 2905 (1318) 2525 (1145) 2665 (1208) 2785 (1263) 2905 (1318) -
P225/75R15 3405 (1544) 2965 (1345) 3125 (1417) 3265 (1481) 3405 (1544) -
P235/75R150CL 3965 (1799) 3185 (1445) 3365 (1526) 3525 (1599) 3685 (1672) 3825 (1735) 3965 (1799)
P215/75R15 3167 (1436) 2745 (1245) 2885 (1309) 3025 (1373) 3167 (1436) - -
TRUCK TIRES USED WITH SINGLE REAR WHEELS
MAX. SINGLE TIRE LOAD CAPACITY AT VARIOUS INFLATION PRESSURES PSI & KILOPASCALS
PER TIRE PSI kPa PSI kPa PSI kPa PSI kPa PSI kPa PSI kPa PSI kPa PSI kPa
PSI kPa PSI kPa PSI kPa
lilt MA*

{207)
THE LOAD
SIZE RANGE 30 35 (240) 40 (276) 45 (310) 50 ( 3 4 5 ) 55 (379) 00 (415) 65 (440) 70 (403) 75 (517) • 0 (551)
7.50-161T D 2440 (1107) 1620 (735) 1770 (803) 1930 (875) 2060 (°34) 2190- (993) 2310 (1048) 2440 (1107)

IT225/75R16 D 2335 (1060) 1500 (680) 1650 (748) 1790 (811) 1940 (880) 2060 (934) 2190 (993) 2335 (1059)
IT225/75R16 E 2680 (1215 - . - 1500 (680) 1650 (748) 1790 (811) 1940 (880) 2060 (934) 2190 (993) 2335 (1059) 2440 (1106) 2560 (1161) 2680 (1215)

IT245/75R16 E 3042 (1380) - - 1700 (771) 1865 (W5) 2030 (920) 2205 (1000) 2335 (1058) 2480 (1125) 2623 (1189) 2765 (1254) 2900 (1315) 3042 (1380)
31xl0.5R15lT B 1775 (805) 1595 (723) 1775 (805)
3M0.50R151T C 2250 (1020) 1595 (723) 1775 (805) 1945 (882) 2100 (953) 2250 (1020)
LT215/85R16 C 1940 (880) - . - • 1495 (678) 1640 (744) 1785 (810) 1940 (880) - -
LT215/85R16 D 2335 (1060) _ 1495 (678) 1640 (744) 1785 (810) 1940 (880) 2050 (930) 2180 (989) 7335 (1060)

LT235/85R16 E 3042 (1380) 1700 (771) 1870 (848) 2030 (920) 2205 (1000) 2335 (1058) 2485 (1127) 2623 (1189) 2765 (1254) 2905 (1317) 3042 (1380)
IT215/75R15 . D 1345 (609) 1475 (668) 1600 (725) 1765 (800) 1845 (836) 1960 (888) 2095 (950)

TRUCK TIRES USED WITH DUAL REAR WHEELS

MAX. SINGLE TIRE LOAD CAPACITY AT VARIOUS INFLATION PRESSURES PSI & KILOPASCALS
PSI kPa PSI kPa PSI kPa PSI kPa PSI kPa PSI kPa PSI kPa PSI kPa PSI kPa
MAX.
TIRE LOAD CAP. CAP.
SIZE RANGE (LSS.) 30 (207) 35 (240) (276) 4 5 (310) 50 (345) 55 (379) 60 (415) 65 (448) 70 ( 4 3 3 ) 75 (517) SO (551)
(kg)
2140 (971) 1430 (649) 1565 (710) 1690 (767) 1815 (823) 1930 (875) 2040 (925) 2140 (971)

2150 (975) 1365 (619) 1500 (680) 1630 (739) 1765 (800) 1875 (850) 1995 (904) 2150 (975)

1765 (800) 1360 (617) 1490 (676) 1625 (737) 1765 (800)
2150 (975) 1360 (617) 1490 (676) 1625 (737) 1765 (800) 1865 (844) 1985 (900) 2150 (975)

INFLATION PRESSURE ADJUSTMENT
Correct t i r e i n f l a t i o n pressure is essential for safe
and satisfactory operation of a vehicle. The f o l l o w i n g
considerations are affected b y incorrect t i r e pressure:
• u n d e r - i n f l a t i o n or over-inflation affect vehicle sta-
b i l i t y a n d can produce either a sluggish response o r
a n over-response to d r i v e r operation;
• unequal i n f l a t i o n pressures (except as specified for
certain d r i v i n g conditions) can produce erratic a n d
unpredictable vehicle response t o driver steering op-
eration;
• u n d e r - i n f l a t i o n results i n r a p i d wear f r o m t h e
tread shoulders;
• u n d e r - i n f l a t i o n causes increased t i r e " f l e x i n g " a n d
can r e s u l t i n complete t i r e failure;
• over-inflation produces a n uncomfortable a n d " j a r -
r i n g " ride;
• over-inflation causes r a p i d wear from t h e center o f
the t r e a d a n d t h e possibility o f cuts, punctures a n d
bruises;
• over-inflation causes decreased t i r e " f l e x i n g " (i.e.,
lost o f a b i l i t y t o cushion road "shock") a n d h a r d ob-
J9022-14
jects on t h e road surface and/or "chuck holes" could
can t i r e damage t h a t could result i n complete t i r e
failure; a n d
• incorrect i n f l a t i o n pressure can cause uneven t r e a d
wear patterns to develop across the t i r e t r e a d surface
and these abnormal wear patterns w i l l reduce t h e
tread life, w h i c h w i l l result i n a necessity for earlier
t i r e replacement.
Measure a n d adjust t h e i n f l a t i o n pressure only
w h e n either t h e tires are cold, have been d r i v e n less
t h a n 2 miles (3.2 k m ) a t a speed less t h a n 40 m p h
(64 km/h), or after t h e vehicle has been p a r k e d for 3
hours (or more).
Do n o t reduce the i n f l a t i o n pressure i f t h e t i r e s are
hot, or have been d r i v e n more t h a n 2 miles (3.2 k m )
at a speed exceeding 40 m p h (64 km/h). H e a t a n d
h i g h speed can cause t h e t i r e a i r pressure t o increase
as m u c h as 6 psi (41 kPa) more t h a n t h e cold infla-
t i o n pressure because o f the a i r expansion caused b y
the increased heat i n t h e t i r e .
When measuring a n d adjusting a tire inflation
p r e s s u r e , a l w a y s u s e a reliable a n d a c c u r a t e
g a u g e to e n s u r e t h e p r o p e r inflation p r e s s u r e .
 • TIRES AND WHEELS 22 - 5

TIRE INFLATION PRESSURES

RAMCHARGER AND RAM TWO-WHEEL DRIVE VEHICLES

LIGHT LOAD FULL LOAD
LOAD WHEEL FRONT TIRES REAR TIRES FRONT TIRES REAR TIRES
TIRE RANGE SIZE (IN) PSI kPa PSI kPa PSI kPa PSI kPa
P195/75R15 STD 15 x 6.5, 7 35 (240) 35 (240) 35 (240) 35 (240)
P205/75R15 STD 15 x 6.5. 7 35 (240) 35 (240) 35 (240) 35 (240)
P235/75R15 XL 15 x 6.5, HD, 7 35 (240) 35 (240) 35 (240) 41 (283)
LT215/85R16 C 16x6 35 (240) 35 (240) 45 (310) 50 (345)
LT215/85R16 D 16x6 35 (240) 35 (240) 50 (345) 65 (448)
LT235/85R16 E 16x6 35 (240) 35 (240) 45 (310) 80 (551)
750-16 LT D 16x6 35 (240) 35 (240) 45 (310) 60 (415)
WITH DIESEL ENGINE
LT 235/85R16 E 16x6 40 (276) 40 (276) 45 (310) 80 (551)
P215/75R15 STD 15x6.5,7 35 (240) 35 (240) 35 (240) 35 (240)

RAM VEHICLES WITH DUAL REAR WHEELS

LIGHT LOAD FULL LOAD
LOAD WHEEL FRONT TIRES REAR TIRES FRONT TIRES REAR TIRES
TIRE RANGE SIZE (IN) PSI kPo PSI kPa PSI kPa PSI kPa
LT215/85R16 C 16x6 40 (276) 40 (276) 45 (310) 50 (345)
LT215/85R16 D 16x6 40 (276) 40 (276) 45' (310) 65 (448)
750-16 LT D 16x6 35 (240) 35 (240) 45 (310) 60 (415)
WITH DIESEL ENGINE
LT215/85R16 C 16x6 45 (310) 45 (310) 50 (345) 50 (345)
LT215/85R16 D 16x6 45 (310) 45 (310) 50 (345) 65 (448)
'50 PSI (345 kPa) for 159 inch wheelbas*.
J9022-13
Because o f the wide v a r i a t i o n i n a i r pressure i n d i - I n most situations, inspection of the t i r e tread wear
cations (inaccuracies) provided b y m a n y o f the pres- w i l l reveal t h e cause o f t h e abnormal wear. T h e i l -
sure gauges o n service s t a t i o n a i r hoses, i t is l u s t r a t i o n below (Fig. 3) depicts the various types o f
suggested t h a t a pencil-type, air-pressure gauge be t i r e t r e a d wear patterns a n d t h e recommended cor-
obtained a n d k e p t i n t h e glove box for personal use rective action.
Rapid wear from t h e t i r e tread shoulders is u s u a l l y
whenever t i r e a i r pressures m u s t be measured.
caused by u n d e r - i n f l a t i o n or a n excessive mileage i n -
The t i r e valve caps (or v a l v e extensions) should a l -
t e r v a l between t i r e r o t a t i o n , or a combination o f b o t h
ways be i n s t a l l e d on t h e valve stem a n d tightened
incidents. I f t h i s type o f wear occurs and the t i r e s are
"finger t i g h t " after a i r pressure measurement/adjust- serviceable, rotate t h e m a n d inflate t h e m w i t h t h e
ment. T h e caps assist i n r e t a i n i n g a i r a n d also pre- recommended a i r pressure when they are cool.
vent foreign m a t e r i a l f r o m e n t e r i n g t h e valve. Rapid wear from t h e t i r e tread center is u s u a l l y
caused b y over-inflation or a n excessive mileage i n -
SPARE TIRE t e r v a l between t i r e r o t a t i o n , or a combination o f b o t h
A conventional spare t i r e is standard equipment incidents. I f t h i s type o f wear occurs and the tires a r e
for a l l R a m T r u c k and Ramcharger vehicles. serviceable, rotate t h e m and inflate t h e m w i t h t h e
recommended a i r pressure w h e n they are cool.
ABNORMAL TIRE TREAD WEAR Cracked t i r e treads are usually caused by alternate
A b n o r m a l t i r e t r e a d wear can be caused b y incor- excessive u n d e r - i n f l a t i o n a n d over-inflation, exceed-
rect i n f l a t i o n pressure, tire/wheel unbalance, w o r n i n g t h e recommended full-load capacity, h i g h temper-
suspension components, i m p r o p e r brake operation, ature, excessive high-speed operation, or a
bent wheels, incorrect f r o n t wheel a l i g n m e n t and ex- combination o f t h e incidents. Tires w i t h cracked
cessive speed w h e n t u r n i n g t h e vehicle. treads should be replaced and the replacement tires
should be properly m a i n t a i n e d to avoid a recurrence
of t h e failure.
22 - 6 TIRES AND WHEELS •
TIRE INFLATION PRESSURES (CONT'D)

RAMCHARGER AND POWER RAM FOUR-WHEEL DRIVE VEHICLES

LIGHT LOAD FULL LOAD
LOAD WHEEL FRONT TIRES REAR TIRES FRONT TIRES REAR TIRES
TIRE RANGE SIZE (IN) PSI kPa PSI kPa PSI kPa PSI kPa
P235/75R15 XL 15 x 6.5, 7 35 (240) 35 (240) 35 (240) 41 (283)
P235/75R15' XL 15 x 6.5,HD 35 (240) 35 (240) 41 (283) 41 (283)
P235/75R15 2
XL 15 x 6.5,HD 41 (283) 41 (283) 41 (283) 41 (283)
31 x 10.50R15 LT C 15 x 7 35 (240) 35 (240) 35 (240) 50 (345)
LT 215/85R16 C 16x6 40 (276) 40 (276) 45 (310) 50 (345)
LT 215/85R16 D 16x6 40 (276) 40 (276) 45 (310) 65 (448)
LT 215/85R16' D 16x6 45 (310) 45 (310) 55 (379) 65 (448)
LT 215/85R16 E 2
16x6 55 (379) 55 (379) 55 s
(379) 65 (448)
LT 235/85R16 E 16x6 35 (240) 35 (240) 45 3
(310) 80 (551)
LT235/85R16' E 16x6 40 (276) 40 (276) 45 3
(310) 80 (551)
LT 235/85R16 E 2
16x6 50* (345) 50 3
(345) 45 3
(310) 80 (551)
750-16 LT D 16x6 35 (241) 35 (241) 50 (345) 60 (415)
750-16 LT 2
D 16x6 50 (345) 50 (345) 50 (345) 60 (415)
31 x 10.5R15 LT B 15 x 7 35 (240) 35 (240) 35 (240) 35 (240)
WITH DIESEL ENGINE
LT 235/85R16 E 16x6 45 (310) 45 (310) 55 (379) 80 (551)

POWER RAM WITH DlJAL REA R WHEEI.S

LT215/85R16 C 16x6 45 (310) 45 (310) 50 (345) 50 (345)
LT215/85R16 D 16x6 45 (310) 45 (310) 50 (345) 65 (448)
LT 215/85R16' D 16x6 50 (350) 50 (345) 65 (448) 65 (448)
LT 215/85R16 2
D 16x6 65 (448) 65 (448) 65 (448) 65 (448)
750-16 LT D 16x6 35 (240) 35 (240) 50 (345) 60 (415)
750-16 LT' D 16x6 40 (276) 40 (276) 55 (379) 60 (415)
750-16 LT 2
D 16x6 55 (379) 55 (379) 55 (379) 60 (415)
WITH DIESEL ENGINE
LT 215/85R16 C 16x6 50 (345) 50 (345) 50 (345) 50 (345)
LT 215/85R16 D 16x6 50 (345) 50 (345) 65 (448) 65 (448)
7.50-16 LT D 16 x 6 45 (310) 45 (310) 55 (379) 60 (415)
'Equipped for snow plow service, but not carrying blade. ' 5 5 PSI 3 7 9 kPa) for heavy duty snow plow package.
'Equipped for snow plow service and carrying blade.
J9022-11

CONDITION RAPID W E A R WEAR O N

C R A C K E D TREADS FEATHERED E D G E BALD SPOTS SCALLOPED WEAR
AT CENTER O N E SIDE

EFFECT

OVER-INFLATION UNBALANCED
OR LACK EXCESSIVE CAMBER INCORRECT T O E
OF ROTATION WHEEL LACK OF
ROTATION
UNDER-INFLATION OF TIRES
CAUSE OR OR

EXCESSIVE SPEED* WORN OR OUT-

OF-ALIGNMENT
SUSPENSION.

OR TIRE DEFECT*
A D J U S T PRESSURE TO
ADJUST CAMBER ADJUST TOE-IN DYNAMIC OR ROTATE TIRES A N D
CORRECTION SPECIFICATIONS WHEN
TIRES ARE C O O L TO TO STATIC INSPECT S U S P E N S I O N
ROTATE TIRES SPECIFICATIONS SPECIFICATIONS B A L A N C E WHEELS SEE G R O U P 2

• H A V E TIRE INSPECTED FOR FURTHER U S E RN797

Fig. 3 Abnormal Tire Tread Wear Patterns
 • TIRES AND WHEELS 22 - 7

Excessive wear from one t r e a d shoulder can be r i m separation is prevented because the t i r e a i r pres-
caused by excessive speed on t u r n s or b y a n incorrect sure retains each t i r e bead "seated" i n t h e " v a l l e y "
camber angle. A n incorrect negative camber angle between the " r i d g e " a n d the r i m flange. I n addition,
w i l l cause excessive wear f r o m the inside t i r e shoul- w h e n t i r e failure occurs, t h e "ridges" also aid i n re-
der w h i l e a n incorrect positive camber angle w i l l t a i n i n g the t i r e beads i n the " v a l l e y s " u n t i l the vehi-
cause excessive wear outside t i r e shoulder. I f t h i s cle is safely stopped.
type of t r e a d wear occurs, measure the camber angle.
I f t h e camber angle is w i t h i n t h e specified l i m i t s ,
caution the owner about excessive speed w h e n t u r n -
i n g . I f the t i r e s are serviceable, rotate t h e m and ad-
j u s t t h e m w i t h the recommended a i r pressure.
A n incorrect wheel " t o e " position w i l l cause t h e
t i r e tread surface to develop a feathered edge. One
side of the t r e a d w i l l be rounded w h i l e t h e opposite
side w i l l have a feathered edge. T h i s type tread wea-
rindicates t h a t t h e t i r e is side s l i p p i n g and scuffing
as i t moves over the street/road surface.
A feathered t r e a d edge t h a t faces t o w a r d the vehi-
cle indicates excessive " t o e - i n " . A feathered tread
edge t h a t faces away from t h e vehicle indicates ex-
cessive "toe-out". The direction t h a t a feathered edge
Fig. 4 Wheei Safety Rim
has developed can be determined b y passing your DUAL REAR WHEELS
hand over t h e t i r e tread surface. B e n t steering R a m T r u c k Models D-350 and W-350 t h a t are
knuckle arms can also cause t h i s type of wear. equipped w i t h d u a l rear wheels have eight-stud hole
I f a feathered edge develops, measure a n d correct rear wheels w i t h four equally-spaced stud holes t h a t
the "toe" position as necessary a n d rotate the tires i f are flanged o u t w a r d a n d four t h a t are flanged i n -
they are serviceable. w a r d . The outer wheel m u s t be installed so t h e
flanged stud holes m a t e correctly w i t h t h e flanged
WHEELS stud holes i n the i n n e r wheel (Fig. 5).
A locating p i n i n t h e h u b provides assistance for
STANDARD WHEELS correctly a l i g n i n g t h e i n n e r and outer wheels.
The standard equipment wheels i n s t a l l e d on Ram LOCATING PIN HOLE IN BOTH INNER & OUTER WHEEL MUST EN-
T r u c k and Ramcharger vehicles are drop center, J - GAGE LOCATING PIN IN HUB WHEN WHEELS ARE INSTALLED.
type, steel wheels w i t h safety r i m s .
The steel wheels are the two-piece type t h a t consist
of a r i m and center section (spider). T h e two sections
are welded together to f o r m a seamless, a i r - t i g h t
unit.
A wheel safety r i m has a " r i d g e " (i.e., a raised
edge) located inboard of each r i m flange and a t t h e
top of the r i m w e l l (Fig. 4). W h e n a t i r e is i n i t i a l l y
inflated, t h e a i r pressure forces t h e t i r e beads over
the "ridges" a n d "seats" t h e m i n t h e "valleys" and
against the r i m flanges. D u r i n g extreme "cornering"
(i.e., t u r n i n g a vehicle a t h i g h speed), t i r e and wheel Fig. 5 Eight-Stud Hole Dual Rear Wheels
22 - 8 TIRES AND WHEELS
TIRE
Page
Cleaning
Inspection
Repair
INSPECTION
To maximize t i r e longevity, inspect tires frequently
for the effects o f incorrect i n f l a t i o n and other causes
of uneven wear, w h i c h can also indicate a need for
tire/wheel balancing, t i r e r o t a t i o n or front-end a l i g n -
ment. Tires should also be inspected frequently for
cuts, abrasions, stone bruises, blisters and for objects
imbedded i n t h e t i r e tread. W e e k l y inspection is rec-
ommended as t h e m i n i m u m i n t e r v a l of t i m e . More
frequent inspections are recommended w h e n extreme
temperature changes occur and w h e n the street/road
surfaces are r o u g h (or l i t t e r e d w i t h debris).
For an additional v i s u a l reminder of t i r e tread con-
dition, tread wear indicators are molded i n t o the bot-
tom of the t i r e tread grooves. These indicators appear
i n t h e form o f 1/2-inch (13-mm) wide bands across
the tread w h e n i t has w o r n down t o a thickness o f
1/16 o f an i n c h (1.58 m m ) or less. The t i r e should be
replaced w h e n these bands become visible. The i l l u s -
t r a t i o n below (Fig. 6) depicts t i r e tread t h a t is s t i l l
acceptable and t i r e tread t h a t has w o r n down to a i n -
dicator (unacceptable).
A s t h e t r e a d d e p t h decreases, t h e t i r e s h a v e
less r e s i s t a n c e t o r o a d h a z a r d s a n d a^e m o r e
l i k e l y t o " h y d r o p l a n e " o n a r o a d s u r f a c e cov-
ered w i t h water.
Fig. 6 Tire Tread Condition
•
SERVICE
INDEX
Page
8 Rotation 9
8 Tire Diagnosis , 10
8 Wide-Tread Tires . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CLEANING
Clean tires w i t h a m i l d soap and water solution
only and rinse t h e m t h o r o u g h l y w i t h water. Do n o t
use caustic solutions o r abrasive materials. To clean
w h i t e sidewalls a n d raised letters/numbers, use a n
approved w h i t e w a l l cleaner only. Do n o t use steel
wool, w i r e brushes or cleaning solutions t h a t have a
m i n e r a l o i l base (e.g., gasoline, p a i n t t h i n n e r a n d
turpentine). These solutions are h a r m f u l to the tires
and w i l l also discolor w h i t e sidewalls and raised let-
ters/numbers.
Most w h i t e sidewall t i r e s have a colored protective
coating t h a t should be removed from the tires before
delivery o f t h e vehicle. T h e p r o t e c t i v e c o a t i n g i s
n o t as f l e x i b l e as r u b b e r a n d i t w i l l e v e n t u a l l y
crack, w h i c h c o u l d cause w h i t e sidewall "check-
i n g " ( i f n o t r e m o v e d ) . I n any event, the tires should
not be d r i v e n more t h a n 50 miles (80 kilometers) be-
fore the protective coating is removed.
To remove t h e protective coating, wet the t i r e side-
w a l l surface t h o r o u g h l y w i t h w a r m water and allow
i t t o "soak" for one m i n u t e . Use a soft-bristle b r u s h
or sponge t o wash t h e protective coating from t h e
tire. T h e coating can also be removed by steam
cleaning. Do n o t use gasoline or other h a r m f u l sol-
vents. Do not use a w i r e brush.
REPAIR
GUIDELINES AND PRECAUTIONS
Punctured t i r e s should be removed from the wheel
and p e r m a n e n t l y repaired on the inside w i t h a com-
b i n a t i o n o f a repair p l u g a n d a vulcanizing patch.
W h e n r e p a i r i n g punctures, always follow the m a n u -
facturer's i n s t r u c t i o n s for a repair k i t i n s t a l l a t i o n .
Only punctures i n t h e t r e a d a r e a are repairable
(Fig. 7 ) .
Never attempt to repair punctures i n the tire
shoulders o r sidewalls.
I n addition, never a t t e m p t t o repair any t i r e t h a t
has any o f t h e following damage conditions:
• bulges or blisters;

J8922-6
Fig. 7 Repairable Puncture Area
• p l y separations;
• broken, cut or cracked beads;
• fabric cracks cuts;
• tread w o r n to the fabric or t o t h e w e a r indicators;
or
• punctures larger t h a n 1/4 of-an-inch i n diameter.
E x t e r n a l l y applied repair plugs, " b l o w o u t " patches
and aerosol sealants should be considered as e m e r -
g e n c y - t y p e repairs only. Tires repaired b y a n y of
these methods should not be d r i v e n a t a speed ex-
ceeding 40 m p h (64 km/h) or for more t h a n 75 miles
(121 k m ) before permanent t i r e repair or replace-
ment of the t i r e .
TIRE REMOVAL/INSTALLATION
The tools used for " d i s m o u n t i n g " a n d " m o u n t i n g "
tires must be smooth and free of sharp edges a n d
b u r r s t h a t could damage a t i r e bead a n d wheel r i m .
A t i r e must be completely deflated before the t i r e
beads are separated f r o m the r i m valley "seats". Be-
fore " m o u n t i n g " a t i r e o n a wheel, ensure t h a t a l l
" r u s t " scale is removed f r o m the r i m . P a i n t the r i m ,
i f necessary. L u b r i c a t i o n , either a m i l d soap solution
or a commercial t i r e bead l u b r i c a n t M U S T be ap-
plied t o both t i r e bead surfaces w h e n either " m o u n t -
i n g " or " d i s m o u n t i n g " a t i r e .
A standard, commercial " t o u r n i q u e t " type t i r e bead
expander can be used t o "seat" r e g u l a r bias-ply t i r e
beads, but bias-belted and radial-ply tires require a
;
type o f bead expander designed for less flexible t i r e
sidewalls.
ROTATION
To equalize tread wear, tires should be rotated a t
the specified i n t e r v a l . T h e first t i r e r o t a t i o n is t h e
most important for establishing the prevention of u n -
TIRES AND WHEELS 22 - 9
even tread wear. A f t e r rotation, adjust the t i r e i n f l a -
t i o n t o t h e a i r pressure recommended o n t h e decal
affixed t o the i n t e r i o r surface o f the driver-side door
pillar.
Because "long-wearing" tires can be more suscepti-
ble t o i r r e g u l a r t r e a d wear, i t i s very i m p o r t a n t t o
rotate t h e tires a t t h e specified i n t e r v a l t o achieve
the t r e a d life p o t e n t i a l of t h e tires. Also, correct
wheel and t i r e balance and f r o n t end alignment must
be m a i n t a i n e d for extended t i r e tread life.
W i t h c o n t i n u e d severe o p e r a t i o n (e.g., t r a i l e r
towing), the tires should be rotated more fre-
q u e n t l y t h a n t h e specified i n t e r v a l .
U n e v e n t i r e t r e a d wear is frequently the cause o f
t i r e induced noises t h a t are a t t r i b u t e d t o axle gears,
bearings, etc. and often cause unnecessary repair t o
other chassis components i n a n effort to eliminate
the noises.
The suggested methods of t i r e r o t a t i o n for R a m
T r u c k and Ramcharger vehicles are i l l u s t r a t e d below
(Figs. 8 and 9). The methods are completely compat-
ible w i t h the t i r e industry's c u r r e n t l y recommended
procedure for r o t a t i o n of radial-ply and bias-ply tires.
Other r o t a t i o n patterns/methods can be used, b u t
they w i l l not necessarily provide a l l the t i r e longev-
i t y benefits t h a t are derived from t h e suggested
methods.
FRONT
5 TIRE 4 TIRE
RN804
Fig. 8 "Rearward Cross" Rotation Pattern
WIDE-TREAD TIRES
Radial-ply, wide-tread tires m u s t be installed i n
complete sets and only when there is adequate clear-
ance for the t i r e i n the wheel w e l l . T i r e s w i t h d i f -
ferent widths must never be intermixed.
CAUTION: The tires installed on van/wagon vehicles
must all have the same circumference to maintain
satisfactory operation. They must also be the same
size, construction and have the same inflation pres-
sure. Intermixing tires of different size or construc-
tion will cause unusual handling, noisy operation
and accelerated wear of the driveline components.
22-10 TIRES AND WHEELS
RN838
Fig. 9 Dual Wheel Tire Rotation Pattern
TIRE DIAGNOSIS
GENERAL INFORMATION
Roughness, vehicle v i b r a t i o n , t i r e " t r a m p " , wheel
" s h i m m y " a n d t i r e "thump/wheel h o p " are usually
the result o f either excessive tire/wheel " r u n o u t " ,
"cupped" t i r e s or tire/wheel unbalance. These prob-
lem conditions can also be caused b y d r i v i n g over
rough or i r r e g u l a r street/road surfaces. Test d r i v i n g
a vehicle on different street/road surfaces w i l l usu-
ally help determine i f t h e street/road surfaces or the
tires are causing the undesirable ride condition.
Always road test a vehicle to determine t h e exact
nature of a problem. D r i v e the vehicle for at least 10
miles (16 k m ) to w a r m t h e tires a n d remove tempo-
rary " f l a t " spots that could have formed w h i l e the ve-
hicle was parked. Note t h e t i r e condition and wear,
and measure and adjust the i n f l a t i o n pressure before
road testing.
PERFORMANCE CHARACTERISTICS
As a result of their unique construction, radial-ply
tires have r i d e , h a n d l i n g a n d a p p e a r a n c e charac-
teristics t h a t are noticeably different from t h e tires
previously used.
I f the low-speed ride q u a l i t y or "feel" of the tires
appears h a r s h , this is a normal characteristic and is
caused by t h e stiff belts used i n radial-ply t i r e con-
struction. Harshness often leads to t h e assumption
t h a t the t i r e s are over-inflated. Do not under-inflate
radial-ply t i r e s i n an attempt to correct t h i s condi-
tion. Inflate radial-ply w i t h t h e recommended a i r
pressure only.
•
Because t h e r a d i a l t i r e plies are positioned a t a 90
degree angle t o t h e t r e a d centerline, they have
h i g h l y flexible sidewalls. I t is t h i s flexibility t h a t
produces t h e characteristic sidewall " b u l g e " a n d
causes t h e t i r e t o appear under-inflated. This is a
n o r m a l condition. Do n o t a t t e m p t t o reduce t h e
"bulge" b y over-inflating t h e t i r e . Measure the i n f l a -
t i o n pressures w i t h an accurate gauge and inflate t h e
tires w i t h t h e recommended a i r pressure only.
A t a speed o f 15 m p h (24 km/h) or less, r a d i a l - p l y
tires can cause a side-to-side or " w a d d l e " m o t i o n .
Wheel balancing w i l l not correct t h i s condition.
Proper i n s t a l l a t i o n of r a d i a l - p l y t i r e s is very impor-
t a n t . Incomplete "seating" o f t h e t i r e bead o n t h e
wheel r i m can produce a h i g h frequency v i b r a t i o n a t
a speed above 45 m p h (72 km/h). Incomplete bead
"seating" can be determined by v i s u a l l y inspecting
the tire. Correction involves r e m o v i n g a n d "re-seat-
i n g " the t i r e on t h e wheel r i m .
Because o f t h e construction, r a d i a l - p l y tires are
sometimes less responsive t o certain methods of
wheel balancing. Radial-ply t i r e balancing is best ac-
complished u s i n g dynamic, two-plane, off-vehicle bal-
ancing equipment.
TIRE THUMP
T i r e " t h u m p " (noise) is caused b y t h e t i r e m o v i n g
over i r r e g u l a r i t i e s i n t h e streets/roads or by i r r e g u -
larities i n t h e t i r e itself. T h e " t h u m p " sound coin-
cides w i t h each wheel r o t a t i o n .
To identify t h e t i r e t h a t is causing the t h u m p , i n -
flate all t h e tires w i t h 45 p s i (310 kPa) of a i r pres-
sure t e m p o r a r i l y and drive over t h e same streets/
roads. I f the " t h u m p " noise does not exist, reduce the
a i r pressure i n one t i r e a t a t i m e repeat t h e road
test. Each road test is accomplished w i t h three o f the
tires w i t h h i g h a i r pressure and one w i t h the recom-
mended a i r pressure. W h e n the t h u m p develops
again, the t i r e t h a t was the most recently reduced to
n o r m a l i n f l a t i o n pressure is t h e defective tire.
TIRE TRAMP
T i r e " t r a m p " is caused b y either tire/wheel static
unbalance or by excessive tire/wheel l a t e r a l r u n o u t .
Static unbalance occurs when a disproportional
amount of w e i g h t (mass) is concentrated at a s m a l l
area on the tire/wheel (Fig. 10). T h i s causes a v i b r a -
tory-type pounding action t h a t is commonly referred
to as t i r e t r a m p or wheel hop. Static balance is
achieved by a n equal d i s t r i b u t i o n of weight (mass)
around t h e circumference o f the tire/wheel.
The most effective method of d e t e r m i n i n g static
unbalance is by the use of off-vehicle wheel balanc-
i n g equipment.
WHEEL SHIMMY
Wheel " s h i m m y " is caused by tire/wheel dynamic
unbalance.
 • TIRES AND WHEELS 22 - 11

ADD BALANCE
WEIGHTS HERE

TIRE OR WHEEL TRAMP, CORRECTIVE

OR WHEEL HOP WEIGHT
LOCATION
J8922-8

Fig. 10 Static Unbalance & Balance

D y n a m i c unbalance results f r o m unequal forces be-
i n g concentrated a t opposing locations on the c i r c u m -
ference of the tire/wheel d u r i n g wheel r o t a t i o n (Fig.
11). T h i s condition causes wheel s h i m m y and v i b r a -
t i o n a t m e d i u m and h i g h wheel r o t a t i o n speeds. D y -
namic balance is achieved b y a n equal d i s t r i b u t i o n of
tire/wheel w e i g h t (mass) a r o u n d t h e plane of r o t a t i o n
(Fig. 11). This equalizes t h e forces a n d allows t h e
wheel to rotate smoothly around the axis t h a t bisects
t h e t i r e and wheel center l i n e .
The most effective method for balancing tires/
wheels is b y t h e use o f equipment t h a t w i l l detect
b o t h static a n d dynamic unbalance. Dynamic, t w o -
plane balancing equipment is recommended.
CAUTION: DO NOT balance a tire/wheel that has
been removed from a vehicle that has not been re-
cently driven at least 10 miles (16 km) to eliminate
any existing "flat spot". The "flat spot" results from
the weight of the vehicle being supported by a
small area of the tire for an extended period of time.
The extent of the "flat spot" on a tire is usually
more severe during cold weather.
Because balancing procedures v a r y w i t h different
types of equipment, follow the manufacturer's operat-
i n g instructions e x p l i c i t l y t o o b t a i n satisfactory re-
sults.
ADD BALANCE
WEIGHTS HERE

CORRECTIVE WEIGHT
HEAVY SPOT LOCATION
WHEEL SHIMMY
AND VIBRATION
J8922-9

Fig. 11 Dynamic Unbalance & Balance

22 - 12 TIRES AND WHEELS +
WARNING: ON-VEHICLE TYPE TIRE/WHEEL BAL- The t i r e r a d i a l " r u n o u t " should n o t exceed 0.09 of-
ANCING EQUIPMENT CAN B E USED ON THE REAR an-inch (2.29 m m ) a n d t h e t i r e l a t e r a l " r u n o u t "
WHEELS OF VEHICLES EQUIPPED WITH A "LIMIT- should n o t exceed 0.10 of-an-inch (2.54 m m ) . I f the
ED-SLIP" (SURE-GRIP OR TRAC-LOK) DIFFEREN- t i r e r a d i a l and/or l a t e r a l " r u n o u t " exceeds t h e speci-
TIAL, BUT ONLY AFTER RAISING THE REAR END fied l i m i t , i t w i l l be necessary t o measure t h e wheel
AND REMOVING THE WHEEL OPPOSITE THE ONE r a d i a l and/or l a t e r a l " r u n o u t " t o determine whether
TO B E BALANCED. IN ADDITION, DO NOT EXCEED the t i r e o r t h e wheel i s causing t h e excessive
35 MPH (56 KM/H) WHEN ROTATING THE WHEELS. "runout". ,
AS A RESULT OF THE DIFFERENTIAL ACTION, THE Wheel r a d i a l " r u n o u t " (i.e., t h e wheel perimeter ec-
centricity) i s measured o n t h e wheel r i m i m m e d i -
ACTUAL WHEEL ANGULAR VELOCITY IS TWICE
ately inside t h e location where t h e wheel cover
THE SPEED INDICATED ON THE VEHICLE SPEED-
r e t a i n i n g " n i b s " are n o r m a l l y "seated" ( F i g . 13).
OMETER. THE CENTRIFUGAL FORCE PRODUCED
Wheel l a t e r a l " r u n o u t " (i.e., t h e w h e e l h o r i z o n t a l de-
BY A TIRE ROTATING AT HIGH SPEED COULD
v i a t i o n ) i s measured on t h e w h e e l r i m flange imme-
CAUSE DAMAGE AND PERSONAL INJURY.
diately i n b o a r d o f t h e curved lip/J-hook (Fig. 13).
Identify a n d m a r k t h e wheel r a d i a l and l a t e r a l m a -
TIRE AND WHEEL RUNOUT j o r " r u n o u t s " for reference.
Excessive r a d i a l or l a t e r a l " r u n o u t " o f a t i r e o r
wheel can cause roughness, vehicle v i b r a t i o n , t i r e
" t r a m p " , wheel "hop", excessive t i r e t r e a d wear a n d
wheel tremor.
Before measuring the tire/wheel " r u n o u t " , d r i v e
the vehicle for a t least 10 miles (16 k m ) t o remove
any temporary flat spots t h a t could have formed i n
the tires w h e n parked. F l a t spots m u s t be removed t o
avoid false indications when measuring t h e r u n o u t .
Measure t h e " r u n o u t " w i t h either a d i a l indicator
or w i t h wheel alignment equipment. A l l measure-
ments should be accomplished w i t h t h e t i r e s i n f l a t e d
w i t h t h e recommended a i r pressure a n d w i t h t h e
wheel bearings properly adjusted ( i f applicable).
Measure the r a d i a l " r u n o u t " (i.e., t h e t i r e perime-
ter eccentricity) a t both the center and outside ribs o f
the t i r e tread face. Measure the l a t e r a l " r u n o u t " (i.e.,
the t i r e horizontal deviation) a t t h e t i r e sidewall i m -
J8922-11
mediately above the buffing r i b on t h e sidewall ( F i g .
12). Identify a n d m a r k t h e t i r e r a d i a l a n d l a t e r a l Fig. 13 Wheel Radial/Lateral "Runout" Measurement
m a j o r " r u n o u t s " for reference.
The wheel r a d i a l " r u n o u t " f o r 15-inch wheels
should n o t exceed 0.030 of-an-inch (0.762 m m ) a n d
for 16-inch wheels should not exceed 0.045 of-an-inch
(1.143 m m ) . The wheel l a t e r a l " r u n o u t s " should not
exceed 0.045 of-an-inch (1.143 m m ) for a l l wheels.
Refer to t h e Wheel " R u n o u t " Specifications chart.

WHEEL "RUNOUT" SPECIFICATIONS

RADIAL LATERAL
WHEEL S I Z E
RUNOUT RUNOUT

15X6.5 inch 0.030 in (0.762 mm) 0.045 in (1.143 mm)

15X7.0 inch 0.030 in (0.762 mm) 0.045 in (1.143 mm)
16X6.0 inch 0.045 in (1.143 mm) 0.045 in (1.143 mm)

J9022-4
J9022-17
Fig. 12 Tire Radial/Lateral "Runout" Measurement
 • TIRES AND WHEELS
I f t h e t i r e " r u n o u t " (either r a d i a l or lateral) ex-
ceeds the specified l i m i t b u t t h e corresponding wheel
" r u n o u t " i s w i t h i n t h e specified l i m i t , t h e t i r e
" r u n o u t " can be reduced t o a n acceptable amount b y
c h a n g i n g t h e t i r e position o n the wheel so t h a t t h e
previously m a r k e d major " r u n o u t s " o n the t i r e a n d
o n t h e wheel are 180 degrees apart.
With disc brakes, excessive wheel lateral
"runout" can also be caused by excessive rotor
h u b - t o - b o r e "runout". R e f e r t o the rotor i n s p e c -
t i o n p r o c e d u r e in G r o u p 5—Brakes.
VEHICLE VIBRATION
Vehicle v i b r a t i o n can be caused b y tire/wheel u n -
balance or excessive " r u n o u t " ; defective or tires w i t h
extreme t r e a d wear; n y l o n overlay " f l a t spots" (per-
formance t i r e s only); incorrect wheel bearing adjust-
m e n t ( i f applicable); loose or w o r n suspension/
steering components; certain t i r e tread patterns;
incorrect d r i v e shaft angles or excessive drive shaft/
yoke " r u n o u t " ; defective or w o r n U-joints; excessive
b r a k e rotor or d r u m " r u n o u t " ; loose engine or trans-
mission supports/mounts; and b y engine operated ac-
cessories.
VIBRATION TYPES
There are two types o f vehicle v i b r a t i o n :
• mechanical and
• audible.
Mechanical vehicle v i b r a t i o n can be " f e l t " t h r o u g h
t h e seats, floor p a n and/or steering wheel. I t w i l l
u s u a l l y produce some visible m o t i o n i n the rear view
m i r r o r , fenders, i n s t r u m e n t panel a n d steering
wheel.
A u d i b l e vehicle v i b r a t i o n i s heard or "sensed"
above n o r m a l background noise and, i n some circum-
stances, i t occurs as a " d r o n i n g or d r u m m i n g " noise,
w h i l e i n other situations i t produces a buffeting sen-
sation t h a t i s "felt or sensed" b y the vehicle occu-
pants r a t h e r t h a n being heard.
Mechanical and audible vehicle vibrations are sen-
s i t i v e t o changes i n t h e engine torque, t h e vehicle
speed and/or t h e engine speed (rpm). They usually
occur w i t h i n one (or sometimes w i t h i n two) well-de-
f i n e d range o f conditions i n terms o f vehicle speed,
engine speed (rpm) a n d engine torque application.
22 - 13
ENGINE TORQUE SENSITIVE VIBRATION
This v i b r a t i o n condition can be improved or caused
to be more severe b y either accelerating, decelerat-
i n g , coasting, or m a i n t a i n i n g a constant vehicle
speed and constant engine torque.
VEHICLE SPEED SENSITIVE VIBRATION
This v i b r a t i o n condition always occurs a t the same
vehicle speed regardless of the engine torque, engine
speed (rpm) or the transmission gear selected.
ENGINE SPEED (RPM) SENSITIVE VIBRATION
This v i b r a t i o n condition occurs a t v a r y i n g vehicle
speeds w h e n a different transmission gear is selected.
I t can sometimes be isolated b y increasing or de-
creasing the engine speed (rpm) w i t h the t r a n s m i s -
sion i n N E U T R A L position.
VIBRATION DIAGNOSIS
A v i b r a t i o n diagnosis should always begin w i t h a
p r e l i m i n a r y 10 mile (16 k m ) t r i p (to " w a r m " t h e ve-
hicle and tires) and t h e n a road test t o identify the
characteristics of t h e v i b r a t i o n . Corrective action
should not be attempted u n t i l t h e v i b r a t i o n type,
magnitude and speed range have been identified v i a
a road test.
D u r i n g the road test, drive the vehicle on a street/
road t h a t is smooth and free o f i r r e g u l a r surface ar-
eas. I f v i b r a t i o n exists, note and record the f o l l o w i n g
information:
• identify the vehicle speed range w h e n the v i b r a -
t i o n occurs;
• identify the type o f v i b r a t i o n (i.e., mechanical or
audible);
• identify t h e v i b r a t i o n sensitivity (i.e., engine
torque sensitive, engine speed (rpm) sensitive or ve-
hicle speed sensitive); and
• determine i f the v i b r a t i o n is affected by changes i n
vehicle speed, engine speed (rpm) and engine torque.
W h e n the v i b r a t i o n type, the sensitivity, the vehi-
cle speed range a n d t h e source of a n y v i b r a t i o n
changes have been identified, refer t o the V i b r a t i o n
Diagnosis chart for probable causes. Consider correct-
i n g only those causes coded i n the chart t h a t are re-
lated t o the v i b r a t i o n condition.
22 - 14 TIRES AND WHEELS •

VIBRATION DIAGNOSIS

Correction Codes For Mechanical Vibrations Within Specific M P H (km/h) R a n g e s

Vibration
Sensitivity 10 20 30 4 >0 60 70 80 90
(16 km) (32 km) (48 km) (64 km) (8CI km) (96 km) (112 km) (12 8 km) (1 44 km)
rRR and SSC: — ; 1
W D
Vehicle tAn i
Speed '• 11
TLR """"
Sensitive I I I . 1 AV1 *
1
Torque 1 UJ ai
Sensitive U IA • A •
„ f*C
Engine
Speed — E A — •
Sensitive

Correction C o d e s For Audible Vibrations Within Specific MPH (km/h) R a n g e s

Vibration
Sensitivity 10 20 30 40 50 60 70 80 90
(16 km) (32 km) (48 km) (64 km) c (80 km) (96 km) (112 km) (128 km) (144 km)
•

UJ
Vehicle II 1 IA/L,
Speed • JU ana Wr 1
Sensitive IV

Torque
Sensitive

Engine
^ UJ and TED|

CM an
Speed — A C >B — •
Sensitive , nFA A >1 J8922-12
• 1

Refer to t h e following cause codes and descriptions
for explanations w h e n referring t o the chart.
T R R — T i r e and Wheel Radial Runout.
Vehicle speed sensitive, mechanical v i b r a t i o n . T h e
" r u n o u t " w i l l not cause v i b r a t i o n below 20 m p h (32
km/h). The vehicle speed t h a t is required to cause v i -
b r a t i o n w i l l increase as the a m o u n t of " r u n o u t " de-
creases.
W H - W h e e l Hop.
Vehicle speed sensitive, mechanical v i b r a t i o n . T h e
wheel " h o p " generates rapid up-down movement i n
t h e steering wheel and the i n s t r u m e n t panel. The v i -
b r a t i o n is most noticeable i n the 20 - 40 m p h (32 - 64
km/h) vehicle speed range. The wheel " h o p " w i l l not
cause v i b r a t i o n below 20 m p h (32 km/h). Wheel
" h o p " i s caused by a tire/wheel t h a t has a r a d i a l
" r u n o u t " of more t h a n 0.045 of-an-inch (1.14 m m ) . I f
the wheel " r u n o u t " is acceptable and t h e combined
" r u n o u t " cannot be reduced b y repositioning the t i r e
on the wheel, replace the defective tire.
TB—Tire/Wheel Balance.
Vehicle speed sensitive, mechanical v i b r a t i o n .
Static tire/wheel unbalance w i l l not cause v i b r a t i o n
below 30 m p h (46 km/h). D y n a m i c tire/wheel u n b a l -
ance w i l l n o t cause v i b r a t i o n below 40 m p h (64 k m /
h).
TLR-Tire/Wfaeel Lateral runout.
Vehicle speed sensitive, mechanical v i b r a t i o n . T h e
" r u n o u t " w i l l n o t cause v i b r a t i o n below 50 - 55 m p h
(80 - 88 km/h) unless i t extremely excessive. E x -
t r e m e l y excessive l a t e r a l " r u n o u t " w i l l also cause
front-end " s h i m m y " .
T W - T i r e Wear.
Vehicle speed sensitive, audible v i b r a t i o n . Abnor-
m a l t i r e wear causes s m a l l v i b r a t i o n i n t h e 30 - 55
m p h (88 km/h) vehicle speed range a n d w i l l produce
a " w h i n e " noise at h i g h speed. T h e w h i n e w i l l
change to a " g r o w l " noise w h e n t h e speed i s reduced.
W - T i r e Waddle.
Vehicle speed sensitive, mechanical v i b r a t i o n . I r -
regular t i r e u n i f o r m i t y can cause " w a d d l e " (side-
to-side) m o t i o n d u r i n g speeds u p to 15 m p h (24 k m /
h). I f the m o t i o n (waddle) is excessive: identify t h e
defective tire(s) by r e m o v i n g each t i r e (one a t a
time); s u b s t i t u t i n g i t w i t h a k n o w n good t i r e ; a n d
road testing. W h e n identified, replace t h e defective
tire(s).
 • TIRES AND WHEELS
U A J — U n i v e r s a l J o i n t (Drive Shaft) Angles.
Torque/vehicle speed sensitive, mechanical/audible
v i b r a t i o n . Incorrect drive shaft angles cause mechan-
ical v i b r a t i o n below 20 m p h (32 km/h) and i n the 70
m p h (112 km/h) range. The incorrect angles can also
produce a n audible v i b r a t i o n i n the 20 - 50 m p h (32 -
80 km/h) range.
U J — U n i v e r s a l Joints.
Engine torque/vehicle speed sensitive, mechanical/
audible v i b r a t i o n . I f t h e needle bearings, bearing
cups or b e a r i n g ends of the spiders are either w o r n ,
damaged, over-tightened or loose, they w i l l cause v i -
b r a t i o n w i t h almost a n y vehicle speed/engine torque
condition. . ticeable w h e n t h e transmission is shifted i n t o t h e
D S Y - D r i v e Shaft a n d Yokes.
Vehicle speed sensitive, mechanical/audible v i b r a -
t i o n . The condition w i l l not cause v i b r a t i o n below 35
m p h (56 km/h). Excessive " r u n o u t " , unbalance, miss-
i n g balance weights, undercoating on t h e shaft tube,
dfents and bends i n t h e shaft tube w i l l cause t h e v i -
bration. Identify t h e actual cause and repair/replace
as necessary.
W B - W h e e l Bearings.
Vehicle speed sensitive, mechanical/audible vibra-
t i o n . Loose wheel bearings cause " s h i m m y - l i k e " v i -
b r a t i o n a t 35 m p h (56 km/h) a n d above. Rough or
damaged bearings w i l l also produce a " g r o w l " noise
at low vehicle speed and/or a " w h i n e " noise a t h i g h
vehicle speed. T h e wheel bearings must be adjusted
or replaced, as applicable.
A N — A x l e Noise.
Engine torque/vehicle speed sensitive, mechanical/
audible v i b r a t i o n . T h e axle w i l l not cause mechanical
v i b r a t i o n unless the axle shaft is bent. W o r n or dam-
aged axle d r i v e p i n i o n gear shaft or differential gears
and bearings w i l l cause noise a t v a r y i n g speed
ranges i n r e l a t i o n to the amount of engine torque ap-
plied. Replace t h e defective component(s) as neces-
sary.
22-15
S S C — S u s p e n s i o n a n d Steering Components.
Vehicle speed sensitive, mechanical v i b r a t i o n .
W o r n , damaged or loose suspension/steering compo-
nents (i.e., steering dampener, steering knuckles, p i t -
m a n a r m , springs, spring U-bolts or center bolts,
shock absorbers, t i e r o d ball-stud ends, etc.) can
cause mechanical v i b r a t i o n a t speeds above 20 m p h
(32 km/h). Identify a n d repair or replace t h e defec-
t i v e component(s).
E A — E n g i n e Driven Accessories.
Engine speed sensitive, mechanical/audible v i b r a -
t i o n . V i b r a t i o n can be caused by loose or broken A/C
compressor (or bracket), PS p u m p (or bracket), water
pump, a l t e r n a t o r (or bracket), etc. U s u a l l y more no-
N E U T R A L position a n d t h e engine speed ( r p m ) i n -
creased. Inspect t h e engine d r i v e n accessories i n t h e
engine compartment and repair/replace as necessary.
A D B — A c c e s s o r y Drive Belts.
Engine speed sensitive, audible v i b r a t i o n . Loose/
w o r n d r i v e belts can cause a v i b r a t i o n t h a t produces
either a " d r o n i n g , f l u t t e r i n g or r u m b l i n g " noise. I n -
spect the drive belts and tighten/replace t h e m as nec-
essary.
D E M — D a m a g e d Engine or Transmission Sup-
p o r t Mounts.
Engine speed sensitive, mechanical/audible v i b r a -
t i o n . I f a support m o u n t is either loose, w o r n or bro-
ken, noise or vehicle v i b r a t i o n w i l l be t h e result i f
either t h e engine, transmission or an engine acces-
sory contacts t h e vehicle body. Inspect t h e support
mounts and repair/replace as necessary.
E S — E x h a u s t System.
Engine speed sensitive, mechanical/audible vibra-
t i o n . I f loose or broken exhaust components contact
the vehicle body they w i l l cause noise and, i n some
instances, vehicle v i b r a t i o n . I n addition, i f mis-
aligned exhaust components (e.g., muffler, converter,
pipes, or hangers) contact t h e vehicle body or t h e
d r i v e l i n e components, t h e result w i l l be noise and/or
vehicle v i b r a t i o n . Inspect t h e exhaust system for
loose, broken a n d mis-aligned components a n d re-
pair/replace as necessary.
22 - 16 TIRES AND WHEELS •
WHEEL S E R V I C E

INDEX
Page Page
Cleaning . . . . 16 Wheel Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Inspection 16 Wheel Bearing Service ..... ... 18
Lug Nut Tightening 16 Wheel Covers '. 17

INSPECTION
T h e wheels i n s t a l l e d o n R a m T r u c k a n d Ram-
charger vehicles w i l l provide m a x i m u m d u r a b i l i t y
and performance w h e n properly serviced and m a i n -
tained.
A frequent inspection r o u t i n e is recommended To
ensure t h a t t h e r i m s a n d wheels are i n good condi-
t i o n . The wheel inspections should accomplished dur-
i n g t i r e inspections and w h e n the tires are replaced.
Replace any wheel t h a t is cracked, is bent, is se-
verely dented, has excessive " r u n o u t " or has b r o k e n
welds. T h e t i r e i n f l a t i o n valve should also be i n -
spected frequently for wear, leakage, cuts and loose-
ness. The valve should be replaced i f defective or i t s
condition is doubtful.
Fig. 14 Safety-Rim Wheel Lug Nut Tightening
Pattern
CLEANING
1 1 8 LBS. FORCE THESE NUMBERS SHOW THE
Clean the wheels w i t h a m i l d soap and water solu- S E Q U E N C E I N W H I C H S T U D N U T S
t i o n only and rinse t h o r o u g h l y w i t h water. Never use ARE T O BE TIGHTENED.

abrasive or caustic m a t e r i a l s , especially o n a l u m i -

325 FT. LBS.
n u m or chrome-plated wheels because t h e surface
T O R Q U E
w i l l be etched or the p l a t i n g severely damaged. A f t e r
cleaning a l u m i n u m or chrome-plated wheels, apply a
coating of protective wax to preserve the finish and
the lustre.

LUG NUT TIGHTENING

PU884

SAFETY-RIM WHEELS
A l w a y s t i g h t e n safety-rim wheel l u g nuts i n a
crisscross p a t t e r n (Fig. 14) w i t h the specified torque.
The l u g nuts have r i g h t - h a n d threads.
DUAL REAR WHEELS
W h e n R a m T r u c k Models D-350 and W-350 are
equipped w i t h d u a l rear wheels, a special, heavy
d u t y l u g n u t t i g h t e n i n g wrench is required for cor-
rect l u g n u t t i g h t e n i n g (Fig. 15). Therefore, i t is rec-
ommended to remove and i n s t a l l dual rear wheels
only w h e n a proper facility and wrench are available.
The dual rear wheels have eight-stud holes. Four
stud holes are equally-spaced, o u t w a r d flanged holes
and four stud holes are equally spaced, i n w a r d
flanged holes. T h e outer wheel must be installed so
Fig. 15 Dual Rear Wheel Tightening Pattern
t h a t i t s flanged stud holes mate correctly w i t h t h e
flanged stud holes i n the inner wheel (Fig. 16).
A l o c a t i n g p i n i n t h e hub provides assistance for
correctly a l i g n i n g t h e inner and outer wheels ( F i g .
16).
INSTALLATION
The t i r e s on b o t h wheels must be completely raised
off t h e ground w h e n t i g h t e n i n g the l u g n u t s t o en-
sure correct wheel centering and m a x i m u m wheel
clamping.
A 1 and 1/8-inch diameter flanged-type wheel l u g
n u t w i t h r i g h t - h a n d threads is used for r e t a i n i n g
d u a l rear wheels on the hubs. A special, heavy d u t y
 • TIRES AND WHEELS
LOCATING PIN HOLE IN BOTH INNER & OUTER WHEEL MUST EN-
G A G E L O C A T I N G PIN IN HUB WHEN WHEELS ARE INSTALLED.
Fig. 16 Eight-Stud Hole Dual Rear Wheels
wheel l u g n u t w r e n c h is necessary t o correctly
t i g h t e n the n u t s w i t h the required torque (Fig. 15).
The dual r e a r wheel l u g nuts should be tightened
according t o t h e f o l l o w i n g procedure:
• t i g h t e n t h e wheel l u g nuts i n the numbered se-
q u e n t i a l p a t t e r n u n t i l they are " s n u g " t i g h t (Fig. 15);
• t i g h t e n t h e wheel l u g nuts i n the numbered se-
q u e n t i a l p a t t e r n (Fig. 15) w i t h 440 N-m (325 ft-lb)
torque;
• t i g h t e n t h e l u g n u t s i n the numbered sequential
p a t t e r n (Fig. 15) a second t i m e w i t h the specified
torque t o ensure t h a t t h e wheels are t h o r o u g h l y
mated; and
• r e - t i g h t e n t h e l u g nuts w i t h the specified torque
after 100 m i l e s (160 kilometers) and after 500 miles
(800 kilometers) o f vehicle operation.
The wheel l u g nuts should be tightened w i t h
t h e s p e c i f i e d t o r q u e a t e v e r y chassis l u b r i c a t i o n
interval thereafter.
WHEEL BALANCING
Wheel b a l a n c i n g can be accomplished w i t h either
on- or off-vehicle equipment. However, when u s i n g
on-vehicle b a l a n c i n g equipment, observe the follow-
i n g precaution.
F o r vehicles w i t h a "limited-slip" (Sure-Grip o r
T r a c - L o k ) r e a r a x l e d i f f e r e n t i a l , d o n o t use o n -
vehicle e q u i p m e n t t o balance a r e a r wheel/tire
unless t h e o p p o s i t e wheel/tire is r e m o v e d f r o m
the hub.
W h e n b a l a n c i n g a l u m i n u m or chrome-plated
wheels, use care to avoid damaging the wheel surface
w h e n i n s t a l l i n g t h e balance weights. Use o n l y self-
a d h e r i n g t y p e weights o n a l u m i n u m wheels a n d
i n s t a l l t h e m o n t h e b a c k side o f t h e w h e e l
(whenever possible).
WHEEL COVERS
To avoid d a m a g i n g a wheel cover d u r i n g removal
or i n s t a l l a t i o n , care should be used t o ensure t h a t
force is applied only at the correct areas on the wheel
cover.
22-17
CAUTION: Do not pry outward or apply inward force
to a wheel cover at the immediate area of the tire
valve stem hole. A wheel cover is structurally stron-
ger and will withstand the force required for re-
moval and installation around the perimeter of the
wheel cover away from the tire valve stem hole.
WARNING: HANDLE WHEEL COVERS WITH EX-
TREME CARE DURING REMOVAL AND INSTALLA-
TION BECAUSE THE SHARP EDGES CAN CAUSE
PERSONAL INJURY.
REMOVAL
(1) To remove a wheel cover, s t a r t b y p r y i n g i t
loose ( w i t h a pry bar) f r o m t h e wheel r i m 180 de-
grees opposite the t i r e valve stem hole.
(2) Continue p r y i n g a l t e r n a t e l y around t h e p e r i m -
eter o f the wheel cover and t o w a r d the t i r e valve
stem hole u n t i l t h e wheel cover is completely de-
tached f r o m the wheel r i m .
INSTALLATION
(1) Use a rubber m a l l e t t o i n s t a l l a wheel cover.
(2) To i n s t a l l a wheel cover, insert the t i r e valve
stem t h r o u g h the wheel cover valve stem hole a n d
t h e n "seat" t h i s p o r t i o n o f t h e wheel cover on t h e
wheel r i m .
(3) Continue a p p l y i n g i n w a r d force w i t h a rubber
m a l l e t alternately around the perimeter o f the wheel
cover and away from the t i r e valve stem hole u n t i l
the wheel cover is completely "seated" on the wheel
rim.
(4) F i n a l l y , apply i n w a r d force w i t h a r u b b e r m a l -
let to the wheel cover 180 degrees opposite the t i r e
valve stem hole to complete t h e i n s t a l l a t i o n .
16-INCH WHEEL TRIM RING AND WHEEL
COVER
A special t r i m r i n g is available for 16-inch diame-
ter wheels. The t r i m r i n g provides a reduced diame-
ter perimeter surface area t h a t is the same as t h a t
r e q u i r e d for a standard 15-inch diameter wheel cover
(Fig. 17). The procedures for r e m o v i n g and i n s t a l l i n g
the special t r i m r i n g are s i m i l a r to the procedures for
a wheel h u b cap.
The combined t r i m r i n g and wheel cover can be re-
moved as a u n i t by p r y i n g o u t w a r d on the t r i m r i n g
( w i t h a p r y bar) 180 degrees opposite the t i r e valve
stem hole.
To i n s t a l l , first position the t r i m r i n g on the wheel
r i m w i t h the t i r e valve stem hole properly aligned
around the valve stem and extension before i n s t a l l -
i n g t h e wheel cover (Fig. 17). Use the standard wheel
cover i n s t a l l a t i o n procedure (above) t o i n s t a l l t h e
wheel cover on the t r i m r i n g .
22 - 18 TIRES AND WHEELS
Fig. 17 16-Inch Wheel Trim Ring & Wheel Cover
WHEEL BEARING SERVICE
FRONT WHEELS
TWO-WHEEL DRIVE (2WD) VEHICLES
(1) Block the brake pedal i n the u p (non-depressed)
position.
(2) Raise a n d support the vehicle. Remove t h e
wheel/tire.
(3) Remove t h e retainer, a n t i - r a t t l e spring a n d t h e
disk brake caliper.
(4) Separate t h e brake caliper from t h e rotor a n d
remove t h e inboard brake pad.
Support the caliper w i t h wire at a n o u to f the
way location. D o n o t allow the caliper t o hang
b y t h e b r a k e f l u i d hose.
( 5 ) Remove t h e dust cap, the cotter p i n , t h e n u t
lock, t h e r e t a i n i n g n u t , the t h r u s t washer, a n d t h e
outer wheel bearing from the rotor/hub (Fig. 18).
(6) Carefully slide t h e rotor/hub from t h e steering
k n u c k l e spindle. D o n o t a l l o w t h e seal o r t h e i n -
ner wheel bearing to contact the steering
k n u c k l e spindle threads (the t h r e a d s a n d t h e
b e a r i n g c o u l d be damaged).
(7) Remove t h e splash shield, the bearing seal a n d
the i n n e r wheel bearing from the rotor/hub. Discard
the seal.
(8) Thoroughly clean both wheel bearings a n d t h e
i n t e r i o r surface of the rotor/hub (i.e., remove a l l t h e
hardened l u b r i c a n t deposits).
To clean a wheel bearing, soak i t i n c l e a n i n g
solvent. Strike t h e flat o f the b e a r i n g against a
h a r d w o o d b l o c k several times (immerse t h e
b e a r i n g i n solvent between the contacts w i t h t h e
block) t o loosen a n d wash t h e particles o f h a r d -
ened l u b r i c a n t f r o m the bearing. Repeat this
p r o c e d u r e u n t i l each bearing is clean.
•
BRAKE INNER
Fig. 18 Front Hub Area (Typical)
(9) D r y b o t h bearings w i t h compressed a i r b u t do
not spin t h e rollers. After d r y i n g , lubricate b o t h
bearings w i t h engine oil.
(10) T u r n the bearing rollers slowly w h i l e a p p l y i n g
force a n d examine t h e m for " p i t t i n g " and roughness.
I f t h e b e a r i n g rollers are p i t t e d or rough, replace t h e
cup a n d t h e bearing.
A l w a y s replace excessively w o r n a n d defective
bearings.
(11) I f t h e wheel bearings are reusable, remove t h e
engine o i l , pack t h e m w i t h multi-purpose, N L G I
Grade 2 E P (extreme pressure) l u b r i c a n t (or a n
e q u i v a l e n t l u b r i c a n t ) , and place t h e m i n a clean, cov-
ered container u n t i l i n s t a l l a t i o n t i m e .
I f a b e a r i n g packer tool is n o t available, h a n d
p a c k l u b r i c a n t i n t o a l l t h e cavities between t h e
cage a n d t h e rollers.
(12) I f a bearing and cup are to be replaced, remove
t h e cup w i t h a brass drift or a n appropriate removal
tool. I n s t a l l t h e replacement bearing cup w i t h a n ap-
p r o p r i a t e i n s t a l l a t i o n tool.
(13) A p p l y a coat of l u b r i c a n t to t h e complete i n t e -
r i o r surface (cavity and bore) of t h e rotor/hub ( F i g .
18).
Lubricate the l i p of the replacement bearing
seal b e f o r e i n s t a l l a t i o n .
(14) I n s t a l l t h e inner wheel bearing i n t h e rotor/
h u b bore, i n s t a l l a replacement bearing seal i n t h e
bore w i t h a n appropriate seal i n s t a l l a t i o n tool a n d
i n s t a l l t h e splash shield. T i g h t e n t h e splash shield
a t t a c h i n g bolts w i t h 25 N*m (220 in-lbs).
(15) Before i n s t a l l i n g the rotor/hub on the steering
k n u c k l e spindle, inspect the bearing and seal contact
surfaces on t h e spindle for b u r r s and roughness. Re-
move a l l t h e b u r r s and r o u g h surfaces.
 • TIRES AND WHEELS 22 - 19

(16) A p p l y a coat o f multi-purpose, N L G I Grade 2
EP l u b r i c a n t (or a n equivalent l u b r i c a n t ) to t h e spin-
dle.
(17) Position t h e rotor/hub bore a t t h e spindle a n d
carefully insert t h e spindle i n t o t h e seal and t h e i n -
ner wheel bearing. D o n o t a l l o w t h e seal o r t h e i n -
ner bearing t o contact the spindle threads (the
t h r e a d s , t h e b e a r i n g a n d t h e b e a r i n g seal c o u l d
b e d a m a g e d ) . "Seat" t h e rotor/hub against the steer-
i n g knuckle.
(18) I n s t a l l t h e outer wheel bearing, t h e washer
and t h e r e t a i n i n g n u t (Fig. 18).
(19) T i g h t e n t h e r e t a i n i n g n u t w i t h 47 N*m (35 f t -
lbs) torque w h i l e r o t a t i n g the rotor/hub. Stop t h e ro-
tor/hub r o t a t i o n a n d "back-off" t h e r e t a i n i n g n u t
w i t h a wrench a n d completely release t h e wheel
bearing "preload" torque. Next, "finger t i g h t e n " t h e
r e t a i n i n g n u t , i n s t a l l t h e n u t lock a n d i n s t a l l a re-
placement cotter p i n (Fig. 18).
(20) The result o f t h e adjustment should be a
0.0001- to 0.0030-inch wheel b e a r i n g "end play".
SPECIFICATIONS
(21) Clean t h e dust cap a n d apply a coat o f l u b r i -
cant t o the i n t e r i o r surface. D o not fill the dust c a p
w i t h l u b r i c a n t . I n s t a l l t h e dust cap on t h e rotor/
hub.
(22) I n s t a l l t h e i n b o a r d brake pad on t h e caliper
adapter.
(23) Position t h e caliper over t h e rotor and i n s t a l l
the retainer a n d t h e a n t i - r a t t l e spring. T i g h t e n t h e
clips w i t h l / 2 - i n c h b o l t 20 N * m (180 in-lbs) torque.
(24) I n s t a l l t h e wheel/tire and t i g h t e n the l u g nuts
w i t h t h e specified torque. Refer t o t h e Torque Speci-
fications c h a r t for t h e correct torque value.
(25) Remove t h e supports, lower t h e vehicle, r e -
move t h e block f r o m t h e brake pedal and test drive
the vehicle.
FOUR-WHEEL DRIVE (4WD) VEHICLES
Refer t o G r o u p 2 — F r o n t S u s p e n s i o n for front
wheel bearing service.
REAR WHEELS
Refer to . G r o u p 3- - R e a r A x l e s for rear wheel
b e a r i n g service.

TORQUE SPECIFICATIONS

COMPONENT SET-TO-TORQUE RECHECK T O R Q U E

Lug Nut (Cone)

1/2-20 142 N T H (105 ft-lbs)
5/8-18 271 N*m (200 ft-lbs)

Lug Nut (Flanged)

5/8-18 440 N T H (325 ft-lbs)

Front Hub Nut (2WD) 47 NTTI (35 ft-lbs) 41-54 N-m (30-40 ft-lbs)

Brake Caliper Retainer Clip 20 N*m (100 in-lbs)

J9022-16
 • GROUP 23-1

BODY
CONTENTS
Page. Page

DOOR SYSTEMS 20 REFINISHING PROCEDURES 32

FIXED GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 SHEET METAL . . . . . . . . . . . 10
INTERIOR TRIM 1

INTERIOR TRIM
INDEX
Page Page
Bench Seat Mounting . . . . . . . . . . . . . . . . . . . . . . . 4 Model Identification 1
Bucket Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Outside Air Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Carpet and Mat Assembly . . . . . . . . . . . . . . . . . . . 7 Rear Jump Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Rear View Mirror .1
Console Lock 4 Rear View Mirror Button 1
Safety Belts—Rear Seat 6
Cowl Side Trim Panel . . . . . . . . . . ... . . . . . . . . . . . 2
Seat Belts and Retractors . . . . . . . . . . . . . . . . . . . . 6
Headliner . 7 Storage Tray . . . . . . 8
Interior Trim . .... 5 Uni-Belts—Front Seats 6

MODEL IDENTIFICATION (4) Thoroughly.sand the w i n d s h i e l d m o u n t i n g sur-

AD4 = Ramcharger Two-Wheel-Drive face (the side w i t h least surface area) of t h e m i r r o r
AD8 = Ramcharger Four-Wheel-Drive b u t t o n w i t h a clean piece o f fine g r i t sandpaper a n d
A D l , 2 and 3 = Light Duty Truck Two- wipe the surface clean w i t h a clean paper towel sat-
Wheel-Drive urated w i t h alcohol.
ADS, 6 and 7 = Light Duty Truck Four- (5) U s i n g k i t 4054099 or equivalent, crush t h e v i a l
Wheel-Drive i n the plastic housing of t h e accelerator. T h i s satu-
rates felt applicator. Remove paper sleeve. A p p l y a
REAR VIEW MIRROR (FIG. 1) generous amount of Accelerator on t h e m o u n t i n g sur-
face of the m i r r o r b u t t o n .
REMOVAL
(1) Loosen t h e set screw a n d slide t h e m i r r o r u p MIRROR
and o f f t h e button. .
WINDSHIELD
(2) I n s t a l l a t i o n is accomplished b y s l i d i n g the m i r -
ror over t h e b u t t o n and t i g h t e n i n g t h e set screw.
Care should be exercised n o t t o over t i g h t e n t h e
screw.

REAR VIEW MIRROR BUTTON (FIG. 1)

REPLACEMENT
(1) U s i n g a wax pencil, locate a n d m a r k t h e mount-
i n g position of t h e b u t t o n o n t h e outside of t h e
wind-shield.
(2) I f the v i n y l p a d h a d r e m a i n e d o n t h e w i n d -
shield glass, apply " l o w h e a t " t o i t w i t h a n electric
heat g u n u n t i l the v i n y l softens; t h e n peel the v i n y l
pad f r o m t h e glass. -
(3) T h o r o u g h l y clean the i n n e r surface o f t h e w i n d -
shield glass i n the m o u n t i n g area o f t h e m i r r o r but-
t o n u s i n g a m i l d abrasive cleaning powder such as BUTTON
Ajax, Comet, or equivalent, o n a clean cloth satu- PR695
rated w i t h alcohol. Then, apply alcohol t o a paper
towel a n d wipe off any traces o f r e m a i n i n g cleaner. Fig. 1—Rearview Mirror
 23 - 2 BODY •
(6) A l l o w t h e accelerator t o d r y for five minutes. v e n t push or p u l l h a n d l e located o n the v e n t assem-
Do n o t touch the m o u n t i n g surface o f the b u t t o n or bly. To remove v e n t assembly, remove screws and re-
glass. move assembly. To i n s t a l l v e n t assembly, place
(7) A p p l y a t h i n f i l m o f accelerator t o t h e i n n e r assembly i n t o position a n d secure w i t h m o u n t i n g
surface of t h e windshield i n t h e b u t t o n m o u n t i n g screws.
area. A l l o w one m i n u t e to dry. Do not touch the sur-
face.
(8) A p p l y one drop o f adhesive to t h e center o f the
w i n d s h i e l d m o u n t i n g surface o f the m i r r o r b u t t o n as
shown o n t h e attached sketch and, u s i n g the bottom
of t h e Adhesive tube, q u i c k l y d i s t r i b u t e t h e adhesive
evenly over the entire bonding surface o f t h e button.
(9) Position the bottom s t r a i g h t edge o f the m i r r o r
b u t t o n o n t h e horizontal l i n e and center i t o n t h e
v e r t i c a l l i n e ; then, press i t f i r m l y t o t h e glass and
apply pressure for about one m i n u t e . Proper location
is essential as cement sets up very fast.
(10) A l l o w five minutes for t h e adhesive to set;
t h e n , remove any excess adhesive residue from t h e
w i n d s h i e l d i n the attachment area u s i n g a n alcohol-
dampened cloth.
(11) Slide t h e m i r r o r d o w n w a r d onto t h e b u t t o n
and t i g h t e n the screw.

COWL SIDE TRIM PANEL (FIGS. 2 AND 3)

The t r i m panel is secured t o t h e cowl side panel
w i t h screws. Refer t o the i l l u s t r a t i o n s for screw loca-
tions. Fig. 3—Right Side Trim Panel

Fig. 4—Outside Air Vent

Fig. 2—Left Side Trim Panel and Air Vent
OUTSIDE AIR VENT (FIGS. 2 AND 4)
The a i r vent is mounted on t h e lower side cowl
(Drivers side) w i t h m o u n t i n g screws. To operate the
 • BODY 23-3

BUCKET SEAT-LEFT SIDE (FIG. 5) INSTALLATION

(1) To i n s t a l l seat assembly, secure t h e hinge sec-
REMOVAL t i o n o f the riser to the underbody w i t h nuts.
(1) To remove complete seat, adjuster, a n d riser, r e - (2) T h e seat can be installed b y m o u n t i n g seat t o
move nuts m o u n t i n g riser to underbody. riser spacers.
(2) To remove i n d i v i d u a l assemblies refer t o the as- (3) Connect gas prop to seat.
sembly i n (Fig. 5). (4) Lock should line up w i t h lock catch mounted o n
the underbody.
SEAT ASSEMBLY v

Fig. 6—Bucket Seat, Right Side

8923-56
LOCK ASSEMBLY
Fig. 5 — B u c k e t Seat, Left Side
REMOVAL
INSTALLATION
(1) To remove lock from riser, remove screws secur-
(1) To i n s t a l l complete seat adjuster a n d riser as
i n g lock to riser.
one assembly, place assembly into position i n vehicle
(2) Remove. clip from inside end of l i n k .
and secure n u t s to riser located on underbody.
(3) Remove lock from riser.
(2) To i n s t a l l i n d i v i d u a l assemblies refer t o (Fig. 5).
INSTALLATION
BUCKET SEAT-RIGHT SIDE (FIG. 6) (1) I n s t a l l lock to riser.
The passenger seat is equipped w i t h a t i l t seat (2) I n s t a l l linkage to lock lever clip.
riser for access t o the rear seating area. T h i s is a gas (3) Adjust lock to eliminate vertical freeplay a t
prop operated mechanism w i t h a lock and release le- rear o f seat.
ver located o n t h e side and on the rear o f t h e seat.
LOCK CATCH
REMOVAL The lock catch is mounted t o t h e underbody w i t h
(1) To remove t h e seat assembly, remove t h e n u t s screws. To remove lock catch, remove screws and re-
m o u n t i n g the hinge section of the riser t o the under- . move catch.
body of vehicle. The lock catch can be adjusted w i t h slotted holes i n
(2) Disconnect gas prop on bottom of seat. m o u n t i n g area.
(3) Release the lock from the lock catch and remove .
the seat assembly from vehicle. LATCH LEVER
(4) The seat m a y be removed w i t h o u t t h e riser b y The l a t c h lever assembly has a knob, lever handle,
escutcheon, spring p i n and snap r i n g . F o r removal or
removing bolts from seat to riser spacer.
i n s t a l l a t i o n of assembly, refer t o (Fig. 6).
23 - 4 BODY •
BENCH SEAT MOUNTING (FIG. 7)
Bench seats are mounted t o t h e floor p a n w i t h fas-
teners accessible from underneath t h e vehicle. Refer
HINGE
to (Fig. 7) for m o u n t i n g locations.

PLATE
HINGE PIN
VIEW IN
VIEW IN DIRECTION OF ARROW D
DIRECTION OF ARROW C

SEAT CUSHION

FLOOR PAN
RY666A

Fig. 9—Folding Seat Cushion

NUT' PU836
HINGE
Fig. 7—Bench Seat Mounting AND LATCH
ARM REST SEAT BACK
FOLDING REAR SEAT (FIGS. 8, 9, AND 10)
The rear seat is mounted to t h e underbody w i t h
studs mounted t h r o u g h brackets on t h e seat. F o r re-
moval or assembly refer to (Fig. 10). Operation is ac-
complished b y releasing seat l a t c h a n d folding seat
over a n d upward. The seat is r e t a i n e d i n i t s folded
position b y relocating seat b e l t t i p h a l f out from be-
tween seat cushion and back. P u l l t i p h a l f over top of
seat and attach to buckle h a l f as shown i n F i g . 8.

BELT TIP HALF

NUT SUPPORT RY670

Fig. 10—Folding Seat Mounting

INSTALLATION
(1) Place console into position i n vehicle.
(2) Secure console w i t h m o u n t i n g screws.
(3) Close console door.

BELT BUCKLE HALF CONSOLE LOCK

RD156 REMOVAL
(1) Open console door.
Fig. 8—Folding Rear Seat Retention
(2) Remove m o u n t i n g screws on inner portion o f
CONSOLE (FIG. 11) door.
(1) Open console door. (3) Remove lock from door.
(2) Located i n the bottom of t he console, are screws
m o u n t i n g console to underbody, remove these screws. INSTALLATION
(3) Remove console from vehicle. (1) Place lock into position i n door.
 • BODY 23 - 5

(2) Secure w i t h m o u n t i n g screws. INSIDE PANEL VIEW IN ROOF INNER

(3) Close door a n d check for correct l a t c h i n g a n d BRACKET CIRCLE^ * P A N E L

k e y cylinder operation. SCREW

iSS-ga TRIM
SCREW ASH PANEL H^V"" PANEL
RECEIVER
BEZEL
DOOR SCREW
VIEW IN CIRCLE F
UNTRIAAMED JOBS LOWER
RIGHT SIDE ONLY TRIM
LOCK
ASH PANEL
VIEW IN DIRECTION RECEIVER FASTENER
I PANEL
OF ARROW A BEZEL

-SCREW FLOOR
VIEW IN SCREW PANEL
CIRCLE E TRIMMED <$>
JOBS RIGHT TRIM ;, LOWER
s C L , P

SIDE ONLY PANEL" TRIM PANEL

_ RETAINER
VIEW IN VIEW IN DIRECTION
<@)|l2 IN LBS. (1 N « m ) CIRCLE C QF ARROW D RB513

Fig. 12—Interior Trim AD4 and AD8

MOUNTING ROOF RAIL k REAR WINDOW

TRIM PANEL" UPPER*
: TRIM PANEL
UNDERBODY J9023-49

Fig. 11—Console
INTERIOR TRIM (FIGS. 12 AND 13)
The side t r i m r i g h t and left is mounted w i t h screws
to t h e side panel i n t e r i o r . T h e floor m a t or carpet QUARTER
overlaps the b o t t o m edge of the t r i m panel. Refer to WINDOW
TRIM
(Fig. 12) for r e m o v a l or i n s t a l l a t i o n of t h e side t r i m PANEL
panel.
W h e n r e m o v i n g a t r i m panel t h a t is overlapped b y
REAR WINDOW
a n adjoining panel, loosen or remove the end attach- LOWER TRIM
REAR WINDOW
i n g screw t o prevent possible damage to b o t h panels. LOWER TRIM PANEL HOOK PANEL JO023-58
To assure correct a l i g n m e n t when i n s t a l l i n g t h e
t r i m panels, i n s t a l l the screws finger t i g h t , a l i g n the Fig. 13—Interior Trim — Club Cab
panels a t each end and t i g h t e n the screws. Use care
not t o o v e r t i g h t e n the screws or the t r i m panels w i l l
be damaged.
23 - 6 BODY •

Fig. 3—Center Lap Belts

BELT ASSEMBLY

Fig. 1—Front Seat Uni-Belt

COVER SPACER SPACER TRIM

BUCKLE HALF
INNER
RBI358
Fig. 4—Seat Belt Mounting Folding Rear Seat
and inboard retractors mounted o n t h e seat frame
rear cross member. The center buckle t i p h a l f is
mounted to t h e latch mechanism. Torque t h e belt
bolts to 350 i n c h pounds (40 N»m ± 17 N«m).

SEAT BELTS AND RETRACTORS

Fig. 2—Front Seat Uni-Belts
UNi-BELTS—FRONT SEATS
The uni-belts are mounted to t h e p i l l a r as
shown i n (Figs. 1, 2, a n d 3). The buckle h a l f is lo-
cated on the inboard side of the seat, mounted to t h e
underbody. The ' B ' p i l l a r h a l f of the belt is secured
w i t h bolts torqued to 350 inch pounds ± 150 i n c h
pounds (40 N i r i ± 17 N»m).
SAFETY BELTS-REAR SEAT
The rear folding seat (Figs. 4 and 5) is available
w i t h t h e outboard buckles mounted to the underbody
For assembly and views refer t o (Figs. 1-5). T h e
center belt mountings are typical. Be sure when belts
or retractors are replaced t h a t the bolts are tightened
to 350 i n . lbs. ± 150 i n . lbs. (40 N - m ± 17 N*m) for
safety requirements.
SEAT BELT AND HARNESS OPERATION
A h a r d p u l l on the shoulder belt w i l l N O T lock t h e
belt. The retractor has a p e n d u l u m w e i g h t w h i c h
locks t h e shoulder belt d u r i n g r a p i d deceleration of
the vehicle.
Belts from different models are not interchangeable
and no attempt should be made to m i x belt lengths.
 • BODY 23 - 7

Safety belts should be w o r n whenever the vehicle HEADLINER

ROOF INNER CENTERING HOLES
is i n motion. The operation and m o u n t i n g of the belts
PANEL
should not be tampered w i t h a t any time. W h e n re-
m o v a l , installation, or repair is necessary, refer t o i l -
FASTENER
lustrations for proper system locations and m o u n t i n g
VIEW IN
hardware. I f the belts are removed for any reason, IRECTION
a n d the vehicle is t o be d r i v e n , t h e seat belt r e t a i n - ARROW C
i n g bolts should be reinstalled t o prevent exhaust
fumes from e n t e r i n g the vehicle. ROOF
INNER
PANEL
HEADLINER-ALL MODELS (FIGS 6, 7 AND 8)
REAR
The headliner is mounted t o t h e roof panel w i t h HEADLINER
RETAINER
screws. O n A D 4 a n d A D 8 models t h e headliner is
OULDING
t w o piece and is j o i n e d b y a p u s h o n moulding.
12 IN. LBS.
TRIM TRIM 0 N # m
> MOULDING
CARPET OR MAT ASSEMBLY- -FRONT AND REAR SCREW' PANEL PANEL CAP
(FIG. 9) SECTION D-D
SECTION A-A SECTION B-B RB425

REMOVAL Fig. 6—Headliner AD4 and AD8

(1) Remove seats, front and rear.
(2) Remove retainers and scuff plates.

JUMP SEAT

SEAT BELT
RETRACTOR SEAT BELT
BUCKLE

HEADLINER
-SCREW PU838A

Fig. 7—Headliner AD1, 2, 3, 5, 6 and 7

VISOR ROOF INNER
PANEL

J9023-53 INNER
VIEW IN CIRCLE Z BACK
PANEL
Fig. 5—Jump Seat Belts
(3) Remove front floor protective covers.
(4) Remove storage t r a y 4 (four screws).
(5) Remove m a t or carpet, front and rear from ve-
hicle.

INSTALLATION
(1) Place carpet or m a t i n t o position a n d secure VIEW IN DIRECTION
front and rear. OF ARROW Y PANEL
RAIL
(TYPICAL) PANEL J9023-56
(2) I n s t a l l retainers and scuff plates.
(3) I n s t a l l protective covers.
Fig. 8—Full Headliner
23 - 8 BODY •
SIDE WHEELHOUSE RETAINER RETAINER SCREW
CARPET OR MAT

RETAINER

CARPET OR MAT

VIEW IN CIRCLE A

REAR RETAINER SCREW

CARPET OR MAT

SCUFF
FRONT PLATE
CARPET OR MAT
SCUFF
PLATE
PROTECTIVE COVER CARPET
CARPET OR MAT OR MAT

VIEW IN CIRCLE C

UNDERBODY'
CARPET
VIEW IN CIRCLE D OR MAT RN917

Fig. 9—Carpet orMat Assembly—Typical

(4) I n s t a l l storage t r a y 4 (four screws). SCREW-
(5) I n s t a l l seat front and rear.

STORAGE TRAY (FIG. 10)

The storage t r a y is located behind the front seat o n
a l l pickups. The t r a y is secured to the floor p a n b y
four (4) screws.

INSTALLATION AND REMOVAL

(1) Position t r a y on floor p a n .
(2) Insert four (4) screws.
(3) F o r removal, reverse t h e above procedure.

FLOOR PAN RR23A51

Fig. 10—Storage Tray

• BODY 23 - 9

REAR JUMP SEAT-CLUB CAB (FIG. 11)

The back assembly is mounted t o t h e side window
opening area of t h e cab sheet m e t a l w i t h n u t a n d
washer w i t h o u t t r i m panel, w i t h t r i m panel the back
is mounted t o t h e panel assembly. Refer t o (Fig. 11)
for assembly of back. The folding j u m p seat is
mounted t o the t r i m m e d underbody o f the cab. Place
the seat assembly support studs t h r o u g h holes i n
floor pan a n d secure w i t h n u t and washers. The floor
covering is embossed o n t h e backside for location of
holes for j u m p seat i n s t a l l a t i o n .

VIEW IN DIRECTION OF BACK

ARROW B ASSEMBLY J9023-55

Fig. 11—Rear Jump Seat—Club Cab

23 - 10 BODY •
S H E E T METAL

INDEX
Page Page
Battery Tray 14 Hood Release (Inside) 11
Bolt Torque . 19 Latch Lock Assembly 15
Bumpers 10 Liftgate 15
Grille , 12 Liftgate Hardware 15
Hinge—Liftgate ..... 15 Model Identification 10
Hold Down Mountings 15 Radiator Core Support, Fender and Splash Shield . 13
Hood 11 Tailgate . 18

MODEL IDENTIFICATION
A D = Ramcharger Two-Wheel-Drive
A W = Ramcharger Four-Wheel-Drive
D = L i g h t D u t y T r u c k Two-Wheel-Drive
W = L i g h t D u t y T r u c k Four-Wheel-Drive
FRONT
BUMPER FRAME
BUMPERS IMPACT
CHANNEL

FRONT (FIG. 1)

REMOVAL
(1) Remove bumper guard ( i f so equipped).
(2) Remove bumper t o bracket fasteners a n d l i f t
bumper off o f m o u n t i n g brackets.
(3) Reverse above procedure for i n s t a l l a t i o n .

FRONT BUMPERS
BUMPER
Place t h e brackets t o t h e bumper, assemble w i t h VIEW IN DIRECTION GUARD
bolts, p l a i n washer, lock washer a n d nuts. L i n e u p OF ARROW Z J9023-51
the bumper brackets w i t h the holes i n the frame and
secure w i t h bolts, nuts, and washer. W h e n the as- Fig. 1—Front Bumper, All
sembly is mounted t o t h e vehicle, check t h e a l i g n -
SIDE
ment t o body sheet m e t a l . F o r assembly procedures RAIL
refer to (Fig. 1).

REAR
BRACKETS
REMOVAL (FIG. 2}
(1) Remove bumper guards ( i f so equipped).
(2) Remove bumper t o bracket fasteners a n d l i f t
bumper off o f m o u n t i n g brackets.
(3) Reverse above procedure for installation.

REAR BUMPERS-STEP AND NON-STEP

The rear bumper is mounted t o brackets i n t h e
same manner as t h e front bumpers. The assembly is
then mounted to t h e chassis w i t h bolts a n d nuts. ^ ^ 8923-57
Check t o see t h a t there is proper a l i g n m e n t w i t h
body sheet metal. See (Fig. 3) for installation. Fig. 2—Rear Bumper, Standard
 • BODY 23 - 11

FRAME BOLT

CABLE

SHIELD

STEP RADIATOR
BUMPER 8923-58 GRILL SUPPORT
RB1346

Fig. 3—Step Bumper, All

Fig. 4—Latch and Cable Mounting
HOOD RELEASE (INSIDE) (Figs. 4 and 5)

REMOVAL
(1) Open hood.
(2) Disconnect hood l a t c h release cable f r o m latch
assembly.
(3) Release cable assembly f r o m r o u t i n g clip along
body sheet m e t a l .
(4) Remove grommet f r o m dash.
(5) F r o m inside t h e vehicle remove m o u n t i n g
screws securing release handle t o lower section of i n -
strument panel.
(6) Route t h e hood release cable assembly o u t of
the dash and remove f r o m vehicle.

INSTALLATION
(1) F r o m inside, route t h e hood release cable as-
sembly t h r o u g h the dash.
(2) M o u n t the release handle t o the lower section o f
the i n s t r u m e n t panel. RADIATOR CORE
(3) I n s t a l l grommet t o dash panel. SUPPORT PU798
(4) Secure t h e cable t o t h e rear r o u t i n g clip along
the body sheet metal. Fig. 5—Cable Routing
(5) Route t h e cable over t h e support flange and HOOD ALIGNMENT (FORE AND AFT)
connect the cable to the l a t c h assembly.
The following sequence o f hood alignment, lock and
(6) Adjust t h e cable t o shroud clip t o insure slack
s t r i k e r adjustment m u s t be followed. A n imporperly
between the clip and the latch.
adjusted lock or s t r i k e r could cause the hood to open
(7) Test hood latch release for proper function.
to the safety catch.
(1) Loosen b o t h hinge m o u n t i n g bolts a t hood
HOOD
mounting.
(2) Loosen hood latch f r o m g r i l l e support.
ADJUSTMENTS (FIGS. 6 AND 7) (3) Close hood a n d adjust so approximately 3/16
THe hinge screw holes are oversized a n d elongated inch clearance is obtained between back of hood and
to p e r m i t u p a n d down adjustment a n d "fore" a n d cowl.
" a f t " adjustment a t the hood.
(4) Raise hood to approximately 30 degrees and
The hinge m o u n t i n g a t t h e fender panel provides
t i g h t e n hinge t o hood m o u n t i n g bolts.
up and down adjustment (Fig. 7).
23.-12 BODY

(3) I f new hood is t o be i n s t a l l e d , remove a l l ser-

viceable components f r o m old hood.
(4) Inspect hood hinges for proper operation a n d
wipe clean w i t h a suitable solvent.
(5) L u b r i c a t e hood hinges w i t h a suitable l u b r i c a n t .

INSTALLATION
(1) I n s t a l l a l l serviceable components f r o m o l d hood
and any new parts as necessary.
(2) W i t h a n assistant position hood on vehicle and
a l i g n holes t o hinge, i n s t a l l bolts snugly b u t do n o t
tighten.
(3) To a l i g n hood, latch, and s t r i k e r , see steps (1)
t h r u (7) under Hood A l i g n m e n t .

HINGE REPLACEMENT
(1) Raise hood t o f u l l open position and loosen hood
hinge bolts.
(2) Support the hood on t h e side the hinge i s being
removed. Remove t h e hinge.
Fig. 6—Hood Adjusting Points (3) Position n e w hinge against fender shield a n d
i n s t a l l bolts and t i g h t e n snugly.
(4) A l i g n hood t o hinge, i n s t a l l bolts snugly, do not
tighten.
(5) To a l i g n hood, latch, and s t r i k e r , see steps (1)
t h r u (7) under Hood A l i g n m e n t .

LATCH AND STRIKER

REMOVAL
(1) Raise hood a n d remove hood latch a t t a c h i n g
bolts.
(2) Remove hood l a t c h assembly.
(3) Loosen and remove a t t a c h i n g bolts o f s t r i k e r as-
sembly and remove s t r i k e r from g r i l l e support.

INSTALLATION
W h e n i n s t a l l i n g a n e w l a t c h , m a k e s u r e assem-
bly is w e l l lubricated.
(1) Position l a t c h assembly a n d i n s t a l l bolts. The
m o u n t i n g holes are elongated t o allow l a t e r a l a n d
Fig.7—Hinge Adjusting Points v e r t i c a l adjustment.
(2) Position s t r i k e r assembly and i n s t a l l bolts, b u t
(5) T i g h t e n l a t c h , and lower the hood and check v i -
do not t i g h t e n .
sually for proper front fender pad pressure.
(6) Open the hood. U s i n g a substance such as clay ADJUSTMENT
or other suitable m a t e r i a l capable o f receiving a n i m - To adjust hood l a t c h a n d s t r i k e r see steps 1
pression, coat t o p side o f p r i m a r y l a t c h s t r i k e r a r m . t h r o u g h 7 under Hood A l i g n m e n t .
Close hood t o o b t a i n a f u l l latch position.
(7) Disengage hood l a t c h and check l a t c h i m p r i n t GRILLE (Figs. 8 and 9)
i n subtance used. A properly adjusted l a t c h w i l l show
a centered position on striker. I f i m p r i n t is not
REMOVAL
proper, readjust hood latch.
(1) Remove g r i l l e upper a t t a c h i n g screws.
(2) Remove lower g r i l l e a t t a c h i n g screws.
REMOVAL
(3) Remove a t t a c h i n g screws located a t each end of
(1) Raise hood to f u l l open position.
grille.
(2) W i t h a n assistant remove t h e bolts and remove
(4) Remove lower g r i l l e a t t a c h i n g screws ( g r i l l e to
the hood from vehicle.
extension).
• BODY 23 - 13

(5) Remove a t t a c h i n g screws a t each end o f g r i l l e (3) Remove headlamp bezels.

extension. (4) Remove upper and lower g r i l l e panels.
(5) Remove headlamps.
INSTALLATION (6) Disconnect b a t t e r y t r a y f r o m radiator core sup-
(1) Place g r i l l e extension i n opening a n d i n s t a l l port panel.
sheet metal screws loosely. (7) Remove horns.
(2) Center g r i l l e extension and t i g h t e n screws. (8) Remove screws a t t a c h i n g splashshield t o sup-
(3) Place g r i l l e i n opening and center, and i n s t a l l port.
screws. (9) Remove f r o n t end sheet m e t a l mount system,
i n c l u d i n g studs.
(10) Remove screws f r o m r i g h t fender t o r i g h t
splashshield so t h a t r i g h t fender panel can swing
out, p i v o t i n g a t t h e cowl, a l l o w i n g disengagement
from radiator core support panel.

CAUTION: Care must be taken to avoid damage to

fender or cowl panel.

(11) Remove r a d i a t o r core support panel.

INSTALLATION
(1) I n s t a l l " U " n u t s o n lower flange of radiator core
support panel and i n s t a l l panel.
(2) I n s t a l l screws a t t a c h i n g splashshield t o support.
(3) I n s t a l l f r o n t end sheet m e t a l m o u n t system.
(4) Engage r i g h t fender and secure to wheelhouse
and radiator core support panel. T i g h t e n screws.
(5) I n s t a l l horns.
(6) I n s t a l l and r e f i l l radiator.
(7) A t t a c h b a t t e r y t r a y t o radiator core support
panel.
(8) I n s t a l l and a i m headlamps.
(9) I n s t a l l lower and upper g r i l l e panels.
(10) I n s t a l l headlamp bezels.
(11) I n s t a l l and connect battery.

Fig. 9—Grille Extension

RADIATOR CORE SUPPORT, FENDER, AND
SPLASH SHIELD
The radiator core support and fender assembly at-
t a c h w i t h " U " nuts, screws a n d nuts. The splash
shield mounts on t h e inner side of sheet m e t a l w i t h
screws.

RADIATOR CORE SUPPORT (FIG. 10)

REMOVAL Fig. 10—Radiator Core Support, Fender and Splash

(1) Raise hood and remove battery. Shield
(2) D r a i n and remove radiator (save coolant).
23 - 14 BODY •
COWL GRILLE (FIG. 11)
WASHER
REMOVAL STRAP
(1) Remove wiper arms.
(2) Raise hood.
(3) Remove m o u n t i n g screws.
(4) Disengage rear o f g r i l l e from w i n d s h i e l d weath-
erstrip and remove g r i l l e .
(5) Reverse above procedure for i n s t a l l a t i o n .
SCREW

SCREW PU803

Fig. 12—Battery Tray

DASH PANEL
PU802
and g r i l l e . F o r m o u n t i n g o f sheet m e t a l front end to
cowl and cowl g r i l l e refer to (Fig. 13).
Fig. 11—Cowl Grille Be sure to note t h a t t h e fender end is mounted i n
two different manners to t h e sheet metal. One w a y
BATTERY TRAY (Fig. 12) shown is w i t h t h e use of two studs and t h e other is
using a stud on t h e lower m o u n t i n g and a 5/16-18 x
REMOVAL FRONT END SCREW GRILLE
(1) Disconnect battery cables. SHEET METAL
(2) Remove battery h o l d downs a n d remove battery
from tray.
(3) Remove " C " n u t and screw f r o m lower brace to
tray attachment.
(4) Remove brace f r o m fender housing support.
(5) Remove t r a y from front end sheet metal.

INSTALLATION
(1) Place " U " nuts o n t r a y assembly a n d a l i g n to
holes.
(2) Place t r a y into f r o n t end sheet m e t a l .
(3) A t t a c h w i t h screws, washers a n d nuts.
(4) Position brace to fender housing support and se-
cure w i t h " C " n u t , screw and washer.
(5) Position lower end o f brace t o b a t t e r y t r a y .
(6) Secure w i t h " C " n u t , screw, and washer.
(7) I n s t a l l battery and battery h o l d downs.
(8) Connect battery cables to b a t t e r y posts.
ROWER COWL
FRONT END MOUNTING (FIG. 13) VIEW IN DIRECTION
The front end sheet metal attaches to t h e body OF ARROW A RN924
w i t h spacers between t h e rear of fender and cowl, to
achieve sheet metal alignment a t t h e cowl p l e n u m Fig. 13—Front Fender to Body and Cowl
 • BODY 23 - 1i

TRIM PANEL RB514

Fig. 14—Liftgate Trim Panel

1-1/4 screw a n d washer i n t h e top m o u n t i n g w i t h
spacers used under either method. Be sure d u r i n g re-
moval t h a t t h e same amount o f spacers removed are
replaced d u r i n g i n s t a l l a t i o n .
Fig. 15—Liftgate Ajar Connection
HINGE—LIFTGATE (Fig. 17)
LIFTGATE HARDWARE (Figs. 14 thru 17)
REMOVAL
LIFT ROD (1) Support liftgate w h e n r e m o v i n g a hinge.
(2) Remove hinge t o liftgate bolts.
REMOVAL (3) Remove hinge t o roof bolts.
(1) Remove upper l i f t rod stud from roof panel. (4) Remove hinge assembly.
(2) Remove lower l i f t rod stud from liftgate.
(3) Remove l i f t rod from liftgate. INSTALLATION
(4) Support liftgate w h e n r e m o v i n g l i f t rod. (1) I n s t a l l hinge t o roof.
(2) I n s t a l l hinge t o liftgate.
INSTALLATION (3) Adjust hinge for proper alignment.
(1) I n s t a l l upper l i f t rod stud t o roof panel.
(2) I n s t a l l lower stud to liftgate. LIFTGATE (Fig. 17)
(3) Check l i f t rod and liftgate for proper function.

LATCH LOCK ASSEMBLY (Fig. 16) REMOVAL

(1) Open liftgate.
(2) Remove m o u n t i n g bolts f r o m hinges to liftgate.
REMOVAL (3) Remove liftgate l i f t rod studs from roof section.
(1) Open liftgate. (4) Remove liftgate and l i f t rods from vehicle.
(2) Remove liftgate t r i m panel (Fig. 14).
(3) Remove l a t c h lock cover (Fig. 16). INSTALLATION
(4) Disengage r i g h t and left l a t c h tubes (Fig. 16). (1) Place liftgate and l i f t rods i n t o position o n ve-
(5) Disconnect liftgate ajar w i r i n g (Fig. 15). hicle.
(6) Remove l a t c h lock assembly. (2) I n s t a l l l i f t rod studs i n t o roof section.
(3) I n s t a l l liftgate t o hinges.
INSTALLATION (4) Check for alignment and proper operation.
(1) I n s t a l l l a t c h lock assembly.
(2) Engage r i g h t and left l a t c h tubes t o l a t c h lock. HOLD DOWN MOUNTINGS
(3) Check ajar s w i t c h w i r i n g for i n s t a l l a t i o n .
(4) I n s t a l l l a t c h lock cover. For specific body m o u n t i n g refer to (Fig. 18) to
(5) I n s t a l l liftgate t r i m panel. identify correct hardware. Be sure to torque hold
(6) Check lock and latch for proper operation. down fasteners.
23 - 16 BODY •

Fig. 16—Liftgate Latch and Striker

Fig. 17—Liftgate Installation

Fig. 18—Body Hold-Down Mounting ^
23-18 BODY •

SHEET METAL
TAILGATE VIEW I N
CHECK ARM CIRCLE E

VIEW I N DIRECTION
OF ARROW B RN921

Fig. 19— Tailgate to Body

TAILGATE (Fig. 19)
REMOVAL
(1) Open tailgate.
(2) A n g l e gate so slot i n check a r m lines up w i t h
body hinge.
(3) Slip check a r m away from hinge.
(4) Remove bottom of gate from slot i n lower hinge
on r i g h t side, facing gate.
(5) Remove left side o f gate by s l i d i n g out of lower
hinge.
INSTALLATION
(1) Slide gate i n t o left lower hinge.
(2) Place r i g h t side into slotted hinge.
(3) I n s t a l l check arms t o gate, n o t i n g m a r k i n g t o
correct position o f a r m and body.
(4) B r i n g gate up t i l l top o f check a r m slotted sec-
t i o n slips onto hinge.
TAILGATE, LOCK, AND LINKAGE (FIG. 20)
REMOVAL
(1) Remove screws m o u n t i n g lock to i n n e r tailgate
sheet m e t a l .
(2) Lower handle and lock assembly out o f opening
i n f r o n t t a i l g a t e sheet metal.
(3) Disconnect clip from lock to linkage.
(4) Remove s t r i k e r plates on left and r i g h t ends o f
tailgate.
(5) Remove linkage t h r o u g h ends of gate.

Fig. 20—Tailgate Linkage

 • BODY 23 - 19

INSTALLATION (3) Remove screws and washer assemblies f r o m bar

Lubricate locks before i n s t a l l a t i o n . to side panels.
(1) Insert lock i n t o opening o f t a i l g a t e . (4) Remove screws a n d washer assemblies f r o m
(2) Guide l i n k a g e i n t o ends o f t a i l g a t e . struts t o wheel housing.
(3) Secure s t r i k e r plates to end o f gate. (5) Remove u n i t s from vehicle.
( 4 ) Insert l i n k a g e i n t o lock assembly a n d i n s t a l l INSTALLATION
clips. (1) Install b a r assembly loosely tofloorp a n .
(5) Secure lock t o t a i l g a t e w i t h screws. (2) Install bar assembly loosely to side panels.
(6) Check locks for proper function, adjust fore and (3) Install struts to bar w i t h bolts.
aft t o e l i m i n a t e gate rattles. (4) Install struts t o wheel housing.
(5) Secure a l l loose bolts and screws.
SPORT BAR ASSEMBLY (FIG. 21)
SAE CLASSIFICATION
ROLL BAR
GRADE 5 GRADE 8

MARKINGS FOUND
ON TOP OF BOLT
HEAD INDICATE
GRADE

120° 60°
RN885

Fig. 22—Bolt Head Identification

BOLT TORQUE
GRADE 5 GRADE 8
Size Ft. Lbs. N«m Ft. Lbs. N-m
1/4-20 95 In. Lbs. 11 125 In. Lbs. 14
1/4-28 95 In. Lbs. 11 150 In. Lbs. 17
5/16-18 200 In. Lbs. 23 270 In. Lbs. 31

5/16-24 20 27 25 34
3/8-16 30 41 40 54
RN919 3/8-24 35 48 45 61
7/16-14 50 68 65 88
Fig. 21—Sport Bar Assembly 7/16-20 55 75 70 95
1/2-13 75 102 100 136
REMOVAL
1/2-20 85 115 110 149
(1) Remove bolts f r o m bar struts, located on bar as-
9/16-12 105 142 135 183
sembly. 9/16-18 115 156 150 203
(2) Remove screws and washer assemblies f r o m bar 5/8-11 150 203 195 264
to floor p a n . 5/8-18 160 217 210 285
3/4-16 175 237 225 305
23 - 20 BODY •

DOOR SYSTEMS

CONTENTS

Page Page

GLASS SYSTEMS 24 LATCH AND LOCK SYSTEM ...20

LATCH A N DLOCK SYSTEMS

INDEX
Page Page

Blind Rivets 20 General Information 20

Door Adjustment 20 Hinge Replacement . . . . . . . . . . . . . . . . . . . . . . . 20
Door Weatherstrip 23 Latch Assembly 21
Electric Door Lock Motor 23 Linkage Adjustment 21
Front Door Trim Panel 20 Lock Cylinder 22

GENERAL INFORMATION (5) Reverse above procedure for i n s t a l l a t i o n .

Figure 1 i s meant t o serve as a n index or compo-

nent guide. They are m e a n t to show component name
and location. Service procedures on i n d i v i d u a l compo-
nents can be found i n t h i s section also. Use (Fig. 1)
as a tool t o identify the p a r t and its location on or i n
the door assembly.
Care s h o u l d be exercised t o keep a l l under-
coating o r rustproofing materials away f r o m
d o o r c o m p o n e n t s . A s i g n i f i c a n t cause o f d o o r
system m a l f u n c t i o n i s c o n t a m i n a t i o n b y r u s t
prevention materials.
BUND RIVETS
The 1/4 i n c h b l i n d r i v e t s used to secure various
door components should be removed as follows: drive
out the center o f the r i v e t w i t h a d r i f t punch t h e n
d r i l l out t h e r i v e t w i t h a 1/4 inch d r i l l b i t . Compo-
nents should be reinstalled using a 1/4-20 x 1/2 screw
(6030163) a n d n u t (118613) or t h e i r equivalents
torqued to 90 i n . lbs.
HINGE REPLACEMENT
(1) Support door w i t h a padded floor jack.
(2) M a r k o u t l i n e of hinge on door and body to aid
i n assembly.
(3) Remove hinge to body screws.
(4) Remove hinge to door screws and remove hinge.
DOOR ADJUSTMENT
Door adjustments should be made by loosening one
hinge a t a t i m e and moving door into position. Sup-
port door w i t h a padded floor jack.
FORE A N D A F T adjustments are made by loosen-
i n g bolts, a t t a c h i n g hinge to body pillars, and mov-
i n g door t o desired position.
U P A N D D O W N adjustments are made b y loosen-
i n g bolts, a t t a c h i n g hinge to door p i l l a r , and m o v i n g
door to desired position. U p and down adjustments
require loosening of both upper and lower hinges.
I N A N D O U T adjustments are made by loosening
the bolts, a t t a c h i n g hinge to door, and m o v i n g door
to desired position.
FRONT DOOR TRIM PANEL (FIG. 2)
REMOVAL
(1) Remove remote control handle and spacer.
(2) Remove window regulator handle and spacer.
(3) Remove screws attaching lower t r i m panel to
door.
(4) Remove screw a t armrest.
(5) U s i n g a t r i m stick or other suitable flat tool,
gently p r y t r i m panel away f r o m door.
(6) Reverse above procedure for i n s t a l l a t i o n .
 BODY 23 - 21

LINKAGE
CLIP
PIVOT

OUTSIDE
HANDLE

Fig. f—Front Door Lock and Latch System

OUTSIDE HANDLE
REMOVAL
(1) Raise glass to f u l l u p position.
(2) Remove door t r i m panel o r access panel.
(3) Disconnect handle l i n k from latch assembly.
(4) Remove fasteners securing handle t o door and
remove handle and l i n k .
(5) Reverse above procedure for installation.
LATCH ASSEMBLY (FIG. 3)
REMOVAL
(1) Raise glass to f u l l u p position.
(2) Remove door t r i m panel or access panel.
(3) Disconnect a l l l i n k attachments a t latch.
(4) Remove l a t c h a t t a c h i n g screws a n d l i f t latch
out t h r o u g h access holes.
(5) Reverse above procedure for i n s t a l l a t i o n .

LINKAGE ADJUSTMENT
U-NUT TAPE
(1) Locate t h e .312 (8mm) diameter access hole i n
TRIM the door face a t the l a t c h area.
PANEL (2) Loosen door latch adjusting screw t h r o u g h t h e
TAPE access hole.
(3) Push u p o n t h e latch lever t h r o u g h t h e access
hole t o remove a l l slack from t h e linkage.
(4) T i g h t e n adjusting screw w h i l e h o l d i n g latch le-
ver i n position.

PLUG J9023-59

Fig. 2—Door Trim Panel

23 - 22 BODY •
LOCKING KNOB LOCK CYLINDER (4) Remove lock cylinder retainer and remove lock
cylinder a n d l i n k f r o m door.
(5) Reverse above procedure for i n s t a l l a t i o n .

LOCK CYLINDER PROCEDURES

The f o l l o w i n g procedures w i l l allow t h e repair or
replacement o f lock cylinders w h i l e r e t a i n i n g t h e
o r i g i n a l key. I t is no longer necessary to replace a n
entire set o f lock cylinders w h e n only one is defec-
tive.
K i t s are available t h r o u g h M O P A R for repair o f
cylinders or a n equivalent k i t m a y be used. A l l nec-
essary components are supplied i n the k i t for repairs,
along w i t h a key code book and instructions.

ESTABLISHING LOCK CYLINDER CODE

(FIG. S)

Fig. 3—Link Attachment to Latch

LOCK CYLINDER

Fig. 5—Door Lock Cylinder Components

When the key or code number is not available the
following procedure should be used to establish t h e
code number.
( 1 ) Remove door lock cylinder from vehicle.
(2) Remove cover from cylinder and discard.
(3) Remove each spring, driver and tumbler, one at
a time.
(4) Measure a n d record t h e code using t h e code
DOOR PANEL PU512 plate.
(5) Reassemble t h e same t u m b l e r , driver a n d
Fig. 4—Lock Cylinder spring i f not damaged.
LOCK CYLINDER (Fig. 4) (6) Continue the coding procedures t h r o u g h a l l sets
of springs, drivers and tumblers.
(7) Assemble a new cover.
REMOVAL
(1) Raise glass to f u l l up position. DOOR LOCK CYLINDER REPAIR (FIG. 5)
(2) Remove door t r i m panel. ( 1 ) Remove lock cylinder from door.
(3) Remove lock cylinder l i n k from latch.
• BODY 23 - 23

(2) The removed production lock cylinder, covers,
drivers, springs, and t u m b l e r s should be scrapped. I f
t h e new springs get tangled, do not p u l l t h e m a p a r t
. . . unscrew t h e m from each other so -they a r e n o t
stretched and distorted.
(3) Establish the k e y code.
(4) Assemble new drivers a n d t u m b l e r s , springs,
and cover.
The lever a n d E - r i n g m a y be reused i f not dam-
aged.
(5) Test assembled door lock cylinder for f u n c t i o n
and r e i n s t a l l into door.
ELECTRIC DOOR LOCK MOTOR
REMOVAL
(1) Raise glass t o f u l l u p position.
(2) Remove door t r i m panel or access panel.
(3) Disconnect motor from w i r i n g harness.
(4) Disconnect motor l i n k f r o m motor.
(5) Remove motor m o u n t i n g screws and l i f t motor
out t h r o u g h access hole.
(6) Reverse procedure for i n s t a l l a t i o n .
(3) Remove t r i m panel, and watershield.
(4) W o r k i n g t h r o u g h access hole remove linkage
and m o u n t i n g plate t o remote control.
(5) Remove remote control.
INSTALLATION
(1) Slide remote control m o u n t i n g plate t h r o u g h ac-
cess hole and i n t o door.
(2) Connect l i n k a g e a n d i n s t a l l screws t o remote
control assembly.
(3) I n s t a l l remote control handle a n d adjust for-
w a r d t o eliminate excess handle t r a v e l .
(4) I n s t a l l t r i m panel, remote and regulator handle.
DOOR WEATHERSTRIP (FIG. 7)
The weatherstrip i s i n s t a l l e d b y p u s h i n g i t over the
fence, m a k i n g sure t h a t contact is made w i t h t h e
fence around corners and c l i n c h i n g i t t i g h t l y around
entire perimeter to avoid w a t e r leaks, puckering and
stretching. T r i m ends to overlap 6.3mm (.25).
BUTYL DOOR

Fig. 7—Door Weatherstrip and Attachments

Fig. 6—Remote Control Assembly

REMOTE CONTROL (FIG. 6)

REMOVAL
(1) Remove regulator handle shown i n (Fig. 6).
(2) Remove remote control handle.
23 - 24 BODY •
GLASS SYSTEMS

INDEX

Page Page
Blind Rivets 24 Side Glass Replacement 25
General Information 24 Vent Wing And Glass Run Assembly . 25
Glass And Weatherstrip 25 Vent Wing Glass 25
Manual Window Regulator . . . . . . . . . . . . . . . . . . 26

GENERAL INFORMATION BLIND RIVETS

F i g u r e 1 is meant t o serve as a n index or compo-
n e n t guide. I t is meant t o show component name a n d
location. Service procedures o n i n d i v i d u a l compo-
nents can be found i n t h i s section also. Use (Fig. 1)
as a tool to identify t h e p a r t a n d i t s location on or i n
the door assembly.
Care should b e exercised t o keep a l l under-
coating o r rustproofing materials away from
d o o r c o m p o n e n t s . A s i g n i f i c a n t cause o f d o o r
system malfunctions is c o n t a m i n a t i o n b y r u s t
prevention materials.
The 1/4 i n c h b l i n d rivets used t o secure various
door components should be removed as follows: drive
out the center o f t h e r i v e t w i t h a d r i f t punch t h e n
d r i l l out t h e r i v e t w i t h a 1/4 i n c h d r i l l b i t . Compo-
nents should be reinstalled using a 1/4-20 x 1/2 screw
(6030163) a n d n u t (118613) or t h e i r equivalent
torqued t o 90 i n . lbs. (10 N*m).

PIVOT

Fig. 1—Door Glass System

 • BODY 23 - 25

PLASTIC SNAP-IN (5) I n s t a l l belt weatherstrip b y a l i g n i n g clips to

holes i n door and press i n .
(6) Raise or lower vent t o m a i n t a i n a .06 (1.6mm)
fore-aft glass freeplay t h e n w i t h glass up, t i g h t e n up-
per screws.
(7) H o l d vent against glass (glass down) a n d
t i g h t e n lower screws.

VENT WING GLASS

REMOVAL
(1) Remove t r i m panel.
(2) Remove screw from lower glass pivot.
(3) Remove upper glass p i v o t r i v e t a n d remove
glass.
(4) Transfer l a t c h handle t o replacement glass.

INSTALLATION
(1) Lubricate lower glass p i v o t w i t h Spray W h i t e
Lube or equivalent.
(2) I n s t a l l lower glass pivot i n t o frame and i n s t a l l
screw.
(3) I n s t a l l upper glass p i v o t r i v e t .
(4) I n s t a l l t r i m panel.
ASSEMBLY VIEW IN DIRECTION
OF ARROW A RN941 SIDE GLASS REPLACEMENT

Fig. 2 — Vent Wing and Glass Run REMOVAL

VENT WING AND GLASS RUN ASSEMBLY (FIG. 2) (1) Remove rear stationary glass.
(2) Remove inner and outer weatherstrips.
(3) Remove regulator a r m f r o m lower channel.
REMOVAL (4) Remove glass from door.
(1) Lower glass and remove inner weatherstrip. (5) Remove lower channel f r o m glass.
(2) W h e n removing i n n e r belt w e a t h e r s t r i p use
care not to scratch the beltline paint. INSTALLATION
(3) Free t h e clip on the inner section o f the w e a t h - Before i n s t a l l i n g glass, lubricate a l l moving parts
erstrip w i t h a w i r e hook or suitable tool. of regulator w i t h Spray W h i t e Lube or equivalent.
(4) P u l l back upper glass r u n 8 to 10 inches (20-25 (1) I n s t a l l lower channel o n glass.
Cm). (2) Position glass into door opening.
(5) Remove upper and lower vent w i n g a t t a c h i n g (3) I n s t a l l regulator a r m roller i n t o channel o f
screws. glass l i f t bracket.
(6) Remove vent w i n g , t a k i n g care to avoid p a i n t (4) Position glass into r u n channels a n d adjust
damage f r o m glass lower pivot adjusting screws. glass.
(5) I n s t a l l rear stationary glass.
INSTALLATION (6) I n s t a l l inner and outer weatherstrips.
(1) I n s t a l l plastic n u t and " I F n u t on vent w i n g as-
sembly. GLASS AND WEATHERSTRIP (FIG. 3)
(2) I n s t a l l vent w i n g assembly i n t o door t a k i n g
care not to damage p a i n t w i t h lower pivot adjusting To assemble window glass t o door (Fig. 3) insert
screw. glass t o everseal. Place channel assembly onto ever-
(3) I n s t a l l upper and lower vent w i n g attachment seal. Press seal onto channel securely and lubricate
screws. channel. Lower regulator t o down position. Place
(4) Move glass r u n back to vent w i n g b y p l a c i n g glass and channel assembly i n t o slot opening i n door
r u n adjacent to door channel and press i n t o channel and lower i t to the bottom of door. Reach t h r o u g h the
u s i n g wide bladed screwdriver or s i m i l a r tool. Press access hole i n door a n d i n s t a l l regulator to lower
i n b o t h inside corners to insure hidden l i p engages i n channel o n glass, and to upper channel. I n s t a l l vent
channel. w i n g . Test glass for proper movement. Adjust vent
23 - 26 BODY •
INNER PANEL

Fig. 3—Glass and Weatherstrip Fig. 4—Window Regulator

up to e l i m i n a t e fore and aft freeplay. T h e n i n s t a l l (6) D r i l l out regulator m o u n t i n g rivets and remove
the weatherstrip assembly front and rear to door. regulator t h r o u g h access hole.

MANUAL WINDOW REGULATOR (FIG. 4) INSTALLATION

(1) Insert upper regulator a r m i n t o door mounted
channel.
REMOVAL (2) M o u n t regulator to door panel w i t h 1/4-20
(1) Lower window to f u l l down position. screws and nuts torqued to 90 i n . lbs. (10 N*m).
(2) Remove t r i m panel and watershield. (3) Slide glass onto regulator arms and i n t o rear
(3) On stereo equipped vehicles remove lower t r i m glass r u n .
panel and remove speaker. (4) I n s t a l l and adjust vent w i n g .
(4) Remove vent w i n g . (5) Raise glass to f u l l up position.
(5) Slide glass forward off of regulator arms and (6) I n s t a l l stereo speaker ( i f so equipped).
lower glass to door bottom. (7) I n s t a l l t r i m panel and watershield.
 BODY 23 - 27

FIXED GLASS

INDEX
Page Page
Liftgate Glass and Weatherstrip 29 Roof Vent 31
Quarter Panel Glass (Fixed) 30 Sliding Glass Section 28
Rear Window 28 Vented Side Window - Club Cab . 32
Rear Window (Sliding Glass Type) 28 Windshield 27

WINDSHIELD (FIG. 1) (5) Remove glass from opening.

REMOVAL (FIG. 2)
(1) Cover cowl panel t o protect paint finish.
(2) Remove w i p e r arms and blades. Refer to Wiper
Section i n t h i s service m a n u a l .
(3) Remove t h e retainer cap. P r y out one end o f re-
t a i n e r a n d carefully p u l l retainer f r o m around
weatherstrip.
(4) W i t h a n assistant supporting the w i n d s h i e l d on
t h e outside, f r o m inside cab, push one corner o f glass
out o f weatherstrip. Progressively force e n t i r e glass
out o f weatherstrip.
(6) The weatherstrip w i l l r e m a i n i n place on w i n d -
shield opening i f so desired.
INSTALLATION (FIG. 3)
M i n e r a l spirits o n l y should be used as a l u b r i c a n t
to a i d i n s t a l l a t i o n .
(1) I n s t a l l weatherstrip ( i f removed) on w i n d s h i e l d
opening fence carefully, m a k i n g sure weatherstrip is
properly seated.
(2) W i t h a n assistant's aid, slide one corner of glass
into lower glass groove of weatherstrip.

RN898

Fig. 1 — Windshield Assembly

23 - 28 BODY •

PU866

Fig. 4—Rear Window Removal

PU867

Fig. 3—Windshield Installation Fig. 5—Rear Window Installation

(3) Move glass into groove as far as possible a n d
u s i n g a fiber wedge force l i p o f weatherstrip over
glass around i t s entire circumference.
(4) Start a t one of lower corners of windshield and
i n s e r t retainer i n groove. Care should be t a k e n not to
overstretch l o c k i n g s t r i p when i n s t a l l i n g i n weather-
s t r i p . I n s t a l l locking s t r i p cap.
(5) Water test windshield area and inspect for
leaks.
(6) I n s t a l l windshield wiper arms and blades.
REAR WINDOW
REPLACEMENT (FIGS. 4, 5, 6)
REMOVAL
(1) P r y out one end o f m y l a r retainer i f applicable
and carefully p u l l retainer from around weatherstrip.
(2) F r o m inside t h e cab, push one corner o f glass
out o f weatherstrip. Progressively force entire glass
f r o m weatherstrip.
INSTALLATION
(1) Assemble weatherstrip to glass.
(2) Insert m y l a r l o c k i n g s t r i p to weatherstrip ( i f ap-
plicable).
(3) I n s t a l l cord i n weatherstrip retainer.
(4) Place the assembly t o t h e glass opening.
(5) I n s t a l l the assembly u s i n g the i n s t a l l a t i o n cord.
REAR WINDOW (SLIDING GLASS TYPE FIG. 6)
The procedure for service o n the s l i d i n g glass w i n -
dow assembly is s i m i l a r t o t h e w i n d s h i e l d .
To service the s l i d i n g glass sections follow t h a t pro-
cedure.
SLIDING GLASS SECTION
REMOVAL
(1) Remove the complete rear w i n d o w assembly.
(2) Place assembly i n a clean padded area.
(3) Loosen screws located on t h e bottom o f t h e
frame.
(4) Carefully spread frame apart.
(5) Remove s l i d i n g glass section from assembly.
 • BODY 23 - 29

Fig. 6 — R e a r Windo (Sliding Glass Type)

INSTALLATION INSTALLATION
(1) I n s t a l l s l i d i n g glass section i n t o t r a c k i n assem- (1) I n s t a l l cord i n weatherstrip retainer (Fig. 7).
bly. (2) I n s t a l l glass and weatherstrip assembly t o l i f t -
(2) Tighten a l l screws o n frame assembly. gate opening.
(3) Check correct t r a v e l and l a t c h i n g o f s l i d i n g sec-
tions.
(4) Install rear window assembly t o vehicle.
(5) Check t o see t h a t d r a i n holes are clear.

LATCH AND CATCH

The latch a n d catch are located on the s l i d i n g glass
sections on t h e inside o f cab w i t h screws.
To service t h e latch or catch remove or replace
screws.

LIFTGATE GLASS AND WEATHERSTRIP

REMOVAL
(1) Insert fiber stick between glass w e a t h e r s t r i p
r e t a i n e r and panel.
(2) W i t h a n assistant gently force glass a n d weath-
e r s t r i p retainer away f r o m frame.
(3) Remove glass and weatherstrip retainer assem-
b l y from liftgate. Fig. 7—Installation Cord
23 - 30 BODY •
(3) I n s t a l l t h e assembly to the door frame b y u s i n g
an i n s t a l l a t i o n cord.
(4) Clean glass.

QUARTER PANEL GLASS (FIXED)

REMOVAL
(1) Remove i n t e r i o r quarter glass t r i m (Fig. 8).

Fig. 10—Installing Quarter Window Spacers

Fig. 8—Quarter Window Garnish Moulding
(2) Remove exterior mouldings (Fig. 9).
(3) W i t h a n electric knife ( M i l l e r tool 4386 or
equivalent) cut existing b u t y l tape as close as possi-
ble to fence flange.
(4) Remove t h e glass f r o m opening b y a p p l y i n g a n
even pressure to t h e glass.

INSTALLATION
(1) Remove r e m a i n i n g b u t y l tape on body opening
surface as close as possible to t h e m e t a l surface. I f
original glass is to be installed, remove a l l b u t y l tape
f r o m glass surface.
(2) Apply p r i m e r to glass and allow 10 m i n u t e s for
p r i m e r to dry. A v o i d contact w i t h p r i m e d surface.

SECTION A - A SECTION B-B

RB430
Fig. 9—Quarter Window Mouldings
Fig. 11—Installing Butyl Tape
 • BODY 23 - 31

(3) Check q u a r t e r w i n d o w spacers for proper instal-

l a t i o n (Fig. 10).
(4) A p p l y b u t y l tape t o e n t i r e periphery o f fence
(Fig. 11).
(5) C u t excess tape away a n d b u t t t h e ends firmly
together.
(6) I n s t a l l q u a r t e r glass to b u t y l seal (Fig. 12)

SPACER RB432

Fig. 12—Installing Quarter Window

(7) Compress glass t o seal to achieve a good seal.
(8) Test quarter glass for water leaks.
(9) I f leakage occurs, a d d i t i o n a l sealing m a y be re-
quired. Use a suitable w i n d s h i e l d sealer (Fig. 13).

SEALER
Fig. 14—Roof Vent
INSTALLATION
(1) I n s t a l l cover.
(2) A t t a c h hinge.
(3) I n s t a l l handle t o cover u s i n g r i v e t i n H a n d l e
Package.

VENT COVER SEAL

REMOVAL
(1) Open cover.
(2) Remove cover hinge.
(3) Remove cover seal from frame.

INSTALLATION
Fig. 13—Sealing Quarter Window (1) Clean seal area of frame.
(2) U s i n g a weatherstrip cement i n s t a l l seal.
(10) I n s t a l l mouldings.
(3) I n s t a l l cover hinge.
(11) Clean glass.
(4) W a t e r test vent.

ROOF VENT (Fig. 14) FRAME

VENT COVER REMOVAL

(1) Remove i n n e r t r i m r i n g .
REMOVAL (2) B r e a k t h e seal between frame and roof panel.
(1) Open cover. (3) Remove frame/cover assembly.
(2) D r i l l upper r i v e t head f r o m cover/handle.
(3) Remove vent cover hinge. INSTALLATION
(4) Remove cover. (1) Clean frame and roof sealing surfaces.
23 - 32 BODY •
(2) I n s t a l l seal t o frame.
(3) I n s t a l l frame to roof.
(4) I n s t a l l i n n e r t r i m r i n g a n d t i g h t e n .
(5) W a t e r test frame area.
N o t e : R.T.V. Silicone Sealer m a y be used for addi-
t i o n a l sealing.

HANDLE

REMOVAL
(1) Open v e n t cover.
(2) D r i l l r i v e t head from handle to cover.
(3) D r i l l r i v e t head f r o m handle to frame.
(4) Remove handle.
NUT PU848
INSTALLATION
(1) Place handle i n position. Fig. 15 — Vented Side Widow — Club Cab
(2) I n s t a l l handle to cover u s i n g a r i v e t i n Handle
Package.
(3) I n s t a l l handle t o frame u s i n g a r i v e t i n Handle
Package.

VENTED SIDE WINDOW - CLUB CAB (Fig. 15)

REMOVAL
(1) Remove l a t c h a t t a c h i n g screw from window
frame.
(2) Remove hinge assembly screws a n d remove
glass f r o m vehicle.
(3) Reverse above procedure for i n s t a l l a t i o n and
check w i n d o w sealing.

REFINISHING P R O C E D U R E S

INDEX
Page Page
Base Coat/Clear Finish 32 Flexible Panel Refinishing 35
Buffing and Polishing 34 Paint Bake Oven Treatment (Textured Grilles) . . . 36
Color Application 35 Paint Charts 38
Color Coating Procedure 34 Paint Repairs (Galvanized Metals) 33
Color Sanding, Buffing, and Polishing 34 Painting Plastic Components 35
Corporate Identity Codes and Color Charts 38 Preparing Surface for Paint 34
Definitions (Technical Terms) 33 Rust Protection . 34
Fiberglass Finishes 37 Safety Measures 36

BASE COAT/CLEAR FINISH turbo-bell, sprays t h e clear coat (topcoat) on t h e ve-

Vehicles today are sprayed i n a hospital clean en-
vironment to e l i m i n a t e d i r t a n d foreign substances.
The p a i n t used is a t w o p a r t application. The base
coat w h i c h is applied on top o f a special eight stage
primer, gives t h e vehicle i t s color. After t h e color
(base coat) is applied, a special spray g u n , called a
hicle. T h i s clear coat gives t h e p a i n t finish i t s h i g h
gloss a n d d u r a b i l i t y .
To determine correct color a n d p a r t n u m b e r o f
enamel used o n the car, refer to code on body number
plate a n d t h e n locate corresponding code o n p a i n t
chart. Proper safety equipment should be used and
w o r k should be done i n a w e l l ventilated area.
 • BODY
DEFINITIONS OF TECHNICAL TERMS
SINGLE COAT
A single coat is a spray p a t t e r n applied f r o m left to
r i g h t . The r e t u r n i n g r i g h t to left p a t t e r n is applied
so t h a t i t covers approximately h a l f of t h e preceding
p a t t e r n . This process is. repeated u n t i l coverage of
the panel is complete.
DOUBLE COAT
A double coat is a spray p a t t e r n applied f r o m left
to r i g h t t h e n back again over t h e same area. A panel
is covered by overlapping each double coat b y a t
least 50%.
DRYING
D r y i n g or hardening o f a film goes t h r o u g h several
stages/First is k n o w n as "dust free" and is t h e t i m e
required for a f i l m to reach t h e condition where, i f
any dust settles on i t , dust w i l l not become imbed-
ded, b u t may be wiped off after film has hardened.
S e c o n d stage is k n o w n as "tack free" and is t h e t i m e
required for a film to reach t h e condition where i t
may be touched w i t h l i g h t pressure of finger. T h i r d
is " h a r d d r y " and is the t i m e required for film t o be-
come thoroughly h a r d so t h a t i t may be rubbed and
polished.
DEGREASE-DEWAX
T h i s is w i p i n g w i t h a clean cloth saturated w i t h a
commercial cleaner. Essential to good p a i n t adhesion.
FEA THEREDGING
T h i s is tapering of edges o f a finish so t h a t w h e n a
finger is passed over i t no break w i l l be felt. Feath-
eredging is usually done w i t h water and sandpaper
on a sand block. This t e r m applies to t h e sanding of
a defect to the p r i m e or color coat.
FERROUS AND NON-FERROUS METALS
Ferrous metals are those w h i c h are made f r o m i r o n
(steel). Non-ferrous metals are those w h i c h are n o t
made from iron or do not present a n i r o n (steel) sur-
face, such as a l u m i n u m , a l u m i n u m alloys, brass, cop-
per, and magnesium.
FLASH TIME
T h i s is t h e t i m e required for a n applied coat of
p a i n t to lose most of its solvent.
MIST COAT
T h i s is over t h i n n i n g t h e color and s p r a y i n g wet.
U s u a l l y the final coat.
PRIMING
The function of a p r i m e r is to act as a surfacer for
the finished color coat. I t also forms a bond between
t h e m e t a l surface and the color coat.
23 - 33
A glazing p u t t y is used for filling i n small imper-
fections w h i c h are too deep t o be t a k e n care of by
surfacer coats. I t m a y be applied either before or af-
ter the last coat o f p r i m e r surfacer.
REDUCERS
Reducers are m i x t u r e s of v o l a t i l e liquids used to
reduce a l k y d and synthetic p r i m e r s and enamels to
the proper consistency for application.
SANDING BLOCK
As a r u l e a sanding block is a flexible rubber block,
to w h i c h sandpaper m a y be fastened. I t offers a good
g r i p for t h e operator.
Wherever possible sanding should be done w i t h a
block as i t distributes the pressures and gives a more
u n i f o r m surface.
SURFACING
The function of a surfacer i s t o prepare a smooth
surface for t h e color coats.
TACK RAG
This is a piece o f cheesecloth t h a t has been dipped
i n t h i n , n o n - d r y i n g v a r n i s h a n d t h e n w r u n g out. I t is
kept i n a container so t h a t v a r n i s h w i l l not harden
but w i l l r e m a i n tacky. Tack r a g is used t o wipe off a
surface t o remove dust and l i n t .
THINNERS
T h i n n e r s are m i x t u r e s of v o l a t i l e liquids used to
t h i n lacquer type finishing m a t e r i a l s to proper con-
sistency for application.
UNDERCOATS
A l l products used t o prepare the surface to receive
color coats are classified as undercoats, such as p r i m -
ers, surfacers, putties, p r i m e r surfacers and sealers.
PAINT REPAIRS ON GALVANIZED METALS
To perform p a i n t repairs on galvanized rocker pan-
els or any other galvanized steel surfaces, care must
be exercised w h e n preparing bare galvanized surface
to properly accept p r i m e r surfacer and finish paint.
Do not use shortcut methods nor i n t e r m i x i n g of ma-
terials.
METAL PREPARATION
(1) W i r e b r u s h or steel wool entire m e t a l surface
and remove a l l grease or o i l , w i t h wax and grease re-
mover.
(2) Thoroughly sand affected area to remove a l l
corrosion products f r o m exposed m e t a l surface w h i l e
carefully feathering a l l p a i n t edges.
(3) Treat bare m e t a l panel w i t h a conditioner ac-
cording to label directions.
23 • 34 BODY
(4) Rinse w i t h clean w a t e r a n d blow o f f w i t h com-
pressed air.
REFINISHING
(1) A p p l y one l i g h t coat o f p r i m e r for adhesion.
(2) A p p l y p r i m e r surfacer i f r e q u i r e d .
(3) Sand w h e n dry a n d proceed w i t h application o f
f i n i s h coats according t o p a i n t manufacturers recom-
mendations.
RUST PROTECTION
Prior t o a p p l y i n g a n y p a i n t t o t h e sheet m e t a l
clean the area t o be repainted.
E l i m i n a t e a l l f i n g e r p r i n t s , chemically t r e a t a l l bare
metal.
This conditions the exposed m e t a l t o resist rust.
BUFFING AND POLISHING
M i n o r imperfections i n p a i n t f i n i s h n o r m a l l y can
be removed b y sanding, b u f f i n g a n d polishing. The
following procedure should be used w h e n w o r k i n g o n
these m i n o r conditions:
(1) Wet sand b y h a n d affected area u s i n g # 6 0 0 pa-
per w h i c h has been soaked i n m i n e r a l spirits. Cau-
t i o n should be used n o t t o r u b too h a r d over any of
the affected areas or o n ridges.
(2) Remove sand sludge.
(3) Tack off area w i t h a clean, soft cloth.
(4) B u f f entire area u s i n g a fine b u f f i n g compound.
COLOR SANDING, BUFFING, AND POLISHING
(1) W r a p a piece o f 600 g r i t or finer w e t or d r y
sandpaper around a t w o i n c h b y three i n c h (2 x 3)
rubber squeegee.
(2) A p p l y a few drops of m i n e r a l o i l or w a t e r over
and around the p a i n t condition. (Baby o i l can be sub-
stituted for m i n e r a l oil).
(3) Sand the p a i n t condition i n a l i g h t circular mo-
t i o n i n order to j u s t sand the top of t h e orange peel.
Use rubber squeegee t o check t h e sanding operation
after three or four passes, m a k i n g c e r t a i n not to over
sand.
(4) Use a buffing machine w i t h a c u t t i n g pad and
very fine compound t o b u f f out t h e sanding m a r k s .
(5) E i t h e r b y h a n d or machine, remove wheel
m a r k s w i t h a cleaner and polisher a n d detail w o r k
area u n t i l clean.
COLOR COATING PROCEDURE FOR PAINTING
SECTIONS OF A PANEL-USING ACRYLIC ENAMEL
(1) Dewax and degrease complete panel by using
correct solvents. Follow instructions a n d procedures
p r i n t e d on label o f product being used.
•
(2) Sand the area t o be repaired t o w i t h i n 1/16 o r
1/8 o f a n i n c h of b r e a k l i n e o r breaklines. 360 or 400
g r i t w e t sanding paper can be used or 280 or 320 g r i t
dry sanding paper can be used.
(3) Use blow g u n w i t h approximately 30 pounds a i r
pressure and a good t a c k r a g t o remove dust and d i r t
f r o m complete w o r k area a n d adjacent panels.
(4) A p p l y 3/4 i n c h m a s k i n g tape to t h e breakline or
breaklines and allow approximately 3/16 of an i n c h
of t h e tape t o "overlap" t h e b r e a k l i n e or breaklines,
t h e n use t h e finger t o f l u f f u p w a r d t h i s 3/16 of a n
inch portion tape. Complete t h e m a s k i n g operation
w i t h paper and tape t o cover adjacent panels.
(5) M i x t h e color w e l l o n a p a i n t shaker and c u t
the color w i t h t h e correct solvents i n a container
w h i c h has m a r k e d measurements so as t o follow t h e
manufacturers instructions o n how t h e i r materials
should be used.
(6) Adjust a i r pressure a t t h e a i r regulator
o n l y — n o t b y a i r restrictor or k i n k i n g t h e 5/16 I . D .
hose w h i c h should have large I.D. f i t t i n g s .
(7) A p p l y the color w i t h a good spraying technique,
not t w i s t i n g the w r i s t , u n t i l coverage and match i s
accomplished.
(8) Remove t h e m a s k i n g w h e n cured or d r y a n d
clean u p or detail as necessary.
PREPARING THE SURFACE FOR PAINT
T h i s operation is t h e backbone or foundation for
f i n i s h color. I t primes m e t a l t o insure adhesion a n d
fills m i n o r surface imperfections.
(1) Degrease and dewax t h e metal.
(2) A p p l y self-etching p r i m e r .
(3) To b u i l d substrate back to o r i g i n a l thickness
use a h i g h blend p r i m e r .
(4) Sand undercoats (refer t o p a i n t manufacturer
for recommended sandpaper g r i t ) .
(5) Respray w i t h p r i m e r surface u n t i l t h e under-
coat meets i t s o r i g i n a l thickness.
(6) Resand undercoat w i t h manufacturers recom-
mended sandpaper.
(7) Reclean surface.
(8) Remove overspray f r o m exterior a n d apply
sealer recommended.
(9) Tack r a g entire surface t o remove l i n t and dust.
(10) M i x base coat.
(11) A p p l y base coat w i t h l i g h t single coats. A l l o w
for proper flash-off. Note: A p p l y sufficient amount o f
base coat to achieve coverage. I f coverage is difficult
to determine, tape on a n opacity card on m a s k i n g pa-
per next to the surface t o be painted.
(12) A l l o w proper d r y t i m e for base coat. Note: Do
not use tack r a g t o remove d i r t from base coat. T h i s
w i l l only d i s t u r b t h e unprotected metallic flake a n d
increases the d i r t problem.
 BODY 23 - 3 i

POLYPROPYLENE G R O U P VINYL GROUP

ARS GROUP
BLUE-GREEN FLAME

LITTLE VISIBLE SMOKE

POLYPROPYLENE VINYL MATERIAL

MATERIAL

COPPER WIRE RB536

Fig. 1—Flame Test to Identify Plastic Materials

(13) M i x t h e clear coat according to manufacturers FLEXIBLE PANEL REPAIR
recommendations. I t may not be necessary t o replace a damaged flex-
(14) A p p l y clear coat w i t h l i g h t single coats. A l l o w ible panel. Flexible panels are repairable using a
for proper flash-off. product such as 3 M 8101 S t r u c t u r a l Adhesive or
(15) A p p l y sufficient a m o u n t of clear coat t o d u p l i - equivalent. For best results follow manufacturers i n -
cate O.E.M. finish. structions.
(16) Clean spraying equipment a n d d e t a i l car for
customer pick-up. PAINTING PLASTIC COMPONENTS

To p a i n t plastic t r i m components i t i s necessary to:

COLOR APPLICATION
The most i m p o r t a n t step i n color coat application is
to follow the manufacturers instructions for t h e prod-
uct being used. S i m i l a r products f r o m different m a n -
ufacturers w i l l generally require different methods of
application. Specific instructions o n l i n e pressure,
coverage, t h i n n i n g , etc. are u s u a l l y available from
p a i n t supply manufacturers.
METALLIC COLOR AND PEARL COATS
M e t a l l i c color can appear to v a r y i n richness. V a r i -
a t i o n can be described as:
A closed p a t t e r n t h a t appears l i g h t e r w i t h fine me-
t a l l i c dispersion.
A n open p a t t e r n t h a t appears richer w i t h m e t a l l i c
flakes less noticeable.
A n open p a t t e r n is achieved b y l o w e r i n g a i r pres-
sure to 20-30 lbs. a t g u n , reducing acrylic lacquer
color 100% w i t h a blend o f acrylic lacquer t h i n n e r
a n d a l l purpose retarder.
FLEXIBLE PANEL REFINISHING
(1) Clean a l l surfaces w i t h a w a x and grease re-
mover such as DX-330 A C R Y L I - C L E A N or equiva-
lent.
(2) Sand surface w i t h # 4 0 0 sandpaper and reclean
surface as per step 1.
(3) A p p l y one f u l l w e t coat.
(4) A l l o w 10 to 15 m i n u t e s flash t i m e .
(5) A p p l y a final f u l l w e t coat.
(6) A l l o w t o dry 2 to 3 hours.
(1) Identify the type o f plastic to be painted.
(2) Follow procedures recommended for the differ-
ent types o f plastics.
To determine w h i c h plastic is being used, c u t a
small sliver o f plastic from the backside o f the p a r t
to be painted. H o l d t h e sliver i n needle nose pliers
and b u r n the plastic (Fig. 1).
(1) The A B S (Acrylo-nitrile/butadiene/styrene)
group w i l l b u r n w i t h a heavy black smoke.
(2) The polypropylene group burns w i t h no readily
visible smoke.
(3) N y l o n can be identified b y the d i s t i n c t odor o f
b u r n i n g wool d u r i n g t h e b u r n , r a t h e r t h a n b y t h e
color or i n t e n s i t y of the smoke.
(4) The v i n y l group w i l l b u r n w i t h a blue green
tint.
T o test for v i n y l , h e a t a piece of c o p p e r w i r e
r e d hot. I m m e d i a t e l y a p p l y the w i r e e n d to a
nonvisible portion o f p l a s t i c until a glob of p l a s -
tic a d h e r e s to the w i r e . P l a c e the glob into a
flame a n d observe the color.
The following chart shows t h e types o f plastics
commonly used o n t r i m components, a n d t h e proce-
dure to follow.
23 - 36 BODY •
Plastic Type Examples Painting Use 30-35 pounds a i r pressure a t t h e g u n . A s t h e
Procedures f i l m b u i l d s heavier, i t w i l l be necessary t o allow
Rigid Vinyl Bumper Filler Flex Agent longer flash off times between double coats to avoid
Required t r a p p i n g t h i n n e r . Trapped t h i n n e r can r e s u l t i n
RIM Urethane Fascias Flex Agent p i n h o l i n g or b u b b l i n g .
(Reaction Required
Most c o l o r s w i l l h a v e a d e q u a t e h i d i n g after
Injection
Moulding) a p p l y i n g t h e m i n i m u m n u m b e r o f d o u b l e coats.
TPU (Thermo- End Caps Soft Flex Agent Some deep look colors m a y r e q u i r e a d d i t i o n a l
plastic (Same as RIM) Required double c o a t s .
Urethane) (d) A i r d r y for a p p r o x i m a t e l y four hours a t 70°-
TPO (Thermo- Bumper Fillers Flex Agent 85°F before i n s t a l l i n g or p u t t i n g i n t o service.
plastic Olefin) Required T h e n e w finish i s n a t u r a l l y s o f t a n d p l i a b l e .
FRP (Fiberglass Nose Cones Same as Steel
When t h e proper D u r a c r y l thinner (DTL) is used
Reinforced (Hard)
Polyester) for the p r e v a i l i n g t e m p e r a t u r e , t h e f i n i s h s h o u l d
Phenolic Ash Trays Same as Steel h a v e a d e q u a t e gloss. I f c o m p o u n d i n g i s d e s i r e d ,
Nylon Spoilers, Same as Steel a m i n i m u m of t w o w e e k s s h o u l d b e allowed. U s e
Louvers only D X R - 2 5 (a f i n e h a n d r u b b i n g c o m p o u n d ) o r
ABS (Acrylo- Louvers No Flex Agent D R X - 1 6 c o m p o u n d w i t h a p o w e r buffer u s i n g
nitrile/Butadiene only a v e r y l i g h t p r e s s u r e .
/Styrene)
*See " D e f i n i t i o n s o f Technical T e r m s " on f i r s t page
Polypropylene Hard Seat Back, No Flex Agent
Garnish of " R E F I N I S H I N G P R O C E D U R E S " .
Moulding Dash
WARNING: BECAUSE OF THE NATURE OF THE
PRODUCTS SHOWN IN THESE FINISHING SYS-
RIGID ABS
TEMS, THEY MUST BE BLENDED WITH OTHER
R i g i d A B S requires no p r i n t e r . The appropriate
COMPONENTS. BEFORE OPENING THE PACK-
p a i n t w i l l adhere satisfactorily to t h i s plastic.
AGES, B E SURE YOU UNDERSTAND THE WARN-
(1) Wash p a r t thoroughly w i t h a cleaning solvent
ING MESSAGES ON THE LABELS OF ALL
such as DuPont Prep Sol, or equivalent.
COMPONENTS SINCE THE MIXTURE IS LIABLE TO
(2) Color coat t h e part, u s i n g t h e appropriate color.
HAVE HAZARDS IN ALL ITS PARTS. OBSERVE ALL
(3) A l l o w to dry. I n s t a l l p a r t .
APPLICABLE PRECAUTIONS.
SOFT EXTERIOR PLASTICS (FILLERS,
FASCIAS, ETC.)
SAFETY MEASURES
Paints to be used on soft exterior parts require ad-
ditives to allow t h e p a i n t to flex w i t h o u t cracking.
(1) Wash p a r t thoroughly w i t h a cleaning solvent Use only with adequate ventilation. Do not take in-
such as DuPont Prep Sol, or equivalent. ternally. Do not use if you have chronic (long term)
(2) Sand t h e surface w i t h 400 g r i t o r finer paper. lung or breathing problems, or if you have ever had
Reclean surface. a reaction to isocyanates. If engineering and admin-
(3) Use t h e following D i t z l e r Flexative A g e n t (or istrative controls of air contaminants are not feasi-
equivalent). ble, use a fresh air supplied respirator that
(a) M i x D D L (Duracryl acrylic lacquer a n d respirator supplier recommends as effective for iso-
Flexible additive (DX-1798) a n d D y r a c r y l lacquer cyanate vapors and mists. Follow directions for res-
t h i n n e r ( D T L ) as follows: pirator use. Wear the respirator for the whole time
of spraying and until all vapors and mists are gone.
Duracryl Avoid breathing of vapor or spray mist. Avoid con-
Acrylic Flexible tact with eyes and skin.
Lacquer Additive Duracryl
DDL DX-1798 DTL Thinner Yield
1 pint or 1 pint or 1-1/2 pints 3-1/2 pints
8 ounces 8 ounces or 12 ounces 1-3/4 pints PAINT BAKE OVEN TREATMENT (WITH TEXTURED
GRILLES)
(b) M i x i n t h e D u r a c r y l ( D D L ) color a n d F l e x i -
ble additive (DX-1798) thoroughly before adding To avoid warpage, a l l models w i t h t e x t u r e d grilles
the D u r a c r y l t h i n n e r (DTL) best suited for t h e a m - and bezels should be covered w i t h paper or other ma-
bient temperature. t e r i a l to shield g r i l l e assembly f r o m heat before ve-
(c) A p p l y a m i n i m u m of eight to t e n w e t double hicle enters p a i n t bake ovens, or be completely
coats,* a l l o w i n g flash t i m e between double coats. removed from vehicle.
 • BODY 23 - 37

FIBERGLASS FINISHES (7) A l l o w t o dry and sand smooth w i t h fine sand-

paper to m i n i m i z e sand scratches.
Fiberglass should be treated m u c h t h e same as (8) Blow surface off w i t h a i r a n d t a c k r a g t h e sur-
body steel; however, i t is a non-corrosive m a t e r i a l face.
a n d does not require chemical conditioners. (9) I f enamel top coats are t o be used a synthetic
Replacement or new panels m a y contain silicone primer- surfacer is also recommended.
oils o n t h e surface due t o the m a n u f a c t u r i n g process (10) A p p l y color coats as recommended, b y m a n u -
used. These oils must be removed f r o m t h e surface, facturer.
to prevent c r a t e r i n g o f the freshly painted surface.
FLEXIBLE PANEL REPAIR AND REFINISHING
(TPO)
FIBERGLASS SURFACE PREPARATION
Flexible bumper fascias o n P-Body vehicles are
U n d e r most repair situations when w o r k i n g w i t h
thermoplastic olefin (TPO). F o r r e p a i r a n d r e f i n i s h
fiberglass, t h e w o r k i n g area should be w e l l v e n t i -
use 3 M system 2 or equivalent. I m p o r t a n t : Do N o t
lated, a n d consideration should be given t o protective
use repair a n d r e f i n i s h methods f o r thermoplastic
clothing. Respiratory masks a n d safety glasses
urethane (TPU) or R I M urethane.
should also be worn.
The procedure does not represent a complete fiber FLEXIBLE PANEL REPAIR (TPO)
glass repair, b u t does reflect t h e basic steps t o be I t may not be necessary t o replace a damaged flex-
t a k e n i n t h e repair.
ible fascia i f t h e damage is m i n o r i n n a t u r e . Flexible
(1) I n a w e l l ventilated area, using alcohol, wash panels are repairable u s i n g products such as 3 M sys-
new molded parts l i b e r a l l y w i t h a clean cloth.
t e m 2, polytac adhesion promoter flexible parts r e -
(2) Thoroughly clean t h e surface w i t h w a x a n d
pair, or equivalent. F o r best results, follow
grease remover.
manufacturers instructions. Never use 3 M flexible
(3) Re-clean surface a n d wipe dry w i t h clean rags.
parts p u t t y or body f i l l e r on thermoplastic olefin fas-
(4) I f there are j o i n t s t o be filled or t h e sanding op-
cias.
e r a t i o n exposes air pockets or glass strands, glaze a
coat o f body f i l l e r over the entire surface. FLEXIBLE PANEL REFINISH (TPO)
(5) A l l o w t o cure, sand and re-clean. To e l i m i n a t e outlie on r e p a i r area showing t h r o u g h
(6) A p p l y p r i m e r or surfacer as directed. top coat, apply coat o f 3 M flexible parts coating or
equivalent.
 CORPORATE IDENTITY CODE

Corporate White-8367 Corporate Blue-12785 Corporate Red-71831

The first two digits are accent or roof color. The second two digits are basic body color.
For special colors (coded 999) furnish Special Order (SO) Number.
Painted grilles are painted in exterior colors.

EXTERIOR PAINT

Paint
Code Color Name

HE4 Colorado Red Clear-Coat

HY3 Sand Metallic Clear-Coat
JT8 Dark Tundra Metallic Clear-Coat
GG7 Dark Forest Green Metallic Clear-Coat
HQ7 Aquamarine Blue Metallic Clear-Coat
JB6 Dark Spectrum Blue Metallic Clear-Coat
JB2 Light Spectrum Blue Metallic Clear-Coat
GB4 Daytona Blue Metallic Clear-Coat
DX8 Black Clear-Coat
HS3 Dover Gray Metallic Clear-Coat
HA2 Sterling Silver Metallic Clear-Coat
GW7 Bright White Clear-Coat

INTERIOR TRIM COLOR

Color
Code Color Name
R8 Bordeaux
17 Tundra
S8 Charcoal
 • HEATING AND AIR CONDITIONING
HEATING AND AIR-CONDITIONING
CONTENTS
Page
AIR-CONDITIONING 29
AIR-CONDITIONING SERVICE PROCEDURES . . . 6
AIR-CONDITIONING TEST PROCEDURES 11
COMPRESSOR SERVICE 29
HEATER
INDEX
Page
Defroster Duct .. 8
Faceplate 6 Resistor Block
General Information 1 Service Procedures .
Heater Assembly 7 Temperature and Mode Control Cables
Heater Control 6
GENERAL INFORMATION
Throughout t h i s group, references may be made t o
a p a r t i c u l a r vehicle by n u m b e r or letter designation.
A chart showing the breakdown of these designations
is included i n t h e I n t r o d u c t i o n Section at the front o f
t h i s service m a n u a l .
A l l models use a B l e n d - A i r type heater. Outside
a i r enters the heater t h r o u g h the cowl opening and
passes t h r o u g h a p l e n u m chamber to the heater core.
Hood louver a i r i n t a k e or a i r i n t a k e a t rear o f hood
a t windshield wiper opening m u s t be kept free o f
snow, ice, and other obstructions for heater or a i r
conditioning t o pick up sufficient outside air. A tem-
perature control door i n t h e heater housing directs
incoming a i r t h r o u g h t h e heater core and/or t h e
heater core by-pass. The a m o u n t of blend (heated and
non-heated a i r ) is determined b y the setting of the
temperature lever on the i n s t r u m e n t panel. D i r e c t i o n
of the blended a i r is controlled b y the H e a t - D e f r o s t
lever on the i n s t r u m e n t panel.
The blower switch, i n conjunction w i t h a resistor
block, controls t h e speed o f the blower motor, and
hence the velocity of the a i r flow from the heater
outlets.
The resistor block consists o f two helically w o u n d
w i r e resistors connected t o t e r m i n a l s w h i c h are me-
chanically attached to a glass-filled phenolic board.
T h i s assembly is bolted t o the p l e n u m .
The blower s w i t c h controls the blower motor speed
by selectively connecting i n series, one, two or none
of t h e resistors t o the blower motor.
A self-adjusting clip, on each of t w o control cables
has been incorporated t o simplify cable adjustment.
T h i s clip snaps onto the control cable core w i r e and
24 - 1
Page
EVAPORATOR HEATER ASSEMBLY 36
HEATER 1
REFRIGERANT SYSTEM SERVICE
PROCEDURES ....22
Page
Heater Diagnosis 2
7
6
6
w i l l slide along the w i r e under a specific load to pro-
vide a n automatic cable adjustment.
HEATER OUTPUT CHECK
Proper function of t h e heater system c a n be
checked b y measuring the temperature o f the a i r a t
t h e heater o u t p u t duct under the i n s t r u m e n t panel.
Set the heater controls, as shown below, and measure
t h e temperature using a thermometer and compare
t h e m w i t h the values listed i n the reference chart.
Should the temperature not meet the m i n i m u m v a l -
ues shown, refer t o "Heater Diagnosis" for possible
causes and corrections.
TEST CONDITIONS
(1) Remove radiator pressure cap.
CAUTION: If vehicle has been run recently, wait 15
minutes before removing cap, then place a rag over
the cap and turn it to the first stop. Allow pressure
to escape through the overflow tube and when the
system stabilizes remove the cap completely.
(2) D r a i n one p i n t of coolant from the r a d i a t o r .
(3) W a r m the engine to operating temperature b y
i d l i n g for 20 minutes, w i t h the pressure cap off. Idle
longer i f w o r k i n g outdoors i n cold temperatures.
(4) W i t h the engine i d l i n g , place a thermometer
i n t o the coolant i n the radiator f i l l e r neck.
(5) Engine coolant temperature should stabilize a t
no lower t h a n 187° (or 8° blow the thermostat open-
i n g temperature) d u r i n g the vehicle operating cycle.
(6) I n s t r u m e n t panel control i n h e a t mode.
(7) H i g h blower speed.
(8) Temperature lever to m a x i m u m heat position.
24 - 2 HEATER •

HEATER DIAGNOSIS (MECHANICAL)

| insufficii»nt h e a t 1 1 t o o m i ch
l hoot |

OBSTRUCTED HEATER OUTLETS IMPROPERLY ADJUSTED TEMPERATURE

CONTROL CABLE.

TEMPERATURE DOOR MISDIRECTED

OR BINDING, KINKED OR UNATTACHED DISCONNECTED OR BROKEN, KINKED
CONTROL CABLE (SEE CONTROL CABLE TEMPERATURE CABLE.
SECTION).

BLEND-AIR (TEMP) DOOR

MODE DOOR IMPROPERLY ADJUSTED OR BINDING OR MISDIRECTED
BINDING. UNATTACHED CONTROL CABLE.

ENGINE THERMOSTAT DEFECTIVE.

OBSTRUCTED HEATER HOSE

KINKED HEATER HOSE, SEE ROUTING.

AIR IN HEATER CORE

LOW COOLANT FLOW, INSUFFICIENT

COOLANT IN SYSTEM. DEFECTIVE
THERMOSTAT. WATER PUMP BELT LOOSE.
GREATER THAN 50% MIXTURE
OF ANTIFREEZE. ENGINE TEMPERATURE
LOW SEE GROUP 7. ENGINE COOLING
DIAGNOSIS.

OBSTRUCTED INTAKE IN MANIFOLD

PASSAGE.

HEATER CORE PLUGGED.

WATER VALVE PARTIALLY OR

FULLY CLOSED.
RN605A
 HEATER 24 - 3

H E A T E R B L O W E R M O T O R A N D C O N T R O L S Y S T E M D I A G N O S I S (ELECTRICAL)

BLOWIR MOTOR
INOPERATIVE

FUSE BLOWN

r
INSPECT FUSE
H FUSE GOOD I

CHECK FOR BATTERY VOLTAGE

CHECK FOR SHORT CHECK FOR STALLED MOTOR AT BOTH BtOS OF FUSE

VOLTAGE AT BOTH VOLTAGE AT BATTERY

CORRECT SHORT MOTOR STALLED
ENDS OF FUSE SIDE OF FUSE ONLY

CHECK BLOWER MOTOR

REPLACE FUSE REPLACE MOTOR REPLACE FUSE
GROUND

LOCATE OPEN CONNECTION
AND CORRECT
CHECK MOTOR CONTINUITY
MOTOR RUNS ATTACH JUMPER WIRE BETWEEN MOTOR
GROUND WIRE AND BODY OR ENGINE
(MOTOR IN PASSENGER COMPARTMENT) OR
MOTOR DOES CHECK ATTACHMENT OF GROUND LEAD OF
NOT RUN MOTOR IN ENGINE COMPARTMENT

MAKE SURE FEED WIRE ATTACH JUMPER WIRE FROM THE MOTOR DOES
TERMINALS ARE NOT MOTOR FEEDWIRE TO THE POSITIVE NOT RUN
BACKED OUT OF INSULATOR POST OF THE BATTERY. MAKE SURE
OR OFF CENTER. REASSEMBLE THAT GROUND WIRE IS PROPERLY
MOTOR WIRE CONNECTOR GROUNDED FOR THIS TEST
REPLACE MOTOR
LOCATE OPEN CONNECTION AND CORRECT
NO VOLTAGE IN ANY SWITCH POSITION
REPLACE PUSHBUTTON SWITCH MOTOR RUNS

VOLTAGE IN ALL CHECK RESISTOR

SWITCH POSITIONS REMOVE WIRING CONNECTORS FROM CONTINUITY AND
RESISTOR TERMINALS. MAKE SURE RESISTOR CONNECTIONS
THAT TERMINALS ARE NOT
BACKED OUT OF INSULATOR.
CHECK FOR BATTERY VOLTAGE IN
EACH FAN SWITCH POSITION NO VOLTAGE IN ONE OR
REPLACE RESISTOR MORE LEADS

VOLTAGE AT BATTERY TERMINAL
REPLACE BLOWER SWITCH*
REMOVE WIRING CONNECTOR FROM CHECK BLOWER SWITCH
SWITCH TERMINALS. MAKE SURE AND CONNECTIONS
TERMINALS ARE PROPERLY
LOCKED IN SOCKET OF INSULATOR. •IF BLOWER SWITCH HAS FAILED
CHECK FOR BATTERY VOLTAGE AT DUE TO BURNING OR CHARRING
BATTERY TERMINAL IN INSULATOR. CHECK CURRENT DRAW OF
THE BLOWER MOTOR

BLOWER MOTOR OPERATE BLOWER FUSE BLOWS CHECK AND

CORRECT REPLACE RESISTOR REPLACE
OPERATES AT SWITCH IN ALL INDICATING
HIGH SPEED ONLY SHORT BLOCK IF DEFECTIVE FUSE
MODES PRESENCE OF A SHORT

INSPECT RESISTOR INSPECT BLOWER REPLACE

FUSE DOES RESISTOR BLOWER SWITCH BLOWER
BLOCK
NOT BLOW BLOCK SWITCH DEFECTIVE SWITCH
O.K.

RR24D32
24 - 4 HEATER •

BLOWER MOTOR
NOISE/VIBRATION CHART

BLOWER MOTOR NOISE

OR VIBRATION

NO USE VIBRATION

ENGINE ON CHECK MOTOR

MOUNTING
CHECK BLOWER
MOTOR IN ALL
SPEED MODES
MOUNTING
OK
LO<DSE
NOISE PRESENT

A / C BUT A/C
NOT HTR. AND HTR. TIGHTEN

POSSIBLE LEAVE ENGINE ON

RE-CHECK
RADIATOR SHUT BLOWER
FAN OR
MOTOR OFF
COMPRESSOR
NOISE OK

NOISE STILL PRESENT NOISE GONE VIBRATION

STILL PRESENT

PROBLEM NOT CHECK BLOWER

IN BLOWER SCROLL AREA
SYSTEM
REMOVE BLOWER
WHEEL AND
OPERATE BLOWER
MOTOR AT
FOREIGN AAATERIAL IN FAN VIBRATION
LOW SPEED
FAN OR SCROLL RUBBING GONE
HOUSING

YES NO REPLACE BLOWER VIBRATION

REMOVE REPLACE YES WHEEL STILL
FOREIGN MOTOR A DJUST PRESENT
AAATERIAL T O ( "ORRECT

RE-CHECK REPLACE
RE-CHECK RE-CHECK MOTOR

RE-CHECK

NOISE STILL NOISE

PRESENT GONE

REPLACE - RE-CHECK
MOTOR
8924-32
 RB457B

Fig. 1—Heater Assembly

 24 - 6 HEATER •
SERVICE PROCEDURES
FACEPLATE
TAB FLAG FLAG
RETAINER
REMOVAL
MOUNTING
(1) Remove map lamp.
SCREWQ)
(2) Remove screws w h i c h attach faceplate t o base
panel. Make sure t h e screw below t h e Heater-A/C
control is removed (Fig. 2).

HEATER
CONTROL
UNIT
RB459

. Fig. 3—Heater Control

(4) Move t h e l e v e i s t o t h e extreme r i g h t t o adjust
t h e clips.
(5) I n s t a l l faceplate.

TEMPERATURE AND MODE CONTROL CABLES

MOUNTING
SCREWS
LOCATIONS REMOVAL
RB458 (1) Remove faceplate (see "Faceplate Removal").
(2) Open glovebox past stops.
Fig. 2 — M o u n t i n g Screw Locations (3) Remove control u n i t f r o m i n s t r u m e n t panel (see
(3) P u l l column shift lever i n position " 1 " . "Heater C o n t r o l Removal").
(4) Remove faceplate b y p u l l i n g t h e top edge rear- (4) Remove cables from control lever pins a n d re-
w a r d to clear t h e brow, disengage attaching clips move flags from retainers (Figs. 4 and 5).
around the bottom o f the faceplate, and complete re-
moval of faceplate. RED-TEMPERATURE
DEPRESS TAB ,
FLAG DOOR
(5) Disconnect wires t o four wheel drive indicator, FOR
YELLOW-MODE
i f equipped. REMOVAL
V DOOR

L
CONTROL CABLE
INSTALLATION ASSEMBLY
(1) Engage attaching clips around bottom of face-
plate, connect four wheel drive indicator w i r i n g , i f
equipped, r o l l faceplate i n t o position, a n d i n s t a l l
m o u n t i n g screws (Fig. 2). PR413C
(2) I n s t a l l map lamp.
Fig. 4—Flag Tab Depressed for Removal
HEATER CONTROL TAB FLAG FLAG
RETAINER

REMOVAL MOUNTING
(1) Remove faceplate (see "Faceplate Removal"). SCREW(2)
(2) Remove attaching screws (Fig. 3).
(3) P u l l control outward.
(4) Disconnect i l l u m i n a t i o n l i g h t a n d switch w i r -
ing. HEATER
(5) Remove cables. CONTROL
UNIT
(6) Remove control u n i t . RB4S9

INSTALLATION Fig. 5—Heater Control

(1) I n s t a l l cables. (5) Detach cables from u n i t b y removing self adjust
(2) Connect i l l u m i n a t i o n l i g h t and switch w i r i n g . clips f r o m crank arms a n d removing flags from re-
(3) I n s t a l l u n i t i n i n s t r u m e n t panel a n d secure tainers (Fig. 6).
with m o u n t i n g screws. (6) Remove cable assemblies t h r o u g h glovebox
opening.
 • HEATER 24 - 7

TAB HEATER ASSEMBLY

REMOVAL
CONTROL (1) Disconnect b a t t e r y negative cable.
CABLE AND SELF-ADJUST (2) Remove w a t e r hoses o n engine side a n d p l u g
FLAG CLIP hoses and inlets on package (Fig. 8).
RECEIVER
BLOWER
WATER MOTOR
HEATER HOSE
ASSEMBLY DOOR ASSEMBLY
CONNECTORS
HOUSING CRANK RB461

Fig. 6—Removing Cables from Unit

(7) Place a 7 m m (1/4 inch) I D . tube over clip and
p r y self-adjust clip off core w i r e i f required (Fig. 7).
SELF ADJUST CLIP

COREWIRE

1/4" ID TUBE WATER

(7mm) HOSES

BLOWER
MOTOR
TO REMOVE
WIRE RB464
-*-TO
CABLE HOUSING INSTALL Fig. 8— Water Hose Connections
PR379A
(3) Remove r i g h t cowl side t r i m panel, i f equipped.
Fig. 7—Removing or Installing Self-Adjust Clip (4) Remove glovebox by removing m o u n t i n g screws
INSTALLATION at base and s w i n g i n g out from t h e bottom to avoid
(1) Position self-adjust clip on cable core w i r e catch and stops.
5 0 m m (2 inches) f r o m t h e s m a l l loop a t heater as- (5) Remove s t r u c t u r a l brace through glovebox
sembly flag end. W i t h a 7 m m (1/4 inch) I D . tube, opening.
snap self-adjust clip o n core w i r e . (6) Remove r i g h t h a l f of i n s t r u m e n t panel lower re-
(2) I n s t a l l cable assemblies t h r o u g h glovebox open- inforcement (8 screws). Be sure to disconnect t h e
ing. ground strap.
(3) A t t a c h self-adjust clips to crank arms a n d re- (7) Disconnect control cables (see "Control Cable
place flags i n receivers o n heater assembly. Removal").
(4) Install flages i n retainers and attach cables to (8) Disconnect blower motor wires on engine side.
control levers on control u n i t . (9) Remove screw t h a t retains package t o cowl side
(5) I n s t a l l control u n i t i n t o i n s t r u m e n t panel (see sheet m e t a l .
"Heater Control Removal"). (10) Remove u n i t r e t a i n i n g nuts on engine side (6
(6) I n s t a l l faceplate (see "Faceplate I n s t a l l a t i o n " ) . nuts).
(7) Move levers to extreme r i g h t - t o adjust clips. (11) Remove u n i t .

RESISTOR BLOCK INSPECTION

(1) Remove screws and mode door crank to separate
cover from housing.
REMOVAL
(2) Carefully slide heater core out.
(1) Remove connector.
(3) Peel dash panel seal below cover. Remove re-
(2) Remove m o u n t i n g screws a n d resistor block
t a i n i n g screws and remove cover from blower motor
from plenum.
assembly.
INSTALLATION (4) Separate fan from motor, motor from housing
(1) Install resistor block and secure w i t h m o u n t i n g and inspect a l l parts.
screws. (5) Reassemble heater assembly using necessary
(2) Install connector. new parts.
24 - 8 HEATER •
INSTALLATION (8) Disconnect shift lever cable, i f equipped.
(1) Position heater assembly t o dash and i n s t a l l re- (9) Lower steering column.
t a i n i n g nuts on engine side. (10) Remove steering c o l u m n studs.
(2) I n s t a l l cowl side r e t a i n i n g screws. (11) Remove r a d i o , i f equipped.
(3) Connect blower mtoor. (12) Remove m o u n t i n g screws a n d remove scoop
(4) Connect control cables (see " C o n t r o l Cable I n - connecting heater u n i t t o center d i s t r i b u t i o n duct, i f
stallation"). equipped.
(5) I n s t a l l r i g h t , lower i n s t r u m e n t panel reinforce- (13) Remove m o u n t i n g screws a n d remove center
ment. d i s t r i b u t i o n duct b y p u l l i n g b o t t o m o f i n s t r u m e n t
(6) I n s t a l l s t r u c t u r a l brace t h r o u g h glovebox open- panel o u t and d r o p p i n g duct out, i f equipped ( F i g .
ing. 11).
(7) I n s t a l l glovebox. (14) Remove heater control (see "Heater C o n t r o l
(8) I n s t a l l r i g h t cowl side t r i m panel, i f equipped. Removal").
(9) U n p l u g i n l e t s a n d w a t e r hoses a n d connect
(15) Remove m o u n t i n g screws and t h e n cover t h a t
hoses t o inlets on package (Fig. 8).
retains i n s t r u m e n t panel w i r i n g and l e t w i r i n g h a n g
(10) Connect b a t t e r y negative cable.
free.
DEFROSTER DUCT (16) Remove m o u n t i n g screw a n d slide left a i r duct
out t h r o u g h i n s t r u m e n t cluster opening, i f equipped.
(17) Remove screws a t t a c h i n g defroster duct to
REMOVAL dash panel.
(1) Disconnect b a t t e r y negative cable. (18) Reach i n t h r o u g h i n s t r u m e n t panel opening
(2) Open glovebox past stops.
and disengage snaps t o separate defroster duct i n t o
(3) Remove r i g h t upper a i r duct b y removing
two pieces.
m o u n t i n g screw and p u l l i n g duct out t h r o u g h glove-
(19) Remove defroster duct halves t h r o u g h i n s t r u -
box openings, i f equipped.
ment cluster opening.
(4) Remove i n s t r u m e n t panel center brace.
(5) Remove r i g h t k i c k pad.
INSTALLATION
(6) Remove r i g h t i n s t r u m e n t panel p i v o t bolt.
To install defroster duct, reverse removal
(7) Remove i n s t r u m e n t panel cluster (see " I n s t r u -
procedure.
m e n t Panel", Group 8).

AIR-CONDITIONING

INDEX
Page Page
A/C System Component 10 Manifold Gauge Set Installation 10
Diagnosing Air-Conditioning 11 Safety Precautions 9
General Information 8

GENERAL INFORMATION
RADIATOR CAP
Air-conditioned vehicles m u s t be equipped w i t h a
r a d i a t o r cap h a v i n g a h o l d i n g pressure o f 14-18 psig
(98 t o 122 kPag). Replace the r a d i a t o r cap t h a t does
not test w i t h i n t h i s specification.
CONDENSER
Inspect t h e condenser for obstruction or foreign-
m a t t e r . Clean i f present.
A n y obstruction t o t h e free flow of a i r across t h e
condenser w i l l decrease heat dissipation from t h e
condenser, decrease t h e efficiency o f the condenser
and, i n t u r n , decrease t h e evaporator's efficiency.
These conditions result i n increasing t h e discharge
pressure and horsepower load on the engine. The use
of a b u g screen is n o t recommended, i t also w i l l
decrease the free flow o f air.
Inspect the condenser for bent or damaged fins.
The bent fins on the condenser deflect a i r flow and
decrease the condenser area.
BUG SCREENS
B u g screens should n o t be i n s t a l l e d on vehicles
equipped w i t h a i r conditioning. A b u g screen i n -
stalled i n f r o n t of t h e condenser w i l l reduce a i r flow
and air-conditioner performance. Under severe heat
conditions a b u g screen m a y cause t h e engine to
over-heat.
RESISTOR BLOCK
The blower motor switch, i n conjunction w i t h a re-

LEFT SUCTION
GAUGE
LEFT "SUCTION GAUGE VALVE"*¥Ol
RIGHT "DISCHARGE
GAUGE VALVE"
CHARGING
HOSE
Fig. 1-^ Manifold Gauge Set Connections
sistor block, controls t h e speed o f the blower motor
and t h e velocity of the a i r flow from t h e heater or
air-conditioning outlets. The resistor block consists of
3 helically-wound w i r e resistors, connected t o t e r m i -
nals w h i c h are mechanically attached t o a phenolic
board. This assembly is bolted t o the p l e n u m .
The blower switch controls the blower motor speed
by selectively connecting i n series one, two, three or
none o f the resistors to the blower motor.
SAFETY PRECAUTIONS
The refrigerant used i n a l l air-conditioning instal-
lations is Refrigerant 12. I t is transparent and color-
less i n both the l i q u i d and vapor state. Since i t has a
b o i l i n g point o f -21.7°F (-29.8°C), a t atmospheric
pressure, i t w i l l be a vapor a t a l l n o r m a l tempera-
tures and pressures. The vapor is heavier t h a n air,
nonflammable and nonexplosive.
REFRIGERANT RECYCLING
R-12 refrigerant contains chloroflorocarbons (CFCs)
t h a t can contribute t o t h e depletion o f t h e ozone
layer i n t h e upper atmosphere. Ozone f i l t e r s o u t
h a r m f u l l r a d i a t i o n from the sun. To assist i n protect-
i n g t h e ozone layer, Chrysler Motors recommends
t h a t a R-12 refrigerant recycling device t h a t meets
SAE standard J1991 be used. Contact a n automotive
service equipment supplier for refrigerant recycling
equipment t h a t is available i n your area. Refer to
the operating instructions provided w i t h t h e recy-
c l i n g equipment for proper operation.
CAUTION: It is non-poisonous except when it is in
direct contact with open flame.
I t is noncorrosive except w h e n combined w i t h wa-
ter. The following precautions must be observed
w h e n h a n d l i n g Refrigerant 12.
CAUTION: Wear safety goggles when servicing the
refrigeration system.
AIR-CONDITIONING 24 - 9
COMPRESSOR INLET GAUGE
(NOT USED ON C-171)
SUCTION PORT
DISCHARGE
LINE RD57A
(Typical)
Refrigerant 12 evaporates so r a p i d l y a t n o r m a l at-
mospheric pressures and temperatures t h a t i t tends
to freeze a n y t h i n g i t contacts. F o r t h i s reason, ex-
treme care must be t a k e n t o prevent a n y l i q u i d re-
frigerant from contacting t h e s k i n and especially the
eyes.
Always wear safety goggles w h e n servicing the re-
frigeration p a r t of the air-conditioning system. Keep
a bottle of sterile m i n e r a l o i l h a n d y w h e n w o r k i n g on
the refrigeration system. Should any l i q u i d refriger-
ant get i n t o the eyes, use a few drops o f m i n e r a l o i l
to wash t h e m out. Refrigerant 12 i s r a p i d l y absorbed
by the o i l . Next, splash the eyes w i t h p l e n t y o f cold
water. C a l l you doctor i m m e d i a t e l y even t h o u g h i r r i -
t a t i o n has ceased after first a i d t r e a t m e n t .
WARNING: DO NOT HEAT REFRIGERANT 1 2
ABOVE 125 DEGREES F. (52°C). THE CAN MAY EX-
PLODE.
I n most instances, moderate heat is r e q u i r e d t o
b r i n g the pressure o f the r e f r i g e r a n t i n i t s container
above t h e pressure of the system w h e n c h a r g i n g or
adding refrigerant. A bucket or large pan o f h o t wa-
ter not over 125°F (52°C) i s a l l the heat r e q u i r e d for
t h i s purpose. Do n o t heat t h e refrigerant container
w i t h a blow torch or any other means t h a t would
raise temperature and pressure above t h i s tempera-
t u r e . Do not weld or steam clean o n or near t h e sys-
t e m components or refrigerant lines.
CAUTION: Keep Refrigerant 1 2 containers upright
when charging system.
When m e t e r i n g Refrigerant 12 i n t o t h e refrigera-
t i o n system, k e e p t h e s u p p l y t a n k o r c a n s i n a n
u p r i g h t p o s i t i o n . I f the r e f r i g e r a n t container is on
its side or upside down, l i q u i d refrigerant w i l l enter
the system and damage the compressor.
CAUTION: Always work in a well-ventilated room.
 24-10 AIR-CONDITIONING
A l w a y s m a i n t a i n good v e n t i l a t i o n i n t h e w o r k i n g
area. A l w a y s discharge t h e refrigerant i n t o t h e ser-
vice bay exhaust system or outside t h e b u i l d i n g .
Large q u a n t i t i e s o f refrigerant vapor i n a s m a l l ,
poorly v e n t i l a t e d room can displace the a i r a n d cause
suffocation.
A l t h o u g h Refrigerant 12 vapor is n o r m a l l y non-poi-
sonous, i t can be changed into a very poisonous gas i f
allowed t o come i n contact w i t h a n open flame. Do
not discharge large quantities of refrigerant i n a n
area h a v i n g a n open flame. A poisonous gas i s pro-
duced w h e n u s i n g t h e flame-type leak detector.
A v o i d i n h a l i n g the fumes from the leak detector.
CAUTION: Do not allow liquid refrigerant to touch
bright metal.
Refrigerant w i l l t a r n i s h b r i g h t metal and chrome
surfaces. A v o i d splashing refrigerant on any surface.
Refrigerant i n combination w i t h moisture is very cor-
rosive and can cause great damage to a l l m e t a l sur-
faces.
MANIFOLD GAUGE SET INSTALLATION
(ALL MODELS)
The M a n i f o l d gauge set, Tool C-3740A, has t w o
compound gauges and one discharge pressure gauge.
W i t h t h e C I 7 1 compressor only suction a n d dis-
charge gauges are used. I n this case t h e compressor
inlet gauge can be left disconnected.
E v a p o r a t o r S u c t i o n G a u g e — t h e left side o f t h e
manifold set is calibrated to register 0 to 30 inches of
vacuum (0 t o -100 kPag) and 0 to 150 psig (0 tolOOO
kPag). T h i s gauge is connected to the suction service
port of t h e compressor. A special service port
adapter, supplied w i t h t h e gauge set, provides t h e
means of connecting t h e gauge set manifold hose to
the service port. When the adpater is installed a t the
port and tightened, the stem of the valve i n t h e ser-
vice port is depressed, opening the service port valve.
D i s c h a r g e P r e s s u r e Gauge—the center o f t h e
manifold set is calibrated to register 0 to 300 psig (0
to 2100 kPag). For a l l tests this gauge is connected
to t h e discharge service port of t h e system. The
needle valve, located below the discharge pressure
gauge, is used to damp out gauge needle oscillations
so t h a t accurate readings can be obtained.
C e n t e r M a n i f o l d Outlet—provides t h e necessary
connection for a long service hose used w h e n dis-
charging t h e system, using a vacuum p u m p t o " p u l l
a v a c u u m " before charging the system, and for con-
necting the supply of refrigerant when c h a r g i n g t h e
system.
M a n i f o l d G a u g e V a l v e s — s h o u l d be closed w h e n
connecting t h e gauge set manifold to t h e service
ports of t h e compressor. The suction gauge valve a t
the left is opened to provide a passage between t h e
suction gauge a n d t h e center manifold outlet. The
•
discharge gauge valve a t the r i g h t is opened t o pro-
vide a passage between the discharge pressure gauge
and the center manifold outlet.
D e t a i l e d instructions for proper use of the m a n i f o l d
gauge set are contained i n t h e test covering each ser-
vice operation employing these gauges.
A/C REFRIGERANT SYSTEM COMPONENTS
C o m p r e s s o r — T h e p r i m e purpose of the compres-
sor is to compress the low pressure refrigerant vapor
f r o m the evaporator i n t o a h i g h pressure, h i g h tem-
perature vapor. The six cylinder C-171 compressor is
used o n a l l models.
C l u t c h P u l l e y a n d C o i l — a r e mounted o n t h e
compressor p rov id ing a convenient w a y t o drive i t
and disengage i t i n accordance t o the cooling needs.
C o n d e n s e r — i s located i n f r o n t o f the engine cool-
i n g radiator. Its function is t o cool t h e hot, h i g h pres-
sure r e f r i g e r a n t gas causing i t t o condense i n t o h i g h
pressure l i q u i d refrigerant.
F i l t e r - D r i e r — i s used to remove any traces o f mois-
t u r e f r o m t h e refrigerant system. T h i s component i n -
corporates t h e sight glass a n d t h e h i g h pressure
r e l i e f valve.
S i g h t Glass—(at the top o f t h e f i l t e r drier) is pro-
vided as a diagnostic tool to observe refrigerant flow
and indicate refrigerant level.
H i g h P r e s s u r e R e l i e f V a l v e — i s a safety device
designed t o open a u t o m a t i c a l l y i f t h e system pres-
sure reaches a predetermined level; i t prevents sys-
t e m component damage.
E x p a n s i o n V a l v e — t h e H-valve is used for a l l ap-
plications. I t s function is to meter refrigerant i n t o
t h e evaporator i n accordance w i t h cooling require-
ments.
E v a p o r a t o r C o i l — i s located i n t h e A/C u n i t and
i t s f u n c t i o n is to cool and d e h u m i d i f y the a i r before i t
enters the vehicle.
F r e e z e C o n t r o l — T h e m a i n function of a freeze
control is t o prevent condensate w a t e r on the face of
the evaporator coil from freezing and r e s t r i c t i n g t h e
Fig. 2—Damped Pressure Cycling Switch
 • AIR-CONDITIONING
airflow. To perform t h i s function, a damped pressure
cycling switch (Fig. 2) is located on the r e f r i g e r a n t
p l u m b i n g (suction line) near the H-valve, and is elec-
t r i c a l l y i n series w i t h the A/C clutch coil. I t i s a n on-
off switch w h i c h t u r n s t h e compressor on-off
depending o n the pressure i n the suction l i n e . T h e
switch is a sealed, specially calibrated u n i t and i f
found defective, must be replaced.
DIAGNOSING AIR -CONDITIONING
The reason for owner dissatisfaction m u s t be thor-
oughly understood before any attempt i s made t o re-
p a i r or replace any parts. I t must be determined i f
t h e condition is t h e refrigerant system, a i r -
conditioning a i r flow, or related to the compressor.
A f t e r confirming the condition, a functional test i n -
v o l v i n g one o f the following diagnostic charts is sug-
TEST PROCEDURES
INDEX
Page
Compressor Oil Level 14
Damped Pressure Cycling Switch 13
Expansion Valve (H-Type) 13
Expansion Valve Test 18
SIGHT GLASS REFRIGERANT LEVEL TEST
The sight glass, w h i c h is an i n t e g r a l p a r t of t h e f i l -
ter-drier, is a refrigerant level indicator (Fig. 1). To
check the refrigerant level, clean the sight glass and
start the engine. Place the air-conditioning controls
on A/C, the fan switch on h i g h and the temperature
lever o n cool. The room temperature should be a t
least 70°F (21°C). A f t e r operating for a few m i n u t e s
i n t h i s manner, check the sight glass.
SIGHT GLASS,
FILTER
DRIER
ASSEMBLY
9024-3
Fig. 1—Filter Drier
24 - 11
R e f r i g e r a n t L i n e s — a r e needed to carry the refrig-
erant between t h e various system components.
S e r v i c e V a l v e s — a t the compressor and t h e dis-
charge muffler are used to test and service the refrig-
erant system.
For safety reasons, t h e h i g h pressure f i t t i n g has
been changed t o meet SAE safety practice J639. A
special adapter is required for performance t e s t i n g
(C4803).
gested. A f t e r t h e condition has been properly
diagnosed a n d corrected, check out the complete sys-
t e m t o assure t h a t i t is peforming satisfactorily.
The following charts have been developed for quick
reference. I f t h e step by step method used is not com-
pletely understood, see the correct section of the Ser-
vice M a n u a l for detailed explanations.
Page
High Pressure Relief Valve 13
Overall Performance Test 16
Sight Glass Refrigerant Level Test 11
Testing System for Leaks 14
(1) I f the sight glass is clear, the A/C clutch is en-
gaged, t h e compressor discharge l i n e is w a r m and
the compressor i n l e t line is cool; t h e system has a
f u l l charge.
(2) I f the sight glass is clear, the A/C clutch is en-
gaged and there is not significant temperature differ-
ence between compressor i n l e t and discharge lines;
the system is empty or nearly empty. Connect a
gauge to the compressor discharge port. I f the gauge
reads less t h a n 25 psi (172 kPag), the damped pres-
sure cycling switch has failed.
(3) I f the sight glass is clear and the A/C clutch is
disengaged; t h e clutch is defective or, the clutch cir-
cuit is open, or the system is out of refrigerant. Per-
form damped pressure cycling switch test t o
determine condition.
(4) I f the sight glass shows foam or bubbles, t h e
system could be low on charge. Occasional foam or
bubbles is n o r m a l when the room temperature is
above 110°F (43°C) or below 70°F<21°C).
Adjust the engine speed to 1300 r p m . Block t h e air-
flow t h r u t h e condenser to increase the compressor
discharge pressure to 225 to 250 psig (1552 to 1724
kPag). I f sight glass s t i l l shows bubbles or foam, sys-
t e m charge level is low.
The refrigerant system w i l l not be low on charge
unless there is a leak. F i n d and repair the leak. I f
the leak can be repaired w i t h o u t discharging the sys-
24-12 AIR-CONDITIONING

C/TYPE BLOWER MOTOR

NOISE/VIBRATION FLOW CHART

BLOWER MOTOR NOISE

OR VIBRATION

NOUSE VIBRATION

ENGINE ON CHECK MOTOR

MOUNTING
CHECK SLOWER
MOTOR IN ALL
SPEED MODES
MOUNTING
OK
LCKDSE
NOISE PRESEhIT

A / C BUT A/C
NOT HTR. AND HTR. TIGHTEN

POSSIBLE LEAVE ENGINE ON RE-CHECK

RADIATOR SHUT BLOWER
FAN OR MOTOR OFF
COMPRESSOR
NOISE OK

NOISE STILL PRESENT NOISE GONE VIBRATION

STILL PRESENT

PROBLEM NOT CHECK BLOWER

IN BLOWER SCROLL AREA
SYSTEM
REMOVE BLOWER
WHEELAND
OPERATE BLOWER
MOT<>R AT
FOREIGN MATERIAL IN FAN VIBRATION LOW SPEED
FAN OR SCROLL RUBBING GONE
HOUSING

YES NO REPLACE BLOWER VIBRATION

REMOVE REPLACE YES WHEEL STILL
FOREIGN MOTOR A DJUST PRESENT
MATERIAL TO (TORRECT

RE-CHECK REPLACE
RE-CHECK RE-CHECK MOTOR

RE-CHECK

NOISE STILL NOISE

PRESENT GONE

REPLACE RE-CHECK
MOTOR
RR24D31
 • AIR-CONDITIONING
tern, t h e l o w refrigerant charge level can be cor-
rected as follows. M a i n t a i n i n g the discharge pressure
of 225 to 250 psig (1550 t o 1720 kPag), add refriger-
a n t gas t h r o u g h compressor suction line u n t i l foam is
cleared f r o m sight glass. T h e n add 13 oz. (368 g) or
one can o f refrigerant.
HIGH PRESSURE RELIEF VALVE
The H i g h P r e s s u r e R e l i e f V a l v e is located on the
discharge muffler. I t s f u n c t i o n is to prevent damage
to the a i r - c o n d i t i o n i n g system i n the event t h a t ex-
cessive pressure develops due to condenser a i r flow
being restricted by, for example, leaves, newspaper,
an overcharge of r e f r i g e r a n t or a i r i n the system.
The h i g h pressure r e l i e f valve vents only a small
a m o u n t of r e f r i g e r a n t necessary to reduce system
pressure a n d t h e n reseats itself. The majority o f the
refrigerant i s conserved i n the system. The valve is
calibrated t o vent a t a pressure of 450 to 550 psig.
(3100 t o 3790 kPag), therefore, t h e fact t h a t t h e
valve vented refrigerant, does not mean the valve is
defective.
DAMPED PRESSURE CYCLING SWITCH
The damped pressure cycling switch is located on
the r e f r i g e r a n t p l u m b i n g , suction line near the H -
valve a n d is electrically i n series w i t h the clutch coil.
I t i s a n on-off switch w h i c h t u r n s the compressor on
and off depending on t h e pressure i n the suction line.
The s w i t c h i s sealed, specially calibrated u n i t and i f
found defective, must be replaced.
Fig. 2—Damped Pressure Cycling Switch
TESTING
(1) Remove t h e wires (boot connector) from t h e
damped pressure cycling switch.
(2) Check c o n t i n u i t y o f the switch. Switch contacts
are closed a t temperatures above 7°C (45°F). I f no
c o n t i n u i t y , replace s w i t c h .
(3) I f contacts are closed, verify switch operation as
follows:
(a) Reconnect wires to pressure cycling switch.
24 - 13
(b) Set temperature control lever to f u l l cool po-
sition.
(c) Set A/C blower motor on low speed and p u s h
A/C button.
(d) Operate engine a t 1300 r p m for approxi-
mately 5 minutes t o stabilize the A/C system and
verify t h a t refrigerant system is f u l l .
(e) I f the compressor clutch cycles o n and off 3
to 10 times per m i n u t e w i t h temperature between
20° to 32°C (68° t o 90°F), t h e pressure c y c l i n g
switch is n o r m a l . I f the compressor clutch fails t o
engage, check for c o n t i n u i t y i n the electrical cir-
cuit. Above 32°C (90°F) the compressor c l u t c h may
be continuously engaged (non-cycling) due to t h e
h i g h heat load. This condition is n o r m a l .
REMOVAL
(1) Remove the electrical wires to the s w i t c h .
(2) Rotate switch counterclockwise to remove f r o m
pressure switch port.
(3) Remove and discard old O-ring.
INSTALLATION
(1) I n s t a l l new O-ring. Refrigerant o i l m u s t be ap-
plied to the new O-ring.
(2) Rotate switch clockwise to i n s t a l l on suction
line pressure switch port. T i g h t e n switch t o 50 ± 5 i n .
lbs. torque.
CAUTION: Power tools should not be used for in-
stallation of the switch. The possibility of stripping
the switch threads occurs above 52 in. lbs. torque.
(3) Connect wires.
(4) Verify operation.
EXPANSION VALVE (H TYPE) (Fig. 3)
REMOVAL
The system m u s t be completely discharged before
opening any refrigerant lines.
(1) Remove the 8 m m x 3 0 m m x 1.25 t h r e a d bolt i n
center of p l u m b i n g sealing plate.
(2) Carefully p u l l refrigerant line assembly towards
front of vehicle (take care n o t to scratch valve seal-
i n g surfaces w i t h tube pilots).
(3) Remove t w o 1/4-20 Torx Head screws. (Hold
valve, once cap screws are removed valve is com-
pletely disconnected).
(4) Carefully remove valve. §
INSTALLATION
(1) Remove and replace two a l u m i n u m N-gaskets
(1 on evaporator plate and 1 on p l u m b i n g plate).
(2) Remove sealing cap from H-valve control head
side sealing surface only and carefully hold i t against
evaporator sealing plate (do not scratch sealing sur-
face) and i n s t a l l two 1/4-20 N C Torx D r i v e Screws
and t i g h t e n 100±30 inch pounds (11 ± 3 N*m).
24 - 14 AIR-CONDITIONING
"H" VALVE
CONTROL
HEAD
ALUMINUM
" N " GASKET
PLUMBING
SEALING PLATE
RN408
Fig. 3—H-Valve Assembly
(3) Remove sealing cap from p l u m b i n g side sealing
surface a n d carefully h o l d p l u m b i n g up to valve and
i n s t a l l t h e 8 m m x 3 0 m m x 1.25 thread bolt a n d
t i g h t e n t o 200 ± 30 i n c h pounds (23 ± 3 N*m).
( 4 ) Connect wires t o damped pressure cycling
switch.
(5) A f t e r expansion valve is installed and system
charged a n d leak checked, repeat performance check.
TESTING THE SYSTEM FOR LEAKS
I f t h e air-conditioning system is not cooling t h e
passenger compartment properly, determine whether
the refrigerant system is fully charged w i t h R12 b y
following t h e procedures i n the "Sight Glass Refrig-
erant level Test" section o f this group.
I f the refrigerant system is empty or low i n refrig-
erant charge, a leak a t any o f the line f i t t i n g s or
component seals is l i k e l y (Fig. 4). To detect a leak i n
the refrigerant system, perform one of the following
procedures as indicated by the symptoms.
EMPTY REFRIGERANT SYSTEM LEAK TEST
(1) Evacuate the refrigerant system to t h e lowest
degree o f vacuum possible. See "Evacuating the Sys-
t e m " for instructions.
(2) Prepare a 14 oz. refrigerant (R12) charge t o be
injected i n t o the system. See " C h a r g i n g the System"
for instructions.
(3) Connect and dispense 14 ozs. of refrigerant
(R12) i n t o t h e evacuated refrigerant system. See
" C h a r g i n g the System".
(4) Proceed to step (2) of Low Refrigerant Level
Leak Test.
LOW REFRIGERANT LEVEL LEAK TEST
(1) Review the "Safety Precautions" section of t h i s
group to determine i f there is s t i l l R12 i n the refrig-
•
EXPANSION
D
AMPE
DPRESS
URE H" VALVE
CY
CLI
NGS
W T
ICH
J9024-32
Fig. 4—Testing for Leaks
erant system.
(2) Position the vehicle i n a breeze free w o r k area
to make i t less difficult to detect a s m a l l leak.
(3) W i t h t h e engine not r u n n i n g , use a n "Electronic
Leak Detector" (or equivalent) a n d search for leaks
(Fig. 12) i n t h e most accessible areas first.
(a) F i t t i n g s , lines, or components t h a t appear
oily u s u a l l y w i l l implicate a refrigerant leak.
(b) T o inspect the evaporator core for leaks, i t
is possible t o insert the leak detector probe i n t o the
opening o n the r i g h t side of the i n s t r u m e n t panel.
(4) Refer t o "Refrigerant Leak Repair Procedures"
for more i n f o r m a t i o n .
COMPRESSOR OIL LEVEL
I t is i m p o r t a n t to have the correct amount o f o i l i n
the A/C system t o ensure proper l u b r i c a t i o n o f the
compressor. Too l i t t l e o i l w i l l result i n damage to the
compressor, w h i l e too m u c h o i l w i l l reduce t h e cool-
i n g capacity o f the system and consequently r e s u l t i n
higher discharge air temperatures.
To provide t h e desired balance for adequate l u b r i -
cation a n d cooling capacity, each compressor is
charged w i t h 7 to 7.25 f l . oz. (207 to 2 1 4 m l ) o f o i l a t
the factory.
The o i l used i n the compressors is a 500 SUS vis-
cosity, wax-free refrigerant oil. O n l y refrigerant o i l
of the same type should be used t o service t h e sys-
tem. Do n o t use any other o i l . T h e o i l container
should be kept t i g h t l y capped u n t i l i t is ready for
use, and t h e n t i g h t l y capped after use to prevent en-
trance o f d i r t and moisture. Refrigerant o i l w i l l
quickly absorb any moisture i t comes i n contact w i t h .
• AIR-CONDITIONING 24 - 15

COMPRESSOR OIL LEVEL ADJUSTMENT*

WHEN REPLACING [SYSTEM CONTAMINATED| COMPLETE LOSS PARTIAL LOSS

A/C SYSTEM OR OF OF
COMPONENTS COMPRESSOR FAILED REFRIGERANT REFRIGERANT

CHECK FOR EVIDENCE CHARGE SYSTEM

DISCHARGE SYSTEM CHECK FOR LEAKS
OF OIL LEAKAGE PARTIALLY WITH R-12

NONE OIL LEAK REMOVE FILTER-DRIER

CHECK FOR LEAKS CORRECT LEAKS
NOTED NOTED AND COMPRESSOR

REMOVE/VISUALLY
DISCHARGE DISCHARGE DISCHARG E SYSTEM CHECK FOR EVIDENCE
INSPECT FOR
SYSTEM SYSTEM AND CORR EOT LEAKS OF OIL LEAKAGE
CONTAMINATION,
AND CLEAN:
H-VALVE *
i *

REPLACE CORRECT REPLACE FILTER- OIL LEAK NONE

COMPONENT LEAK DRIER NOTED NOTED

OIL ADDED REPLACE DISCHARGE ADD R-12

IF REPLACING: COMPONENT SYSTEM AS REQUIRED
• EVAPORATOR-
60 ML (2 FL OZ.)
• CONDENSER-
30 ML (1 FL OZ.)
• FILTER-DRIER-
30 ML (1 FL OZ.)

INSTALL NEW
FILTER-DRIER
C171
DRAIN
OIL
INSTALL
REPLACEMENT
COMPRESSOR

OIL REQUIRED
IN COMPRESSORS:
C-171: 207
TO 214 ML
(7 TO 7J5FL OZ.)
*READ CAREFULLY
"COMPRESSOR OIL LEVEL"
SECTION BEFORE PROCEEDING
WITH CHECK.
EVACUATE AND RECHARGE SYSTEM

CHECK SYSTEM COOLING PERFORMANCE

(SEE OVERALL PERFORMANCE TEST) PU120D
24 - 16 AIR-CONDITIONING
A f t e r the compressor has been installed and oper-
ated i n t h e A/C system, t h e o i l w i l l be distributed
throughout t h e system. Some o f t h e o i l w i l l be
trapped b y components i n the system. A n equivalent
amount o f o i l must be added t o t h e system t o com-
pensate for t h e trapped o i l w h e n replacing the follow-
ing:
Evaporator C o i l : 2 fl. oz. (59.2 m l )
Condenser: 1 fl. oz. (30 m l )
F i l t e r - D r i e r : 1 f l . oz. (30 m l )
I t w i l l n o t be necessary t o check o i l level i n t h e
compressor or to add o i l unless there has been a n o i l
loss due t o a r u p t u r e d line, shaft seal leakage, leak-
age from t h e evaporator, condenser, filter-drier, or
loss due t o a collision. O i l loss a t a leak point w i l l be
evident b y t h e presence o f a w e t , shiny surface
around the leak.
Replacement compressors are also charged w i t h 7-
7.25 fl. oz. (207-214 m l ) . W h e n replacing compressor,
remove, d r a i n o i l , measure a m o u n t and discard old
oil. F o r t h e replacement compressor use t h e same
amount o f r e f r i g e r a n t o i l as recovered from the failed
compressor. T h i s adjustment is not needed i f the sys-
tem has been flushed, r e m o v i n g retained o i l .
The O i l Level A d j u s t m e n t C h a r t should be followed
to determine the need t o perform a n o i l level adjust-
ment.
CHECK OIL LEVEL (BASIC FILL)
(1) Slowly discharge complete system.
(2) W i t h system discharged, disconnect suction and
discharge lines, remove compressor, d r a i n a n d dis-
card o i l t h r o u g h suction port and discharge port on
top.
(3) A d d 5 fluid ounces (148 m l ) of clean refrigerant
oil t h r o u g h the suction port.
(4) I n s t a l l compressor, i n s t a l l a n d t i g h t e n suction
and discharge lines t o compressor. Use new gaskets
to prevent leakage.
(5) Evacuate and charge system.
OVER-ALL PERFORMANCE TEST
H u m i d i t y has an i m p o r t a n t bearing on the temper-
ature of t h e a i r delivered to t h e vehicle's interior.
This is t r u e o f a l l a i r - c o n d i t i o n i n g systems. I t is i m -
portant to understand the effect h u m i d i t y has on t h e
performance of the system. W h e n h u m i d i t y is h i g h ,
the evaporator has t o perform a double duty. I t must
lower the a i r temperature and the temperature of the
•
moisture carried i n the air. Condensing the moisture
i n t h e a i r transfers a great deal o f heat energy i n t o
t h e evaporator fins a n d t u b i n g . This reduces t h e
amount o f heat t h e evaporator can absorb from t h e
air. "
Evaporator capacity used t o reduce t h e a m o u n t o f
moisture i n the a i r is not wasted. W r i n g i n g some o f
t h e moisture out o f the a i r e n t e r i n g the vehicle adds
to the comfort o f the passengers. However, a n owner
m a y expect too m u c h f r o m t h e i r air-conditioning sys-
t e m on h u m i d days. A performance test is t h e best
way to determine whether or not the system is per-
f o r m i n g u p t o standard. T h i s test also provides v a l u -
able clues t o the possible cause o f trouble.
PERFORMANCE TEST PROCEDURE
A i r temperature i n test room must be 70°F (21°C)
m i n i m u m for t h i s test.
(1) Connect a tachometer and manifold gauge set
(Fig. 5).
(2) Set A/C controls t o M a x A/C, temperature lever
on f u l l cool, and blower on h i g h .
(3) S t a r t engine and adjust r p m t o 1000 w i t h A/C
clutch engaged.
(4) E n g i n e should be warmed up w i t h doors, w i n -
dows, and hood closed.
(5) Insert a thermometer i n the left center A/C out-
let and operate t h e engine for 5 minutes. T h e A/C
clutch may cycle depending on ambient conditions.
(6) A f t e r 5 minutes note the discharge a i r temper-
ature. ( I f t h e clutch cycles take, the reading before
the clutch disengages).
(7) Open the hood and disconnect the gray vacuum
line going t o the heater water control valve. Observe
the valve a r m for movement as t h e l i n e is discon-
nected. I f i t does not move refer to the heater valve
controls sections of this group. Plug the vacuum l i n e
to prevent leakage.
(8) Operate t h e A/C for 2 more minutes and t a k e
the discharge a i r temperature reading again. I f the
temperature increased by more t h a n 5°F (2°C), check
the blend a i r door cable for correct operation. I f the
temperature does n o t increase more t h a n 5°F (2°C),
compare t h e discharge a i r temperature, suction, and
discharge pressures w i t h t h e values i n t h e perfor-
mance c h a r t corresponding w i t h t h e garage ambient
temperature. Reconnect the gray vacuum line.
(9) I f the discharge a i r temperature fails to meet
the specifications i n t h e performance temperature
chart, refer t o t h e diagnostic analysis charts for fur-
ther test i n f o r m a t i o n .
• AIR-CONDITIONING 24 - 17

AIR-CONDITIONING REFRIGERANT
SYSTEM DIAGNOSIS

TEMPERATURE IN TEST AREA 21-29° C (70-85° F)

VERIFY R-12 CHARGE-CONNECT MANIFOLD GAUGES
SEE MAINTENANCE AND ADJUSTMENTS SECTION
IF R-12 CHARGE IS LOW, CORRECT LEAK, EVACUATE,
AND CHARGE SYSTEM

BYPASS CYCLING CLUTCH SWITCH LOCATE AND REMOVE BOTH

USING JUMPER WIRE REFER TO VACUUM LINES AT RECIRC
GROUP 8W, WIRING DIAGRAMS DOOR ACTUATOR INSTALL
LT-GN LINE WHERE DK-GN
LINE HAD BEEN
START ENGINE ADJUST IDLE TO
1000 rpm IN PARK OR NEUTRAL
WITH PARK BRAKE SET

CLOSE PASSENGER COMPARTMENT

SET CONTROL TO A/C, PANEL, HIGH
BLOWER, FULL HEAT

i
BLOWER EVAPORATOR COMPRESSOR
ENGINE POSSIBLE
MOTOR SUCTION GAUGE DISCHARGE GAUGE
RPM CAUSE
SPEED PSIG (kPag) 1 PSIG (kPag) 2

20-35 PSIG 140-240 PSIG

4: 1000 J-i HI ~\-\ (140 TO 240 kPog) (966 TO 1656 kPag) — NORMAL

FREEZE 15 INCHES H-VALVE

H-VALVE OF VACUUM STUCK OPEN IF
CONDITIONS
CANNOT BE MET
38 PSIG (262 kPag)
OR MORE THEN H-VALVE
THAW STUCK CLOSED IF
H-VALVE DROPS TO 25 TO 35
PSIG (172 CONDITIONS
TO 240 kPag) CANNOT BE MET

RESTRICTED
RETURN RECIRC DOOR VACUUM LINES TO NORMAL CONDENSER-
RESTRICTED

G 1000 HI 20-30 PSIG

(140 TO 207 kPag)
240 PSIG OR HIGHER
(1656 kPag)
DISCHARGE LINE
-RADIATOR
OVERHEATING-
AIR IN SYSTEM-
OVERCHARGED
SYSTEM-COOLING
FAN INOP.

20-30 PSIG 140 PSIG (966 kPag) DEFECTIVE

(140-207 kPag) OR LESS COMPRESSOR HEAD
GASKET OR
DISCHARGE REEDS
RECONNECT LOW PRESSURE/CYCLING SWITCH
AND RECONNECT THE VACUUM
LINES TO THE RECIRC/ACUATOR

8924-1
24 - 18 AIR-CONDITIONING •

Fig. 5— Typical Manifold Gauge Set Installation

EXPANSION VALVE TEST
Test must b e made a t ambient temperature o f
70° t o 85°F (21°C t o 29°C).
A f t e r performing a l l previously mentioned tests,
conduct the H-valve test as follows:
(1) A/C System—Close the windows a n d operate
the engine a t 1000 r p m . Set air-conditioning controls
for M a x . A/C, h i g h blower, temperature control lever
i n f u l l reheat position and cycling clutch switch elec-
t r i c a l l y bypassed. Disconnect a n d p l u g the water
valve vacuum hose i n t h e engine compartment.
PERFORMANCE TEMPERATURE
(2) Operate t h e system for a t least (5) m i n u t e s i n
order to obtain p a r t i a l stabilization and sufficient re-
heat t o load the system. Pressure a t the discarge ser-
vice port should reach 140-240 psig (966 t o 1656
kPag) (Fig. 6). I f head pressure o f 140-240 psig (966
to 1656 kPag) cannot be obtained, check system
charge level (see system c h a r g i n g section).
(3) P u t crushed d r y ice on control head (completely
cover head) for a m i n i m u m o f 30 seconds.
WARNING: EXTREME CARE MUST B E USED WHEN
HANDLING DRY ICE AS SKIN INJURY CAN OCCUR
IF PROTECTIVE GLOVES ARE NOT WORN.
CHART

Garage Ambient 70°F 80°F 90°F 100°F 110°F

Temperature (21°C) (26.5°C) (32°C) (37.5°C) (43°C)
Discharge Air 38-50°F 42-54°F 46-58°F 50-62°F 54-66°F
Temperature (3-10°C) (6-12°C) (8-14°C) (10-17°C) (12-19°C)
120 psig 16° psig 200 psig 240 psig 280 p jg
S

Compressor Discharge 195 235 270 305 340

Pressure
827 pag
k 1103 kPag 1379 kPag 1655 kPag 1379 kPag
1344 1620 1861 2103 2344
18 psig 20 psig 22 psig 25 psig 26 psig
Evaporator Suction 30 35 39 43 47
Pressure
124 kPag 138 kPag 152 kPag 172 kPag ' 179 kPag
207 241 269 296 324
 • AIR-CONDITIONING 24 - 19

Fig. 6—Expansion Valve (H-Valve Test)

Evaporator suction pressure m u s t drop t o below 15" o f VALVE

v a c u u m (-50 kPag). I f the condition i s n o t met the EE- C O N T R O L

valve is stuck open and should be replaced. Remove d r y HEAD

ice and watch evaporator suction pressure; i t should i n -

crease to a m i n i m u m of 38 psig (262 kPag) a n d t h e n sta-
bilize t o a pressure o f 25 t o 35 psig (172 t o 240 kPag).
A n y H-valve w h i c h does not produce t h i s response is
stuck open and should be replaced.
(4) Reconnect A/C water valve v a c u u m hose (gray) and
set temperature control i n cool position.
(5) Set engine speed a t 1000 r p m and blower on H I .
The evaporator suction pressure should be i n the range
of 20-30 psig (138 to 207 kPag). I f compressor discharge
is h i g h e r t h a n 240 psig (1656 kPag), check for restricted
discharge line, r a d i a t o r overheating, a i r i n system or
PLUMBING
f a u l t y viscous fan drive. I f discharge pressure is less t h a n S E A L I N G PLATE
140 psig (966 kPag), check compressor head gaskets and
discharge reeds. RN408

(6) Reconnect the electrical wires t o the damped pres-

sure cycling clutch switch. Fig. 7—H-Valve Assembly
-20 AIR-CONDITIONING

A/C COMPRESSOR AND CLUTCH DIAGNOSIS

A / C COMPRESSOR NOISY
COMPRESSOR W O N T TURN
PROPERLY CLUTCH ENGAGES
BUT SLIPS OR SMOKES h
COMPRESSOR OFF COMPRESSOR ON CLUTCH SLIPPING BELTS SLIPPING

EVALUATE INSIDE ADJUST BELT

CLUTCH PULLEY VEHICLE MODE- LOW VOLTAGE TENSION
RUBBING MAX A / C AT CLUTCH REPLACE IF
BLOWER-LOW NECESSARY
OUTLETS-OPEN
WINDOWS-
CLOSED
• CHECK WIRING,
MOUNTING CLUTCH
CLUTCH BEARING SWITCHES, CLUTCH
BOLTS LOOSE AMPERAGE AND PULLEY RUBS
NOISY O N COIL
TIGHTEN GROUND

REMOVE BELTS AMPERAGE

LOOSE
RECHECK RUBBING BELTS GREATER THAN COIL
AND BEARING ADJUST 5 AMPS MISMOUNTED
NOISE

Y
CHECK AIR GAP
BELT CLUTCH COIL
RESET IF NOT SEIZED
INTERFERENCE PARTIALLY
.020 INCH TO COMPRESSOR
SHORTED
.035 INCH

BENT PULLEY KNOCKING OR REPLACE

REPLACE PULLEY GRINDING NOISE REPLACE COMPRESSOR
AND FROM COIL AND CLUTCH
ARMATURE COMPRESSOR ASSEMBLY

DEFECTIVE COIL
IF SO REPLACE OIL/GREASE ON
REPLACE COMPRESSOR FRICTION SURFACES

FRONT ALIGNMENT REPLACE

PIN LOOSE OR COMPRESSOR CHECK SHAFT
OUT OF FRONT SEAL FELT
SPECIFICATION COVER

COIL SNAP NOTE: APPLY PARKING BRAKE AND RUN

OIL SATURATED
RING NOT ENGINE IN NEUTRAL ONLY.
FELT REPLACE
PROPERLY *CLUTCH OR BELT SLIPPING CAN BE COMPRESSOR
INSTALLED CAUSED BY OVERCHARGED SHAFT SEAL
SYSTEM OR CONDENSER FAN NOT
RUNNING.
IF BEARING
DEFECTIVE REPLACE CLUTCH
REPLACE GREASE PURGED PULLEY AND
PULLEY AND FROM BEARING ARMATURE
ARMATURE
1 OF 2 RN685A
 AIR-CONDITIONING 24 - 21

A/C C O M P R E S S O R A N D CLUTCH DIAGNOSIS

COMPRESSOR CLUTCH W O N T COMPRESSOR LEAKS

ENGAGE OIL O l REFRIGERANT

DEFECTIVE
NO VOLTAGE VOLTAGE AT CRANKSHAFT
AT CLUTCH CLUTCH NORMAL SEAL
CARTRIDGE

DEFECTIVE
FAULTY CRANKSHAFT
OPEN FUSE
GROUND SEAL
PLATE

DEFECTIVE
PUSHBUTTON SEAL ("O" RING),
SWITCH OPEN COIL
FRONT COVER,
REAR COVER

FAULTY DEFECTIVE
REPLACE COIL COMPRESSOR
WIRING
THRU BOLT

READ
POOR VOLTAGE AT COMPRESSOR
GROUND CLUTCH LOW SERVICE SECTION
FOR REPAIR

DEFECTIVE
CHECK WIRING
COMPRESSOR
AND SWITCHES BODY

CHECK VOLTAGE IF CONTACT OPEN

DROPS FROM CHECK REPLACE
CLUTCH TOWARD REFRIGERANT COMPRESSOR
BATTERY CHARGE

IF CHARGE
OK REPLACE
SWITCH

DAMPED

I
I
PRESSURE I
CYCLING | ^

NOTE: APPLY PARKING BRAKE

AND RUN ENGINE IN NEUTRAL
ONLY.
2 OF 2 RN685A
24 - 22 AIR-CONDITIONING
REFRIGERANT SYSTEM SERVICE PROCEDURES
INDEX
Page
Charging the System 24
Correcting Low Refrigerant Levels 22
Discharging the System 23
REFRIGERANT LEAK REPAIR PROCEDURE
LOST CHARGE
I f t h e system has lost a l l charge due t o a leak:
(1) Evacuate the system.
(2) Charge t h e system w i t h approximately one
pound of refrigerant.
(3) Locate a l l leaks.
(4) Repair a l l leaks.
(5) Replace filter-drier bottle.
CAUTION: Replacement filter-drier units must be
sealed while in storage. The drier used in these
units absorbs and traps moisture quickly upon ex-
posure to the atmosphere. When installing a drier,
have all tools and supplies ready for quick reas-
sembly to avoid keeping the system open any
longer than necessary.
(6) Check system o i l level (see test procedure).
(7) Evacuate and charge the system.
LOW CHARGE
I f t h e system has not lost a l l o f i t s r e f r i g e r a n t
charge; locate and repair a l l leaks. I f i t is necessary
to increase the system pressure t o find t h e leak (be-
cause of an especially low charge), add 1/2 l b (230 g)
of refrigerant. I f there has been a significant o i l loss,
check t h e system o i l level. I f i t has been possible to
repair t h e leak w i t h o u t discharging t h e refrigerant
system and i f an o i l level check was n o t necessary,
use t h e procedure for correcting low refrigerant level.
CORRECTING LOW REFRIGERANT LEVEL
Since the refrigeration system is completely sealed,
the refrigerant level w i l l not be low unless there is a
leak i n the system.
Before adding refrigerant where the cause of a low
level i s not k n o w n , t h e system should be tested for
leaks. Assuming t h a t leaks have been corrected w i t h -
out discharging the system, proceed w i t h p a r t i a l
charge.
I n s t a l l and connect manifold gauge set (Fig. 1).
(1) Close both manifold gauge set valves. Open
manifold gauge set needle valve.
(2) Connect the suction gauge test hose t o t h e suc-
t i o n service port of the compressor. Connect t h e dis-
charge gauge test hose to t h e discharge service port.
•
Page
Evacuating the System 23
Refrigerant Leak Repair Procedure . . . . . . . . . . . . 22
(3) Connect one end of long test hose t o t h e center
manifold o u t l e t , and other end to r e f r i g e r a n t dispens-
ing manifold.
(4) Close t w o dispensing m a n i f o l d valves a n d open
r e m a i n i n g dispensing manifold valve. Remove protec-
tive cap f r o m opened valve.
WARNING: NEVER USE THESE CANS TO CHARGE
INTO THE HIGH PRESSURE SIDE OF THE SYSTEM
(COMPRESSOR DISCHARGE PORT) OR INTO A
SYSTEM THAT IS AT HIGH TEMPERATURE, B E -
CAUSE THE HIGH SYSTEM PRESSURES COULD
BE TRANSFERRED INTO THE CHARGING CAN
CAUSING IT TO EXPLODE.
(5) Screw a can o f R-12 t o t h e opened m a n i f o l d
valve. Be sure gasket is i n place and i n good condi-
tion. T i g h t e n refrigerant can a n d m a n i f o l d l o c k i n g
n u t t o insure a good seal. Do not o v e r t i g h t e n since 6
to 8 foot-pounds (8 to 11 N«m) is sufficient i f gasket
is i n good condition.
(6) T u r n m a n i f o l d valve (above t h e refrigerant can)
completely clockwise to puncture t h e can. T h i s closes
the valve a n d seals the refrigerant i n t h e can.
CAUTION: Do not heat refrigerant 12 above 125°F
(52°C).
(7) Place refrigerant can i n a large p a n o f water
heated t o 125 degrees F (52°C). Place p a n o f water
containing t h e refrigerant can on a n accurate scale
so t h e a m o u n t of refrigerant added can be weighed.
Open t h e refrigerant manifold valve.
(8) Purge a l l a i r from test hoses. A i r i n the system
w i l l be trapped i n the condenser causing a b n o r m a l l y
h i g h discharge pressures a n d i n t e r f e r i n g w i t h con-
densing o f t h e refrigerant.
(a) Loosen both test hoses a t t h e manifold
gauge set. T i g h t e n t h e hoses as soon as t h e a i r is
purged.
(b) Loosen charging hose connection a t m a n i -
fold gauge set. This w i l l purge a i r f r o m the charg-
i n g hose. T i g h t e n connection as soon as a i r is
purged.
(9) W i t h vehicle windows open and hood up, oper-
ate engine a t 1300 r p m .
(10) Place a i r conditioner control on A/C a n d place
the fan s w i t c h on h i g h .
(11) I f necessary, block the condenser t o m a i n t a i n a
discharge pressure o f 225 to 250 psig (1550 t o 1725
 • AIR-CONDITIONING 24 - 23

COMPRESSOR INLET GAUGE

(NOT USED ON C-171)
LEFT "SUCTION
GAUGE VALVE'

SUCTION
INLET PORT
HOT WATER
125°F (52°C)

ADAPTER
REFRIGERANT
MANIFOLD
PU124A

Fig. 1—Adding Partial Charge

kPag). System must be charged t h r o u g h the evapora-
t o r suction service ports as follows:
(a) Slowly open t h e suction service gauge valve.
Meter flow of refrigerant b y adjusting t h e suction
service gauge valve so t h e pressure registered a t
the suction service gauge does n o t exceed 50 psig
(345 kPag). Keep refrigerant container u p r i g h t .
(b) A d d refrigerant gas u n t i l there is no foam
visible a t t h e sight glass. A s soon as a l l foam
clears, note the w e i g h t registered o n t h e refriger-
a n t scale.
(c) W a t c h t h e refrigerant w e i g h i n g scale a n d
add 14 oz. (437 g) o f refrigerant (equivalent to one
can).
Close the suction gauge valve.
CAUTION: Too much refrigerant in the system can
cause abnormally high discharge pressures. Care
must be used so the exact recommended amount of
refrigerant is added after foam clears in the sight
glass.
(d) Close dispensing manifold valve. Remove
test hoses a n d adapters from t h e service ports o f
compressor, a n d i n s t a l l protective caps a t service
ports.
DISCHARGING THE SYSTEM
Since t h e air-conditioning refrigerant system is
pressurized, i t w i l l be necessary to completely dis-
charge t h e system before replacing a n y r e f r i g e r a n t
components. The procedure is as follows:
(1) I n s t a l l gauge set as described under m a n i f o l d
gauge set installation. M a k e sure t h e gauge set
valves are closed before a t t a c h i n g the hoses to t h e re-
frigerant system.
(2) I n s t a l l a long hose to t h e m a n i f o l d gauge set
connector. R u n this hose to t h e o i l collector can near
the shop exhaust system (Fig. 2).
A good o i l collector can may be made f r o m a large
empty coffee can w i t h a plastic top. S l i t t h e plastic
top i n t h e form of a Y to make a n entrance for t h e
refrigerant hose and exit for t h e gas.
(3) Open the compressor discharge and suction l i n e
pressure valves and discharge t h e r e f r i g e r a n t i n t o
the o i l collector can. Watch t o make sure t h e hose
does not blow out of the collector can.
(4) W h e n t h e system has been completely dis-
charged, measure t h e amount o f o i l collected i n t h e
can. The amount of o i l measured should be added t o
the refrigerant system before i t is recharged. A d d
new oil—discard the used o i l .
EVACUATING THE SYSTEM
Whenever the system has been opened t o t h e atmo-
sphere, i t is absolutely essential t h a t t h e system be
evacuated or "vacuumed" to remove a l l t h e a i r a n d
moisture. A i r i n the refrigerant system causes h i g h
24 - 24 AIR-CONDITIONING
Fig. 2—Discha
compressor discharge pressures, a loss i n system per-
formance, a n d oxidation of t h e compressor o i l i n t o
g u m and v a r n i s h . Moisture i n the refrigerant system
can cause the expansion valve to malfunction. U n d e r
c e r t a i n conditions i t can react w i t h the refrigerant t o
f o r m destructive acids. I t is necessary t o adhere t o
the following procedure to keep air and moisture out
of t h e system.
(1) Connect the manifold gauge set to the compres-
sor a n d long test hose from manifold gauge set center
connection to vacuum pump, Tool C-4081, or C-4289,
as shown i n Figure 3.
(2) Open both manifold gauge set valves.
(3) Start t h e vacuum pump and operate u n t i l t h e
evaporator suction gauge registers a t least 26 inches
of v a c u u m (-88 kPag).
I f a t least 26 inches of vacuum (-88 kPag) cannot
be obtained, either the system has a leak or the vac-
u u m pump is defective. Check t h e v a c u u m pump. I f
the p u m p proves to be functioning properly, t h e sys-
t e m has a leak. Charge the system w i t h one pound o f
refrigerant. Locate and reapir a l l leaks. Discharge
t h e refrigerant and evacuate the system.
(4) Continue to operate t h e pump for a t least five
minutes.
(5) Close manifold valves. T u r n off t h e v a c u u m
p u m p and observe evaporator suction gauge for t w o
m i n u t e s . The vacuum level should r e m a i n constant.
•
ng the System
I f the vacuum level falls off, the system has a leak.
Charge t h e system w i t h 1 pound (450 g) o f refriger-
ant. Locate and repair a l l leaks. Discharge t h e sys-
t e m and repeat evacuation procedure.
CHARGING THE SYSTEM
The refrigerant system m u s t have been evacuated
using the previous procedure before charging. Charge
using only R-12 refrigerant. R-12 is available i n b u l k
tanks or 14 ounce (437 g) cvans. Follow t h e safety
precautions for h a n d l i n g R-12 as listed under air-con-
ditioning.
CHARGING WITH 14 OUNCE (437G) CANS
The special refrigerant dispensing m a n i f o l d per-
m i t s charging three cans o f r e f r i g e r a n t a t one t i m e .
When using disposable cans o f t h i s type, carefully
follow the can manufacturers i n s t r u c t i o n s .
WARNING: NEVER USE THESE CANS TO CHARGE
INTO THE HIGH PRESSURE SIDE OF THE SYSTEM
(COMPRESSOR DISCHARGE PORT) OR INTO A
SYSTEM THAT IS AT HIGH TEMPERATURE, BE-
CAUSE THE HIGH SYSTEM PRESSURES COULD
BE TRANSFERRED INTO THE CHARGING CAN
CAUSING IT TO EXPLODE.
Keep t h e refrigerant manifold valves capped when
not i n use. Keep a supply o f extra refrigerant-can-to
 • AIR-CONDITIONING
Fig. 3—Evacu
refrigerant-manifold gaskets on hand so t h e gaskets
can be replaced periodically. This w i l l insure a good
seal w i t h o u t excessive t i g h t e n i n g o f the can o r the
manifold nuts.
(1) A t t a c h center hose f r o m manifold gauge set to
refrigerant dispensing manifold. T u r n refrigerant
manifold valves completely counterclockwise so they
are f u l l y open. Remove protective caps from refriger-
a n t manifold.
(2) Screw refrigerant cans i n t o manifold. Be sure
manifold-to-can gasket is i n place and i n good condi-
t i o n . T i g h t e n can a n d m a n i f o l d nuts to 6 t o 8 foot-
pounds (8 to 11 N»m).
(3) T u r n three r e f r i g e r a n t manifold valves com-
pletely clockwise t o puncture the cans and close the-
manifold valves (Fig. 4).
(4) Purge the a i r f r o m t h e charging line b y loosen-
i n g the charging hose a t the manifold gauge set and
t u r n i n g one o f the r e f r i g e r a n t valves counterclock-
wise to release refrigerant. When the refrigerant gas
starts escaping from the loose connection, re-tighten
t h e hose.
CAUTION: Do not heat refrigerant 12 above 125°F
(52°C).
(5) F u l l y open a l l three refrigerant manifold valves
and place the cans o f refrigerant into a pan contain-
24 - 25
(-88 T O - 9 5 K PAG)
PU125C
ig the System
i n g 125°F (52°C) water. T h e water w i l l w a r m t h e
c h a r g i n g can a n d a i d i n t h e transfer of t h e charge
i n t o t h e system.
(6) S t a r t t h e engine and move the controls t o A/C
low blower position.
The damped pressure cycling switch w i l l prevent
the c l u t c h f r o m engaging u n t i l refrigerant is added
to the system. I f the clutch does engage, replace the
s w i t c h before proceeding any further.
(7) Charge t h r o u g h the suction side of the system
by slowly opening the suction manifold valve. Adjust
the v a l v e as necessary so charging pressure does not
exceed 50 psig (345 kPag). M a i n t a i n the temperature
of t h e w a t e r i n the pan b y adding w a r m water as
necessary.
(8) A d j u s t t h e engine speed to a fast idle of approx-
i m a t e l y 1300 r p m .
(9) W h e n a l l three cans of refrigerant are com-
pletely empty, close t h e manifold gauge set valves
and r e f r i g e r a n t m a n i f o l d valves.
Refrigerant Charge
Truck Model Refrigerant
Ai! 44 oz. max.
24 - 26 AIR-CONDITIONING •
LEFT "SUCTION COMPRESSOR INLET GAUGE
GAUGE (NOT USED ON C-171)

LEFT "SUCTION GAUGE V A L V E "

SUCTION PORT

HOT WATER
52*C (125 F)#

DO NOT HEAT CANS OF

REFRIGERANT OVER
52 C (125 F)AS
- #

THEY MAY EXPLODE REFRIGERANT

MANIFOLD
PU126B

Fig. 4 — C o m p l e t e Charging of the System

SERVICE PROCEDURES
INDEX
Page Page
Compressor Drive Belt Adjustment 27 Handling Tubing and Fittings 26
Compressor Noise 27 Vacuum Control System Adjustments and Tests . . 27
Condensate Drain Tube 29

HANDLING TUBING AND FITTINGS
K i n k s i n t h e refrigerant t u b i n g or sharp bends i n
the refrigerant hose lines w i l l greatly reduce t h e ca-
pacity of t h e entire system. H i g h pressures are pro-
duced i n t h e system w h e n i t is operating. E x t r e m e
care must be exercised to make sure t h a t a l l connec-
tions are pressure t i g h t . D i r t a n d moisture can enter
the system w h e n i t is opened for repair or replace-
ment of lines or components. T h e following precau-
tions m u s t be observed.
The system m u s t be completely discharged before
opening a n y f i t t i n g or connection i n t h e refrigeration
system. Open f i t t i n g s w i t h caution even after t h e
system has been discharged. I f any pressure is no-
ticed as a f i t t i n g is loosened, allow trapped pressure
to bleed off very slowly. Never attempt to rebend
formed lines to f i t . Use the correct line for t h e instal-
lation y o u are r e p a i r i n g .
A good r u l e for t h e flexible hose lines i t to keep the
radius o f a l l bends a t least 10 times t h e diameter o f
the hose. Sharper bends w i l l reduce t h e flow of re-
frigerant. The flexible hose lines should be routed so
they are a t least 3 inches (80 m m ) from the exhaust
manifold. I t is a good practice to inspect a l l flexible
hose lines a t least once a year to make sure they are
i n good condition and properly routed.
U n i f i e d p l u m b i n g connections w i t h a l u m i n u m -
N-gaskets cannot be serviced w i t h O-rings. These
gaskets are n o t reusable a n d do not require lubrica-
t i o n before i n s t a l l i n g (Fig. 1).
The use o f correct wrenches when m a k i n g connec-
tions a r e very i m p o r t a n t . Improper wrenches or i m -
proper use o f wrenches can damage the fittings.
 • AIR-CONDITIONING
The i n t e r n a l parts o f the r e f r i g e r a t i o n system w i l l
r e m a i n i n a state o f chemical s t a b i l i t y as l o n g as
pure-moisture-free Refrigerant 12 a n d refrigerant o i l
is used. A b n o r m a l amounts o f d i r t , moisture or a i r
can upset t h e chemical s t a b i l i t y a n d cause opera-
t i o n a l troubles or even serious damage is present i n
more then m i n u t e q u a n t i t i e s .
Fig. f— Adjust Vacuum Test Bleed Valve
W h e n i t is necessary t o open t h e refrigeration sys-
t e m , have e v e r y t h i n g y o u w i l l need to service t h e
system ready so t h e system w i l l n o t be left open any
longer t h a n necessary. Cap or p l u g a l l lines a n d fit-
t i n g s as soon as they are opened to prevent t h e en-
trance of d i r t and moisture. A l l lines and components
i n parts stock should be capped or sealed u n t i l they
are ready to be used.
A l l tools, i n c l u d i n g t h e r e f r i g e r a n t dispensing m a n -
ifold, the mainfold gauge set and test hoses should be
kept clean a n d dry.
COMPRESSOR DRIVE BELT ADJUSTMENT
Satisfactory performance of t h e air-conditioning
system is dependent upon d r i v e belt condition a n d
tension. I f t h e proper tensions are n o t m a i n t a i n e d ,
belt slippage w i l l greatly reduce air-conditioning per-
formance a n d drive b e l t life. To avoid such adverse
effects, the following service procedure should be fol-
lowed:
(1) A n y belt t h a t has operated for a m i n i m u m of
half-hour is considered t o be a used belt. Adjust a i r -
conditioning drive belts a t t h e t i m e o f new-vehicle
preparation. See C h a r t , "Accessory Belt Drives,"
"Group 7, Cooling."
(2) Measure drive belt tension a t regular service
i n t e r v a l s using a belt tension gauge or torque
method, and adjust as needed.
(3) O n a l l new-belt i n s t a l l a t i o n s , new-belt tension
specifications should be used w h e n t h e belt is first
installed to obtain proper tension. Thereafter, these
replacement belts should be serviced according t o t h e
above procedure. A l w a y s replace belts i n pairs i f so
equipped, otherwise t h e old b e l t w i l l have insuffi-
24 - 27
cient tension a n d t h e load w i l l be p r i m a r i l y o n t h e
new belt. See C h a r t , "Accessory B e l t Drives," "Group
7, Cooling."
COMPRESSOR NOISE
Noises t h a t develop d u r i n g air-conditioning opera-
t i o n can often be misleading. For example: w h a t
sounds l i k e a failed front b e a r i n g or connecting rod,
may be caused b y loose bolts, nuts, m o u n t i n g brack-
ets, or a loose c l u t c h assembly. Improper belt tension
is also often t h e source of a n objectionable noise a n d
can easily be m i s t a k e n for i n t e r n a l compressor t r o u -
bles.
Drive belts are speed sensitive. T h a t is, a t different
engine speeds, a n d depending upon belt tension, belts
can develop u n u s u a l noises t h a t are often m i s t a k e n
for mechanical problems w i t h i n t h e compressor.
ADJUSTMENT PROCEDURES
(1) Select a q u i e t area for testing. Switch compres-
sor on and off several times t o clearly identify com-
pressor noise.
(2) T i g h t e n a l l compressor m o u n t i n g bolts, clutch
m o u n t i n g bolt, c l u t c h coil m o u n t i n g screws and com-
pressor drive belts. Check t h a t p l u m b i n g is not r u b -
b i n g other parts.
(3) M a k e sure t h a t matched drive belts are equally
tensioned. Replace a n y parts t h a t are defective or
missing.
(4) Re-test vehicle; i f noise persists, continue t r o u -
ble shooting system for source o f noise.
VACUUM CONTROL SYSTEM ADJUSTMENTS AND
TESTS
To keep the v a c u u m harness i n place, common v i -
n y l tape (sometimes called plastic tape of electri-
cian's tape) cannot be used as i t w i l l cause the tube
to deteriorate d i r e c t l y under t h e tape, when h i g h u n -
derhood temperatures are involved. A compatible n y -
l o n type of tape such as M S CH69, (#281) available
f r o m K e n d a l l Company, or a n equivalent m u s t be
used.
The test of t h e push b u t t o n switch operation deter-
mines whether or n o t the vacuum and electrical cir-
cuits are properly connected a n d t h e controls are
functioning properly. However, i t is possible t h a t a
vacuum control system t h a t operates perfectly d u r i n g
h i g h manifold v a c u u m provided a t engine idle m a y
not function properly a t h i g h engine speeds. Before
s t a r t i n g this test, stop engine and make certain t h e
vacuum source hose a t engine i n t a k e manifold is
t i g h t on i t s connector.
Start v a c u u m p u m p Tool C-4081, or C-4289, a n d
connect t h e v a c u u m test set Tool C-3707. Adjust
bleed valve on test to obtain a vacuum reading of ex-
24 - 28 AIR-CONDITIONING
Fig. 2— Vacuum Tube Assembly Test
actly 8 inches of m e r c u r y (-27 kPag) w i t h a finger
blocking the prod on end o f test hose (Fig. 1).
I t is essential t h a t t h e bleed valve be adjusted so
the vacuum gauge p o i n t e r w i l l r e t u r n t o exactly 8
inches (-27 kPag) w h e n t h e prod is covered b y a fin-
ger. Otherwise a false r e a d i n g w i l l be obtained when
t h e control circuit i s tested.
A l t e r n a t e l y release a n d reblock the hose prod sev-
eral times. Make sure t h e bleed valve is adjusted so
the vacuum gauge p o i n t e r r e t u r n s to exactly 8 inches
of v a c u u m (-27 kPag) w h e n the prod is covered w i t h
a finger (Fig. 1).
Disconnect engine v a c u u m source hose a t engine
i n t a k e manifold and i n s e r t v a c u u m tester hose prod
i n t o source hose l e a d i n g to push b u t t o n s w i t c h . Place
vacuum gauge on t h e cowl so i t can be observed from
the driver's position as push buttons are operated.
Start t h e test b y depressing t h e control " H e a t "
mode pushbutton. V a c u u m tester gauge needle w i l l
drop u n t i l the actuator has operated, and should t h e n
r e t u r n to 7-1/4 to 8 inches (-25 to -27 kPag) depend-
i n g on vacuum leakage. Continue to depress; "Off,"
" M a x . A/C", "A/C", " V e n t " , "Defrost", a n d " H e a t "
mode pushbutton a l l o w i n g t i m e for actuators t o oper-
ate after each b u t t o n i s pushed, and for the vacuum
to stabilize. Note t h e v a c u u m drop below 8 inches
(-27 kPag) after each operation. The m a x i m u m allow-
able v a c u u m drop below 8 inches (-27 kPag) after
each operation is 3/4 i n c h (-3 kPag). (Bypass the vac-
u u m storage t a n k i f so equipped).
I f the vacuum drop is more t h a n 3/4 inch (-3 kPag),
first recheck the tester for reading exactly 8 inches
(-27 kPag). I f correct, inspect t h e f i t of t h e 7 port
hose connector p l u g o n the push b u t t o n switch. This
p l u g must be positioned a l l the way onto the 7 ports
on the push button s w i t c h .
Fig. 3 — Vacuum Actuator Test
CAUTION: Do not use lubricant on the switch ports
or in the holes in the plug, as lubricant will damage
the vacuum valve in the switch. If it is difficult to
properly position the connector plug all the way on
the switch ports, put a drop or two of clean water in
the holes of the connector plug. This will allow the
plug to slide completely on the switch ports.
I f v a c u u m drop is now w i t h i n l i m i t s , proceed w i t h
the over-all performance test. I f v a c u u m drop is s t i l l
i n excess o f 3/4 i n c h (-3 kPag), remove 7 port connec-
tor from s w i t c h and seal p o r t No. 6 w i t h a finger t o
check source hose. T h e n remove prod from source
line and i n s e r t i t a l t e r n a t e l y i n t o each connector p o r t
except No. 6 (Fig. 2).
Note a m o u n t o f v a c u u m drop below 8 inches (-27
kPag) after each actuator has operated. I f v a c u u m
test gauge comes back t o 8 inches (-27 kPag) a t each
of the 7 ports, the hoses and actuators are not leak-
ing. The c o n t r o l switch is f a u l t y and m u s t be re-
placed. I f excessive v a c u u m drop shows up a t one or
more ports i n connector block, isolate f a u l t y hose or
actuator.
Inspect hose connections to the actuator involved.
Then test w h e t h e r actuator or hose is a t fault; use
the test hose on the actuator involved (Fig. 3).
A leak i n a hose m a y be detected w i t h v a c u u m test
set by r u n n i n g the fingers along the hose and watch-
i n g v a c u u m gauge reading. The tube can be repaired
by c u t t i n g o u t t h e " l e a k " a n d i n s e r t i n g t h e tube
"ends" i n t o a 1/8 i n c h (3 m m ) inside diameter rubber
tube. Wet t h e tube w i t h w a t e r to a i d assembly.
A v a c u u m drop i n excess o f 3/4 inch (-3 kPag) be-
low the 8 inches (-27 kPag) needed i n this test w i l l
not interfere w i t h the engine operation, other t h a n
perhaps to cause a r o u g h idle. I t can, however, i n t e r -
 • AIR-CONDITIONING
fere w i t h the proper operation o f the air-conditioning
and h e a t i n g controls at h i g h speeds and d u r i n g accel-
eration
CONDENSATE DRAIN TUBE
Condensation w h i c h accumulates o n the bottom o f
the evaporator housing is expelled t h r o u g h t h e
molded rubber d r a i n tube i n t o t h e engine compart-
COMPRESSOR SERVICE
Page
A/C Clutch
Installation All
Removal
Voltage and Current Draw
Compressor
GENERAL INFORMATION
The C-171 is a six cylinder, a x i a l type compressor.
The pistons are reciprocated b y a swash plate fas-
tened to t h e drive shaft. W h e n t h e clutch is ener-
gized, the compressor clutch rotates and drives t h e
six pistons i n sequence. The electromagnetic clutch is
b u i l t i n t o the drive pulley assembly (Fig. 1).
The electromagnetic field coil, t h a t does not rotate,
is fastened directly to t h e compressor w i t h a snap
r i n g . T h e positive lead w i r e is connected t o the en-
gine w i r i n g harness and the ground lead is attached
to the compressor housing.
SERVICING THE C-171 COMPRESSOR
The following precautions should be observed w h e n
servicing the C-171 compressor.
(1) The A/C refrigerant system m u s t be completely
discharged before performing any disassembly or re-
pair service to the compressor.
Fig. 1—A/C Clutch Assembly, C-171 Compressor
24 - 29
ment. The tube m u s t be k e p t open to prevent conden-
sation from collecting i n the b o t t o m of the housing.
The squeezed r u b b e r flap a t t h e d r a i n t u b e t i p is
designed to keep engine compartment a i r f r o m enter-
i n g i n t o the system y e t allow condensate drainage. I f
the t i p is not properly formed or has been damaged,
the system w i l l not d r a i n properly. Therefore, i f the
tube i s damaged, i t should be replaced.
INDEX
Page
29 Assembly 34
30 Disassembly 32
30 General Information 29
29 Oil Level 36
32 Servicing the C-171 Compressor 29
(2) Cleanliness is extremely i m p o r t a n t . T h e w o r k
area m u s t be clean a n d free of air-borne dust and
dirt.
(3) Use only wax-free, 500 SUS (Saybolt U n i f o r m
Seconds) viscosity r e f r i g e r a n t o i l . Refrigerant o i l
must be kept i n a sealed container u n t i l ready for
use to prevent m o i s t u r e a n d d i r t f r o m entering.
Never use any other o i l .
(4) To ensure proper l u b r i c a t i o n , the a m o u n t of o i l
used is i m p o r t a n t . I f t h e compressor is to be removed
for repair or replacement, measure the a m o u n t o f re-
frigerant o i l i n t h e compressor so t h a t t h e same
amount can be added w h e n t h e new or repaired com-
pressor is installed.
CAUTION: When replacing the compressor assem-
bly, or if at any time it is anadvertently tipped over
the crankshaft should be rotated by hand several
revolutions to clear oil accumulation from the com-
pressor head before the clutch is energized to
avoid damaging the compressor reed valves.
A/C/ CLUTCH
CLUTCH COIL VOLTAGE AND CURRENT
DRAW TO TEST THE COIL CIRCUIT
(1) Verify battery state o f charge. (Test indicator
should be green.)
(2) Connect a n a m m e t e r (0-10 ampere scale) i n se-
ries w i t h the clutch coil t e r m i n a l . Use a voltmeter (0-
20 volt scale) w i t h clip leads measuring voltage
across the battery a n d A/C clutch.
(3) W i t h A/C control i n A/C mode and blower a t
low speed, start t h e engine and r u n a t n o r m a l idle.
( 4 ) The A/C clutch should engage immediately (car-
bureted engines) or i n 11 seconds after the s t a r t ( E F I
engines). The clutch voltage should be w i t h i n 2 volts
24 - 30 AIR-CONDITIONING •
of t h e battery voltage. I f t h e A/C clutch does n o t en-
gage, check the fuse.
(5) The A/C coil is acceptable, i f t h e c u r r e n t d r a w
is 2.0 to 3.7 amperes a t 11.5 t o 12.5 volts a t c l u t c h
coil w i t h room ambient 21° ± 3°C (70" ± 5°F).
Where voltage is more t h a n 12.5 volts, add electrical
loads as needed by increasing blower speed and/or
switching other electrical accessories on. I f coil cur-
r e n t reads zero, the coil is open and should be r e -
placed. I f t h e ammeter r e a d i n g is 4 amperes or more,
t h e coil i s shorted and should be replaced. I f t h e coil
voltage i s not w i t h i n 2 volts o f t h e b a t t e r y voltage,
check the c i r c u i t external to t h e c l u t c h coil for exces-
sive voltage drop and repair accordingly.

CLUTCH REMOVAL
The procedure for replacing t h e clutch w i t h o u t dis-
charging t h e system is as follows:
(1) Loosen and remove d r i v e belts, and disconnect
t h e field coil lead w i r e .
(2) Remove compressor m o u n t i n g screws.
(3) L i f t compressor up and l a y i t on t h e top o f the
front yoke.
(4) U s i n g a 13 m m socket a n d spanner w r e n c h , tool
C-4563, remove the shaft n u t a n d t h e n lock washer
(Fig. 2).

Fig. 4—Removing Pulley Snap Ring, C-171

PU151A
Fig. 2—Removing Clutch Retaining Nut, C-171
Compressor
(5) Screw clutch front plate p u l l e r , Tool C-4771,
i n t o hub. Tighten enter screw and remove front
plate, and shims (Fig. 3).
CAUTION: Do not use screwdrivers between front
plate assembly and pulley to pry off front plate be-
cause this may damage the front plate assembly.
(6) Remove pulley r e t a i n i n g snap r i n g w i t h Tool C-
4574, and slide pulley assembly off o f compressor
(Fig. 4).
(7) Remove snap r i n g r e t a i n i n g field coil onto com-
pressor housing. After r e m o v i n g screw and w i r e clip,
Compressor
slide field coil off o f housing (Fig. 5).
(8) E x a m i n e fractional faces o f the clutch pulley
and front plate for wear. The pulley and f r o n t plate
should be replaced i f there is excessive wear or scor-
i n g . I f t h e f r i c t i o n surfaces are oily, inspect t h e shaft-
nose area o f t h e compressor for o i l and remove the
felt from t h e f r o n t cover. I f the compressor felt is sat-
urated w i t h o i l , the shaft seal is l e a k i n g and w i l l
have t o be replaced.
(9) Check bearing for roughness or excessive leak-
age o f grease. I f grease from bearing has contami-
nated the faces o f the p u l l e y or front plate o r i f the
bearing is r o u g h , the c l u t c h pulley and front plate
should be replaced.
 • AIR-CONDITIONING
Fig. 5—Removing Clutch Coil, C-171 Compressor
CAUTION: The clutch pulley and the front plate
were mated at the factory by a burnishing opera-
tion. No attempt should be made to separately re-
place either part because it will result in clutch
slippage due to insufficient contact area.
Fig. 6—Installing Clutch Coil, C-171 Compressor
CLUTCH INSTALLA TIOH
(1) A l i g n hole i n back of field coil w i t h p i n i n com-
pressor end housing and position field coil i n t o place
(Fig. 6). M a k e sure t h a t lead wires a r e properly
routed a n d fasten w i t h t h e ground w i r e r e t a i n i n g
screw.
(2) I n s t a l l field coil r e t a i n i n g snap r i n g (bevel side
outward), w i t h snap r i n g pliers, Tool C-4574. W i t h a
screwdriver, press a l l the w a y around snap r i n g t o
ma ke sure i t is properly seated i n t h e groove.
CAUTION: If snap ring is not fully seated it will vi-
brate out resulting in a clutch failure and severe
damage to the front face of the compressor.
24 - 31
Fig. 7—Installing Pulley Assembly, C-171
Compressor
(3) I n s t a l l pulley assembly onto compressor. I f nec-
essary, t a p gently w i t h a block of wood on t h e grease
slinger (Fig. 7).
CAUTION: Do not mar the pulley frictional surface
and straighten out the grease slinger if it has been
distorted by tapping.
(4) I n s t a l l pulley assembly r e t a i n i n g snap r i n g ,
(bevel side outward) w i t h snap r i n g pliers Tool C-
4574. W i t h a screwdriver, press a l l t h e way a r o u n d
the snap r i n g to make sure i t is properly seated i n
the groove.
(5) I f t h e original front plate assembly and p u l l e y
assembly are to be reused, t h e o l d shims can be used.
I f not, place a t r i a l stack o f shims, .100 i n . (2.54mm)
t h i c k , on t h e shaft against t h e shoulder.
(6) I n s t a l l front plate assembly onto shaft m a k i n g
sure t h e k e y enters keyway i n front plate assembly
hub.
(7) W i t h t h e front plate assembly t i g h t against t h e
shims, measure the a i r gap between front plate a n d
pulley face w i t h feeler gauges (Fig. 8). The m i n i m u m
a i r gap should be between .020 a n d .035 inch (0.5
and 0.9mm). I f proper a i r gap is not obtained, add or
subtract shims u n t i l desired a i r gap is obtained.
(8) I n s t a l l lockwasher a n d shaft n u t . T i g h t e n t o
155 ± 20 i n . lbs. (17.5 ± 2 N m i ) using torque
w r e n c h a n d spanner wrench tool C-4563.
Shims m a y compress after t i g h t e n i n g shaft n u t .
Check a i r gap i n four or more places t o verify i f a i r
gap is s t i l l correct. Spin Pulley for f i n a l check.
CLUTCH BURNISH
A f t e r a new clutch has been installed a n d voltage
and amperage are determined t o be satisfactory, cy-
cle t h e clutch a t approximately 5 sec. o n and 5 sec.
off for 20 cycles w i t h t h e system i n A/C mode, h i g h
24 - 32 AIR-CONDITIONING •

Fig. 8—Measuring Air Gap, C-171 Compressor

blower, engine r p m a t 1500-2000. This procedure
(burnishing) w i l l " w e a r - i n " the opposing friction sur-
faces a n d provide a higher clutch torque capability.
COMPRESSOR
Cleanliness is extremely i m p o r t a n t . T h e surfaces
around t h e suction and discharge ports should be
cleaned t h o r o u g h l y before opening t h e system a t
these points.
COMPRESSOR REMOVAL
(1) Discharge the system.
(2) Disconnect the suction and discharge lines f r o m
the suction a n d discharge ports. Cap t h e lines and
the ports immediately to prevent moisture and d i r t
Fig. 2—Removing Compressor thru Bolts
f r o m entering the system.
(3) Disconnect clutch w i r e .
(4) Remove t h e compressor-to-bracket a t t a c h i n g
bolts and remove compressor.
(5) D r a i n oil from the compressor suction and dis-
charge ports. To service the compressor, i t w i l l be
necessary to remove the compressor c l u t c h assembly.
See "Servicing A/C C l u t c h " .
DISASSEMBLY
(1) Remove key from crankshaft o f compressor b y
g r i p p i n g w i t h a side cutter a » L p u l l i n g (Fig. 1).
(2) Remove compressor t h l f p b o l t s u s i n g a 6 m m
alien wrench (Fig. 2).

Fig. 1—Crankshaft Key Removal

 • AIR-CONDITIONING
(3) Remove f r o n t cover b y tapping on the outside
diameter of t h e cover w i t h a plastic hammer (Fig. 3).
(4) Remove O-ring seal from front cover and dis-
card (Fig. 4). Never re-use cover O-rings or valve
plate steel-n-gaskets.
(5) Remove felt f r o m front cover (Fig. 5).
Fig. 4—Removing O-Ring
Fig. 5—Removing Felt
(6) Place compressor front cover on a flat surface
w i t h neck o f cover facing up. U s i n g a brass d r i f t or
non-metallic object, press out gas seal plate (Fig. 6).
24 - 33
Fig. 6—Removing Gas Seal Plate
(7) Remove shaft seal cartridge from crankshaft
(Fig. 7).
Fig. 7—Removing Shaft Seal Cartridge
(8) Carefully remove dowel pins, valve plate, suc-
t i o n reed valve, and steel-n-gasket. Discard steel-
n-gasket. See F i g u r e 8.
(9) Remove rear cover by t a p p i n g the outside d i a m -
eter of t h e cover w i t h plastic h a m m e r (Fig. 9).
(10) Remove O-ring from rear cover and discard
(Fig. 10).
(11) Carefully remove the dowel pins, valve plate,
suction reed valve, and steel-n-gasket. Discard steel-
n-gasket (Fig. 11).
24 - 34 AIR-CONDITIONING
Fig. 8—Disassembly Compressor Front End
W h e n leak is evident because of compressor body
center O-ring, t h e following procedure should be fol-
lowed.
(12) Carefully separate front and rear compressor
housings b y tapping the body lugs w i t h a plastic
hammer. (Fig. 12).
CAUTION: Do not separate front and rear housings
more than one inch (Fig. 13).
•
RB312
Fig. 10—Removing Rear O-Ring
Fig. 11 —Disassembling Compressor Rear End
(13) Remove O-ring and inspect for nicks, cuts, or
burrs, i f found. C u t and discard.
(14) Inspect O-ring sealing surface for scratches,
d i r t , or porosity, I f a scratch or porosity is found,
compressor should be replaced.
ASSEMBLY
(1) I n s t a l l O-ring by carefully stretching a n d pass-
i n g a new, d r y O-ring over t h e rear housing to center
of compressor body.
(2) O i l new O-ring w i t h refrigerant o i l (500 SUS)
and position i n t o seal groove.
(3) M a t e t w o body halves b y carefully p u s h i n g
t h e m together m a k i n g sure O-ring a n d housings are
properly positioned.
(4) I n s t a l l dowel pins i n rear compressor body.
 • AIR-CONDITIONING 24 - 35

(11) Carefully i n s t a l l dowel pins i n front compres-

sor body.
(12) I n s t a l l suction reed valve.
(13) I n s t a l l f r o n t valve plate assembly.
(14) I n s t a l l steel-n-gasket.
(15) Carefully clean crankshaft a n d coat l i g h t l y
w i t h refrigerant o i l .
(16) Lubricate crankshaft gas seal cartridge l i g h t l y
w i t h refrigeration o i l and i n s t a l l o n crankshaft. Car-
tridge must be properly positioned on slot o f crank-
shaft.
(17) Lubricate crankshaft seal seat cavity o f front
housing w i t h refrigeration oil.
(18) Lubricate crankshaft seal seat and seal seat O-
r i n g w i t h r e f r i g e r a t i o n oil. I n s t a l l O-ring on seal seat
and i n s t a l l seal seat i n front cover using a socket
t h a t contacts t h e outer diameter o f t h e seal seat
plate (Figs. 14 a n d 15).

RB314

Fig. 12—Separating Body Halves

FRONT COVER

RB316

Fig. 14—Match Socket to Outer Seal Diameter

(19) Lubricate front cover O-ring w i t h refrigeration
o i l and carefully place i t i n seal groove o f front hous-
ing.
REAR "°" FRONT D D 0 1 C
(20) Carefully i n s t a l l front cover to front compres-
BODY HALF R , N G
BODY HALF R B J 1 5

sor body. I f cover does not v i s u a l l y a l i g n w i t h dowel

F/gf. 13—Compressor Body Half Separation pins on i n s t a l l a t i o n , completely remove cover a n d
make certain t h e carbon seal of the crankshaft seal
(5) I n s t a l l suction reed valve.
cartridge is properly positioned i n the seal cartridge
(6) I n s t a l l rear valve plate assembly. and not s t i c k i n g to the seal seat plate.
(7) I n s t a l l steel-n-gasket.
(21) I n s t a l l compressor t h r u bolts and t i g h t e n f i n -
(8) Apply l i g h t coating of refrigeration o i l to new
ger t i g h t , t h e n torque to 260 i n . lbs. (29 Nnn).
O - r i n g and carefully place into sealing groove of rear
(22) I n s t a l l k e y i n crankshaft.
cover.
(23) I n s t a l l felt shaft seal i n t o front housing and
(9) I n s t a l l rear cover to rear compression housing.
position a t base of housing neck.
(10) H o l d front compressor body and rear cover to-
gether f i r m l y , rotate compressor assembly and place
i t on a bench so i t is setting f i r m l y on rear cover
w i t h crankshaft facing upward.
24 - 36 AIR-CONDITIONING •
(2) I n s t a l l t h e compressor o n t h e vehicle a n d
t i g h t e n d r i v e belts. See group 7, " C o o l i n g " for correct
belt adjustment. Torque compressor m o u n t i n g bolts
to 40 ± 10 f t . lbs.
(3) Reconnect c l u t c h w i r e .
(4) Remove caps f r o m suction and discharge lines
and suction a n d discharge ports. U s i n g new gaskets,
i n s t a l l lines onto compressor and t i g h t e n t o 19 t o 26
N*m (170 t o 230 inch-pounds).
(5) Evacuate a n d charge the system.

CAUTION: Clutch should be cycled off and on with

engine at fast idle, 15 to 20 times to ensure clutch
parts reseat with each other after assembly before
clutch engages with high head pressure at the com-
pressor.

Fig. 15—Installing Seal Seat
(24) I n s t a l l 266 m l (9 fluid ounces) of refrigeration
oil (500 SUS) i n t o t h e compressor t h r o u g h suction
port.
(25) Check compressor operation for smoothness by
r o t a t i n g crankshaft a t least 5 f u l l revolutions.
(26) Check front housing c l u t c h coil alignment p i n
for proper i n s t a l l a t i o n .
(27) I n s t a l l clutch. See " C l u t c h I n s t a l l a t i o n " .
INSTALLATION
(1) Adjust o i l level t h r o u g h the compressor suction
port to 5 fl. oz. (148 m l ) i f necessary. (See " O i l L e v e l "
below).
OIL LEVEL
W h e n a new compressor is i n s t a l l e d a t the factory,
i t contains 7 t o 7.25 fl. oz. (207 to 214 m l ) of a special
wax-free 500 SUS viscosity refrigerant o i l . W h i l e the
a i r - c o n d i t i o n i n g system is i n operation, the o i l is car-
r i e d t h r o u g h t h e e n t i r e system a n d r e t u r n s to t h e
compressor b y w a y o f the suction port. Some of t h i s
oil w i l l be trapped and retained i n various parts o f
the system. Consequently, once the system has been
i n operation, t h e amount of o i l left i n the compressor
w i l l always be less t h a n t h e o r i g i n a l amount. Re-
placement compressors are also charged w i t h 7 t o
7.25 fl. oz. (207-214 m l ) . W h e n replacing a compres-
sor, remove d r a i n o i l , measure the amount, and dis-
card old o i l . For t h e replacement compressor use t h e
same a m o u n t o f refrigerant o i l as recovered f r o m
failed compressor. This adjustment i s not needed i f
the system has been flushed, removing retained o i l .

EVAPORATOR H E A T E R ASSEMBLY

INDEX
Page Page

A/C Distribution Spot Cooler Ducts 42 Faceplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Air Outlet Assemblies 42 General Information 36
Control Chart . . . . . . 40 Louver Assemblies 42
Control Test 40 Operation of All Controls 38
Defroster Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Resistor Block . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Electrical Controls and Circuits . 40 Temperature Control Cable 41
Evaporator Control Unit 41 Vacuum Actuators 41
Evaporator Heater Assembly 43 Vacuum Controls and Circuits 38

GENERAL INFORMATION (Fig. 1). The system is m a n u a l l y controlled by the op-

This air-conditioner is designed specifically for con-
ventional cab t r u c k s w i t h t h e heater-evaporator
package designed t o f i t under the i n s t r u m e n t panel
erator. Controls have been kept simple for ease o f
service a n d operation.
I n t h e b l e n d a i r reheat air-conditioning u n i t , a l l
the a i r e n t e r i n g t h e system passes t h r o u g h the evap-
orator a n d a selected portion passes t h r o u g h t h e
 AIR-CONDITIONING 24 - 37

CENTER DISTRIBUTION RIGHT SPOT

DUCT COOLER DUCT
MOUNTING
SCREW
LEFT SPOT COOLER
DUCT

AIR
OUTLET ASSEMBLIES

DEFROSTER
DUCT

MOUNTING
HEAT/DEFROST SCREW
DOOR ACTUATOR

MOUNTING.
HARNESS
TEMPERATURE CONTROL VACUUM
CABLE (RED FLAG) HARNESS
MOUNTING
NUT

TAB
BLOWER
MOTOR

MOUNTING
RECEIVER VACUUM
NUT
LINES
BLOWER
MOTOR
TEMPERATURE HEATER-A/C FEED WIRES . DRAIN
CONTROL LEVER CONTROL ASSEMBLY TUBE
RB469B
Fig. 1—Heater and Evaporator Assembly
24 - 38 AIR-CONDITIONING
heater core depending on the p o s i t i o n of t h e blend a i r
door. The system controls are located i n the center o f
the i n s t r u m e n t panel w i t h i n easy reach o f the driver.
The combination electrical a n d v a c u u m s w i t c h con-
trols t h e compressor clutch, mode o f operation a n d
blower. Modes are Off, M a x . A/C, A/C, V e n t , Heat,
and Defrost. A four speed blower motor s w i t c h con-
trols t h e a m o u n t o f a i r flow. T h e evaporator-heater
package includes t h e blower motor, i n t a k e duct, w i t h
outside a i r r e c i r c u l a t i n g door, evaporator coil, heater
core, defroster discharge doors, blower motor speed
resistors, v a c u u m harness, v a c u u m actuators and A/
C a i r outlets t o the d i s t r i b u t i o n ducts.
Defrost, Heat, A/C a n d V e n t modes a u t o m a t i c a l l y
supply 100 percent outside air.
The a i r d i s t r i b u t i o n ducts supply a i r from t h e u n i t
to four panel mounted, f u l l y d i r e c t i o n a l , outlets. T w o
outlets are p a r t o f t h e faceplate a n d two are snapped
i n t o the panel on t h e r i g h t side.
Satisfactory performance o f t h e combined air-condi-
t i o n i n g a n d h e a t i n g system is dependent upon correct
operation a n d adjustment of a l l operating controls, as
w e l l as correct f u n c t i o n o f a l l refrigeration system
components. The inspections, tests and adjustments
should be used t o locate the cause o f a m a l f u n c t i o n ,
The tests i n t h i s m a n u a l have been arranged i n a
logical sequence t h a t has proved t o be the surest and
shortest route t o accurate diagnosis. I t is recom-
mended t h a t they be followed a n d performed i n t h e
order t h e y are presented.
OPERATION OF ALL CONTROLS
Operation m u s t be tested as described i n t h e fol-
l o w i n g sequence:
(1) Inspect, test, a n d adjust compressor d r i v e belt.
(2) S t a r t engine a n d adjust engine speed t o 1300
r p m . Use a reliable tachometer.
(3) Move temperature control lever to Cool position
and mode lever t o A/C position.
(4) The i n l e t a i r door should be open to outside air.
Open vehicle windows.
(5) Test t h e blower operation a t a l l four speed po-
sitions. I f t h e blower does not operate correctly refer
to " E l e c t r i c a l Controls a n d C i r c u i t . " Leave t h e
blower s w i t c h i n the " H i g h " ( H i ) position.
(6) T h e compressor should be r u n n i n g and t h e air-
conditioning system i n operation.
I n a d d i t i o n to the six position p u s h b u t t o n selector,
the A/C Heater control consists of:
T e m p e r a t u r e L e v e r — C o n t r o l s the temperature of
the discharge a i r i n a l l modes except Max. A/C and
Off when t h e v a c u u m operated w a t e r valve is closed.
•
M o v i n g t h e lever t o t h e left provides cooler a i r and
m o v i n g i t t o the r i g h t provides w a r m e r a i r .
B l o w e r S w i t c h — T h e system blower can be oper-
ated a t four speeds, f r o m low a t the bottom, m e d i u m
1 a t the lower center, m e d i u m 2 a t the upper center,
to h i g h a t the top s w i t c h position. The blower w i l l be
on and operating a t t h e speed selected, i n a l l push
b u t t o n positions except Off.
A i r D i r e c t i o n a l V a n e s — A i r is deliverd t h r o u g h
four panel outlets. The four outlets are adjustable up,
down, or t o either side and can be shut off by push-
i n g t h e vanes up. Floor a i r is deliverd t h r o u g h t h e
lower outlets.
VACUUM CONTROLS AND CIRCUITS
For a n explanation of the v a c u u m a n d electrical
logic t h a t controls the operation of the u n i t see F i g . 2
and C o n t r o l C h a r t .
M o d e s — T h e v a c u u m and electrical logic is deter-
m i n e d b y t h e push b u t t o n switch. The v a c u u m por-
t i o n o f t h e s w i t c h controls t h e water valve a n d
positions a l l doors i n t h e u n i t except t h e blend a i r
door. The electrical p o r t i o n o f the switch controls the
compressor and blower operation. The f o l l o w i n g is a
breakdown o f t h e v a c u u m a n d electrical logic for
each mode. See control c h a r t i n t h i s section.
OFF
V a c u u m application is as indicated i n F i g . 2. T h e
i n l e t a i r door is closed t o outside, open t o recirculat-
i n g a i r . T h e mode door is i n t h e A/C position. T h e
Heat/Defrost door is i n the Heat position. The heater
core coolant flow is shut-off.
No a i r flows t h r o u g h t h e u n i t and the compressor
is idle because the blower and compressor clutch cir-
cuits are open.
MAX A/C
A l l o f the doors are i n t h e same position as they
are i n Off. T h e M a x . A/C mode merely closes t h e
electrical circuits t o t h e blower motor and t h e com-
pressor clutch. T h i s mode is recommended for i n i t i a l
cool down, extreme outside h u m i d i t y , or h i g h a m b i -
ent temperature.
A/C
This mode i s recommended for use after t h e vehicle
has been cooled t o the desired temperature. T h e vac-
u u m application a t the outside-recirculating a i r door
actuator is transferred t o t h e rod side. T h i s moves
the door away f r o m t h e outside-air i n l e t and closes
the r e c i r c u l a t i n g inlet. T h e water valve is open. A l l
other v a c u u m applications and door positions are the
same for t h e M a x . A/C position. The blower motor
and compressor are on.
 AIR-CONDITIONING 24 - 39

SOLID UNE INDICATES SOLID UNE INDICATES

ENGINE VACUUM VOLET ENGINE VACUUM VIOLET

ACTUATOR

REQRCUUTING^ ^ *
0 1 0

AIR

ON- -OFF ON- -OFF

OFF, MAX A/C A/C, VENT

SOLID UNE INDICATES SOLID UNE INDICATES

ENGINE VACUUM .VIOLET ENGINE VACUUM ^ V I O L E T

ACTUATOR
VvVVA--^==j|

ACTUATOR
OUTSIDE OUTSIDE
'WATER VALVE RECIRCULATING AIR
ACTUATOR „ AIR
m

[GRAY

ON-***OFF

PUSH BUTTON CONTROL

HEAT VACUUM SWITCH
RESTRICTOR IS PART OF
VACUUM CONNECTOR
AND NOT VISIBLE
RN1001

Fig. 2 — Vacuum Circuits, Air Conditioning and Heating

24 - 40 AIR-CONDITIONING •
CONTROL CHART
Control Position Off Max. A/C A/C Vent Heat Defrost
Inlet Air Door (Open To) Inside Inside Outside Outside Outside ; Outside
Mode Door (Open To) A/C A/C A/C A/C Heat Heat
Heat Defrost (Open To) Heat Heat Heat Heat Heat Defrost
Compressor Clutch Off On On Off Off On
Blower Motor Off. On On On On On
Water Valve Off Off On On On On
VENT
RED-TEMPERATURE
The v a c u u m c i r c u i t remains t h e same as i n t h e FLAG DOOR
A/C position b u t t h e compressor clutch electrical cir- YELLOW-MODE
cuit is opened, p r e v e n t i n g the compressor from oper- V DOOR
CONTROL CABLE
ating. The blower motor is used t o force outside a i r ASSEMBLY
into t h e passenger compartment t h r o u g h t h e A/C
outlets i n t h e i n s t r u m e n t panel.

HEAT
PR413C
I n t h e Heat mode t h e outside a i r door i s open same
as A/C mode. Fig. 3—Flag Tab Depressed for Removal
V a c u u m is applied t o t h e top side of the air-condi-
(3) Move temperature lever t o extreme left (cool)
t i o n i n g door actuator, closing off the passage t o t h e
position.
air-conditioning d i s t r i b u t i o n duct a n d opening t h e
(4) Push A/C b u t t o n .
passage t o t h e heater-defroster duct. Since t h e heat-
(5) Refer to C o n t r o l Chart. Check position o f doors,
er-defroster door is i n the heat position, t h e f u l l flow
operation o f compressor clutch, blower motor and w a -
of heated a i r goes t h r o u g h t h e heater outlets, except
ter valve. The water valve is open when there is no
for a s m a l l amount t h a t bleeds t h r o u g h the defroster
vacuum t o valve.
outlets. The water valve is open, the blower switch i s (6) Check blower s w i t c h by m o v i n g i t to a l l four po-
activated and t h e compressor is off. sitions a n d n o t i n g a i r flow change. I n case o f m a l -
function refer to E l e c t r i c a l Control Circuit.
DEFROST
(7) Check operation o f blend a i r door b y m o v i n g
W h e n t h e defrost mode is selected a l l conditions
temperature lever f r o m f u l l w a r m toward cool posi-
are t h e same as for heater operation, except t h a t no
t i o n . Discharge a i r temperature should change w i t h
vacuum is applied t o t h e defrost door actuator w h i c h lever movement i f t h e engine coolant is w a r m .
is s p r i n g loaded t o defrost position. T h e door opens (8) Repeat steps 5 a n d 6 i n each push-button posi-
the defroster outlets a n d p a r t i a l l y closes off t h e tion.
heater outlets. T h e heater outlets are left open f a r I f actuation of t h e doors is slow or incomplete,
enough to direct about 30 percent of the a i r to t h e check for mechanical misalignment, b i n d i n g or vac-
floor. The other 70 percent is defrost a i r directed t o u u m leaks. T h e air-conditoning door has a seven sec-
the windshield area. The compressor clutch w i l l be ond v a c u u m delay i n mode s w i t c h i n g from Off, M a x
engaged. A/C, A/C, or V e n t to Heat or Defrost. Check temper-
ature control cable for correct adjustment.
ELECTRICAL CONTROLS AND CIRCUITS
FACEPLATE
The electrical feed for the a i r conditioning circuit i s
from t w o fuses i n the fuse block. One 20 ampere fuse
protects t h e compressor clutch circuit, a n d one 30 REMOVAL
ampere fuse protects t h e blower motor control circuit. (1) Remove map l a m p .
See (Fig. 3) for complete electrical control circuit. (2) Remove six (6) screws w h i c h attach faceplate t o
base panel (5 screws under brow of dash and 1 screw
below t h e Heater-A/C control).
CONTROL TEST
(3) P u l l column shift lever i n position " 1 " .
Test operation of controls i n t h e following manner. (4) Remove faceplate by p u l l i n g top edge r e a r w a r d
(1) Inspect compressor drive belt. Adjust i f neces- to clear t h e brow, disengage a t t a c h i n g clips around
sary. bottom of faceplate, a n d complete removal of face-
(2) S t a r t engine. plate.
(5) Disconnect wires to four wheel drive indicator, i f
equipped.
 • AIR-CONDITIONING 24 - 41

INSTALLATION EVAPORATOR CONTROL UNIT

(1) Connect four wheel drive indicator, i f equipped.
(2) Engage attaching d i p s around b o t t o m o f face-
REMOVAL
plate, r o l l faceplate into position, and i n s t a l l m o u n t -
(1) Remove faceplate (see "Faceplate Removal").
i n g screws.
(2) Remove attaching screws.
(3) I n s t a l l map lamp.
(3) P u l l control u n i t out, away f r o m i n s t r u m e n t
TEMPERATURE CONTROL CABLE panel.
(4) Disconnect blower control switch w i r i n g connec-
tor.
REMOVAL (5) Disconnect three (3) w i r i n g connectors t o con-
(1) Remove faceplate (see "Faceplate Removal"). trol.
(2) Open glovebox past stops. (6) Disconnect i l l u m i n a t i o n l i g h t .
(3) Remove control u n i t from i n s t r u m e n t panel b y (7) Disconnect vacuum harness.
removing m o u n t i n g screws and p u l l i n g u n i t out. (8) Disconnect temperature control cable (see "Tem-
(4) Remove cable from control lever p i n and remove perature Control Cable Removal").
flag from retainer (Fig. 3). (9) Remove control.
(5) Detach cable from u n i t by r e m o v i n g self-adjust
clip from crank a r m and flag from retainer. INSTALLATION
(6) Remove cable assembly t h o u g h glovebox open- (1) Connect temperature control cable (see "Tem-
ing. perature Control Cable Installation").
(7) Place a 7 m m (1/4 inch) I D . tube over clip and (2) I n s t a l l i l l u m i n a t i o n l i g h t .
p r y self-adjust clip off core w i r e i f required (Fig. 4). (3) I n s t a l l three (3) w i r i n g connectors t o pushbut-
ton switch and vacuum harness.
(4) Connect blower motor control switch w i r i n g
connector.
(5) Place control u n i t i n place i n i n s t r u m e n t panel
and secure w i t h attaching screws.
(6) I n s t a l l faceplate.

RESISTOR BLOCK

REMOVAL
(1) Remove connector from resistor block.
(2) Remove m o u n t i n g screws (Fig. 6).
(3) Remove resistor block.
Fig. 4—Removing or instailing Self-Adjust Clip INSTALLATION
INSTALLATION (1) Place resistor block on plenum.
(1) Position self-adjust clip on cable core w i r e (2) I n s t a l l m o u n t i n g screws.
5 0 m m (2 inches) from t h e small loop a t evaporator (3) Connect w i r i n g connector.
assembly flag end. W i t h a 7 m m (1/4 inch) I.D. tube,
snap self-adjust clip on core w i r e (Fig. 4). VACUUM ACTUATORS
(2) I n s t a l l cable assemblies t h r o u g h glovebox open- The mode a n d a i r recirculator actuators are ser-
ing. viced t h r o u g h the glovebox opening after opening the
(3) A t t a c h self-adjust clip t o crank a r m and i n s t a l l glovebox past its stops.
flag i n receiver on evaporator assembly. The heater/defroster actuator is serviced under the
(4) I n s t a l l flags i n retainers a n d attach cable to i n s t r u m e n t panel on t h e left end o f t h e A/C-ULV
control lever on control u n i t . unit.
(5) I n s t a l l control u n i t i n t o i n s t r u m e n t panel a n d
secure w i t h m o u n t i n g screws.
(6) I n s t a l l faceplate (see "Faceplate I n s t a l l a t i o n " ) .
24 - 42 AIR-CONDITIONING •
AIR-CONDITIONER DISTRIBUTION AND (6) Remove m o u n t i n g screw and slide left a i r duct
SPOTCOOLER DUCTS out t h r o u g h i n s t r u m e n t cluster opening (Fig. 1).

INSTALLATION
CENTER DISTRIBUTION DUCT To i n s t a l l left bi-level duct, reverse r e m o v a l proce-
dure.
REMOVAL
(1) Disconnect battery negative cable.
AIR OUTLET ASSEMBLIES RIGHT SIDE
(2) Open glove box past stops.
(3) Remove r i g h t upper a i r duct b y r e m o v i n g
m o u n t i n g screw and p u l l i n g duct out t h r o u g h glove- REMOVAL
box opening (Fig. 1). B o t h r i g h t side outlets are held i n place w i t h
(4) Remove i n s t r u m e n t panel center brace. spring loaded r e t a i n i n g clips.
(5) Remove r i g h t k i c k pad. (1) W i t h outlet facing o u t a n d louver vanes open,
(6) Remove r i g h t i n s t r u m e n t panel pivot bolt. grasp adjusting vane w i t h fingers.
(7) Remove i n s t r u m e n t panel cluster (see " I n s t r u - (2) P u l l smoothly a n d f i r m l y to unseat clips a n d
ment Panel", Group 8). complete removal t o w a r d rear o f vehicle.
(8) Disconnect shift indicator cable.
INSTALLATION
(9) Lower steering column.
(1) Position outlet assembly i n panel opening, mak-
(10) Remove steering c o l u m n studs.
i n g sure l e t t e r i n g stamped "Top" is up. (ribs o n hous-
(11) Remove radio.
i n g match notches on i n s t r u m e n t panel).
(12) Remove m o u n t i n g screws a n d remove scoop
(2) Press housing assembly u n t i l b o t h r e t a i n i n g
connecting heater u n i t t o center d i s t r i b u t i o n duct.
clips lock i n t o place.
(13) Remove m o u n t i n g screws a n d remove center
d i s t r i b u t i o n duct b y p u l l i n g bottom of i n s t r u m e n t
LOUVER ASSEMBLIES (Fig. 1)
panel out and dropping duct out (Fig. 1).

INSTALLATION REMOVAL
To i n s t a l l center d i s t r i b u t i o n duct, reverse removal (1) Remove faceplate (see "Faceplate Removal").
procedure. (2) Set faceplate w i t h t r i m surface down, insert a
small screwdriver t i p i n t o t h e outlet housing pivot
RIGHT Bl LEVEL DUCT hole.
(3) W h i l e forcing down louver assembly p i v o t p i n ,
REMOVAL
p u l l louver assembly out of rear of faceplate.
(1) Disconnect battery negative cable.
(2) Open glove box past stops. INSTALLATION
(3) Remove r i g h t upper a i r duct by r e m o v i n g (1) Position louver assembly, bottom pivot first,
m o u n t i n g screw and p u l l i n g duct out t h r o u g h glove- into t h e faceplate outlet housing. T h e bottom pivot
box opening (Fig. 1). p i n is of smaller diameter t h a n t h e top pivot p i n .
(2) W h i l e deflecting theupper louver assembly pivot
INSTALLATION
p i n , carefully swing t h e assembly i n t o housing, so
To i n s t a l l r i g h t bi-level duct, reverse removal pro-
the felt pads are not damaged. Insure top and bottom
cedure.
pivot pins are properly engaged.
LEFT BI-LEVEL DUCT (3) I n s t a l l faceplate.

REMOVAL DEFROSTER DUCT

(1) Disconnect battery negative cable.
(2) Remove i n s t r u m e n t panel cluster (see " I n s t r u - REMOVAL
ment Panel", Group 8). (1) Disconnect battery negative cable.
(3) Disconnect shift indicator cable. (2) Open glove box past stops.
(4) Remove heater control (see "Heater C o n t r o l Re- (3) Remove r i g h t upper a i r duct b y r e m o v i n g
moval"). m o u n t i n g screw and p u l l i n g duct out t h r o u g h glove-
(5) Remove m o u n t i n g screws and cover t h a t retains box opening (Fig. 1).
instrument panel w i r i n g and l e t w i r i n g h a n g free. (4) Remove i n s t r u m e n t panel center brace.
(5) Remove r i g h t k i c k pad.
(6) Remove r i g h t i n s t r u m e n t panel pivot bolt.
 • AIR-CONDITIONING 24 - 43

(7) Remove i n s t r u m e n t panel cluster (see " I n s t r u - (12) Disconnect temperature control cable f r o m
m e n t panel", Group 8). u n i t through glovebox a n d tape o u t o f w a y (see
(8) Disconnect shift indicator cable. "Temperature Control Cable Removal").
(9) Lower steering column. (13) Disconnect vacuum lines f r o m extension o n
(10) Remove steering c o l u m n studs. control u n i t and unclip v a c u u m lines f r o m defroster
(11) Remove radio. duct (see Fig. 1).
(12) Remove m o u n t i n g screws a n d remove scoop ; (14} Remove w i r i n g connector from resistor block.
connecting heater u n i t t o center d i s t r i b u t i o n duct. (15) Remove blower motor connector on engine
(13) Remove m o u n t i n g screws a n d remove center side.
(16) Disconnect vacuum lines on engine side, m a k e
d i s t r i b u t i o n duct b y p u l l i n g bottom o f i n s t r u m e n t
sure grommet is free from dash panel.
p a n e l out a n d dropping duct out (Fig. 1).
(17) Remove r e t a i n i n g nuts o n engine side.
(14) Remove heater control (see "Heater C o n t r o l
(18) Remove screw t h a t retains package t o cowl
Removal").
side sheetmetal.
(15) Remove m o u n t i n g screws and cover retains i n -
(19) Remove package. Plastic i n s t r u m e n t panel
s t r u m e n t panel w i r i n g and l e t w i r i n g h a n g free.
may have to be flexed o u t w a r d .
(16) Remove m o u n t i n g screw and slide left a i r duct
o u t t h r o u g h t h e i n s t r u m e n t cluster opening (Fig. 1).
(17) Remove screws a t t a c h i n g defroster duct t o
dash panel (Fig. 1).
(18) Reach i n t h r o u g h i n s t r u m e n t panel opening
a n d disengage snaps t o separate defroster duct into
t w o pieces.
(19) Remove defroster duct halves t h r o u g h i n s t r u -
m e n t cluster opening.

INSTALLATION
To i n s t a l l defroster duct, reverse removal proce-
dure. Fig. 5—Evaporator Heater Assembly
INSPECTION
EVAPORATOR HEATER ASSEMBLY
(1) Remove n u t t h a t attaches three door arms t o
doors on the top cover of the u n i t a n d remove t h e
REMOVAL three arms (Fig. 6).
(1) Disconnect battery negative cable. Discharge re-
f r i g e r a n t , disconnect refrigerant a n d heater lines
f r o m u n i t on engine side.
(2) P l u g heater hoses and u n i t and remove conden-
sate tube (Fig. 1).
(3) Move transfer case and/or gear shift levers
away f r o m i n s t r u m e n t panel.
(4) Remove r i g h t cowl side t r i m panel i f so
equipped.
(5) Remove glovebox by r e m o v i n g m o u n t i n g screws ATTACHING
a t base a n d s w i n g i n g out from t h e bottom t o avoid NUTS RB463
catch and stops.
Fig. 6—Removing Door Arms
(6) Remove s t r u c t u r a l brace t h r o u g h glovebox
opening. Remove screws, loosen nuts. (2) Remove screws to separate cover f r o m housing.
(7) Remove ash receiver. (3) Slide out evaporator core.
(8) Remove r i g h t h a l f of lower reinforcement by re- (4) Remove m o u n t i n g screw and slide o u t heater
m o v i n g screws a t t a c h i n g i t t o t h e i n s t r u m e n t panel core.
a n d one to t h e cowl side t r i m panel. (5) Disconnect blower motor feed w i r e on engine
(9) Detach radio ground strap. side.
(10) Remove center d i s t r i b u t i o n duct (see A i r - C o n - (6) Remove r e t a i n i n g screws to separate blower mo-
d i t i o n e r D i s t r i b u t i o n and Spot Cooler Ducts). tor from housing.
(11) Remove floor a i r d i s t r i b u t i o n duct. (7) Separate fan from motor (Fig. 7).
24 - 44 AIR-CONDITIONING •
(8) Inspect a l l parts.
(9) Assemble evaporator heater u n i t u s i n g neces-
sary new p a r t s b y reversing t h i s disassembly proce-
dure.

INSTALLATION
T o i n s t a l l evaporator heater u n i t , reverse r e m o v a l
procedure. B e sure to r e f i l l the cooling system a n d
evacuate a n d recharge t h e system. Check operation
of a l l controls and performance o f the A/C system.

Fig. 7— Removing Blower Wheel

 • EMISSION CONTROL SYSTEMS 25 - 1

EMISSION CONTROL SYSTEMS

CONTENTS
Page Page
AIR INJECTION SYSTEM 17 EXHAUST EMISSION CONTROLS 9
EVAPORATIVE EMISSION CONTROLS . . . . . . . . 2 SERVICE PROCEDURES 22

GENERAL INFORMATION cated mileage, or w h e n t h e emissions maintenance

r e m i n d e r l i g h t remains on continuously w i t h t h e key
A l l Federal models regardless of Gross Vehicle i n t h e O N position, whichever occurs first. A f t e r per-
Weight R a t i n g (GVWR) must meet L i g h t D u t y Cycle f o r m i n g t h e required maintenance, t h e E M R l i g h t
Emission Standards.
m u s t he reset to t u r n the l i g h t off.
Vehicles b u i l t for sale i n California a n d Canada
60,000 miles:
h a v i n g a G V W R o f 8,500 lbs. (3855 k g ) or less m u s t
(a) Replace EGR Valve.
meet L i g h t D u t y Cycle Emission Standards.
(b) Clean EGR passage.
Vehicles b u i l t for sale i n California a n d Canada
'(c) Replace P C V Valve.
h a v i n g a G V W R of 8,501 lbs. (3856 kg) or more m u s t
conform to Heavy D u t y Emission Cycle Standards. 82,500 miles:
Maintenance requirements f o r L i g h t D u t y a n d (a) Replace Oxygen Sensor.
Heavy D u t y Cycle emission systems differ because o f 120,000 miles:
different load and operating conditions. (a) Replace EGR Valve.
(b) Clean EGR passage.
EMISSION MAINTENANCE REMINDER (EMR) (c) Replace P C V Valve.
LIGHT F a i l u r e to perform t h e required maintenance
and only reset the E M R l i g h t may be a v i o l a t i o n of
The Emissions Maintenance Reminder System federal l a w . O n l y after performing t h e r e q u i r e d
(EMR) is incorporated into the engine controller. The maintenance, should the E M R l i g h t be reset.
engine controller records t h e vehicles mileage a n d
stores i t i n t o memory every 8 miles. A t t h a t t i m e , RESETTING EMR LIGHT
the engine controller checks for t h e 60,000, 82,500, (1) Connect D R B I I tool to the diagnostic connector.
and 120,000 mileage t r i p points. W h e n the current (2) Refer to D R B I I F u n c t i o n a l Flow D i a g r a m i n the
mileage matches one of the above mentioned t r i p 1990 P o w e r t r a i n Diagnostic Procedures m a n u a l .
points, the E M R l i g h t is activated. (3) Follow the d i a g r a m to RESET E M R L I G H T . Re-
The following parts are to be replaced a t t h e i n d i - set E M R l i g h t .
25-2 EMISSION CONTROL SYSTEMS •
EVAPORATIVE EMISSION CONTROLS

INDEX
Page Page
Crankcase Inlet Air Filter 8 Vacuum Schematics 4
Evaporation Control System . . . . . . . . . . . . . . . . . . 4 Vehicle Emission Control Information (VECI) Label . 2
Positive Crankcase Ventilation (PCV) System 6

VEHICLE EMISSION CONTROL INFORMATION

(VECI) LABEL IMPORTANT VEHICLE INFORMATION

A l l vehicles are equipped w i t h a combined Vehicle THIS VEHICLE CONFORMS TO U.S. EPA
REGULATIONS APPLICABLE T01990 MODEL YEAR
Emission C o n t r o l I n f o r m a t i o n (VECI) label. T h e l a - NEW LIGHT-DUTY TRUCKS WITH A CURB WEIGHT
bel, w h i c h is located i n the engine compartment (Fig. GREATER THAN 3,450 POUNDS AT ALL ALTITUDES.
1), l i s t s t h e vehicles' engine f a m i l y and displacement, * BASIC IGNITION TIMING AND IDLE FUEL/AIR MIXTURE HAVE
SJUTER
LCR5.9T5HGF8
SPARKPLUGS
.035 in. GAP
BEEN PRESET AT THE FACTORY. SEE Tf€ SERVICE MANUAL LCRTE RN12YC
evaporative f a m i l y , emission control system, certifi- FOR PROPER PRXEDURES AND OTHER ADOfHONAL
INFORMATION.
IDLE* MAN AUTO
cation application, engine t i m i n g specifications, idle ' ADJUSTMENTS MADE BY OTHER THAN APPROVED SERVICE TIMING 10BTC 10BTC
MANUAL PROCEDURES MAY VIOLATE FEDERAL AND STATE LAWS.
speeds ( i f adjustable), a n d spark p l u g gap (Fig. 2 ) . CAUTION: APPLY PARKING BRAKE WHEN SERVICING VEHICLE NO ADJUSTMENTS NEEDED

The label also contains an engine v a c u u m schematic.

There are u n i q u e labels for vehicles b u i l t for sale i n
the state o f C a l i f o r n i a (Fig. 3), the country o f Canada
(Fig. 4 ) and Heavy D u t y Cycle. Canadian V E C I l a -
bels are w r i t t e n i n both the E n g l i s h and French l a n - r — c : : : > ——
.eacrn WOKM V .
guages. These labels are permanently attached a n d
cannot be removed w i t h o u t defacing i n f o r m a t i o n a n d
CO w r, , " ' i s m

destroying i t . m
o
I f any difference exists between t h e specifications
or v a c u u m hose r o u t i n g shown on the label and those
shown i n t h e Service M a n u a l , those shown on the la-
bel should be used.

VECI LABEL
OfTKMMl VACUUM OPERATED ACCESSORIES WHEN EQUIPPED

Fig. 2 Federal VECI Label—Typical

J9025-26

Fig. 1 VECI Label Location

 EMISSION CONTROL SYSTEMS 25 - 3

IMPORTANT VEHICLE INFORMATION IMPORTANT VEHICLE INFORMATION

=If•<
THIS VEHICLE C O N F O R M S T OU.S. EPA AND STATE OF
CALIFORNIA REGULATIONS APPLICABLE T01990 MODEL
THIS HEAVY-DUTY VEHICLE CONFORMS TO U.S. EPA
YEAR NEW LIGHT-DUTY TRUCKS AND MEDIUM-DUTY VEHICLES REGULATIONS APPLICABLE T01990 MODEL YEAR NEW
PROVIDED THAT T H I S VEHICLE I SONLY INTRODUCED INTO
LIGHT-DUTY TRUCKS AT ALL ALTITUDES UNDER Tr€
C O M M E R C E F O R S A L E INT H E STATE O F CALIFORNIA.
o+ SPECIAL PROVISION OF 40 CFR 86.085-1 (b).
5.2 LITER

!!
SPARKPLUGS
* BASIC mmm mm AND OLE PUB/AIR MOTURE HAVE LCR5.9T5H6D6 .035 in. GAP 5.9 LITER
BEEN PRESET AT THE HCTDRY. SEE TIC SERVICE MANUAL LCRTE RN12YC ' BASIC IGNITION TIMING AND IDLE FUEL/AIR MIXTURE HAVE SPARK PLU6S
FOR PROPER PROCEDURES AM) OTHER AODrnONAL BEEN PRESET AT THE FACTORY. SEE THE SERVICE MANUAL LCR5JT5HHY1 .035 m GAP
INFORMATION.

&
IDLE* AUTO FOR PROPER PROCEDURES AND OTHER ADDITIONAL LCRTE
' ADJUSTMENTS MADE BY OTHER THAN APPROVED SERVICE TIMING 10BTC
INFORMATION.
MANUAL PROCEDURES MAY VIOLATE FEDERAL AND STATE LAWS. IDLE* MAN AUTO
NO ADJUSTMENTS NEEDED ' ADJUSTMENTS MADE BY OTHER THAN APPROVED SERVICE

0
CAUTION: APPLY PARKING BRAKE WHEN SERVICING VEHICLE MANUAL PROCEDURES MAY VIOLATE FEDERAL AND STATE LAWS. TIMING 10BTC 108TC
RHC/CO/NOiSTDS. MtJOnM NO ADJUSTMENTS NEEDED
CAUTION: APPLY PARKING BRAKE WHEN SERVICING VEHICLE FAMILY N0X EMISSION LHUT2.3

o g
r—c:::>—-v*
ntma JSSHL

LO

CO
in in
o CO
m
5 o
5 "I

• OPTIONAL VACUUM OPERATED ACCESSORIES

'WHEN EQUIPPED

Fig. 3 California VECI Label—Typical

Fig. 5 Heavy Duty Cycle Label—Typical

mm mmm CONTROL IN^AMATIQTT

THIS VEHICLE WAS BUILT FOR SALE IN CANADA AND WAS DESIGNED TO MEET THE
EMISSION REQUIREMENTS OF THE CANADA MOTOR VEHICLE SAFETY ACT.
IT WAS NOT DESIGNED TO COMPLY WITH THE REQUIREMENTS OF OTHER COUNTRIES.
SPARK PLUGS
• BASIC IGNITION TIMING AND FUEL INJECTION MIXTURE HAVE BEEN 0.9 mm GAP
PRESET AT THE FACTORY. ADJUSTMENTS SHOULD NOT BE MADE
O DURING ROUTINE SERVICE.
MH2VC
IDLEB AUTO.
O TIMING BTC 10°
CO CAUTION: APPLY PARKINS BRAKE WHEN SERVICING VEHICLE.

RENSEtGNEMENTS RELATIFS AU SYSTEMS ANTIPOLLUTION

LE PRESENT VEHICULE A ETE FABRIQUE POUR ETRE VENOU AU CANADA ETIL A
ETE CONCU OE MANIERE A SE CONFORMER AUX NORMES ANTIPOLLUTION DE LA
LOISUR LA SECURITE DES VEH1CULES AUTOMOBILES DU CANADA.
IL NEST PAS DESTINE A SE CONFORMER AUX NORMES DAUTRES PAYS.
BOUGIES
' LE CALAGE DE LALLUMAGE INITIAL ET LE MELANGE DIRECTION E CARTE MENT 0 9 mm
DESSENCE ONT ETE PREREGLES A USINE. NEFFECTUEZ AUCUN
§ 3
REGLAGE LORS DE TRAVAUX DENTRETIEN REGUUERS.
RM12VC
REGLAGE DU RALENTI • MAN. AUTO.
AVERT1SSEMENT: SERREZ LE FREIN DE STATIONEMENT POUR FAIRE DISTRIBUTION AV P H . 10° 10°
LENTRETIEN OU LA REPARATION DU VEHICULE.

flTTtl I nilWW MSSSUKRanF M VHCUOM OffRATTO ACCFSSOWS ( M J CtAKTT Of OfCHABGfftAlfi

- • Acassowfs Mcmunrs HJNCTKWAUT A ofwrssw*
nmtntowmo
UlOASOUAWSi
COUIP1

J9025-29

Fig. 4 Canada VECI Label—Typical

25 - 4 EMISSION CONTROL SYSTEMS
VACUUM SCHEMATICS
I n case o f contradictions between t h e schematics
shown i n t h e service m a n u a l (Fig. 6 or 7) and the
Vehicle E m i s s i o n C o n t r o l I n f o r m a t i o n (VECI) label,
refer t o t h e V E C I label.
EVAPORATION CONTROL SYSTEM
The evaporation control system prevents the emis-
sion of gasoline vapors f r o m t h e fuel t a n k i n t o t h e at-
mosphere. W h e n fuel evaporates i n the fuel t a n k , the
vapors pass t h r o u g h vent hoses or tubes t o a carbon
filled evaporative canister where they are tempo-
r a r i l y h e l d u n t i l they can be d r a w n i n t o the i n t a k e
manifold w h e n the engine is r u n n i n g .
The vapors are d r a w n into t h e engine a t idle as
w e l l as off idle. This system is called a Bi-level Purge
System where there is a dual source of vacuum to re-
•
move fuel vapor from canister. The source of v a c u u m
at idle i s a tee i n t h e P C V system. Refer t o t h e ap-
propriate Engine V a c u u m Schematic.
The evaporative canister i s a feature on a l l models
for t h e storage o f fuel vapors f r o m the fuel t a n k .
O n l y u s e fuel r e s i s t a n t h o s e w h e n r e p l a c i n g
e v a p o r a t i o n c o n t r o l s y s t e m hoses.
ROLLOVER AND PRESSURE RELIEF VALVE
A l l vehicles are equipped w i t h a combination pres-
sure r e l i e f and rollover valve. T h e d u a l f u n c t i o n
valves relieve fuel t a n k pressure and prevent f u e l
flow t h r o u g h the fuel t a n k vent hoses i n the event o f
vehicle rollover.
The valve incorporates a pressure r e l i e f mechanism
t h a t releases fuel t a n k pressure t o t h e atmosphere
w h e n t h e fuel t a n k pressure increases above the cal-
i b r a t e d sealing value. Refer t o Group 14 F u e l T a n k
Section for service.

POWER
BRAKE
BOOSTER
TO HEATER-AC
CONTROL

DIVERTER
VALVE*
DOWNSTREAM AIR

VAPOR
CANISTER
-OPTIONAL VACUUM OPERATED ACCESSORIES *WHEN EQUIPPED J9025-11

Fig. 6 Engine Vacuum Schematic—3.9L Engine

 • EMISSION CONTROL SYSTEMS 25 - 5

POWER

r
BRAKE
L.„_r — \ X
BOOSTER
B
TO SPEED VACUUM -
CONTROL RESERVOIR

HEATED AIR
TEMP. SENSOR

M
o O
M P MM
TO AIR THROTTLE
BODY
BRESHER ICLEANERl
CAP CHECKI
ORIFICE E
VALVE VALVE HEATED
COVER AIR DIAPH.
TO ATMOSPHERE
J O FUEL DOWNSTREAM
T A N K AIR PUMP'
PRESSURERELIEF/" AIR
ROLLOVER VALVE AIR SWITCH
RELIEF YAIYE
•OPTIONAL VACUUM OPERATED ACCESSORIES
J9025-19

Fig. 7 Engine Vacuum Schematic—5.2L and 5.9L Engine

EVAPORATIVE CANISTER F u e l t a n k pressure vents i n t o t h e canister. Fuel va-
A sealed, maintenance free, evaporative canister is pors are t e m p o r a r i l y h e l d i n t h e canister u n t i l they
used on a l l vehicles. T h e canister is mounted under can be d r a w n i n t o t h e i n t a k e manifold. The canister
t h e r i g h t side o f t h e vehicle b e h i n d t h e wheel w e l l purge solenoid allows t h e canister t o be purged a t
(Fig. 8). The evaporative canister i s f i l l e d w i t h gran- predetermined t i m e a n d engine conditions.
ules of a n activated carbon m i x t u r e . Fuel vapors en-
t e r i n g t h e canister a r e absorbed b y t h e charcoal CANISTER PURGE SOLENOID
granules. V a c u u m for t h e evaporative canister i s controlled
by t h e Canister Purge Solenoid (Fig. 9). The solenoid
is controlled b y t h e Single Board Engine Controller
(SBEC). The SBEC controls t h e solenoid b y switching
the g r o u n d c i r c u i t on a n d off based on engine operat-
i n g conditions. W h e n energized, t h e solenoid pre-
vents v a c u u m f r o m reaching t h e evaporative
canister. W h e n n o t energized t h e solenoid allows vac-
u u m t o flow t h r o u g h t o canister.
D u r i n g w a r m - u p a n d for a specified t i m e period af-
ter h o t starts t h e engine controller grounds t h e purge
solenoid causing i t t o energize, preventing vacuum
f r o m r e a c h i n g t h e evaporative canister valve. When
EVAPORATIVE the engine reaches a n operating temperature of ap-
CANISTER p r o x i m a t e l y 27°C (80°F), t h e SBEC removes t h e
ground t o t h e solenoid. The de-energizing solenoid a l -
J9025-21
lows v a c u u m t o flow t o t h e canister and purge fuel
Fig. 8 Evaporative Canister vapors t h r o u g h t h e t h r o t t l e body.
25 - 6 EMISSION CONTROL SYSTEMS •
The purge solenoid w i l l also be energized for short POSITIVE CRANKCASE VENTILATION (PCV)
periods d u r i n g c e r t a i n idle a n d off idle conditions, i n SYSTEM
order t o update t h e fuel delivery c a l i b r a t i o n .
A l l models a r e equipped w i t h a closed crankcase
EGR AIR SWITCHING CANISTER v e n t i l a t i o n system (Fig. 11). T h i s system consists of a
crankcase P C V valve mounted on t h e cylinder head
cover, w i t h a hose extending f r o m t h e valve t o t h e
base o f t h e t h r o t t l e body.

Fig. 9 Canister Purge Solenoid

PRESSURE-VACUUM FILLER CAP
The fuel t a n k is sealed w i t h a pressure-vacuum re- CRANKCASE VENT VALVE
l i e f filler cap (Fig. 10). The r e l i e f valves i n t h e cap HOSE ASSEMBLY RR25G51
are a safety feature a n d operate only to prevent ex-
Fig. 11 PCV System
cessive pressure or v a c u u m i n t h e t a n k caused b y a
malfunction i n t h e system or damage t o t h e vent A closed engine crankcase i n l e t a i r filter w i t h a
lines. hose connecting i t t o t h e t h r o t t l e body a i r cleaner
PLASTIC
housing provides t h e source of a i r for the system.

VENTILATION SYSTEM OPERATION

The positive crankcase v e n t i l a t i o n (PCV) system
operates b y m a n i f o l d vacuum (Fig. 12). Filtered a i r is
routed i n t o t h e crankcase t h r o u g h t h e a i r cleaner
hose a n d crankcase i n l e t a i r filter forcing crankcase
vapors t h r o u g h t h e P C V valve into a passage i n t h e
t h r o t t l e body. I t t h e n becomes p a r t of the calibrated
air/fuel m i x t u r e t o be consumed i n the combustion
chamber. T h e P C V system constantly ventilates t h e
crankcase t o help prevent sludge formation and va-
pors f r o m e n t e r i n g the atmosphere.
GASKET
RN348

Fig. 10 Pressure Vacuum Filler Cap

The cap has a threaded configuration w h i c h allows
the seal to be broken a n d pressure t o be relieved
w i t h o u t separation of t h e cap f r o m t h e filler tube.
Approximately t w o and a h a l f t u r n s are required to
remove the cap.
I f replacement o f the filler cap is necessary, i t must
be replaced w i t h a n identical cap t o ensure correct
system operation.
C A U T I O N : T o relieve fuel t a n k pressure, t h e
fuel filler cap m u s t be r e m o v e d p r i o r t o discon-
necting any fuel system component.
Fig. 12 Typical Closed Crankcase Ventilation
System
 • EMISSION CONTROL SYSTEMS 25 - 7

PCV VALVE INSPECTION AND SERVICE PROCEDURE

The Positive Crankcase V e n t i l a t i o n valve contains
a spring loaded plunger t h a t meters t h e amount o f
crankcase vapors routed i n t o t h e combustion cham-
ber based o n intake manifold v a c u u m .
W h e n the engine is not operating or d u r i n g a n en-
gine backfire, t h e spring forces t h e plunger back
against t h e seat preventing vapors f r o m flowing
t h r o u g h the valve (Fig. 13).
(1) W i t h engine i d l i n g , remove the P C V valve from
cylinder head cover. I f t h e valve is n o t plugged, a
hissing noise w i l l be heard as a i r passes t h r o u g h the
valve and a strong v a c u u m felt when a finger is
placed over t h e valve i n l e t . (Fig. 16).
PCV VALVE
GROMMET

J9025-20

Fig. 13 Engine Off or Engine Backfire—No Vapor

Flow
D u r i n g periods of h i g h m a n i f o l d v a c u u m , such as
idle or c r u i s i n g speeds, manifold v a c u u m is sufficient VACUUM MUST BE FELT AGAINST FINGER RR25G52
to completely compress t h e s p r i n g a n d p u l l t h e
plunger to t h e top of the valve (Fig. 14). I n t h i s po- Fig. 16 Check Vacuum at PCV Valve
s i t i o n there is m i n i m a l vapor flow t h r o u g h the valve. (2) I n s t a l l t h e P C V valve. Remove t h e crankcase
i n l e t a i r filter. H o l d a piece o f stiff paper (parts tag)
loosely over t h e opening o f t h e cylinder head cover.
(Fig. 17).

J8925-14

Fig. 14 High Intake Manifold Vacuum—Minimal

Vapor Flow
D u r i n g periods of moderate i n t a k e manifold vac-
u u m t h e plunger is only pulled p a r t w a y back from
t h e i n l e t , r e s u l t i n g i n m a x i m u m vapor flow t h r o u g h
t h e valve (Fig. 15).

CRANKCASE

Fig. 17 Check Vacuum at Crankcase Inlet Air Filter

Opening

J8925-15
(3) After a l l o w i n g approximately one m i n u t e for
crankcase pressure to reduce, t h e paper should be
Fig. 15 Moderate Intake Manifold d r a w n against the opening i n the cylinder head cover
Vacuum—Maximum Vapor Flow w i t h noticeable force.
25 - 8 EMISSION CONTROL SYSTEMS •
(4) T u r n off engine a n d remove P C V valve from necessary t o disassemble t h e t h r o t t l e b o d y f o r
cylinder head cover. T h e valve should r a t t l e w h e n t h i s service.
shaken (Fig. 18).
CRANKCASE INLET AIR FILTER
The crankcase i n l e t a i r cleaner (Fig. 19) m u s t be
kept clean a n d lubricated. A t t h e recommended i n -
t e r v a l remove t h e crankcase i n l e t a i r cleaner a n d
wash i t t h o r o u g h l y i n kerosene, or s i m i l a r solvent.
Lubricate or w e t the f i l t e r b y i n v e r t i n g t h e crankcase
i n l e t a i r cleaner and f i l l i n g w i t h S A E 30 engine o i l .
Position t h e a i r cleaner t o allow excess o i l t o d r a i n
thoroughly t h r o u g h t h e v e n t nipple. More frequent
service m a y be necessary for vehicles operated exten-
sively on short r u n , stop a n d go, or extended engine
idle service.

Fig. 18 Shake PCV Valve

Replace t h e PCV valve and retest t h e system i f i t
does not operate as described i n t h e preceding tests.
Do n o t attempt to clean the o l d P C V valve.
(5) I f the paper is not held against t h e opening i n
the cylinder head cover after t h e new valve is i n -
stalled, t h e P C V valve hose m u s t be replaced a n d t h e
passage i n the t h r o t t l e body cleaned.
(6) To clean the t h r o t t l e body passage, t u r n a 1/4
inch d r i l l b y hand t h r o u g h t h e passage t o dislodge
the solid particles t h e n blow o u t t h e passage w i t h 8925-28
shop air. I f necessary use a smaller d r i l l t o avoid re-
m o v i n g a n y metal f r o m t h e t h r o t t l e body. I t i s n o t Fig. 19 Crankcase Inlet Air Filter
 • EMISSION CONTROL SYSTEMS 25 - 9

E X H A U S T EMISSION CONTROLS

INDEX
Page Page
EGR Diagnosis ....... ... .14 Exhaust G a s Recirculation (EGR) Systems . . . . . . 12
EGR Diagnosis Chart . . . . . . . . . . . . . . . . . . . . . . 15 Heated Inlet Air System . . . . . . . . . . . . . . . . . . . . . 9
EGR Diagnostic Solenoid Removal . . . . . . . . . . . . 16 Oxygen Sensor ( 0 S e n s o r ) — S B E C Input . . . . . . 11
2

HEATED INLET AIR SYSTEM ambient and heat stove inlets is determined b y t h e
position o f the blend door i n t h e a i r cleaner snorkel.
The heated a i r i n l e t system controls and m a i n t a i n s
t h e temperature of t h e a i r e n t e r i n g t h e t h r o t t l e body. VACUUM SENSOR
DIAPHRAGM AIR CONTROL
B y m a i n t a i n i n g the i n l e t a i r temperature t h e air-fuel VALVE
m i x t u r e can be calibrated m u c h leaner t o reduce hy-
drocarbon emissions, improve engine w a r m - u p char-
acteristics, a n d m i n i m i z e icing.
The system consists o f a d i a p h r a g m t h a t operates
t h e blend door i n t h e a i r cleaner ( t h a t opens t o either
heated a i r or ambient air), a heated a i r temperature
sensor, and a a i r duct hose connected t o a heat stove
on t h e exhaust manifold (Fig. 1). T h e a i r cleaner
b l e n d door opens t o ambient (outside) a i r or pre- AIR HEATED ^fT /
heated a i r from the heat stove or a position i n be- BY MANIFOLD I ^^mm^l
tween t h e m .

HOLD DOWN
AIR CLEANER
NUT HEATED AIR
ASSEMBLY
ENTERS
THROTTLE BODY RR25G55

GASKET
Fig. 2 Heated Air Inlet System Operation
ELBOW
The blend door v a c u u m d i a p h r a g m is opposed b y a
spring. T h r o t t l e body i n l e t a i r temperature adjust-
m e n t w i l l occur only w h e n the i n t a k e manifold vac-
STUD
HEATED u u m is above the operating v a c u u m of the v a c u u m
AIR diaphragm.
DUO-
The system is designed t o m a i n t a i n t h e t h r o t t l e
body i n l e t a i r a t a calibrated temperature. W h e n the
ambient a i r temperature is 9°C (15°F) or more above
t h e system calibration temperature the a i r flow w i l l
be t h r o u g h the outside (ambient) a i r inlet.
W h e n the ambient a i r temperature is 12°C (10°F)
or more below the system c a l i b r a t i o n temperature a i r
flow w i l l be t h r o u g h heat stove i n l e t of t h e a i r
cleaner.
J9025-24 A t intermediate temperatures the a i r entering the
t h r o t t l e body is a blend o f ambient a i r and heat stove
Fig. 1 Heated Air Inlet System air. The colder the ambient a i r the greater the flow
of a i r t h r o u g h the stove, and t h e w a r m e r the a i r t h e
The adjustment o f the t h r o t t l e body i n l e t a i r t e m - greater the flow t h r o u g h the snorkel.
perature is performed by i n t a k e m a n i f o l d vacuum.
The heated a i r temperature sensor i n the a i r cleaner HEATED AIR INLET SYSTEM SERVICE
senses i n l e t a i r temperature and controls t h e flow o f A n improperly operating heated a i r i n l e t system
v a c u u m t o t h e a i r cleaner blend door d i a p h r a g m can affect d r i v e a b i l i t y and the vehicles exhaust emis-
(Fig. 2). The amount o f a i r allowed t o enter f r o m the sion.
 25-10 EMISSION CONTROL SYSTEMS •
P e r f o r m t h e following procedure to determine i f t h e VACUUM DIAPHRAGM PUMP
a i r i n l e t system is functioning properly. VACUUM

(1) Ensure t h a t the heat stove t o a i r cleaner flexi-

ble connector (Fig. 3), a i r cleaner duct and a l l vac-
u u m hoses are properly attached a n d i n good
condition.

AIR
TEMPERATURE
SENSOR TO V A C U U M
RETAINING DIAPHRAGM

RF403A

Fig. 4 Testing Vacuum Diaphragm

VACUUM DIAPHRAGM

TO VACUUM Removal
SOURCE (1) Remove the a i r cleaner housing f r o m vehicle.
(2) Disconnect v a c u u m hose f r o m b l e n d door dia-
J9025-25 phragm.
(3) D r i l l out the r e t a i n i n g r i v e t (Fig. 5).
fig, 3 Typical Vacuum Hose Routing
V I E W IN DRILL T H R O U G H R I V E T O N T A B
'(S) W i t h a cold engine and a m b i e n t temperature
less thafli 42°G <108°F.) the heat control door (valve
CIRCLE A \
A-B-*
plate) i n the snorkel should be i n the u p or h e a t o n
"-position.
(3) W i t h t h e engine warmed up and r u n n i n g , check
the a i r temperature entering t h e snorkel or a t t h e
sensor. W h e n the air temperature e n t e r i n g t h e outer
end o f snorkel is 57°C (135°F) or higher t h e door
should be i n the d o w n position (heat off).
{4) Remove the air cleaner f r o m the engine and a l -
low i t t o cool down to 42°C (108°F.) W i t h 20 inches o f
v a c u u m applied to the sensor the door should be i n
t h e u p or (heat o n position). I f the door does not
rise t o the h e a t o n position, check the v a c u u m dia-
p h r a g m for proper operation.
H E A T E D A I R INLET
, (5) T o test the diaphragm, apply 25 inches o f vac- VACUUM DIAPHRAGM
u u m w i t h v a c u u m p u m p Tool C-4207 or equivalent VIEW I N C I R C L E B
RP1012
(Fig. 4). The diaphragm should not bleed down more
t h a n 10 inches i n 5 minutes. The door should not l i f t
Fig. 5 Removing Diaphragm Rivet
off t h e b o t t o m o f the snorkel a t less t h a n 2.0 inches
of v a c u u m a n d be i n f u l l u p position w i t h no more
t h a n 4.0 inches vacuum.
(6) I f the vacuum diaphragm does not perform cor-
rectly, replace the vacuum d i a p h r a g m a n d repeat
steps 2 and 3.
(7) I f the v a c u u m diaphragm performs correctly b u t
proper temperature is n o t m a i n t a i n e d , replace t h e
sensor and repeat the temperature checks i n steps 2
a n d 3.
 • EMISSION CONTROL SYSTEMS 25 - 11

(4) T i p t h e diaphragm slightly f o r w a r d t o disen-

gage lock. W h e n t h e diaphragm i s free, slide t h e
complete assembly t o one side t o disengage operating
r o d from heat control door (Fig. 6).

Fig. 6 Servicing Diaphragm

(5) W i t h t h e v a c u u m diaphragm removed, check
t h e door for freedom o f t r a v e l . W h e n t h e door is
raised to t h e u p position, i t should f a l l freely w h e n
released. I f i t does not, observe door t o snorkel side
w a l l s for interference or obstructions. Inspect t h e
hinge p i n for b i n d i n g . I f necessary use compressed
a i r t o remove obstructions.

INSTALLATION
(1) Insert operating rod into heat control door. Po-
s i t i o n d i a p h r a g m t a n g i n t o opening a n d r i v e t t a b i n
place (Figs. 6 and 5).
Fig. 8 Air Temperature Sensor Installation
(2) A p p l y 4 inches o f vacuum to d i a p h r a g m nipple.
The heat control door should operate freely. M a n u - OXYGEN SENSOR (0 SENSOR)-SBEC INPUT
2

ally operating heat control door c o u l d cock t h e

The 0 sensor is located i n t h e exhaust down pipe
operating r o dor diaphragm restricting proper
2

on 3 . 9 L engines ( F i g . 9) a n d o n 5.2L and 5.9L en-

o p e r a t i o n o f the system.
gines above t h e left exhaust manifold outlet (Fig.
(3) Assemble a i r cleaner.
10). T h e 0 sensor provides a n i n p u t voltage t o t h e
2
(4) I n s t a l l a i r cleaner assembly o n vehicle and test
Single B o a r d Engine Controller (SBEC) r e l a t i n g t h e
operation.
oxygen content of the exhaust gas. T h e SBEC uses
HEATED AIR TEMPERATURE SENSOR t h i s i n f o r m a t i o n to fine t u n e t h e air-fuel r a t i o b y ad-
j u s t i n g injector pulse w i d t h .
Removal The 0 sensor produces voltages f r o m 0 to 1 volt,
2

(1) W i t h a i r cleaner housing removed from vehicle
remove and discard retainer clip (Fig. 7). A new clip
is supplied w i t h a n e w sensor.
(2) Remove and discard the sensor a n d gasket.
INSTALLATION
(1) Position gasket onto sensor. I n s t a l l sensor i n t o
position i n a i r cleaner (Fig. 8).
(2) Support sensor outer edges and securely i n s t a l l
r e t a i n e r clip t o ensure gasket forms a t i g h t a i r seal.
D o n o t a t t e m p t t o a d j u s t sensor.
(3) Connect vacuum hoses to sensor.
depending upon t h e oxygen content o f the exhaust
gas i n the exhaust manifold. W h e n a large amount of
oxygen i s present (caused b y a lean air-fuel m i x t u r e ) ,
t h e sensor produces a l o w voltage. W h e n there is a
lesser amount present ( r i c h air-fuel m i x t u r e ) i t pro-
duces a higher voltage. B y m o n i t o r i n g t h e oxygen
content a n d converting i t t o electrical voltage, t h e
sensor acts as a rich-lean switch.
The oxygen sensor is equipped w i t h a heating ele-
m e n t t h a t keeps the sensor a t proper operating tem-
perature d u r i n g a l l operating modes. M a i n t a i n i n g
25 - 12 EMISSION CONTROL SYSTEMS
correct sensor temperature a t a l l t i m e s allows t h e
system t o enter i n t o C L O S E D L O O P operation
sooner.
I n " C L O S E D L O O P " operation t h e SBEC monitors
the 0 sensor i n p u t (along w i t h other inputs) and ad-
2
j u s t s t h e injector pulse w i d t h accordingly. D u r i n g
" O P E N L O O P " operation t h e SBEC ignores t h e 0
sensor i n p u t a n d adjusts injector pulse w i d t h t o a
preprogrammed value (based on other sensor inputs).
Fig. 9 Heated Oxygen Sensor Locatiori^—3.9L
Engine
4-WAY HEATED 0 SENSOR
2 HEATED Oj SENSOR
Fig. 10 Heated Oxygen Sensor Location—5.2L and
5.9L Engines
HEATED OXYGEN SENSOR (02 SENSOR)
SERVICE
O n 3.9L engines the oxygen sensor is located i n t h e
exhaust systems Y-pipe (Fig. 9). O n 5.2L a n d 5.9L
engines the oxygen sensor is located above t h e outlet
of the left exhaust manifold (Fig. 10).
(1) Disconnect engine harness f r o m Oxygen Sensor
Connector.
CAUTION: Take care not to pull on oxygen sensor
wires when servicing the 0 sensor.2
•
WARNING: THE EXHAUST PIPE MAY B E EX-
TREMELY HOT. AVOID CONTACT WITH THE EX-
HAUST PIPE WHEN SERVICING THE OXYGEN
SENSOR.
(2) Remove 0 sensor w i t h Tool C-4907.
2
2 The o r i g i n a l 0 sensor t h r e a d s w e r e coated
2
w i t h a n anti-seize c o m p o u n d . T h e c o m p o u n d
m u s t b e r e m o v e d f r o m t h e t h r e a d s i n t h e ex-
h a u s t m a n i f o l d p r i o r t o sensor installation.
(3) Clean the threads i n the exhaust manifold w i t h
a n 18 m m X 1.5 + 6 E tap.
(4) I f the o r i g i n a l sensor is t o be reinstalled, t h e
sensor threads m u s t be coated w i t h a n anti-seize
compound (Loctite 771-64 or equivalent). N e w 0 2
sensors are packaged w i t h compound on t h e threads
and no additional compound is required.
(5) T i g h t e n sensor t o 27 N - m (20 ft. lbs.) torque.
EXHAUST GAS RECIRCULATION (EGR) SYSTEMS
The E G R system reduces oxides of nitrogen (Nox)
i n engine exhaust a n d helps prevent spark knock.
This is accomplished b y a l l o w i n g a predetermined
amount o f hot exhaust gas t o recirculate and d i l u t e
the incoming fuel/air m i x t u r e . T h i s d i l u t i o n reduces
peak flame temperature d u r i n g combustion.
The E G R system consists o f t h e E G R valve, vac-
u u m transducer, EGR solenoid, and connecting hoses
(Fig. 11).
Fig. 11 EGR System
The E G R solenoid (Fig. 12) is controlled b y the ve-
hicles Single Board E n g i n e Controller (SBEC). T h e
SBEC monitors engine coolant temperature a n d
other operating conditions to determine w h e n the so-
lenoid is energized. W h e n energized b y t h e SBEC,
the solenoid prevents v a c u u m from reaching t h e
EGR valve transducer. W h e n t h e solenoid is not en-
ergized, vacuum flows t h r o u g h t h e solenoid to t h e
vacuum transducer. Refer to Modes of Operation i n
 • EMISSION CONTROL SYSTEMS
the D u a l P o i n t F u e l I n j e c t i o n section o f Group 14 for
a description o f solenoid operation based on engine
operating conditions.
EGR AIR SWITCHING CANISTER
Fig. 12 EGR Solenoid
The v a c u u m transducer is controlled b y exhaust
system back-pressure. W h e n back-pressure is h i g h
enough i t w i l l close a bleed valve i n t h e transducer
a l l o w i n g v a c u u m t o actuate t h e E G R valve. I f back-
pressure does not close t h e bleed valve vacuum w i l l
be bled off.
Operation
Engine V a c u u m flows t h r o u g h the E G R valve sole-
noid t o the v a c u u m transducer t h r o u g h a connecting
hose. V a c u u m flows o n l y w h e n t h e solenoid is not en-
ergized (no voltage applied). T h e transducer is con-
nected to t h e E G R v a l v e b y a v a c u u m hose a n d a
back-pressure hose. T h e transducer is controlled b y
exhaust back pressure a n d is ported t o t h e exhaust
manifold t h r o u g h a hose connecting i t t o the bottom
of the E G R valve (Fig. 13).
W h e n t h e solenoid is n o t energized a n d exhaust
gas back-pressure e n t e r i n g E G R valve i n l e t is h i g h
enough, back pressure holds transducer bleed valve
closed. T h i s allows v a c u u m t o activate and operate
the E G R valve.
EGR SYSTEM ON-BOARD DIAGNOSTICS
(CALIFORNIA VEHICLES ONLY)
A l l vehicles b u i l t for sale i n t h e state o f California
have a n On-Board Diagnostics test t h a t can be per-
formed w i t h t h e D R B I I diagnostic tester t o check t h e
E G R system for failures. T h e SBEC monitors E G R
system performance a n d registers a f a u l t code i f t h e
system has failed o r is degraded a n d t h e dash-
mounted check engine l i g h t is t u r n e d o n i n d i c a t i n g
immediate service is r e q u i r e d . The Diagnostic Sys-
t e m Check i s activated o n l y d u r i n g selected engine/
d r i v i n g conditions t o avoid incorrect diagnosis.
I f a m a l f u n c t i o n is i n d i c a t e d b y a check engine
l i g h t and a f a u l t code for E G R system, proper opera-
25-13
VACUUM TRANSDUCER
*
EXHAUST GAS
BACK PRESSURE
INLET
J9025-32
Fig. 13 EGR System Operation
t i o n o f t h e E G R system should be checked u s i n g t h e
Service Procedures. I f the EGR system is found t o be
f u n c t i o n i n g correctly, t h e on-board diagnostics sys-
t e m should t h e n be checked.
EGR SYSTEM SERVICE
A m a l f u n c t i o n i n g E G R system can cause engine
spark knock, sags or hesitation, rough idle, engine
s t a l l i n g a n d poor d r i v e a b i l i t y . To ensure proper oper-
a t i o n o f t h e E G R system inspect a l l passages for
blockage. Check m o v i n g parts for b i n d i n g . Inspect
the complete system for leaks. Replace system com-
ponents or hoses t h a t are leaking.
Inspect a l l hoses connections between t h r o t t l e body,
i n t a k e m a n i f o l d , E G R control valve, and E G R sole-
noid. Replace a n y v a c u u m harness components t h a t
are l e a k i n g or damaged.
Refer t o E G R Control System Test a n d E G R Gas
F l o w Test t o check E G R System operation.
E G A CONTROL SYSTEM TEST
WARNING: APPLY PARKING BRAKE AND/OR
BLOCK WHEELS BEFORE TESTING THE EGR SYS-
TEM.
(1) E n g i n e should be w a r m e d u p and operating a t
n o r m a l idle speed. A p p l y the p a r k i n g brake.
(2) A l l o w t h e engine t o idle i n n e u t r a l w i t h t h e
t h r o t t l e closed, t h e n q u i c k l y accelerate engine speed
to approximately 2,000 R P M , w h i l e w a t c h i n g t h e
groove (movement indicator) on the EGR valve stem.
(Fig. 14).
25 - 14 EMISSION CONTROL SYSTEMS •
• Movement of the v a l v e stem indicates t h a t the EGR valve a n d connect hand h e l d v a c u u m p u m p
control system is f u n c t i o n i n g correctly. Perform the Tool C-4207 or a n equivalent to the nipple.
EGR Gas F l o w Test. (3) S t a r t engine and slowly apply v a c u u m to E G R
• I f no movement of t h e valve stem is visible, Refer valve v a c u u m motor.
to the EGR D I A G N O S I S c h a r t i n t h i s Group. (4) Engine R P M should m o m e n t a r i l y drop as vac-
u u m reaches 3 to 5 inches H g and continue to drop
EGR GAS FLOW TEST as more v a c u u m is applied (engine m a y even stall).
• I f engine R P M m o m e n t a r i l y drops (the SBEC w i l l
SPRING VACUUM BACK PRESSURE
PISTON MOTOR increase R P M t h r o u g h the A I S motor w h e n i t senses
TRANSDUCER
a drop i n RPM), exhaust gas is c i r c u l a t i n g t h r o u g h
DIAPHRAGM the system. Successful completion of t h e E G R Gas
Flow Test and t h e Control System Test indicates a
fully-functional EGR system.
MOVEMENT • I f engine speed does n o t drop, a defective E G R
INDICATOR valve or plugged EGR passage is indicated. Remove
the E G R valve. Inspect for blockage i n t h e passages
i n t h e i n t a k e m a n i f o l d below the E G R valve. I n t a k e
m a n i f o l d passages should be checked for deposits a n d
cleaned i f necessary. Replace the E G R v a l v e i f ob-
BACK PRESSURE structions are not found i n the EGR system.
SIGNAL TUBE
STEM PROTECTOR
INLET OUTLET
EGR DIAGNOSIS
RR25G64
A l l tests m u s t be made w i t h f u l l y w a r m engine
Fig. 14 EGR and Back Pressure Transducer r u n n i n g continuously for at least t w o m i n u t e s .
Assembly—Typical
(1) Connect tachometer to engine. WARNING: APPLY PARKING BRAKE AND/OR
(2) Remove v a c u u m hose (or rubber elbow) from BLOCK WHEELS BEFORE PERFORMING EGR DI-
AGNOSIS.

CONDITION
EGR Valve Stem Does Not Move On
System Test.
EGR Valve Stem Does Not Move on
System Test. But, Operates
Normally on External Vacuum
Source.
Engine Will Not Idle. Dies Out on
Return to Idle or Idle is Very Rough
or Slow.
EMISSION CONTROL SYSTEMS 25-15
EGR DIAGNOSIS CHART
POSSIBLE CAUSE CORRECTION
Cracked, leaking, disconnected or Verify correct hose connections.
plugged hoses. Replace hose harness if damaged or
plugged hoses are found.
Disconnect hose harness from EGR
vacuum transducer and connect
auxiliary vacuum supply. Raise and
maintain engine RPM to 2000 RPM.
Apply 10 in. of vacuum and check
valve movement. If valve does not
move replace EGR valve/transducer
assembly. If valve opens
approximately 3 mm (1/8 inch)
apply vacuum to valve nipple and
check for a leaking diaphragm. The
valve should remain open 30
seconds or longer. If leakage
occurs, replace EGR
valve/transducer assembly. If valve
does not leak check control system.
Defective control system or plugged Remove throttle body. Inspect EGR
passages. vacuum source and associated
passages in throttle body for
obstructions. Clean passages as
necessary. Use low air pressure to
inspect for air flow through
passages. Recheck for normal EGR
operation.
High EGR valve leakage in closed If removal of vacuum hose from EGR
position. valve does not correct rough idle,
remove EGR valve/transducer
assembly. Inspect poppet and
ensure that it is seated. Replace
valve/transducer if defective.
J9025-13
25-16 EMISSION CONTROL SYSTEMS •
EGR VALVE REMOVAL (3) Reconnect v a c u u m hose to valve/transducer as-
(1) Disconnect v a c u u m hose t o E G R valve/ . sembly.
transducer assembly.
(2) Remove EGR m o u n t i n g bolts (Fig. 15). EGR DIAGNOSTIC SOLENOID REMOVAL
(1) Remove v a c u u m hose and electrical connector
f r o m solenoids (Fig. 16).

PRESS HERE

Fig. 15 EGR Mounting

(3) Remove EGR valve and gasket. Discard gasket.
Clean i n t a k e manifold surface and check for cracks.
INSTALLATION
(1) Place new EGR gasket o n i n t a k e manifold.
(2) I n s t a l l E G R valve. T i g h t e n m o u n t i n g bolts t o
23 N-m (200 i n . lbs.) torque.
Fig. 16 Servicing the Solenoid Pack
(2) Remove m o u n t i n g fastener and remove solenoid
pack.
(3) Depress t a b o n top o f solenoid to be replaced
and slide t h e solenoid d o w n w a r d o u t o f m o u n t i n g
bracket.
(4) Reverse above procedure to i n s t a l l .
 • EMISSION CONTROL SYSTEMS 25 - 17

AIR I N J E C T I O N S Y S T E M
INDEX
Page Page
Air Injection Pump 19 Coolant Temperature Sensor 20
Air Switching System . . 20 Diverter Valve 19
Air Switch/Relief Valve 19 General Information 17
Check Valve (Air Injection Tube) 20

GENERAL INFORMATION catalytic convertor (refereed t o as downstream)

The a i r injection system consists o f a belt-driven
a i r pump, a n a i r control valve (either a diverter
valve, relief valve or switch/relief valve), a n d rubber
hoses and check valves to protect t h e hoses and i n -
jection tubes from hot exhaust gases (Fig. 1, 2 or 3).
The a i r injection system adds a controlled amount
of a i r to the exhaust gases a i d i n g the o x i d a t i o n of hy-
drocarbons a n d carbon monoxide i n t h e exhaust
stream. The system is designed t o not interfere w i t h
the a b i l i t y o f the EGR system t o control n i t r o u s ox-
ide (NOx) emissions. A i r is injected a t either the ex-
haust manifold (referred to as upstream) or a t a the
t h r o u g h the a i r switch/relief valve.
The a i r s w i t c h i n g valve is operated b y manifold
vacuum. The vacuum supply for the air switch/relief
valve is controlled by the a i r switching solenoid. The
solenoid is controlled by t h e Single Board Engine
Controller (SBEC).
A i r is injected upstream a t the exhaust manifold
for a short t i m e d u r i n g engine warm-up. Once the
engine reaches operating temperature, the a i r flow is
switched downstream where i t w i l l assist the oxida-
t i o n process i n t h e catalyst b u t not interfere w i t h
EGR operation.
Heavy D u t y Cycle (HDC) vehicles w i t h the 5.9L
engine are equipped w i t h a d u a l a i r pump system.

AIR SWITCHING AND AIR INJECTION AIR SWITCHING AND

Fig. 1 Air injection System—3.9L Engine

25 - 18 EMISSION CONTROL SYSTEMS

Fig. 2 Air Injection System—5.2L Engine and Light Duty Cycle 5.9L Engines

Fig. 3 Air Injection System—5.9L Engine, Heavy Duty Cycle

 • EMISSION CONTROL SYSTEMS
AIR INJECTION PUMP
The a i r p u m p is mounted on the front of the engine
and d r i v e n by a belt connected to the crankshaft p u l -
ley (Fig. 4). I n t a k e a i r passes t h r o u g h a f a n a t the
front of the pump. Foreign materials are separated
f r o m the a i r b y centrifugal force. A i r is delivered t o
the a i r injection m a n i f o l d and check valve tube as-
sembly b y a rubber hose t h r o u g h t h e diverter valve
and s w i t c h i n g valve. Hoses are secured to a l l f i t t i n g s
by clamps.
DRIVE HUB
CENTRIFUGAL FILTER FAN RF410
Fig. 4 Air injection Pump
The a i r injeetion system is n o t completely
noiseless. U n d e r n o r m a l c o n d i t i o n s , n o i s e rises
i n p i t c h as e n g i n e s p e e d i n c r e a s e s . T o d e t e r m i n e
i f excessive n o i s e i s t h e f a u l t o f t h e a i r i n j e c t i o n
system, disconnect t h e d r i v e belt a n d operate
t h e engine. I f noise does n o t exist, p r o c e e d w i t h
diagnosis.
The only serviceable component of t h i s p u m p is the
centrifugal fan filter. Do not assume the p u m p is de-
fective i f i t squeaks w h e n t u r n e d b y hand.
D O N O T L U B R I C A T E P U M P . Wipe a l l o i l off of
pump housing. O i l i n t h e pump w i l l cause r a p i d de-
t e r i o r a t i o n and failure.
CAUTION: If the engine or underhood compartment
is to be cleaned with steam or high pressure deter-
gent, the centrifugal fan filter should be masked off
to prevent liquids from entering the pump.
25-19
DIVERTER VALVE
A diverter valve is used on some vehicles. The pur-
pose of the diverter valve (Fig. 5) i s to prevent back-
fire i n t h e exhaust system during sudden
deceleration.
Fig. 5 Diverter Valve
Sudden t h r o t t l e closure at the b e g i n n i n g of deceler-
ation t e m p o r a r i l y creates a n air-fuel m i x t u r e t h a t is
too r i c h to b u r n . This m i x t u r e becomes burnable
when i t reaches the exhaust area a n d combines w i t h
injector air. The next f i r i n g o f t h e engine w i l l i g n i t e
this air-fuel m i x t u r e . T h e d i v e r t e r valve senses the
sudden increase i n i n t a k e m a n i f o l d v a c u u m causing
the valve t o open, a l l o w i n g a i r f r o m the a i r p u m p to
pass t h r o u g h t h e valve a n d silencer to t h e atmo-
sphere.
A pressure r e l i e f valve, incorporated i n the same
housing as t h e diverter valve, controls pressure
w i t h i n the system b y d i v e r t i n g excessive pump out-
p u t a t higher engine speeds t o atmosphere t h r o u g h
the silencer.
AIR SWITCH/RELIEF VAL VE
The purpose of the switch/relief valve (Fig. 6) is
twofold. F i r s t , the valve directs a i r injection flow to
either the exhaust port location or to the downstream
injection point. I n addition, the valve regulates sys-
t e m pressure by c o n t r o l l i n g t h e o u t p u t of the a i r
pump a t h i g h speeds. W h e n the pressure reaches a
certain level, some of the o u t p u t i s vented to the at-
mosphere t h r o u g h the silencer.
25 - 20 EMISSION CONTROL SYSTEMS
A i r is i n i t i a l l y injected a t the upstream location as
close to t h e exhaust valves as possible. A s t h e engine
temperature increases, exhaust gas recirculation
(and t h e 0 feedback system) begin functioning.
2
When t h i s happens, t h e a i r injection p o i n t m u s t be
switched t o the downstream location for the best pos-
sible operation.
RBI 198
Fig. 6 Switch/Relief Valve
The switch/relief valve is controlled b y m a n i f o l d
vacuum. The vacuum supply to t h e switch/relief
valve is controlled by t h e Single Board E n g i n e Con-
troller (SBEC) t h r o u g h t h e a i r s w i t c h i n g solenoid
(Fig. 7). When the solenoid is energized v a c u u m is
not supplied to the a i r switch/relief valve. W h e n the
solenoid is not energized, vacuum is supplied t o t h e
air switch/relief valve.
Fig. 7 Air Switching Solenoid
•
W h e n t h e engine is cold, a m a n i f o l d vacuum signal
is sent t o t h e switch/relief v a l v e a n d t h e valve directs
a i r injection upstream (to t h e exhaust port location).
W h e n engine temperature rises, t h e SBEC v a c u u m
solenoid shuts off t h e m a n i f o l d v a c u u m signal t o t h e
s w i t c h r e l i e f valve. A bleed orifice i n t h e v a c u u m
l i n e allows the v a c u u m signal t o go t o zero. W i t h o u t
a v a c u u m signal, the valve switches t h e a i r injection
to the downstream location.
AIR SWITCHING SYSTEM
A t start-up t h e a i r s w i t c h i n g solenoid is energized
and a i r is injected upstream. W h e n t h e fuel injection
system enters C L O S E D L O O P operation a i r w i l l be
injected downstream u n t i l a n O P E N L O O P idle con-
d i t i o n occurs.
CHECK VALVE (AIR INJECTION TUBE)
A check valve is located i n t h e injection tube as-
semblies t h a t lead t o t h e exhaust manifolds and t h e
catalyst injection points (Fig. 1, 2 or 3).
The check valve has a one-way diaphragm w h i c h
prevents hot exhaust gases f r o m b a c k i n g up into t h e
hose and pump. The check valve w i l l protect the sys-
t e m i n t h e event o f p u m p belt f a i l u r e , abnormally
h i g h exhaust system pressure, or a i r hose ruptures.
COOLANT TEMPERATURE SENSOR
The coolant temperature sensor is located i n t h e
coolant crossover passage a t t h e f r o n t o f the i n t a k e
m a n i f o l d (Fig. 8). T h e sensor monitors engine t e m -
perature. T h e SBEC energizes or de-energizes the a i r
s w i t c h i n g solenoid based on engine operating temper-
ature.
Fig. 8 Coolant Temperature Sensor

Condition
EXCESSIVE BELT NOISE
EXCESSIVE PUMP NOISE.
CHIRPING
EXCESSIVE PUMP NOISE CHIRPING,
RUMBLING, OR KNOCKING
NO AIR SUPPLY (ACCELERATE ENGINE TO
1500 RPM AND OBSERVE AIR FLOW FROM
HOSES. IF THE FLOW INCREASES AS THE
RPM'S INCREASE, THE PUMP IS FUNCTION-
ING NORMALLY. IF NOT, CHECK POSSIBLE
CAUSE.
AIR SUPPLY UPSTREAM WITH NO VACUUM
APPLIED TO SWITCH/RELIEF VALVE.
EMISSION CONTROL SYSTEMS 25 - 21
AIR PUMP DIAGNOSIS
Possible Cause Correction
(a) Loose belt. (a) Tighten belt (see Group 7 "Cooling
System").
(b) Seized pump. (b) Replace pump.
(a) Insufficient break-in. (a) Recheck for noise after 1600 km. (1,000
miles) of operation.
(a) Leak in hose. (a) Locate source of leak using soap solution
and correct.
(b) Loose hose. (b) Reassemble and replace or tighten hose
clamp.
(c) Hose touching other engine parts. (c) Adjust hose position.
(d) Switch/relief valve inoperative. (d) Replace switch/relief valve.
(e) Check valve inoperative. (e) Replace check valve.
(f) Pump mounting fasteners loose. (f) Tighten mounting screws as specified.
(g) Pump failure. (g) Replace pump.
(a) Loose drive belt. (a) Tighten to specifications.
(b) Leaks in supply hose. (b) Locate leak and repair or replace as
required.
(c) Leak at fitting(s). (c) Tighten or replace clamps.
(d) Check valve inoperative. (d) Replace check valve.
(a) Defective Air Switching Control Solenoid. (a-1) With the engine running, connect volt-
meter to the light blue with red tracer of
the air switching solenoid connector and
ground. Voltmeter should pulse between
0 and 14 volts. Solenoid is okay. If the
voltage pulses between 0-2 volts replace
solenoid dual assembly. Voltmeter not
pulsating but reads within 1 volt of bat-
tery voltage, perform next test.
(a-2) Turn the engine off. Disconnect the SBEC
60-way connector. Turn ignition switch to
ON position. Connect a voltmeter to cav-
ity 36 and ground. Voltmeter reads with-
in 1 volt of battery voltage. Replace the
computer. If voltmeter reads 0 volts
(without vacuum actuated electrical
switch), repair wire of cavity 36 for open
circuit. If voltmeter reads 0 volts with
vacuum actuated electrical switch, per-
form next test.
(a-3) Turn ignition switch off. Disconnect the
vacuum actuated electrical switch con-
nector. Connect an ohmmeter between
the terminals of the switch. Ohmmeter
shows continuity, repair wire of SBEC
connector cavity 36. Ohmmeter does not
show continuity, replace switch.
(a-4) Engine running connect voltmeter to
green wire of the air switching solenoid
connector and ground. Voltmeter read-
ing within 1 volt of battery voltage, re-
place the computer. If voltmeter reads
between 0 and 1 volt, repair wire in
cavity 36 of SBEC 60-way connector for
short to ground.
(b) Switch/relief valve inoperative. (b) Replace switch/relief valve.
J9025-15
25 - 22 EMISSION CONTROL SYSTEMS •
SERVICE PROCEDURES
INDEX
Page Page
Air Injection Pump 22 Diverter Valve 25
Centrifugal Filter Fan .. !
24 General Information 22
Check Valve (Injection Tube Assemblies) 25 Switch/Relief Valve 25

GENERAL INFORMATION remove b e l t (Fig. 1).

For satisfactory emission control and engine dura-
b i l i t y , the a i r p u m p m u s t be operating a t a l l times
(except w h e n p e r f o r m i n g diagnosis tests). To ensure
proper operation o f t h e a i r pump the a i r p u m p drive
belt should be i n good condition and adjusted t o t h e
specified tension. Inspect t h e condition o f t h e a i r
p u m p belt a n d adjust belt tension t o specifications.
Refer t o Group 7, Cooling System.
A i r pump service involves replacing either t h e cen-
t r i f u g a l fan f i l t e r or t h e entire pump. Do n o t disas-
semble pump f o r any reason. D o not c l a m p p u m p
i n a vise o r u s e a h a m m e r o r p r y b a r o n the
p u m p housing.
AIR INJECTION PUMP
SINGLE PUMP SYSTEM-LIGHT DUTY CYCLE
VEHICLE
Removal
(1) Remove a i r hose f r o m air p u m p outlet elbow, or
control valve.
(2) Loosen a i r p u m p pivot and adjusting bolts and
(3) Remove pivot and adjusting bolts f r o m p u m p
brackets a n d remove pump pulley a n d brackets as a n
assembly.
(4) Remove a i r pump pulley, brackets and diverter
valve, switch/relief valve or o u t l e t elbow from a i r
pump (Fig. 2 and 3).
Installation
(1) I n s t a l l a i r pump pulley, d i v e r t e r valve, switch/
relief valve and brackets on a i r p u m p . Use new gas-
k e t on p u m p flange. T i g h t e n t h e a i r p u m p pulley
screws and outlet elbow m o u n t i n g screws t o 11 N-m
(95 i n . lbs.) torque. T i g h t e n bracket attachment bolts
to 41 N - m (30 ft. lbs.) torque.
(2) Position pump assembly o n engine and i n s t a l l
the air hose t o the diverter valve, switch/relief valve
or outlet elbow. I n s t a l l pump p i v o t and adjusting
bolts loosely.
(3) I n s t a l l drive belt and adjust. Refer to Group 7,
Cooling System. Do not p r y o n a i r p u m p h o u s i n g .
T i g h t e n m o u n t i n g bolts to 41 N n n (30 ft. lbs.) torque.
DUAL AIH PUMP SYSTEM-HEAVY DUTY
CYCLE VEHICLE WITH ENGINE
Removal
(1) Remove air hose from the a i r switch r e l i e f valve
at each a i r p u m p (Fig. 4).
(2) Loosen a i r pump pivot and adjusting bolts on
both pumps. Remove belt.
(3) Remove a i r pump a t t a c h i n g bolts f r o m lower
pump a n d remove lower pump r e l i e f valve a n d
adapter as a n assembly.
(4) Remove a i r pump pivot and adjusting bolts f r o m
upper a i r pump. Remove upper p u m p and diverter
valve as a n assembly.
(5) Remove a i r pump pulley, diverter valve, a n d
adaptor f r o m a i r pumps.

Installation
(1) I n s t a l l air pumps pulleys, diverter valves, and
adaptors t o a i r pumps.
(2) I n s t a l l new gasket on p u m p flange o f lower
pump. T i g h t e n a i r pump pulley screws, diverter
valve screws and adaptor screws t o 11 N - m (95 i n .
lbs.) torque.
(3) I n s t a l l lower air pump assembly and t i g h t e n at-
BRACKET RH1433
taching bolts to 41 N-m (30 ft. lbs.) torque. I n s t a l l a i r
Fig. 1 Single Air Pump Removal/Installation hose to diverter valve.
 EMISSION CONTROL SYSTEMS 25 - 23
•

Fig. 2 Air Injection System-3.9L Engine

Fig. 3 Air Injection System—5.2L Engine and Light Duty Cycle 5.9L Engines
 25 - 24 EMISSION CONTROL SYSTEMS •

Fig. 4 Dual Air Pump System 5.9L Engine, Heavy Duty Cycle
(4) I n s t a l l upper a i r p u m p assembly a n d t i g h t e n
pivot and adjusting bolts loosely. I n s t a l l a i r hose t o
diverter valve.
(5) I n s t a l l accessory d r i v e belt and adjust belt t e n -
sion. Refer t o Group 7, Cooling System. D o not p r y
on a i r p u m p h o u s i n g to adjust belt tension.
T i g h t e n p i v o t and adjusting bolts t o 4 1 N-m (30 f t .
lbs.) torque.

CENTRIFUGAL FILTER FAN

REMOVAL
A damaged filter fan may be removed by i n s e r t i n g
needle nose pliers between the plastic f i l t e r fins and
b r e a k i n g f a n from h u b . (Fig. 5). Care should be
t a k e n t o prevent fragments from entering the a i r i n -
take hole. D o not insert screwdriver blade between
pump and f i l t e r . I t is seldom possible to remove t h e
fan w i t h o u t destroying i t . Do not attempt to remove
the m e t a l d r i v e hub.

INSTALLATION
I n s t a l l t h e new f i l t e r f a n by d r a w i n g i t into posi-
t i o n , using t h e belt pulley and pulley m o u n t i n g
screws. D r a w the f a n down evenly by alternately
t i g h t e n i n g t h e screws, ensuring t h a t t h e outer edge
of t h e f a n slips into t h e housing (Fig. 6). A s l i g h t
amount of interference w i t h the housing bore is nor-
m a l . Do n o t attempt t o i n s t a l l a f a n by h a m m e r i n g
Fig. 5 Removing Centrifugal Filter Fan
or pressing i t on. After a new fan is installed, i t may
squeal upon i n i t i a l operation u n t i l its outside diame-
t e r sealing l i p has worn i n . This m a y require 32-48
k m (20-30 miles) of operation.
 • EMISSION CONTROL SYSTEMS
Fig. 6 Installing Centrifugal Filter Fan
DIVERTER VALVE
The d i v e r t e r valve is not adjustable or serviceable.
I t m u s t be replaced as a complete u n i t i f i t does not
operate properly. A n improperly operating diverter
valve w i l l m a k e excessive noise. E i t h e r t h e relief
valve or t h e d i v e r t e r valve are n o t functioning nor-
m a l l y i f a i r escapes from t h e silencer a t engine idle
speed.
REMOVAL
(1) Remove a i r and v a c u u m hoses from the diverter
valve (Fig. 2 or 3).
(2) Remove diverter valve m o u n t i n g screws. Re-
move valve.
(3) Remove gasket m a t e r i a l f r o m diverter valve
and m o u n t i n g surface.
INSTALLATION
(1) Position n e w gasket o n m o u n t i n g surface.
(2) Position diverter valve o n m o u n t i n g flange a n d
t i g h t e n m o u n t i n g screws t o 1 1 N»m (95 i n . lbs.)
torque.
(3) R e i n s t a l l a i r a n d v a c u u m hoses t o diverter
valve.
SWITCH/RELIEF VALVE
The switch/relief valve is n o t serviceable. I f vac-
u u m i s applied t o t h e valve and a i r injection is not
upstream (to exhaust manifold crossover tube) or i f assembly.
a i r injection is b o t h upstream and downstream, the
valve is i m p r o p e r l y operating and must be replaced.
The r e l i e f valve i s not f u n c t i o n i n g n o r m a l l y i f air es-
capes f r o m the silencer a t engine idle speed.
25 - 25
REMOVAL
(1) Remove a i r a n d v a c u u m hoses from t h e a i r
switch/relief valve (Fig. 2, 3 o r 4).
(2) Remove valve m o u n t i n g screws. Remove valve.
(3) Remove gasket m a t e r i a l from valve and mount-
i n g flange.
INSTALLATION
(1) Position n e w gasket o n m o u n t i n g flange.
(2) Position valve on m o u n t i n g flange and t i g h t e n
m o u n t i n g screws t o 11 N»m (95 i n . lbs.) torque.
(3) I n s t a l l a i r and vacuum hoses to valve.
CHECK VALVE (Injection tube assemblies)
The check valve is not repairable and m u s t be re-
placed w i t h a n e w check valve. To determine i f the
valve is n o t functioning n o r m a l l y , remove t h e a i r
hose f r o m check valve i n l e t tube. I f exhaust gas es-
capes f r o m i n l e t tube, the valve must be replaced. I f
t h e exhaust m a n i f o l d injection tube assembly j o i n t is
l e a k i n g , remove injection tube assembly and replace
gasket m a t e r i a l . I f tube n u t connection i s leaking,
t i g h t e n t o 34-47 N-m (25-35 ft. lbs.) torque.
NON THREADED TYPE CHECK VALVE
Removal
(1) Release clamp and disconnect a i r hose from
check valve i n l e t .
(2) Remove screws or tube n u t securing injection
t u b e t o exhaust manifolds o r exhaust pipe.
(3) Remove t h e injection tube assembly f r o m en-
gine.
(4) Remove gasket m a t e r i a l from exhaust m a n i f o l d
a n d injection tube flanges.
Installation
(1) I n s t a l l new gaskets on exhaust manifold flanges
a n d i n s t a l l injection tube assembly. T i g h t e n flange
m o u n t i n g a n d injection tube bracket screws t o 12
N m (100 i n . lbs.) torque. O n tube n u t j o i n t assem-
#
blies, i n s t a l l tube n u t and t i g h t e n to 34-37 N»m (24-
35 ft. lbs.) torque.
THREADED TYPE CHECK VALVE
Removal
Removal of the lower tube assembly m a y require
removal of the upper a i r p u m p and A/C compressor.
Refer t o groups 24 and 25.
(1) Release clamp and disconnect air hose f r o m the
check valve i n l e t .
(2) Unscrew the check valve from the injection tube
Installation
(1) I n s t a l l check valve o n tube assembly. T i g h t e n
to 34 N-m (25 f t . lbs) torque.
(2) I n s t a l l a i r hose to t h e check valve i n l e t a n d
t i g h t e n clamp.